RM38T0EC _51 Engine / Hybrid System _144958 M20F-FXS, M20G-FXS ENGINE MECHANICAL _0604255 CYLINDER HEAD A

M20F-FXS, M20G-FXS ENGINE MECHANICAL  CYLINDER HEAD  REASSEMBLY  


CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)
A536548N01
6.083,1.188 6.75,1.354 0.667,0.167 1.167,3.667 2.167,3.833 1,0.167 4.167,0.833 4.5,0.833 false 4.219,0.448 4.552,0.448 false 4.198,0.167 4.531,0.167 false 4.167,1.458 4.5,1.458 false 4.135,1.25 4.635,1.25 false 4.094,1.719 4.344,1.719 false 5.802,1.719 6.052,1.719 false 5.031,1.542 5.344,1.271 5.344,1.271 5.458,1.271 false 1,2.708 1.333,2.708 false 1.75,1.75 1.969,1.75 false 2.958,1.792 3.208,1.792 false 2.698,1.469 3.031,1.469 false 2.708,1.271 3.042,1.271 false 2.604,0.833 2.854,0.833 false 2.417,0.458 2.75,0.458 false 2.375,0.156 2.708,0.156 false 3.417,5.25 3.792,5.25 false 4.292,5.083 4.667,5.083 false 1.667,3.667 1.667,3.302 false 0.708,2.646 0.865,2.844 0.156,0.198 10 false ● 1.26,1.698 1.417,1.896 0.156,0.198 10 false ● 1.396,1.708 1.552,1.906 0.156,0.198 10 false ★ 2.677,1.719 2.833,1.917 0.156,0.198 10 false ● 2.344,1.188 2.5,1.385 0.156,0.198 10 false ● 4.615,1.615 4.771,1.813 0.156,0.198 10 false ● 6.313,1.594 6.469,1.792 0.156,0.198 10 false ● 4.948,1.135 5.104,1.333 0.156,0.198 10 false ● 5.729,1.188 5.885,1.385 0.156,0.198 10 false ★ 4.208,0.167 4.417,0.365 0.208,0.198 10 false x8 4.188,0.438 4.396,0.635 0.208,0.198 10 false x8 4.198,0.917 4.406,1.115 0.208,0.198 10 false x8 4.125,1.25 4.333,1.448 0.208,0.198 10 false x8 4.094,1.448 4.302,1.646 0.208,0.198 10 false x8 4.125,1.781 4.333,1.979 0.208,0.198 10 false x8 5.031,1.573 5.24,1.771 0.208,0.198 10 false x4 3.896,5.552 4.104,5.75 0.208,0.198 10 false x8 4.563,5.385 4.771,5.583 0.208,0.198 10 false x8 1.74,3.333 1.948,3.531 0.208,0.198 10 false x7 2.188,2.177 2.396,2.375 0.208,0.198 10 false x4 3.313,1.75 3.521,1.948 0.208,0.198 10 false x8 3.208,1.344 3.417,1.542 0.208,0.198 10 false x8 3.156,1.188 3.365,1.385 0.208,0.198 10 false x8 3.094,0.875 3.302,1.073 0.208,0.198 10 false x8 2.885,0.375 3.094,0.573 0.208,0.198 10 false x8 2.781,0.063 2.99,0.26 0.208,0.198 10 false x8 4.74,0.01 5.115,0.313 0.375,0.302 18 false 16 4.594,0.323 4.969,0.625 0.375,0.302 18 false 15 4.698,0.698 5.073,1 0.375,0.302 18 false 14 5.031,1.063 5.406,1.365 0.375,0.302 18 false 10 4.573,1.333 4.948,1.635 0.375,0.302 18 false 8 4.729,1.563 5.104,1.865 0.375,0.302 18 false 2 5.885,1.135 6.26,1.438 0.375,0.302 18 false 6 6.448,1.552 6.823,1.854 0.375,0.302 18 false 4 4.906,4.917 5.281,5.219 0.375,0.302 18 false 11 3.073,5.135 3.448,5.438 0.375,0.302 18 false 12 0.917,3.615 1.333,3.917 0.417,0.302 18 false 5 0.833,2.573 1.208,2.875 0.375,0.302 18 false 4 1.563,1.625 1.938,1.927 0.375,0.302 18 false 3 2.792,1.677 3.167,1.979 0.375,0.302 18 false 1 2.49,1.375 2.865,1.677 0.375,0.302 18 false 7 2.5,1.104 2.875,1.406 0.375,0.302 18 false 9 2.25,0.719 2.625,1.021 0.375,0.302 18 false 13 2.125,0.354 2.5,0.656 0.375,0.302 18 false 15 2.094,0.01 2.469,0.313 0.375,0.302 18 false 16 6.115,1.198 6.813,1.385 0.698,0.188 8 false 25 (255, 18) 1.208,3.667 2.188,3.844 0.979,0.177 8 false 6.5 (66, 58 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

