Cylinder Head ASSY (3MZ-FE): Overhaul

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE W/HEAD STRAIGHT SCREW PLUG NO. 1 (RH CYLINDER)
1. Using a straight hexagon wrench 14, remove the 2 screw plugs.
REMOVE W/HEAD STRAIGHT SCREW PLUG NO. 2 (LH CYLINDER)
1. Using a straight hexagon wrench 14, remove the 2 screw plugs.
REMOVE VALVE LIFTER
HINT:

Store the lifters in the correct order so that they can be returned to the original locations when reassembling.
REMOVE INTAKE VALVE
1. Using SST, compress the spring, then remove the 2 retainer locks, retainer, spring and valve.
  SST 09202-70020 (09202-00010)
  
  Fig 1: Compressing Spring Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Store the valves, springs, seats and retainers in the correct order so that they can be returned to the original locations when reassembling.
REMOVE EXHAUST VALVE
1. Using SST, compress the spring, then remove the 2 retainer locks, retainer, spring and valve.
  SST 09202-70020 (09202-00010)
  
  Fig 2: Compressing Spring Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Store the valves, springs, seats and retainers in the correct order so that they can be returned to the original locations when reassembling.
REMOVE VALVE STEM OIL O SEAL OR RING
1. Using needle-nose pliers, remove the oil seal.
REMOVE VALVE SPRING SEAT
REMOVE SEMI-CIRCULAR PLUG
INSPECT CYLINDER HEAD FOR FLATNESS
1. Using a precision straight edge and feeler gauge, measure the warpage on the surfaces which contacts the cylinder block and manifolds.
  Maximum warpage:
  
  0.05 mm (0.0020 in.) for cylinder block surface
  
  0.10 mm (0.0039 in.) for intake manifold surface
  
  0.10 mm (0.0039 in.) for exhaust manifold surface
  
  If the warpage is greater than maximum, replace the cylinder head.
  
  Fig 3: Measuring Warpage On Surfaces Of Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD FOR CRACKS
1. Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
  If cracked, replace the cylinder head.
  
  Fig 4: Checking Combustion Chamber Using Dye Penetrate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTAKE VALVE
1. Inspect the valve overall length.
  Standard overall length: 95.45 mm (3.7579 in.)
  
  Minimum overall length: 94.95 mm (3.7382 in.)
  
  If the overall length is less than minimum, replace the valve.
  
  Fig 5: Identifying Length Of Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of the valve stem.
  Valve stem diameter:
  
  5.470 to 5.485 mm (0.2154 to 0.2159 in.)
  
  Fig 6: Measuring Diameter Of Valve Stem Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect the valve head margin thickness.
  Standard margin thickness: 1.0 mm (0.039 in.)
  
  Minimum margin thickness: 0.5 mm (0.020 in.)
  
  If the margin thickness is less than minimum, replace the valve.
  
  Fig 7: Identifying Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST VALVE
1. Inspect the valve overall length.
  Standard overall length: 95.40 mm (3.7559 in.)
  
  Minimum overall length: 94.90 mm (3.7362 in.)
  
  If the overall length is less than minimum, replace the valve.
  
  Fig 8: Identifying Valve Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of the valve stem.
  Valve stem diameter:
  
  5.465 to 5.480 mm (0.2152 to 0.2157 in.)
  
  Fig 9: Measuring Diameter Of Valve Stem Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect the valve head margin thickness.
  Standard margin thickness: 1.0 mm (0.039 in.)
  
  Minimum margin thickness: 0.5 mm (0.020 in.)
  
  If the margin thickness is less than minimum, replace the valve.
  
  Fig 10: Identifying Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INNER COMPRESSION SPRING
1. Using vernier calipers, measure the free length of the spring.
  Free length: 45.50 mm (1.7913 in.)
  
  If the free length is not as specified, replace the spring.
  
  Fig 11: Measuring Free Length Of Spring Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a steel square, measure the deviation of the spring.
  Maximum deviation: 2.0 mm (0.079 in.)
  
  If the deviation is greater than maximum, replace the spring.
  
  Fig 12: Measuring Deviation Of Spring Using Steel Square
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a spring tester, measure the tension of the spring when the spring is the specified installed length.
  Installed tension:
  
  186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at 33.8 mm (1.331 in.)
  
  If the installed tension is not as specified, replace the spring.
  
  Fig 13: Measuring Tension Of Spring Using Spring Tester
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE GUIDE BUSHING OIL CLEARANCE
1. Using a caliper gauge, measure the inside diameter of the valve guide bushing.
  Bushing inside diameter:
  
  5.510 to 5.530 mm (0.2169 to 0.2177 in.)
2. Subtract the valve stem diameter measurement from the valve guide bushing inside diameter measurement.
  Standard oil clearance:
  
  0.025 to 0.060 mm (0.0010 to 0.0024 in.) for intake
  
  0.030 to 0.065 mm (0.0012 to 0.0026 in.) for exhaust
  
  Maximum oil clearance:
  
  0.08 mm (0.0031 in.) for intake
  
  0.10 mm (0.0039 in.) for exhaust
  
  If the clearance is greater than maximum, replace the valve and valve guide bushing.
  
