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Home >> Toyota >> 2015 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FE) (Service Information) (Except Hybrid) (2 Of 2) >> Cylinder Head >> Reassembly [08/2014 - 11/2016] >> Procedure

Reassembly [08/2014 - 11/2016]: Procedure

  1. INSTALL SPARK PLUG TUBE 

    HINT: 

    When using a new cylinder head sub-assembly, the spark plug tubes must be replaced.

    1. Apply adhesive to a new spark plug tube as shown in the illustration.
      GTY455249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

      Standard Application Width

      1.0 to 3.0 mm (0.0394 to 0.118 in.)

      NOTE:
      • Install the spark plug tube within 3 minutes of applying adhesive.
      • Be careful not to deform the spark plug tube.
      • Do not expose the spark plug tube to engine oil for at least 1 hour after installing it.
    2. Using a wooden block and hammer, tap in the spark plug tube.
      GTY443535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cylinder Head Top Surface

      Standard Protrusion Height

      72.9 mm (2.87 in.)

      NOTE:

      To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.

  2. INSTALL NO. 1 STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs.
      GTY424754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      *B for Bank 2

      Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

  3. INSTALL NO. 2 STRAIGHT SCREW PLUG 
    1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs.
      GTY456015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      *B for Bank 2

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

  4. INSTALL VALVE SPRING SEAT 
    1. Install the valve spring seat to the cylinder head sub-assembly.
  5. INSTALL VALVE STEM OIL SEAL 
    1. Apply a light coat of engine oil to new valve stem oil seals.
      GTY426917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Intake Side *B for Exhaust Side
      *a Gray
      (for Intake Side)      		 *b Black
      (for Intake Side)
      *c Black
      (for Exhaust Side)      		 *d Gray
      (for Exhaust Side)
      NOTE:

      Pay attention when installing the valve stem oil seals. For example, installing an intake side valve stem oil seal to the exhaust side or installing an exhaust side valve stem oil seal to the intake side can cause installation problems later.

      HINT: 

      • for Intake Side

        The intake side valve stem oil seals is gray or black.

      • for Exhaust Side

        The exhaust side valve stem oil seals is black or gray.

    2. Using SST, push in the valve stem oil seals.
      GTY445560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
      • SST: 09201-41020 
      NOTE:

      Failure to use SST will cause the valve stem seal to be damaged or improperly seated.

  6. INSTALL EXHAUST VALVE 
    GTY479604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Inner Compression Spring
    *a Valve Spring Retainer Diameter
    *b No. 1 Valve Rocker Arm Sub-assembly Roller Width

    HINT: 

    Type A and Type B can be distinguished by the shape of the compression spring.

    Type No. 1 Valve Rocker Arm Sub-assembly Roller Width Valve Spring Retainer Diameter Inner Compression Spring Shape
    A 10.7 mm (0.421 in.) 23.4 mm (0.921 in.) Straight
    B 8.0 mm (0.315 in.) 18.9 mm (0.744 in.) Taper
    1. Sufficiently apply engine oil to the tip area of the exhaust valve shown in the illustration.
      GTY429048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 30 mm (1.18 in.) or more
    2. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly.
      NOTE:

      Install the same parts in the same combination to their original locations.

    3. Type A:
      1. GTY443669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.

        • SST: 09202-70020 
          1. 09202-00010
          2. 09202-01010
          3. 09202-01020
      2. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
        NOTE:

        Be careful not to damage the retainer.

        GTY478300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Type B:
      1. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.
        GTY473459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inner Compression Spring
        *2 Valve Spring Retainer
        *3 Cylinder Head
        *a Up
        NOTE:
        • Install the inner compression spring with its taper side facing upward (towards the valve spring retainer).
        • Install the same parts in the same combination to the original locations.
      2. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
        GTY482022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09202-70020 
          1. 09202-01010
          2. 09202-01020
        • SST: 09202-00020 
      3. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
        GTY472733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Be careful not to damage the retainer.

  7. INSTALL INTAKE VALVE 
    GTY479604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Inner Compression Spring
    *a Valve Spring Retainer Diameter
    *b No. 1 Valve Rocker Arm Sub-assembly Roller Width

    HINT: 

    Type A and Type B can be distinguished by the shape of the compression spring.

    Type No. 1 Valve Rocker Arm Sub-assembly Roller Width Valve Spring Retainer Diameter Inner Compression Spring Shape
    A 10.7 mm (0.421 in.) 23.4 mm (0.921 in.) Straight
    B 8.0 mm (0.315 in.) 18.9 mm (0.744 in.) Taper
    1. Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration.
      GTY438488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 30 mm (1.18 in.) or more
    2. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly.
      NOTE:

      Install the same parts in the same combination to their original locations.

    3. Type A:
      1. GTY443047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.

        • SST: 09202-70020 
          1. 09202-00010
          2. 09202-01010
          3. 09202-01020
      2. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
        GTY482238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Be careful not to damage the valve spring retainer.

    4. Type B:
      1. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.
        GTY473459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inner Compression Spring
        *2 Valve Spring Retainer
        *3 Cylinder Head
        *a Up
        NOTE:
        • Install the inner compression spring with its taper side facing upward (towards the valve spring retainer).
        • Install the same parts in the same combination to the original locations.
      2. GTY482671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.

        • SST: 09202-70020 
          1. 09202-01010
          2. 09202-01020
        • SST: 09202-00020 
      3. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
        GTY472732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Be careful not to damage the valve spring retainer.

  8. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem caps.
    2. Install the valve stem caps on the valves.
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