CYLINDER HEAD REASSEMBLY

PROCEDURE

  1. INSTALL CYLINDER HEAD STUD BOLT

    Tip:

    If a cylinder head stud bolt is deformed or the threads are damaged, replace it.

    1. Using an E8 "TORX" socket wrench, install the cylinder head stud bolts.

      for stud bolt A and B

      12 N*m

      122 kgf*cm

      9 ft.*lbf

      for stud bolt C

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    2. Using an E6 "TORX" socket wrench, install the cylinder head stud bolt.

      for stud bolt D

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

      A298138C01

      *a

      Cylinder Head Cover Side

      *b

      Intake Manifold Side

      *c

      Exhaust Manifold Side

      *d

      40 mm (1.57 in.)

      *e

      15 mm (0.591 in.)

      *f

      58.5 mm (2.30 in.)

      *g

      20 mm (0.787 in.)

      *h

      13 mm (0.512 in.)

      *i

      35 mm (1.38 in.)

      *j

      14 mm (0.551 in.)

      *k

      47 mm (1.85 in.)

      *l

      12 mm (0.472 in.)

      *m

      37 mm (1.45 in.)

      -

      -

  2. INSTALL NO. 1 STRAIGHT SCREW PLUG WITH HEAD

    1. Apply adhesive to the No. 1 straight screw plugs.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using a 6 mm hexagon wrench, install the 4 No. 1 straight screw plugs.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

  3. INSTALL NO. 1 WATER BY-PASS PIPE

    A203751C01

    *a

    45 to 55°
    Tip:

    When using a new cylinder head sub-assembly, a No. 1 water by-pass pipe must be installed.

    1. Apply adhesive to a new No. 1 water by-pass pipe so that it covers the entire circumference of the part which contacts the hole of the cylinder head sub-assembly.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the No. 1 water by-pass pipe as shown in the illustration.

  4. INSTALL WATER OUTLET

    A203748C01

    *a

    79 to 85 mm

    *b

    51 to 61°
    Tip:

    When using a new cylinder head sub-assembly, a water outlet must be installed.

    1. Apply adhesive to a new water outlet so that it covers the entire circumference of the part which contacts the hole of the cylinder head sub-assembly.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the water outlet.

      Standard protrusion

      79 to 85 mm (3.11 to 3.35 in.)

      Standard angle

      51 to 61°

  5. INSTALL ELBOW

    A203747C01

    *a

    56.5 to 62.5 mm

    *b

    20 to 30°
    Tip:

    When using a new cylinder head sub-assembly, an elbow must be installed.

    1. Apply adhesive to a new elbow so that it covers the entire circumference of the part which contacts the hole of the cylinder head sub-assembly.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the elbow.

      Standard protrusion

      56.5 to 62.5 mm (2.22 to 2.46 in.)

      Standard angle

      20 to 30°

  6. INSTALL VALVE SPRING SEAT

    1. Install the valve spring seats to the cylinder head sub-assembly.

  7. INSTALL VALVE STEM OIL SEAL

    1. Apply a light coat of engine oil to a new valve stem oil seal.

    2. A111374C02

      *1

      Valve Stem Oil Seal

      Using SST, push in the valve stem oil seal.

      09201-41020

      Note:

      Failure to use SST will cause the valve stem oil seal to be damaged or improperly seated.

  8. INSTALL INTAKE VALVE

    1. A101416C03

      *a

      50 mm (1.97 in.)

      Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

    2. Place the cylinder head sub-assembly on a wooden block.

    3. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly.

      Note:

      Install the same parts in the same combination to their original locations.

    4. A111290N06

      Using SST, compress the inner compression spring and place the valve spring retainer lock around the intake valve stem.

      09202-70020

    5. Using a 5 mm pin punch and plastic-faced hammer, lightly tap the intake valve stem tip to ensure a proper fit.

      Note:

      Be careful not to damage the intake valve stem tip.

  9. INSTALL EXHAUST VALVE

    1. A101419C03

      *a

      50 mm (1.97 in.)

      Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.

    2. Place the cylinder head sub-assembly on a wooden block.

    3. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly.

      Note:

      Install the same parts in the same combination to their original locations.

    4. A111289N05

      Using SST, compress the inner compression spring and place the valve spring retainer lock around the exhaust valve stem.

      09202-70020

    5. Using a 5 mm pin punch and plastic-faced hammer, lightly tap the exhaust valve stem tip to ensure a proper fit.

      Note:

      Be careful not to damage the exhaust valve stem tip.