Disassembly and Reassembly

CYLINDER HEAD

COMPONENTS:

DISASSEMBLY
1. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1
(a) Using a 14 mm straight hexagon wrench, remove the 2 screw plugs.
2. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2
(a) Using a 14 mm straight hexagon wrench, remove the 2 screw plugs.
3. REMOVE VALVE LIFTER

HINT: The lifters must be returned to their original locations when reassembling.

4. REMOVE INTAKE VALVE
(a) Using SST, compress the valve spring and remove the 2 retainer locks, retainer, spring, seat and valve.
SST 09202-70020 (09202-00010)

HINT: The valves, spring seat, valve springs, spring retainers and retainer locks must be returned to their original locations when reassembling.

5. REMOVE EXHAUST VALVE
(a) Using SST, compress the valve spring and remove the 2 retainer locks, retainer, spring, seat and valve.
SST 09202-70020 (09202-00010)

HINT: The valves, spring seat, valve springs, spring retainers and retainer locks must be returned to their original locations when reassembling.

6. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the oil seal.
7. REMOVE VALVE SPRING SEAT
8. REMOVE SEMICIRCULAR PLUG

9. REMOVE VALVE GUIDE BUSHING
(a) Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

(b) Using SST and a hammer, tap out the guide bushing.
SST 09201-10000, 09201-01055, 09950-70010 (09951-07100)

REASSEMBLY

1. INSTALL VALVE GUIDE BUSHING
(a) Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
Diameter: 10.295 to 10.313 mm (0.4053 to 0.4060 inch)
If the bushing bore diameter of the cylinder head is greater than 10.313 mm (0.4060 inch), machine the bushing bore to the dimension of 10.345 to 10.363 mm (0.4073 to 0.4080 inch).

Bushing Diameter:

HINT: Different bushes are used for the intake and exhaust.

Bushing Length:

(b) Heat the cylinder head to approximately 80 to 100°C (176 to 212°F)
(c) Using SST and a hammer, tap in a new guide bushing to the specified protrusion height.
SST 09201-10000, 09201-01055, 09950-70010 (09951-07100)

Protrusion Height:

(d) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and the valve stem.

Standard Oil Clearance:

2. INSTALL RING W/HEAD PIN
(a) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
Protrusion height: 3 mm (0.12 inch)

3. INSTALL RING PIN
(a) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height.
Protrusion height: 3 mm (0.12 inch)

4. INSTALL SPARK PLUG TUBE
(a) Using paint, mark the standard position from the edge.
Standard protrusion height: 42.4 to 43.4 mm (1.669 to 1.709 inch)

HINT: Use either end of the spark plug tube.

(b) Apply adhesive to the spark plug tube where it will be pressed into the cylinder head.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:
^ Install the spark plug tube within 3 minutes after applying adhesive.
^ Do not deform the spark plug tube.
^ Do not expose the seal to coolant for at least 1 hour after installing.

(c) Using a press and wooden block, install the spark plug tube to the required protrusion height.

NOTICE: Be careful not to drip the adhesive.

5. INSTALL PCV PIPE
(a) Using a wooden block and hammer, tap in 2 new PCV pipes until their top edges are flush with the cylinder head edge.

NOTICE: Be careful not to damage the cylinder head edge.

6. INSTALL STUD BOLT
(a) Install the stud bolts on the intake side.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
7. INSTALL STUD BOLT
(a) Install the stud bolts on the exhaust side.
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)

8. INSTALL VALVE STEM OIL SEAL
(a) Apply a light coat of engine oil on the valve stem.

NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later.

HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray.

(b) Using SST, push in a new oil seal.
SST 09201-41020

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

9. INSTALL INTAKE VALVE
(a) Install the valve, spring seat, valve spring and spring retainer.

NOTICE: Install the same part in the same combination to the original locations.

(b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem.
SST 09202-70020 (09202-00010)

10. INSTALL EXHAUST VALVE
(a) Install the valve, spring seat, valve spring and spring retainer.

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

(b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem.
SST 09202-70020 (09202-00010)

(c) Using a plastic-faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit.

NOTICE: Be careful not to damage the installed valve stem tip.

11. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil on the valve lifter.

NOTICE: Install the same part in the same combination to the original locations.

(b) Install the valve lifter.
(c) Check that the valve lifter rotates smoothly by hand.

12. INSTALL SEMICIRCULAR PLUG
(a) Remove any old seal packing (FIPG) material.
(b) Apply seal packing to the semi circular plug grooves.
Seal packing: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(c) Install the 2 semi-circular plugs to the cylinder heads.

NOTICE:
^ Install the plugs so that it is flush with the top of the cylinder head.
^ Install the semi circular plugs within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

13. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2
(a) Using a 14 mm straight hexagon wrench, install 2 new gaskets and the 2 screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
14. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1
(a) Using a 14 mm straight hexagon wrench, install 2 new gaskets and the 2 screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)