  Fig 14: Measuring Inside Diameter Of Valve Guide Bushing Using Caliper Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE GUIDE BUSHING
1. Heat the cylinder head up to 80 to 100 °C (176 to 212 °F).
  
  Fig 15: Heating Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the valve guide bushing.
  SST 09201-10000, 09201-01055, 09950-70010 (09951-07100)
  
  Fig 16: Taping Out Valve Guide Bushing Using SST And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE GUIDE BUSHING
1. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
  Diameter: 10.295 to 10.313 mm (0.4053 to 0.4060 in.)
  
  Fig 17: Measuring Bushing Bore Diameter Of Cylinder Head Using Caliper Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the bushing bore diameter of the cylinder head is greater than 10.313 mm (0.4060 in.), machine the bushing bore to the dimension of 10.345 to 10.363 mm (0.4073 to 0.4080 in.).
  
  HINT:
  
  Bushing diameter:
  
  Fig 18: Identifying Intake And Exhaust Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bushing length:
  
  Fig 19: Bushing Diameter Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Heat the cylinder head up to 80 to 100 °C (176 to 212 °F).
  
  Fig 20: Bushing Length Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, tap in a new valve guide bushing to the specified protrusion height.
  SST 09201-10000, 09201-01055, 09950-70010 (09951-07100)
  
  Protrusion height:
  
  11.1 to 11.5 mm (0.437 to 0.453 in.) for intake
  
  8.9 to 9.3 mm (0.350 to 0.366 in.) for exhaust
  
  Fig 21: Taping In Valve Guide Bushing Using Hammer And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a sharp 5.5 mm reamer, ream the valve guide bushing to obtain the standard specified clearance between the valve guide bushing and valve stem.
  Standard oil clearance:
  
  0.025 to 0.060 mm (0.0010 to 0.0024 in.) for intake
  
  0.030 to 0.065 mm (0.0012 to 0.0026 in.) for exhaust
  
  Fig 22: Reaming Valve Guide Bushing Using Reamer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE SEATS
1. Apply a light coat of Prussian blue (or white lead) to the valve face.
2. Lightly press the valve against the seat.
  NOTE: Do not rotate the valve.
3. Check the valve face and seat according to the following procedure.
  1. If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
  2. If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
  3. Check that the seat contact is in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 to 0.055 in.).
    
    Fig 23: Identifying Width Of Valve
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPAIR VALVE SEATS
NOTE: Releasing the seat cutter pressure gradually helps to make smoother valve seat faces.
1. If the seating is too high on the valve face, use the 30° and 45°Cutters to correct the seat.
  
  Fig 24: Identifying Valve Face Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the seating is too low on the valve face, use the 60° and 45°Cutters to correct the seat.
3. Lap the valve and valve seat by hand with an abrasive compound.
4. Recheck the valve seating position.
  
  Fig 25: Identifying Valve Face Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE LIFTER
1. Using a micrometer, measure the lifter diameter.
  Lifter diameter:
  
  30.966 to 30.976 mm (1.2191 to 1.2195 in.)
  
  Fig 26: Measuring Lifter Diameter Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE LIFTER OIL CLEARANCE
1. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
  Lifter bore diameter:
  
  31.009 to 31.025 mm (1.2208 to 1.2215 in.)
2. Subtract the lifter diameter measurement from the lifter bore diameter measurement.
  Standard oil clearance:
  
  0.033 to 0.059 mm (0.0013 to 0.0023 in.)
  
  Maximum oil clearance: 0.07 mm (0.0028 in.)
  - If the oil clearance is greater than maximum, replace the valve lifter.
  - If necessary, replace the cylinder head.
INSPECT CAMSHAFT GEAR BACKLASH
1. Install the camshaft timing gear.
2. Install the camshafts to the cylinder head.
  NOTE:
  - Install the camshafts with the valves and sub gear removed.
  - Install the camshafts with their timing marks matched.
    
    Fig 27: Measuring Lifter Bore Diameter Of Cylinder Head Using Caliper Gauge
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the dial indicator to the teeth of the intake camshaft at a right angle (90°).
4. Measure the backlash of the camshaft timing gear at least 4 positions.
  Standard backlash:
  
  0.020 to 0.200 mm (0.0008 to 0.0079 in.)
  
  Maximum backlash: 0.30 mm (0.0118 in.)
INSPECT CAMSHAFT THRUST CLEARANCE
1. Install the camshafts.
  
  Fig 28: Locating Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
  Standard thrust clearance:
  
  0.040 to 0.090 mm (0.0016 to 0.0035 in.)
  
  Maximum thrust clearance: 0.12 mm (0.0047 in.)
  - If the thrust clearance is greater than maximum, replace the camshaft.
  - If necessary, replace the bearing caps and cylinder head together.
INSPECT CAMSHAFT OIL CLEARANCE
1. Clean the bearing caps and camshaft journals.
2. Clean the camshafts.
3. Place the camshafts on the cylinder head.
  
