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Reassembly [11/2021 - ]: Procedure

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  1. INSTALL INTAKE VALVE GUIDE BUSH 
    1. GTY1077042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-assembly.

        Standard Intake Valve Guide Bush Bore Diameter

        10.285 to 10.306 mm (0.405 to 0.406 in.)

        New Guide Bush Selection Chart

        Bush Size Specified Condition
        STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
        O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

        Standard Bush Length

        41.3 to 41.7 mm (1.63 to 1.64 in.)

        HINT: 

        • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the intake valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 intake valve guide bush.
        • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.
      2. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
        WARNING:

        Be sure to wear protective gloves.

      3. Using SST and a hammer, tap in a new intake valve guide bush to the specified protrusion height.
        • SST: 09201-10000 
          1. 09201-01050
        • SST: 09950-70010 
          1. 09951-07100

        Standard Protrusion Height

        18.35 to 18.60 mm (0.722 to 0.732 in.)

      4. Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the standard oil clearance.

        Standard Oil Clearance

        0.025 to 0.060 mm (0.000984 to 0.00236 in.)

  2. INSTALL EXHAUST VALVE GUIDE BUSH 
    1. GTY1076359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head sub-assembly.

        Standard Exhaust Valve Guide Bush Bore Diameter

        10.285 to 10.306 mm (0.405 to 0.406 in.)

        New Guide Bush Selection Chart

        Bush Size Specified Condition
        STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
        O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

        Standard Bush Length

        43.3 to 43.7 mm (1.70 to 1.72 in.)

        HINT: 

        • If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the exhaust valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 exhaust valve guide bush.
        • If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.
      2. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
      3. Using SST and a hammer, tap in a new exhaust valve guide bush to the specified protrusion height.
        • SST: 09201-10000 
          1. 09201-01050
        • SST: 09950-70010 
          1. 09951-07100

        Standard Protrusion Height

        18.75 to 19.00 mm (0.738 to 0.748 in.)

      4. Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the standard oil clearance.

        Standard Oil Clearance

        0.030 to 0.065 mm (0.00118 to 0.00256 in.)

  3. INSTALL SPARK PLUG TUBE 
    NOTE:

    When using a new cylinder head sub-assembly, the spark plug tubes must be replaced.
    1. GTY1076542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Standard Application Width *b Distance (A)
      *c Distance (B) *d Protrusion Height (A)
      *e Protrusion Height (B) *f 9°
      1. Apply adhesive to a cylinder head sub-assembly as shown in the illustration.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        Standard Application Width

        1.0 to 6.0 mm (0.0394 to 0.236 in.)

        Distance (A)

        1.0 mm (0.0394 in.)

        Distance (B)

        7.0 mm (0.276 in.)

      2. Using a wooden block and hammer, tap in the 4 new spark plug tubes to the specified protrusion height.

        Standard Protrusion Height (A)

        74.9 mm (2.95 in.)

        Standard Protrusion Height (B)

        78.3 mm (3.08 in.)

        NOTE:
        • Be careful not to deform the spark plug tube.
        • Do not add engine oil for at least 1 hour after the installation.
  4. INSTALL FUEL INJECTOR TUBE 
    NOTE:

    When using a new cylinder head sub-assembly, the fuel injector tubes must be replaced.
    1. GTY1077121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Standard Application Width *b Distance (A)
      *c Distance (B) *d Protrusion Height (A)
      *e Protrusion Height (B) *f 6°
      1. Apply adhesive to a cylinder head sub-assembly in as shown in the illustration.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        Standard Application Width

        1.0 to 6.0 mm (0.0394 to 0.236 in.)

        Distance (A)

        1.0 mm (0.0394 in.)

        Distance (B)

        7.0 mm (0.276 in.)

      2. Using a wooden block and hammer, tap in the 4 new fuel injector tubes to the specified protrusion height.

        Standard Protrusion Height (A)

        61.2 mm (2.41 in.)

        Standard Protrusion Height (B)

        63.9 mm (2.52 in.)