1 INTAKE VALVE GUIDE BUSH 11122 (Click here) - -
2 EXHAUST VALVE GUIDE BUSH 11126 (Click here) - -
3 SPARK PLUG TUBE - (Click here) - -
4 RING PIN 11115A (Click here) - -
5 STUD BOLT 17159 (Click here) - -
6 NO. 1 STRAIGHT SCREW PLUG 11117E - - -
7 INTAKE VALVE SPRING SEAT 13734A - - -
8 EXHAUST VALVE SPRING SEAT 13734B - - -
9 INTAKE VALVE STEM OIL SEAL 13711E (Click here) - -
10 EXHAUST VALVE STEM OIL SEAL 13715A (Click here) - -
11 INTAKE VALVE 13711 (Click here) - -
12 EXHAUST VALVE 13715 (Click here) - -
13 INTAKE VALVE COMPRESSION SPRING 13711M (Click here) - -
14 EXHAUST VALVE COMPRESSION SPRING 13715H (Click here) - -
15 VALVE SPRING RETAINER 13741B - - -
16 VALVE SPRING RETAINER LOCK 13741A (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part
V100135

MP grease ★ Precoated part

PROCEDURE

Hide 11122 1.INSTALL INTAKE VALVE GUIDE BUSH

a.
A465009C02
2.24,4.167 2.781,3.958 true 1.5,3.615 1.021,4.042 1.021,4.042 1.573,3.448 true 2.063,4.115 2.375,4.271 0.313,0.156 10 false *a 0.708,4.052 1.031,4.229 0.323,0.177 10 true SST 0.531,0.135 0.802,0.438 0.271,0.302 18 false i 4.146,0.135 4.417,0.438 0.271,0.302 18 false ii 0.542,2.573 0.813,2.875 0.271,0.302 18 false iii 4.135,2.604 4.406,2.906 0.271,0.302 18 false iv
*a Protrusion Height - -


i.

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.




ii.

Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).

CAUTION:

Be sure to wear protective gloves.



iii.

Using SST and a hammer, tap in the selected intake valve guide bush.

SST
09201-10000  (09201-01050)
09950-70010  (09951-07100)

Standard Protrusion Height:

13.35 to 13.60 mm (0.526 to 0.535 in.)



iv.

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.)




Hide 11126 2.INSTALL EXHAUST VALVE GUIDE BUSH

a.
A465010C02
3.021,4.01 3.427,3.781 true 1.313,3.542 2.271,3.115 2.271,3.115 1.417,3.75 true 3.479,3.677 3.792,3.833 0.313,0.156 10 false *a 2.302,3.021 2.708,3.24 0.406,0.219 10 false SST 0.469,0.073 0.667,0.365 0.198,0.292 18 false i 4.177,0.073 4.375,0.365 0.198,0.292 18 false ii 0.448,2.469 0.646,2.76 0.198,0.292 18 false iii 4.177,2.458 4.448,2.75 0.271,0.292 18 false iv
*a Protrusion Height - -


i.

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.




ii.

Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).

CAUTION:

Be sure to wear protective gloves.



iii.

Using SST and a hammer, tap in the selected intake valve guide bush.

SST
09201-10000  (09201-01050)
09950-70010  (09951-07100)

Standard Protrusion Height:

13.75 to 14.00 mm (0.541 to 0.551 in.)



iv.

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.)




Hide 3.INSTALL SPARK PLUG TUBE

Z101186

HINT:

When using a new cylinder head sub-assembly, the spark plug tubes must be replaced.



a.
A465011C04
0.792,0.813 1.073,1.167 0.281,0.354 18 false i 4.229,0.125 4.51,0.479 0.281,0.354 18 false ii 1.896,1.427 2.208,1.625 0.313,0.198 10 false *a 1.875,2.583 2.188,2.781 0.313,0.198 10 false *b 5.875,2.406 6.188,2.604 0.313,0.198 10 false *c
*a 1.0 to 7.0 mm (0.0394 to 0.276 in.) *b 1.0 mm (0.0394 in.)
*c Protrusion Height - -


i.

Apply adhesive to 4 new spark plug tubes as shown in the illustration.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent


NOTICE:
·

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.




ii.

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.)


