Cylinder Head: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.

INSTALL VALVE STEM OIL SEAL
1. Using SST, push in a new oil seal.
  SST 09201-41020
  
  Fig 1: Installing Valve Stem Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The intake valve oil seal is gray and the exhaust valve oil seal is black.
  
  NOTE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later.
  
  Fig 2: Identifying Intake And Exhaust Valve Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE VALVE
1. Place the cylinder head on wooden blocks.
2. Install the valve, seat, spring and retainer onto the cylinder head.
  
  Fig 3: Identifying Valve, Seat, Spring And Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, compress the spring, and place the 2 retainer locks around the valve stem.
  SST 09202-70020 (09202-00010)
  
  Fig 4: Compressing Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic-faced hammer and discarded valve (with its tip wrapped with tape), lightly tap the installed valve to fit it into place.
  NOTE: Be careful not to damage the valve stem tip.
INSTALL EXHAUST VALVE
1. Place the cylinder head on wooden blocks.
  
  Fig 5: Tapping Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the valve, seat, spring and retainer onto the cylinder head.
  
  Fig 6: Identifying Valve, Seat, Spring And Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, compress the spring, and place the 2 retainer locks around the valve stem.
  SST 09202-70020 (09202-00010)
  
  Fig 7: Compressing Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic-faced hammer and discarded valve (with its tip wrapped with tape), lightly tap the installed valve to fit it into place.
  NOTE: Be careful not to damage the valve stem tip.
  
  Fig 8: Tapping Valve Lifter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE LIFTER
1. Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied.
  NOTE: Install the valve lifters in their original places.
INSTALL NO. 1 CAMSHAFT BEARING
1. Clean the contact surface of the bearing and the bearing cap.
  NOTE: Do not apply engine oil to the contact surfaces of the camshaft bearing and bearing cap.
2. Align the bearing claw with the claw groove of No. 1 and No. 2 bearing cap, and push in the No. 1 camshaft bearing.
  
  Fig 9: Pushing In No. 1 Camshaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CAMSHAFT BEARING
1. Clean the contact surface of the bearing and the bearing cap.
  NOTE: Do not apply engine oil to the contact surfaces of the camshaft bearing and cylinder block.
2. Install the No. 2 camshaft bearing onto the cylinder head.
  
  Fig 10: Identifying Camshaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT POSITION SENSOR
1. Install the camshaft position sensor with the bolt.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 11: Identifying Camshaft Position Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
1. Using SST, install a new gasket and the ECT sensor.
  SST 09817-33190
  
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 12: Identifying ECT Sensor & Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PRESSURE SWITCH
1. Apply adhesive to 2 or 3 threads of the oil pressure switch.
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
2. Using a 24 mm deep socket wrench, install the oil pressure switch.
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  
  Fig 13: Identifying Oil Pressure Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIO SETTING CONDENSER
1. Install the condenser with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 14: Identifying Radio Setting Condenser
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002