Cylinder Head: Reassembly

1. Install the gear spring (1), sub-gear (2) and wave washer (3).

   HINT:

   Attach the pins on the gears to the gear bolt washer ends.

   Fig 1: Installing Gear Spring, Sub-Gear & Wave Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using snap ring pliers, install the snap ring.
   Fig 2: Installing Snap Ring Using Snap Ring Pliers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mount the hexagon head portion of the camshaft in a vise.
   NOTE: Be careful not to damage the camshaft.
   Fig 3: Mounting Hexagon Head Portion Of Camshaft In Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, align the holes of the driven main gear and sub-gear by turning the-sub gear clockwise, and temporarily install a service bolt.

   SST 09960-10010 (09962-01000, 09963-00500) 

   Fig 4: Aligning Holes Of Driven Main Gear & Sub-Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Align the gear teeth of the driven main gear and sub-gear, and tighten the service bolt.

   Recommended service bolt 

   SERVICE BOLT
   
   

   Thread Diameter	Thread Pitch	Bolt Length
   6 mm	1.0 mm	16 to 20 mm (0.63 to 0.79 in.)

1. Insert a new oil seal into the camshaft timing tube until it reaches the stopper.
   NOTE:

   • Be careful of the installation direction.
   • Do not turn over the lip of the oil seal.
     Fig 5: Inserting New Oil Seal Into Camshaft Timing Tube

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
3. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.

   SST 09960-10010 (09962-01000, 09963-00500) 

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

   NOTE: Be careful not to damage the timing tube.
   Fig 6: Tightening Bolts Using SST & Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount the hexagon head portion of the camshaft in a vise.
   NOTE: Be careful not to damage the camshaft.
   Fig 7: Mounting Hexagon Head Portion Of Camshaft In Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
6. Using a 10 mm hexagon wrench, install the bolt.

   Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 

   Fig 8: Tightening Bolt Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the seal washer and screw plug.

   Torque: 15 N*m (152 kgf*cm, 11 ft.*lbf) 

HINT:

When using a new cylinder head, the spark plug tubes must be installed.

1. Apply adhesive to the end of the spark plug tube.

   Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. 

   NOTE:

   • Install the spark plug tube within 3 minutes after applying adhesive.
   • Be careful not to deform the spark plug tube.
   • Be careful not to expose the seal to coolant for at least 1 hour after installing it.
   Fig 9: Applying Adhesive To End Of Spark Plug Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a wooden block and hammer, tap in a new spark tube until there is 40.9 to 42.1 mm (1.610 to 1.658 in.) protruding from the camshaft bearing cap installation surface of the cylinder head.
   NOTE: To avoid tapping in a new spark plug tube too far, measure the protrusion length while tapping it.
   Fig 10: Tapping In Spark Tube Using Wooden Block & Hammer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply adhesive to the end of the spark plug tube.

   Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. 

2. Using SST and a hammer, tap in a new tight plug as shown in Fig 11.

   SST 09550-60010 (09951-00300), 09950-70010 (09951-07100) 

   Fig 11: Tapping Tight Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. 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 14: Pushing Valve Stem Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil in a new oil seal.
   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.

   HINT:

   The intake valve oil seal is gray/brown and the exhaust valve oil seal is black/gray.

   Fig 15: Applying Light Coat Of Engine Oil In Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the valve, spring seat, valve spring and spring retainer.
2. Using SST, compress the valve spring and place the 2 spring retainer locks around the valve stem.

   SST 09202-70020 (09202-00010) 

   Fig 16: Compressing Valve Spring & Installing Spring Retainer Locks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer and a discarded valve with its tip wrapped in vinyl tape, lightly tap the installed valve to ensure that it is securely fit.
   NOTE: Be careful not to damage the valve stem tip.
   Fig 17: Tapping Installed Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the valve, spring seat, valve spring and spring retainer.
   NOTE: Install the same parts in the same combination to their original locations.
2. Using SST, compress the valve spring and place the 2 spring retainer locks around the valve stem.

   SST 09202-70020 (09202-00010) 

   Fig 18: Compressing Valve Spring & Installing Spring Retainer Locks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer and a discarded valve with its tip wrapped in vinyl tape, lightly tap the installed valve to ensure that it is securely fit.
   NOTE: Be careful not to damage the valve stem tip.
   Fig 19: Lightly Tapping Installed Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the valve lifter and shim.
2. Check that the valve lifter rotates smoothly by hand.