Reassembly

2AZ-FXE ENGINE MECHANICAL: CYLINDER HEAD: REASSEMBLY

REASSEMBLY

1. INSTALL INTAKE VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Cylinder bore diameter:
10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Select a new guide bush (STD or O/S 0.05).:

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.
(b) Heat the cylinder head to 80 to 100°C (176 to 212°F).
(c) Place the cylinder head on wooden blocks.

(d) Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST: 09201-10000
09201-01050
SST: 09950-70010
09951-07100
Protrusion height:
9.6 to 10.0 mm (0.3779 to 0.3937 in.)

(e) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0024 in.)
2. INSTALL EXHAUST VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Diameter:
10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Select a new guide bush (STD or O/S 0.05).:

(e) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.
Standard oil clearance:
0.030 to 0.065 mm (0.0012 to 0.0026 in.)
3. INSTALL RING PIN

(a) Using a plastic-faced hammer, tap in 4 new ring pins to the specified protrusion height.
Protrusion height:
3 mm (0.12 in.)
4. INSTALL STUD BOLT
NOTICE: If any stud bolt is deformed or the threads are damaged, replace it.

(a) Using E5 and E7 "TORX" sockets, install the stud bolts.

Bolt A - Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
Bolt A - Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
Bolt A - Torque: 9.5 Nm (97 kgf-cm, 84in-lbf)
Bolt A - Torque: 9.5 Nm (97 kgf-cm, 84in-lbf)
5. INSTALL NO. 1 STRAIGHT SCREW PLUG

(a) Using a 14 mm straight hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
Torque: 86 Nm (879 kgf-cm, 64ft-lbf)
6. INSTALL VALVE SPRING SEAT

(a) Install the valve spring seats to the cylinder head.
7. INSTALL VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to new oil seals.
NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.
HINT: The intake valve oil seal is gray and the exhaust valve oil seal is black.

(b) Using SST, push in the oil seal.
SST: 09201-41020
NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated.

8. INSTALL INTAKE VALVE

(a) Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.
NOTICE: Install the same parts in the same combination to the original locations.

(d) Using a 5 mm pin punch and a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTICE: Be careful not to damage the valve stem tip.

9. INSTALL EXHAUST VALVE

(a) Sufficiently apply engine oil to the tip area of the exhaust valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.
NOTICE: Install the same parts in the same combination to the original locations.

(d) Using a 5 mm pin punch and a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTICE: Be careful not to damage the valve stem tip.

10. INSTALL VALVE LIFTER

(a) Apply a light coat of engine oil to the tip of each valve stem.
(b) Install the valve lifters.
NOTICE: Install the valve lifters to their original places.