Part 1

CYLINDER HEAD ASSEMBLY (2TR-FE)





COMPONENTS

OVERHAUL





1. REMOVE VALVE STEM CAP
a. Remove the valve stem caps from the cylinder head.

HINT: Arrange the removed parts in the correct order.





2. REMOVE VALVE LASH ADJUSTER ASSEMBLY
a. Remove the valve lash adjusters from the cylinder head.

HINT: Arrange the removed parts in the correct order.





3. INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
- Keep the lash adjuster free from dirt and foreign objects.
- Only use clean engine oil.

a. Place the lash adjuster into a container full of engine oil.
b. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger. SST 09276-75010
c. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
d. Check the movement of the plunger and bleed the air. OK: Plunger moves up and down.

NOTICE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

e. After bleeding the air, remove the SST. Then quickly and firmly press the plunger with a finger.
OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.





4. REMOVE INTAKE VALVE
a. Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST 09202-70020 (09202-00010)





b. Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order.





5. REMOVE EXHAUST VALVE
a. Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST 09202-70020 (09202-00010)





b. Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order.





6. REMOVE VALVE STEM OIL SEAL
a. Using needle-nose pliers, remove the oil seals.
7. REMOVE VALVE SPRING SEAT
a. Remove the valve spring seats from the cylinder head.





8. REMOVE OIL CONTROL VALVE FILTER
a. Using an 8 mm hexagon wrench, remove the screw plug.
b. Remove the oil control valve filter and gasket.





9. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1
a. Using a 10 mm hexagon wrench, remove the 3 screw plugs and 3 gaskets.

NOTICE: If water leaks from the w/ head straight screw plug No.1 or the plug corrodes, replace it.





10. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2
a. Using a 19 mm hexagon wrench, remove the screw plug and gasket.

NOTICE: If water leaks from the w/ head straight screw plug No.2 or the plug corrodes, replace it.





11. INSPECT CYLINDER HEAD FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of contacting the cylinder block and manifolds.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than the maximum, replace the cylinder head.





12. INSPECT CYLINDER HEAD FOR CRACKS
a. Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks.
If cracked, replace the cylinder head.





13. INSPECT INTAKE VALVE SEAT
a. Apply a light coat of prussian blue (or white lead) to the valve face.
b. Lightly press the valve face against the valve seat.
c. Check the valve face and valve seat by using the following procedure.
(1) If prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
(2) If prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 inch).





14. INSPECT EXHAUST VALVE SEAT





a. Apply a light coat of prussian blue (or white lead) to the valve face.





b. Lightly press the valve face against the valve seat.
c. Check the valve face and valve seat by using to the following procedure.
(1) If prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
(2) If prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 inch).
15. REPAIR INTAKE VALVE SEAT

NOTICE: Keep the lip free from foreign matter.





a. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.





b. If the seating is too low on the valve face, use 60°and 45° cutters to correct the seat.
c. Hand rub the valve and valve seat with an abrasive compound.
d. Check the valve seating position.
16. REPAIR EXHAUST VALVE SEAT

NOTICE: Keep the lip free from foreign matter.

a. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
b. If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.
c. Hand rub the valve and valve seat with an abrasive compound.
d. Check the valve seating position.





17. INSPECT CAMSHAFT
a. Check the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than the maximum, replace the camshaft.





b. Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 42.855 to 42.955 mm (1.6872 to 1.6911 inch)
Minimum cam lobe height: 42.855 mm (1.6872 inch)
If the cam lobe height is less than the minimum, replace the camshaft.





c. Using a micrometer, measure the journal diameter.




Standard journal diameter

If the journal diameter is not as specified, check the oil clearance.





18. INSPECT NO.2 CAMSHAFT
a. Check the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than the maximum, replace the camshaft.





b. Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 42.854 to 42.954 mm (1.687 to 1.6911 inch)
Minimum cam lobe height: 42.854 mm (1.6872 inch)
If the cam lobe height is less than the minimum, replace the camshaft.





c. Using a micrometer, measure the journal diameter.




Standard journal diameter

If the journal diameter is not as specified, check the oil clearance.





19. INSPECT CAMSHAFT THRUST CLEARANCE
a. Install the camshafts.
b. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.10 to 0.24 mm (0.004 to 0.009 inch)
Maximum thrust clearance: 0.26 mm (0.010 inch)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.





20. INSPECT CAMSHAFT OIL CLEARANCE
a. Clean the bearing caps and camshaft journals.
b. Place the camshafts on the cylinder head.
c. Lay a strip of Plastigage across each of the camshaft journals.
d. Install the bearing caps.
Torque: 16 Nm (160 kgf-cm, 11 ft. lbs.)

NOTICE: Do not turn the camshaft.

e. Remove the bearing caps.





f. Measure the Plastigage at its widest point.




Standard oil clearance

Maximum oil clearance: 0.08 mm (0.003 inch)
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head.
g. Completely remove the Plastigage.





21. INSPECT INNER COMPRESSION SPRING
a. Using vernier calipers, measure the free length of the inner compression spring.
Free length: 48.53 mm (1.9106 inch)
If the free length is not as specified, replace the spring.





b. Using a steel square, measure the deviation of the inner compression spring.
Maximum deviation: 1.5 mm (0.059 inch)
Maximum angle (reference): 2°
If the deviation is greater than the maximum, replace the spring.





22. INSPECT INTAKE VALVE
a. Using vernier calipers, measure the valve's overall length.
Standard overall length: 106.26 mm (4.1835 inch)
Minimum overall length: 105.96 mm (4.1716 inch)
If the overall length is less than the minimum, replace the valve.





b. Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 inch)





c. Using vernier calipers, measure the valve head margin thickness.
Standard margin thickness: 1.05 to 1.45 mm (0.0413 to 0.0571 inch)
Minimum margin thickness: 0.50 mm (0.0197 inch)
If the margin thickness is less than the minimum, replace the valve.