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Reassembly [01/2019 - ]: 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.
      GTY607949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Application Width
      *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.

      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.

      GTY941563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
      *b Protrusion Height
  2. INSTALL NO. 2 STRAIGHT SCREW PLUG 

    HINT: 

    If coolant leaks from a No. 2 straight screw plug or a 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 to the cylinder head sub-assembly.

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

      GTY588155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL VALVE SPRING SEAT 
    1. Install the 16 valve spring seats to the cylinder head sub-assembly.
  4. INSTALL VALVE STEM OIL SEAL 
    1. Apply a light coat of engine oil to 16 new valve stem oil seals.
      NOTE:

      Pay attention when installing the intake 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: 

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

      GTY544443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Intake Side
      *b Exhaust Side
      *c Gray
      *d Black
    2. Using SST, push in the 16 valve stem oil seals.
      • SST: 09201-41020 
      NOTE:
      • Failure to use SST will cause the intake valve stem oil seal to be damaged or improperly seated.
      • Do not push in the intake valve stem oil seals at an angle.
      GTY550046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
  5. INSTALL EXHAUST VALVE 
    1. Sufficiently apply engine oil to the tip area of the exhaust valve shown in the illustration.
      GTY567399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 30 mm (1.18 in.) or more
    2. Install the 8 exhaust valves, 8 inner compression springs and 8 valve spring retainers to the cylinder head sub-assembly.
      GTY602098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inner Compression Spring
      *2 Valve Spring Retainer
      *3 Cylinder Head Sub-assembly
      Top 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 their original locations.
    3. Using SST and wooden blocks, 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 
      GTY610340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    4. 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.
      GTY565896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Hammer
      *b Wooden Block
  6. INSTALL INTAKE VALVE 
    1. GTY580258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 30 mm (1.18 in.) or more

      Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration.

    2. Install the 8 intake valves, 8 inner compression springs and 8 valve spring retainers to the cylinder head sub-assembly.
      GTY602098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inner Compression Spring
      *2 Valve Spring Retainer
      *3 Cylinder Head Sub-assembly
      Top 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 their original locations.
    3. Using SST and wooden blocks, 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 
      GTY573024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    4. 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.
      GTY542832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Hammer
      *b Wooden Block
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