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Reassembly [11/2022 - ]: Procedure

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  1. INSTALL INTAKE VALVE GUIDE BUSH 
    1. GTY1029212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-assembly.

        Standard Intake Valve Guide Bush Bore Diameter

        10.285 to 10.306 mm (0.405 to 0.406 in.)

        Bush Size Specified Condition
        STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
        O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

        Standard Bush Length

        41.3 to 41.7 mm (1.63 to 1.64 in.)

        HINT: 

        • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the intake valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 intake valve guide bush.
        • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.
      2. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
        WARNING:

        Be sure to wear protective gloves.

      3. Using SST and a hammer, tap in the selected intake valve guide bush.
        • SST: 09201-10000 
          1. 09201-01050
        • SST: 09950-70010 
          1. 09951-07100

        Standard Protrusion Height

        13.35 to 13.60 mm (0.526 to 0.535 in.)

      4. Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the standard oil clearance.

        Standard Oil Clearance

        0.025 to 0.060 mm (0.000984 to 0.00236 in.)

  2. INSTALL EXHAUST VALVE GUIDE BUSH 
    1. GTY1029209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-assembly.

        Standard Intake Valve Guide Bush Bore Diameter

        10.285 to 10.306 mm (0.405 to 0.406 in.)

        Bush Size Specified Condition
        STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
        O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

        Standard Bush Length

        43.3 to 43.7 mm (1.70 to 1.72 in.)

        HINT: 

        • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the intake valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 intake valve guide bush.
        • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.
      2. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
        WARNING:

        Be sure to wear protective gloves.

      3. Using SST and a hammer, tap in the selected intake valve guide bush.
        • SST: 09201-10000 
          1. 09201-01050
        • SST: 09950-70010 
          1. 09951-07100

        Standard Protrusion Height

        13.75 to 14.00 mm (0.541 to 0.551 in.)

      4. Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the standard oil clearance.

        Standard Oil Clearance

        0.030 to 0.065 mm (0.00118 to 0.00256 in.)

  3. INSTALL SPARK PLUG TUBE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 HINT: 
    When using a new cylinder head sub-assembly, the spark plug tubes must be replaced.
    1. GTY1029152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 1.0 to 7.0 mm (0.0394 to 0.276 in.) *b 1.0 mm (0.0394 in.)
      *c Protrusion Height - -
      1. Apply adhesive to 4 new spark plug tubes as shown in the illustration.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        NOTE:
        • Install the spark plug tubes within 3 minutes of applying adhesive.
        • Be careful not to deform the spark plug tubes.
        • Do not expose the spark plug tubes to engine oil for at least 1 hour after installing them.
      2. Using a wooden block and hammer, tap in the 4 spark plug tubes to the specified protrusion height.

        Standard Protrusion Height

        77.3 to 78.3 mm (3.04 to 3.08 in.)

        NOTE:

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

  4. INSTALL RING PIN 
    1. GTY1029249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a plastic hammer, tap in 2 new ring pins to the specified protrusion height.

        Standard Protrusion Height

        6.5 to 7.5 mm (0.256 to 0.295 in.)

  5. INSTALL STUD BOLT 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.
    1. GTY1029078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 20 mm (0.787 in.) *b 13 mm (0.512 in.)
      *c 35 mm (1.38 in.) - -
      1. Using an E8 "TORX" socket wrench, install the 7 stud bolts.

        Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

  6. INSTALL NO. 1 STRAIGHT SCREW PLUG 
    1. GTY1029106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply adhesive to the 4 No. 1 straight screw plugs.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        NOTE:

        Install the No. 1 straight screw plugs within 3 minutes of applying adhesive.

      2. Using a 6 mm hexagon wrench, install the 4 No. 1 straight screw plugs to the cylinder head sub-assembly.

        Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

  7. INSTALL INTAKE VALVE SPRING SEAT (for Intake Side) 
  8. INSTALL EXHAUST VALVE SPRING SEAT (for Exhaust Side) 
  9. INSTALL INTAKE VALVE STEM OIL SEAL (for Intake Side) 
    1. GTY1029254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Intake Valve Stem Oil Seal *b Exhaust Valve Stem Oil Seal
      *c Gray *d Black
      *e Correct *f Incorrect
      1. Apply a light coat of engine oil to 8 new valve stem oil seals.
        NOTE:

        Make sure to install each valve stem oil seal to the correct side. Installing an intake valve stem oil seal to the exhaust side or installing an exhaust valve stem oil seal to the intake side can cause installation problems later.

        HINT: 

        The intake valve stem oil seals are gold and the exhaust valve stem oil seals are gray.

      2. Using SST, push in the 8 valve stem oil seals.
        • SST: 09201-41020 
        NOTE:
        • Failure to use SST will cause the valve stem oil seals to be damaged or improperly seated.
        • Do not push in the valve stem oil seals at an angle.
  10. INSTALL EXHAUST VALVE STEM OIL SEAL (for Exhaust Side) 
    1. Perform the same procedure as for the intake side.
  11. INSTALL INTAKE VALVE 
    1. GTY1030583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 30 mm (1.18 in.) or more - -
      1. Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration.
      2. Install the 8 intake valves to the cylinder head sub-assembly.
  12. INSTALL EXHAUST VALVE 
    1. Perform the same procedure as for the intake side.
  13. INSTALL INTAKE VALVE COMPRESSION SPRING (for Intake Side) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 their original locations.
  14. INSTALL EXHAUST VALVE COMPRESSION SPRING (for Exhaust Side) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 their original locations.
  15. INSTALL VALVE SPRING RETAINER 
  16. INSTALL VALVE SPRING RETAINER LOCK 
    1. GTY1029166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST, compress the inner compression spring and install the 8 valve spring retainer locks.
        • SST: 09202-70020 
          1. 09202-01010
          2. 09202-01020
        • SST: 09202-00021 
      2. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
        NOTE:
        • Be careful not to damage the valve stem tip.
        • Be careful not to damage the valve spring retainer.
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