Disassembly and Reassembly

CYLINDER HEAD

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

DISASSEMBLY
1. REMOVE VALVE LIFTER
(a) Remove the valve lifter and adjusting shim.

HINT: Arrange the valve lifters and shims in the correct order.

2. REMOVE INTAKE VALVE
(a) Using SST, compress the compression spring and remove the 2 keepers.
SST 09202-70020 (09202-00010)
(b) Remove the spring retainer, compression spring, valve and spring seat.

HINT: Arrange the valves, compression springs, spring seats and spring retainers in the correct order.

3. REMOVE EXHAUST VALVE
(a) Using SST, compress the compression spring and remove the 2 keepers.
SST 09202-70020 (09202-00010)
(b) Remove the spring retainer, compression spring, valve and spring seat.

HINT: Arrange the valves, compression springs, spring seats and spring retainers in the correct order.

4. REMOVE VALVE STEM OIL SEAL
(a) Using needle nose pliers, remove the oil seal.

5. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY

(a) Mount the hexagon head portion of the camshaft in a vise.

NOTICE:
^ Be careful not to damage the camshaft.
^ Do not remove the 4 bolts shown in the illustration. The bolts determine the backlash of the gear in the timing tube. If any of the bolts are removed, install a new timing tube assembly.

(b) Remove the screw plug and seal washer.

(e) Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.
SST 09960-10010 (09962-01000, 09963-00500)

NOTICE: Be careful not to damage the timing tube.

6. REMOVE CAMSHAFT SUB GEAR

(a) Mount the hexagon head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.

(b) Using SST, turn the sub gear clockwise and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)

(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, sub gear and bolt washer.

HINT: Arrange the driven sub gears and bolt washers (RH and LH sides).

(e) Using a vernier caliper, measure the free distance between the washer ends.
Free distance: 18.2 to 18.8 mm (0.712 to 0.740 in.)
If the free distance is not as specified, replace the washer.

REASSEMBLY
1. INSTALL CAMSHAFT SUB GEAR

(a) Install the bolt washer (1), sub gear (2) and wave washer (3).

HINT: Attach the pins on the gears to the gear bolt washer ends.

(b) Using snap ring pliers, install the snap ring.

(d) Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(e) Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.

2. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY

(a) Insert a new oil seal into the camshaft timing tube until it reaches the stopper.

NOTICE:
^ Be careful of the installation direction.
^ Do not turn over the oil seal lip.

(b) Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
(c) Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

NOTICE: Be careful not to damage the timing tube.

(d) Mount the hexagon head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.

(e) Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
(f) Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
(g) Install the seal washer and screw plug.
Torque: 15 N*m (152 kgf*cm, 11 ft.*lbf)

3. INSTALL SPARK PLUG TUBE

HINT: When using a new cylinder head, the spark plug tubes must be installed.

(a) Apply adhesive to the end of the spark plug tube.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

(b) Using a wooden block and hammer, tap in a new spark tube until there is 48.4 to 49.6 mm (1.906 to 1.953 in.) protruding from the camshaft bearing cap installation surface of the cylinder head.

NOTICE:
Avoid tapping in a new spark plug tube too far
Measure the protrusion length while tapping.

4. INSTALL NO. 1 TIGHT PLUG
(a) Apply adhesive to the end of the spark plug tube.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using SST and a hammer, tap in a new tight plug as shown in the illustration.
SST 09550-60010 (09951-00200), 09950-70010 (09951-07100)

5. INSTALL RING WITH HEAD PIN

6. INSTALL STUD BOLT

7. INSTALL VALVE STEM OIL SEAL

(a) 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.

(b) Apply a light coat of engine oil in a new oil seal.

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 gray/brown and the exhaust valve oil seal is black/gray.

8. INSTALL INTAKE VALVE

(a) Install the valve, spring seat, compression spring and spring retainer.
(b) Using SST, compress the compression spring and place the 2 keepers 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 valve stem tip.

9. INSTALL EXHAUST VALVE

(a) Install the valve, spring seat, compression spring and spring retainer.

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

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