        NOTE:
        • Be careful not to deform the fuel injector tube.
        • Do not add engine oil for at least 1 hour after the installation.
  5. INSTALL RING PIN 
    1. GTY1076460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a plastic hammer, tap in 2 new ring pins to the cylinder head sub-assembly.

        Standard Protrusion Height

        6.5 to 7.5 mm (0.256 to 0.295 in.)

  6. INSTALL STUD BOLT 
    1. GTY1077607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 22.5 mm (0.886 in.) *b 20 mm (0.787 in.)
      *c 46 mm (1.81 in.) *d 24 mm (0.945 in.)
      *e 12 mm (0.472 in.) *f 52 mm (2.05 in.)
      1. Using an E10 "TORX" socket wrench, install the 4 stud bolts.

        Stud Bolt (A) 

        Torque: 19.5 N.m (199 kgf/cm, 14 ft.lbf) 

      2. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

        Stud Bolt (B) 

        Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

  7. INSTALL NO. 3 WITH HEAD STRAIGHT SCREW PLUG 
    1. GTY1077811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply adhesive to the 3 No. 3 with head straight screw plugs.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      2. Using a 6 mm hexagon socket wrench, install the 3 No. 3 with head straight screw plugs to the cylinder head sub-assembly.

        Torque: 25 N.m (255 kgf/cm, 18 ft.lbf) 

        NOTE:

        Do not add engine oil for at least 1 hour after the installation.

  8. INSTALL NO. 2 WITH HEAD STRAIGHT SCREW PLUG 
    1. GTY1076153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 14 mm straight hexagon wrench, install a new gasket and No. 2 with head straight screw plug to the cylinder head sub-assembly.

        Torque: 80 N.m (816 kgf/cm, 59 ft.lbf) 

  9. INSTALL NO. 1 WITH HEAD STRAIGHT SCREW PLUG 
    1. GTY1078459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 14 mm straight hexagon wrench, install a new gasket and No. 1 with head straight screw plug to the cylinder head sub-assembly.

        Torque: 80 N.m (816 kgf/cm, 59 ft.lbf) 

  10. INSTALL INTAKE VALVE SPRING SEAT 
  11. INSTALL EXHAUST VALVE SPRING SEAT 
  12. INSTALL INTAKE VALVE STEM OIL SEAL 
    1. GTY1076303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Intake Valve Stem Oil Seal *b Exhaust Valve Stem Oil Seal
      *c Gold *d Gray
      *e Correct *f Incorrect
      1. Apply a light coat of engine oil to 8 new intake valve stem oil seals.
        NOTE:

        Make sure to install each valve stem oil seal to the correct side. Installing an intake valve stem oil seal to the exhaust side or installing an exhaust valve stem oil seal to the intake side can cause installation problems later.

        HINT: 

        The intake valve stem oil seals are gold and the exhaust valve stem oil seals are gray.

      2. Using SST, push in the 8 intake valve stem oil seals.
        • SST: 09201-41020 
        NOTE:

        Do not push in the valve stem oil seals at an angle.

  13. INSTALL EXHAUST VALVE STEM OIL SEAL 
    1. Perform the same procedure as for the intake valve stem oil seal.
  14. INSTALL INTAKE VALVE 
    1. GTY1076255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 30 mm (1.18 in.) or more - -
      1. Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration.
      2. Install the 8 intake valves.
  15. INSTALL EXHAUST VALVE 
    1. Perform the same procedure as for the intake valve.
  16. INSTALL INTAKE VALVE COMPRESSION SPRING 
    NOTE:

    Make sure to install the compression springs with the taper side (valve spring retainer side) facing up.
    1. GTY1076587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL EXHAUST VALVE COMPRESSION SPRING 
    1. Perform the same procedure as for the intake valve compression spring.
  18. INSTALL VALVE SPRING RETAINER 
  19. INSTALL VALVE SPRING RETAINER LOCK 
    1. GTY1076540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST, install the 16 valve spring retainer locks.
        • SST: 09202-70020 
          1. 09202-01010
          2. 09202-01020
        • SST: 09202-00021 
      2. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
        NOTE:
        • Be careful not to damage the valve stem tip.
        • Be careful not to damage the valve spring retainer.
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