  Fig 29: Measuring Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Lay a strip of Plastigage across each of the camshaft journals.
5. Install the bearing caps.
  Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)
  
  NOTE: Do not turn the camshaft.
6. Remove the bearing caps.
  
  Fig 30: Laying Strip Of Plastigage Across Each Camshaft Journals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Measure the Plastigage at its widest point.
  Standard oil clearance:
  
  Intake #4, #5 journals
  
  0.025 to 0.057 mm (0.0010 to 0.0022 in.)
  
  Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
  
  Maximum oil clearance 0.10 mm (0.0039 in.)
  - If the oil clearance is greater than maximum, replace the camshaft.
  - If necessary, replace the bearing caps and cylinder head together.
  NOTE: Completely remove the Plastigage.
  
  Fig 31: Measuring Plastigage At Its Widest Point
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RING W/HEAD PIN (RH CYLINDER)
1. Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
  Protrusion height: 3 mm (0.12 in.)
  
  Fig 32: Identifying RH Cylinder Protrusion Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RING PIN (LH CYLINDER)
1. Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
  Protrusion height: 3 mm (0.12 in.)
  
  Fig 33: Identifying LH Cylinder Protrusion Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG TUBE
1. Using paint, mark the standard height from the edge.
  Standard protrusion height:
  
  42.4 to 43.4 mm (1.669 to 1.709 in.)
  
  HINT:
  
  Use either end of the spark plug tube.
2. Apply adhesive to the end of the spark plug tube which will be pressed into the cylinder head.
  Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
  NOTE:
  - Install the spark plug tube within 3 minutes after applying adhesive.
  - Do not deform the spark plug tube.
  - Do not expose the spark plug tube to coolant within 1 hour after installing.
    
    Fig 34: Identifying Paint Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a press and wooden block, install the spark plug tube to the required protrusion height.
  NOTE: Be careful not to drip the adhesive.
  
  Fig 35: Installing Spark Plug Tube Using Press And Wooden Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PCV PIPE (RH CYLINDER)
1. Using a wooden block and hammer, tap in 2 new PCV pipes until their top edges are flush with the cylinder head edge.
  NOTE: Be careful not to damage the cylinder head edge.
  
  Fig 36: Taping In 2 PCV Pipes Using Wooden Block And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STUD BOLT
1. Install the stud bolts on the intake side.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
  
  Fig 37: Identifying RH Cylinder Stud Bolt Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STUD BOLT
1. Install the stud bolts on the exhaust side.
  Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
  
  Fig 38: Identifying LH Cylinder Stud Bolt Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE STEM OIL O SEAL OR RING
1. Apply a light coat of engine oil to the valve stem.
  NOTE: Installing the oil seals for intake and exhaust to the opposite valve guide bushing may cause an improper installation.
  
  HINT:
  
  The intake valve oil seal is light brown and the exhaust valve oil seal is gray.
  
  Fig 39: Identifying Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, push in a new oil seal.
  SST 09201-41020
  
  NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
  
  Fig 40: Pushing In Oil Seal Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE VALVE
1. Install the valve, seat, spring, and retainer.
  NOTE: Install the same parts in the same combination to the original locations.
  
  Fig 41: Installing Valve Seat Spring And Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, compress the spring and place the 2 retainer locks around the valve stem.
  SST 09202-70020 (09202-00010)
  
  Fig 42: Compressing Spring Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer and discarded valve (the tip is wrapped with tape), lightly tap the installed valve to fit into place.
  NOTE: Be careful not to damage the installed valve stem tip.
  
  Fig 43: Taping Installed Valve Using Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST VALVE
1. Install the valve, seat, spring, and retainer.
  NOTE: Install the same parts in the same combination to the original locations.
  
  Fig 44: Installing Exhaust Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, compress the spring and place the 2 retainer locks around the valve stem.
  SST 09202-70020 (09202-00010)
  
  Fig 45: Compressing Spring Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer and discarded valve (the tip is wrapped with tape), lightly tap the installed valve to fit into place.
  NOTE: Be careful not to damage the installed valve stem tip.
INSTALL VALVE LIFTER
1. Apply a light coat of engine oil to the valve lifter.
  NOTE: Install the same parts in the same combination to the original locations.
2. Install the valve lifter.
3. Check that the valve lifter is rotated smoothly by hand.
  
  Fig 46: Taping Installed Valve Using Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SEMICIRCULAR PLUG
1. Remove any old seal packing material.
2. Apply seal packing to the plug grooves.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 47: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 2 plugs to the cylinder heads.
  NOTE:
  - Install the plugs so that they are flush with the top of the cylinder head.
  - Install the plugs within 3 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
    
    Fig 48: Identifying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL W/HEAD STRAIGHT SCREW PLUG NO. 1 (RH CYLINDER)
1. Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
  Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
INSTALL W/HEAD STRAIGHT SCREW PLUG NO. 2 (LH CYLINDER)
1. Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs.
  Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)