NOTICE:

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




Hide 11115A 4.INSTALL RING PIN

a.
A465012N01
0.479,0.083 0.76,0.438 0.281,0.354 18 false i

i.

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.)




Hide 17159 5.INSTALL STUD BOLT

Z101186

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.



a.
A465013C03
0.417,0.083 0.698,0.438 0.281,0.354 18 false i 5.385,1.167 5.698,1.365 0.313,0.198 10 false *b 5.375,0.771 5.688,0.969 0.313,0.198 10 false *a 5.792,0.948 6.104,1.146 0.313,0.198 10 false *c
*a 20 mm (0.787 in.) *b 13 mm (0.512 in.)
*c 35 mm (1.38 in.) - -


i.

Using an E8 "TORX" socket wrench, install the 7 stud bolts.

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



Hide 11117E 6.INSTALL NO. 1 STRAIGHT SCREW PLUG

a.
A465014N02
0.448,0.104 0.729,0.458 0.281,0.354 18 false i 4.104,0.083 4.385,0.438 0.281,0.354 18 false ii

i.

Apply adhesive to the 4 No. 1 straight screw plugs.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent


NOTICE:

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



ii.

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)



Hide 13734A 7.INSTALL INTAKE VALVE SPRING SEAT (for Intake Side)

Hide 13734B 8.INSTALL EXHAUST VALVE SPRING SEAT (for Exhaust Side)

Hide 13711E 9.INSTALL INTAKE VALVE STEM OIL SEAL (for Intake Side)

a.
A465017C03
2.667,1.771 2.5,2.083 2.5,2.083 2.333,2.083 false 1.115,1.75 1.333,2.083 1.333,2.083 1.5,2.083 false 4.604,0.75 4.771,0.75 false 0.5,0.073 0.781,0.427 0.281,0.354 18 false i 3.875,0.083 4.156,0.438 0.281,0.354 18 false ii 1.552,2 1.854,2.198 0.302,0.198 10 false *c 1.042,0.646 1.354,0.844 0.313,0.198 10 false *a 2.542,0.656 2.854,0.854 0.313,0.198 10 false *b 2.135,2.01 2.438,2.208 0.302,0.198 10 false *d 4.927,1.729 5.229,1.927 0.302,0.198 10 false *e 5.781,1.74 6.083,1.938 0.302,0.198 10 false *f 4.323,0.677 4.625,0.875 0.302,0.198 10 false SST
*a Intake Valve Stem Oil Seal *b Exhaust Valve Stem Oil Seal
*c Gray *d Black
*e Correct *f Incorrect


i.

Apply a light coat of engine oil to 8 new valve stem oil seals.

NOTICE:

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.



ii.

Using SST, push in the 8 valve stem oil seals.

SST
09201-41020  

NOTICE:
·

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.





Hide 13715A 10.INSTALL EXHAUST VALVE STEM OIL SEAL (for Exhaust Side)

a.

Perform the same procedure as for the intake side.


Hide 13711 11.INSTALL INTAKE VALVE

a.
A472455C02
2.677,1.448 2.99,1.604 0.313,0.156 10 false *a 0.375,0.063 0.604,0.458 0.229,0.396 18 false i 4.104,0.031 4.344,0.302 0.24,0.271 18 false ii
*a 30 mm (1.18 in.) or more - -


i.

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


ii.

Install the 8 intake valves to the cylinder head sub-assembly.



Hide 13715 12.INSTALL EXHAUST VALVE

a.

Perform the same procedure as for the intake side.


Hide 13711M 13.INSTALL INTAKE VALVE COMPRESSION SPRING (for Intake Side)

Z101186

NOTICE:
·

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.




Hide 13715H 14.INSTALL EXHAUST VALVE COMPRESSION SPRING (for Exhaust Side)

Z101186

NOTICE:
·

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.




Hide 13741B 15.INSTALL VALVE SPRING RETAINER

Hide 13741A 16.INSTALL VALVE SPRING RETAINER LOCK

a.
A465019N02
3.094,1.021 3.396,1.021 false 1.219,0.354 0.552,0.667 true 0.427,0.042 0.708,0.396 0.281,0.354 18 false i 4.021,0.021 4.302,0.375 0.281,0.354 18 false ii 3.479,0.969 3.938,1.167 0.458,0.198 10 false SST 0.25,0.635 0.708,0.833 0.458,0.198 10 false SST

i.

Using SST, compress the inner compression spring and install the 8 valve spring retainer locks.

SST
09202-70020  (09202-01010, 09202-01020)
09202-00021  


ii.

Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:
·

Be careful not to damage the valve stem tip.

·

Be careful not to damage the valve spring retainer.