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Reassembly [12/2015 - 08/2016]: Procedure

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  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.
      GTY863183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Application Width
      *b 9.0 to 15.0 mm (0.354 to 0.591 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 after applying adhesive.
      • 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.
      GTY847573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
      *b Protrusion Height
      *c Cylinder Head Casting 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.
      • Be careful not to deform the spark plug tube.
  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.
      GTY547086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Bank 1
      *b 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.
      GTY546493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Bank 1
      *b Bank 2

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

  4. INSTALL VALVE SPRING SEAT 
    1. Install the valve spring seats to the cylinder head.
  5. INSTALL VALVE STEM OIL SEAL 
    1. Apply a light coat of engine oil to new valve stem oil seals.
      GTY699330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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 intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into 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 in the oil seals.
      GTY302172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a CORRECT
      *b INCORRECT
      • SST: 09201-41020 
      NOTE:

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

  6. INSTALL EXHAUST VALVE 

    HINT: 

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

    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
    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. Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration.
      GTY712478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a 30 mm (1.18 in.) or more
    2. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.
      NOTE:

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

    3. Type A:
      1. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
        GTY443669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09202-70020 
          1. 09202-00010
          2. 09202-01010
          3. 09202-01020
    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: 09202-00021 
        • SST: 09202-70020 
          1. 09202-01010
          2. 09202-01020
    5. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
      GTY146656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the retainer.

  7. INSTALL INTAKE VALVE 

    HINT: 

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

    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
    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. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
      GTY720457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a 30 mm (1.18 in.) or more
    2. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.
      NOTE:

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

    3. Type A:
      1. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
        GTY443047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09202-70020 
          1. 09202-00010
          2. 09202-01010
          3. 09202-01020
    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. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
        GTY482671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09202-00021 
        • SST: 09202-70020 
          1. 09202-01010
          2. 09202-01020
    5. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
      GTY128591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the 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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