RM36D0EC _51 Engine / Hybrid System _083059 M20D-FKS ENGINE MECHANICAL _0403048 CYLINDER HEAD A

M20D-FKS ENGINE MECHANICAL CYLINDER HEAD REASSEMBLY

PROCEDURE

Hide Display 1.INSTALL SPARK PLUG TUBE

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

2.25,1.635 2.25,1.188 false 2.188,1.677 2.5,1.875 0.313,0.198 10 false *a 1.667,0.688 1.979,0.885 0.313,0.198 10 false *b 1.667,1.896 1.979,2.094 0.313,0.198 10 false *c

*a	Adhesive
*b	Application Width
*c	Distance

Apply adhesive to a new spark plug tube as shown in the illustration.

Adhesive:: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Standard Application Width:: 1.0 to 7.0 mm (0.0394 to 0.276 in.)

Distance:: 1.0 mm (0.0394 in.)

NOTICE:: ·

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

·

Be careful not to deform the spark plug tube.

·

Do not expose the spark plug tube to engine oil for at least 1 hour after installing it.

2.417,2.948 2.729,3.104 0.313,0.156 10 false *a

*a	Protrusion Height

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 Display 17159 2.INSTALL STUD BOLT

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

1.677,2.604 1.99,2.76 0.313,0.156 10 false *a 2.135,2.76 2.448,2.917 0.313,0.156 10 false *b 1.677,3.063 1.99,3.219 0.313,0.156 10 false *c

*a	20 mm (0.787 in.)
*b	35 mm (1.38 in.)
*c	13 mm (0.512 in.)

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

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

Hide Display 11117E 3.INSTALL NO. 1 STRAIGHT SCREW PLUG

HINT:: If coolant leaks from a No. 1 straight screw plug or a plug is corroded, replace it.

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.

Using a 6 mm straight 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 Display 4.INSTALL VALVE SPRING SEAT

Install the 16 valve spring seats to the cylinder head sub-assembly.

Hide Display 5.INSTALL VALVE STEM OIL SEAL

0.75,1.552 1.042,1.927 1.042,1.927 1.198,1.927 true 2.615,1.563 2.438,1.885 2.438,1.885 2.25,1.885 true 0.667,0.104 0.979,0.302 0.313,0.198 10 false *a 2.635,0.104 2.948,0.302 0.313,0.198 10 false *b 1.271,1.854 1.583,2.052 0.313,0.198 10 false *c 2.073,1.792 2.385,1.99 0.313,0.198 10 false *d

*a	Intake Valve Stem Oil Seal
*b	Exhaust Valve Stem Oil Seal
*c	Gold
*d	Gray

Apply a light coat of engine oil to 16 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.

2.063,1.375 2.667,1.906 true 0.583,0.875 0.771,0.875 false 0.979,2.125 1.292,2.281 0.313,0.156 10 false *a 2.021,2.115 2.333,2.271 0.313,0.156 10 false *b 2.729,1.833 3.104,2.031 0.375,0.198 10 false SST 0.271,0.771 0.802,0.958 0.531,0.188 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 valve stem oil seals to be damaged or improperly seated.

·

Do not push in the valve stem oil seals at an angle.

Hide Display 13711 6.INSTALL INTAKE VALVE

2.51,1.552 2.823,1.75 0.313,0.198 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.

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

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

0.719,0.438 0.542,0.208 true 2.26,0.427 2.083,0.198 false 0.25,0.094 0.708,0.292 0.458,0.198 10 false SST 1.781,0.094 2.24,0.292 0.458,0.198 10 false SST

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

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

Using a plastic-faced 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.

Hide Display 13715 7.INSTALL EXHAUST VALVE

2.479,1.552 2.792,1.75 0.313,0.198 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.

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

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

1.021,0.385 0.729,0.188 false 1.802,0.125 2.354,0.26 true 0.396,0.104 0.854,0.302 0.458,0.198 10 false SST 1.49,0.052 1.948,0.25 0.458,0.198 10 false SST

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

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

Using a plastic-faced 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.