NR Series ENGINE MECHANICAL  CYLINDER HEAD  REASSEMBLY  

1.521,1.281 2,1.688 false 2.042,1.646 2.594,1.948 0.552,0.302 10 false *b 2.333,0.375 2.667,0.635 0.333,0.26 10 false *a

*a	Protrusion Height
*b	Paint Mark

Mark the standard protrusion height from the edge with paint.

Standard Protrusion Height:

87.8 mm (3.46 in.)

0.552,1.375 1.021,1.781 false 0.615,0.469 0.531,0.729 false 0.438,0.729 0.583,0.115 false 1.073,1.74 1.385,2.01 0.313,0.271 10 false *a 0.656,0.375 1.667,0.667 1.01,0.292 10 false *c 0.615,0.031 1.667,0.24 1.052,0.208 10 false *b

*a	Adhesive 1324
*b	1.0 to 7.0 mm (0.0394 to 0.276 in.)
*c	1.0 to 3.0 mm (0.0394 to 0.118 in.)

Apply adhesive to the spark plug tube where it will be pressed into the cylinder head sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

Install the spark plug tube within 3 minutes of applying adhesive.

0.958,0.948 1.323,0.948 true 0.708,3.01 1.479,3.563 true 1.094,0.615 1.458,0.615 true 0.51,2.896 0.823,3.052 0.313,0.156 10 false *a 2.76,3.156 3.073,3.354 0.313,0.198 10 false *b 0.781,0.875 1.094,1.073 0.313,0.198 10 false *c 0.917,0.531 1.229,0.729 0.313,0.198 10 false *d

*a	Paint Mark
*b	Protrusion Height
*c	Wooden Block
*d	Press

Using a press and wooden block, install the 4 spark plug tubes to the specified protrusion height.

Standard Protrusion Height:

87.8 mm (3.46 in.)

NOTICE:

·

Do not tap in the spark plug tube more than specified.

·

Do not start the engine for at least 1 hour after installation.

·

Be careful not to deform the spark plug tubes.

·

Be careful not to spill any adhesive.

Using a 6 mm hexagon wrench, install the 2 No. 1 straight screw plugs to the cylinder head sub-assembly.

Torque:

25 N*m (255 kgf*cm, 18 ft.*lbf)

Using a 10 mm hexagon wrench, install a new cylinder head screw plug gasket and the No. 2 straight screw plug to the cylinder head sub-assembly.

Torque:

44 N*m (449 kgf*cm, 32 ft.*lbf)

Using a 14 mm hexagon wrench, install 2 new No. 2 cylinder head screw plug gaskets and the 2 No. 3 straight screw plugs to the cylinder head sub-assembly.

Torque:

80 N*m (816 kgf*cm, 59 ft.*lbf)

0.698,0.26 1.01,0.417 0.313,0.156 10 false *a 2.646,0.271 2.958,0.427 0.313,0.156 10 false *b 0.688,1.313 1,1.469 0.313,0.156 10 false *c 2.656,1.313 2.969,1.469 0.313,0.156 10 false *d

*a	Intake Side
*b	Exhaust Side
*c	Gold
*d	Gray

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

NOTICE:

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 side valve stem oil seal is gold and the exhaust side valve stem oil seal is gray.

0.531,0.26 1.042,0.771 true 0.552,1.333 0.865,1.49 0.313,0.156 10 false *a 1.927,1.323 2.24,1.479 0.313,0.156 10 false *b 0.271,0.073 0.729,0.271 0.458,0.198 10 false SST

*a	Correct
*b	Incorrect

Using SST, push in the 16 valve stem oil seals.

SST

09201-41020  

NOTICE:

·

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.

2.667,1.646 2.979,1.802 0.313,0.156 10 false *a

*a	30 mm (1.18 in.) or more

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

1.042,0.417 1.521,0.417 false 1.01,1.292 1.49,1.292 false 0.708,1.677 1.167,1.865 false 0.823,1.229 1.135,1.385 0.313,0.156 10 false *1 0.823,0.354 1.135,0.51 0.313,0.156 10 false *2 0.5,1.615 0.813,1.771 0.313,0.156 10 false *3

*1	Exhaust Valve Compression Spring
*2	Valve Spring Retainer
*3	Cylinder Head Sub-assembly
	Top Side

Install the 8 exhaust valves, 8 exhaust valve compression springs and 8 valve spring retainers to the cylinder head sub-assembly.

NOTICE:

·

Install the exhaust valve 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.

1.01,1.063 1.125,0.625 1.125,0.625 0.979,0.615 true 1.979,1.958 2.646,1.917 2.646,1.917 2.469,1.625 true 1.177,0.521 1.635,0.719 0.458,0.198 10 false SST 2.708,1.906 3.021,2.104 0.313,0.198 10 false *a

*a	Wooden Block

Using SST and wooden blocks, compress the exhaust valve compression spring and install the 8 valve spring retainer locks.

SST

09202-70020  
09202-00021  

NOTICE:

Install the same parts in the same combination to their original locations.

1.01,0.646 1.427,0.229 true 2.146,1.938 1.938,2.021 true 1.479,0.115 1.792,0.271 0.313,0.156 10 false *a 1.771,1.958 2.083,2.115 0.313,0.156 10 false *b

*a	Plastic Hammer
*b	Wooden Block

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.

2.656,1.625 2.969,1.781 0.313,0.156 10 false *a

*a	30 mm (1.18 in.) or more

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

1.042,0.417 1.521,0.417 false 1.01,1.292 1.49,1.292 false 0.708,1.677 1.167,1.865 false 0.823,1.229 1.135,1.385 0.313,0.156 10 false *1 0.823,0.354 1.135,0.51 0.313,0.156 10 false *2 0.5,1.615 0.813,1.771 0.313,0.156 10 false *3

*1	Intake Valve Compression Spring
*2	Valve Spring Retainer
*3	Cylinder Head Sub-assembly
	Top Side

Install the 8 intake valves, 8 intake valve compression springs and 8 valve spring retainers to the cylinder head sub-assembly.

NOTICE:

·

Install the intake valve 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.

1.813,1.219 1.51,0.365 1.51,0.365 1.802,0.771 true 2.604,1.969 3.063,1.958 3.063,1.958 3.094,1.615 true 1.365,0.198 1.823,0.396 0.458,0.198 10 false SST 3.073,1.979 3.385,2.177 0.313,0.198 10 false *a

*a	Wooden Block

Using SST and wooden blocks, compress the intake valve compression spring and install the 8 valve spring retainer locks.

SST

09202-70020  
09202-00021  

NOTICE:

Install the same parts in the same combination to their original locations.

2.688,1.896 3.115,1.833 3.115,1.833 3.302,1.5 false 1.906,0.813 2.146,0.26 true 3.094,1.854 3.406,2.052 0.313,0.198 10 false *b 2.104,0.094 2.417,0.292 0.313,0.198 10 false *a

*a	Plastic Hammer
*b	Wooden Block

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.