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Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Mechanical (2ZR-FAE) - Service Information (2 Of 2) (Model Code: ZRE172)) >> Cylinder Head >> Reassembly [08/2013 - ] >> Procedure

Reassembly [08/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL SPARK PLUG TUBE 
    NOTE:

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

    1. Apply adhesive to the shaded area of a new spark plug tube.
      GTY437434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 1.0 to 3.0 mm (0.0394 to 0.118 in.)
      *b 1.0 to 13.0 mm (0.0394 to 0.512 in.)

      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.
      • Be careful not to expose the adhesive to engine oil for at least 1 hour after installing the spark plug tube.
    2. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height.
      GTY430789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cylinder Head Casting Surface

      Standard Protrusion Height

      122 mm (4.80 in.)

      NOTE:

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

  2. INSTALL NO. 2 STRAIGHT SCREW PLUG 
    NOTE:

    If water leaks from the No. 2 straight screw plug or the plug is corroded, replace it.

    1. Using a 10 mm straight hexagon wrench, install 3 new gaskets and the 3 No. 2 straight screw plugs.
      GTY449252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  3. INSTALL VALVE SPRING SEAT 
    1. Install the valve spring seats to the cylinder head sub-assembly.
  4. INSTALL VALVE STEM OIL SEAL 
    1. Apply a light coat of engine oil to a new valve stem oil seal.
      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 close attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal to the exhaust side or installing the exhaust 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 on the valve stem oil seal.
      GTY437381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
      • SST: 09201-41020 
      NOTE:

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

  5. INSTALL INTAKE VALVE 

    HINT: 

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

    Type Inner Compression Spring Shape
    A Straight
    B Tapered
    GTY693823Courtesy 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
    *4 Valve Lash Adjuster Assembly
    1. Type A:
      1. Place the cylinder head sub-assembly on wooden blocks.
      2. Apply engine oil to the tip area of the intake valve as shown in the illustration.
        GTY426980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 30 mm (1.18 in.) or more
      3. 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 the original locations.

      4. Using SST, compress the inner compression spring and install the 2 valve spring retainer lock halves.
        GTY430719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09202-70020 
          1. 09202-00010
      5. Using a plastic hammer, lightly tap the intake valve stem tip to ensure a proper fit.
        GTY161254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Be careful not to damage the intake valve stem tip.
        • Be careful not to damage the valve spring retainer.
    2. Type B:
      1. Place the cylinder head sub-assembly on wooden blocks.
      2. Apply engine oil to the tip area of the intake valve as shown in the illustration.
        GTY426980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 30 mm (1.18 in.) or more
      3. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly.
        NOTE:
        • Install the inner compression spring with its tapered side facing upward (towards the valve spring retainer).
        • Install the same parts in the same combination to the original locations.
        GTY701292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inner Compression Spring
        *2 Valve Spring Retainer
        *3 Cylinder Head Sub-assembly
        *4 Upper Side
      4. Using SST, compress the inner compression spring and install the 2 valve spring retainer lock halves.
        • SST: 09202-70020 
        • SST: 09202-00021 
        GTY492396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Wooden Block
      5. Using a plastic hammer, lightly tap the intake valve stem tip to ensure a proper fit.
        NOTE:
        • Be careful not to damage the intake valve stem tip.
        • Be careful not to damage the valve spring retainer.
        GTY473647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL EXHAUST VALVE 

    HINT: 

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

    Type Inner Compression Spring Shape
    A Straight
    B Tapered
    GTY693823Courtesy 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
    *4 Valve Lash Adjuster Assembly
    1. Type A:
      1. Place the cylinder head sub-assembly on wooden blocks.
      2. Apply engine oil to the tip area of the exhaust valve as shown in the illustration.
        GTY451985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 30 mm (1.18 in.) or more
      3. 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 the original locations.

      4. Using SST, compress the inner compression spring and install the 2 valve spring retainer lock halves.
        GTY452615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09202-70020 
          1. 09202-00010
      5. Using a plastic hammer, lightly tap the exhaust valve stem tip to ensure a proper fit.
        GTY164425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Be careful not to damage the exhaust valve stem tip.
        • Be careful not to damage the valve spring retainer.
    2. Type B:
      1. Place the cylinder head sub-assembly on wooden blocks.
      2. Apply engine oil to the tip area of the exhaust valve as shown in the illustration.
        GTY451985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 30 mm (1.18 in.) or more
      3. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head sub-assembly.
        GTY701292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inner Compression Spring
        *2 Valve Spring Retainer
        *3 Cylinder Head Sub-assembly
        *4 Upper Side
        NOTE:
        • Install the inner compression spring with its tapered side facing upward (towards the valve spring retainer).
        • Install the same parts in the same combination to the original locations.
      4. Using SST, compress the inner compression spring and install the 2 valve spring retainer lock halves.
        • SST: 09202-70020 
        • SST: 09202-00021 
        GTY492109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Wooden Block
      5. Using a plastic hammer, lightly tap the exhaust valve stem tip to ensure a proper fit.
        NOTE:
        • Be careful not to damage the exhaust valve stem tip.
        • Be careful not to damage the valve spring retainer.
        GTY473648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem ends.
    2. Install the 16 valve stem caps.

      HINT: 

      Do not drop the valve stem caps into the cylinder head sub-assembly.

  8. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Inspect each valve lash adjuster assembly before installing it.

      See step  2

    2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.
      NOTE:

      Install the valve lash adjuster assembly to the same place it was removed from.

  9. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the valve lash adjuster assembly tips and valve stem cap ends.
      GTY441299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Valve Lash Adjuster Assembly
      *2 No. 1 Valve Rocker Arm Sub-Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    2. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
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