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Disassembly [10/2015 - ]: Procedure

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  1. REMOVE INTAKE VALVE 
    1. Using SST, compress the compression spring and remove the 8 valve spring retainer locks.
      GTY511925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09202-70020 
      • SST: 09202-00021 
    2. Remove the 8 valve spring retainers, 8 compression springs and 8 intake valves.

      HINT: 

      Arrange the removed parts in the correct order.

  2. REMOVE EXHAUST VALVE 
    WARNING:
    • The exhaust valve is filled with sodium. Sodium is a strong alkali which can produce a dangerous chemical reaction. Be very careful when handling and disposing of it.
    • Do not intensionally expose the sodium in exhaust valve. If sodium enters your eyes, vision loss may occur. If sodium contacts your skin, burns may occur. If a fire occurs due to a chemical reaction with sodium, burns may occur.
    • If the sodium in the exhaust valve is exposed, perform all necessary preparations to safely remove and dispose of the sodium.
    • When removing a damaged exhaust valve, always wear rubber gloves and safety glasses.
    • Do not intentionality cut or break open the exhaust valve to remove the sodium.

    HINT: 

    • The sodium inside the exhaust valve is safe as long as it remains sealed inside the exhaust valve.
    • Exhaust valves filled with sodium can be identified by their "NA" identification mark.
    1. Using SST, compress the compression spring and remove the 8 valve spring retainer locks.
      GTY502174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09202-70020 
      • SST: 09202-00021 
    2. Remove the 8 valve spring retainers, 8 compression springs and 8 exhaust valves.

      HINT: 

      Arrange the removed parts in the correct order.

  3. REMOVE VALVE STEM OIL SEAL 
    1. Using needle-nose pliers, remove the 16 valve stem oil seals.
      GTY510636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE VALVE SPRING SEAT 
    1. Using compressed air and a Magnet Hand, remove the 16 valve spring seats from the cylinder head sub-assembly by blowing air onto them.
      GTY510635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 1 STRAIGHT SCREW PLUG 
    NOTE:

    If coolant leaks from a No. 1 straight screw plug or the plug is corroded, replace it.

    1. Using a 14 mm hexagon wrench, remove the 6 No. 1 straight screw plugs and 6 gaskets.
      GTY519222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.

  7. DISPOSE OF EXHAUST VALVE 
    WARNING:
    • The exhaust valve is filled with sodium. Sodium is a strong alkali which can produce a dangerous chemical reaction. Be very careful when handling and disposing of it.
    • Do not intensionally expose the sodium in exhaust valve. If sodium enters your eyes, vision loss may occur. If sodium contacts your skin, burns may occur. If a fire occurs due to a chemical reaction with sodium, burns may occur.
    • If the sodium in the exhaust valve is exposed, perform all necessary preparations to safely remove and dispose of the sodium.
    • When removing a damaged exhaust valve, always wear rubber gloves and safety glasses.
    • Do not intentionality cut or break open the exhaust valve to remove the sodium.

    HINT: 

    • The sodium inside the exhaust valve is safe as long as it remains sealed inside the exhaust valve.
    • Exhaust valves filled with sodium can be identified by their "NA" identification mark.
    1. Waste disposal preparation
      WARNING:

      Observe the following precautions when performing the disposal procedure.

      1. Have a suitable fire extinguisher close by.
      2. Wear safety glasses.
      3. Wear rubber gloves.
    2. Waste disposal
      1. Remove the damaged exhaust valve from the cylinder head sub-assembly.
      2. Prepare a large container, such as a bucket or oil can, filled with 10 L or more of water and place it in a well ventilated area.
      3. Using pliers or a large pair of tweezers, hold the damaged exhaust valve upright and submerge it into the water.
        WARNING:
        • Make sure to fully submerge the damaged exhaust valve in water.
        • Do not allow any sparks or other flames near the container as hydrogen gas is generated by the chemical reaction.
        • Stay at least 2 m away from the receptacle as a strong chemical reaction occurs.
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