Cylinder Head: Overhaul

REMOVE VALVE LIFTER
1. Remove the valve lifter and adjusting shim.
NOTE: Arrange the valve lifters and shims in correct order.
REMOVE INTAKE VALVE
1. Using SST, compress the compression spring and remove the 2 keepers.
  SST 09202-70020 (09202-00010)
  
  Fig 1: Removing Intake Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the spring retainer, compression spring, valve and spring seat.
NOTE: Arrange the valves, compression springs, spring seats and spring retainers in correct order.
REMOVE EXHAUST VALVE
1. Using SST, compress the compression spring and remove the 2 keepers.
  SST 09202-70020(09202-00010)
  
  Fig 2: Removing Exhaust Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the spring retainer, compression spring, valve and spring seat.
NOTE: Arrange the valves, compression springs, spring seats and spring retainers incorrect order.
REMOVE VALVE STEM OIL O SEAL OR RING
1. Using needle-nose pliers, remove the oil seal.
Fig 3: Removing Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD SUB-ASSEMBLY
1. Clean the cylinder head.
  1. Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.
    NOTE: Be careful not to scratch the cylinder block contact surface.
    
    Fig 4: Removing Gasket Material From Cylinder Block Contact Surface
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using a wire brush, remove all the carbon from the combustion chambers.
    NOTE: Be careful not to scratch the cylinder block contact surface.
    
    Fig 5: Removing Carbon From Combustion Chambers
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using a valve guide bushing brush and solvent, clean all the guide bushes.
    
    Fig 6: Cleaning All Guide Bushes
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Using a soft brush and solvent, thoroughly clean the cylinder head.
    
    Fig 7: Cleaning Cylinder Head
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect for flatness.
  1. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage.
    
    Fig 8: Measuring Cylinder Block Contacting Surface And Manifolds For Warpage
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  Maximum warpage: 0.10 mm (0.0039 in.)
  
  If warpage is greater than maximum, replace the cylinder head.
3. Inspect for cracks.
  1. Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
  If cracked, replace the cylinder head.
INSPECT INTAKE VALVE
1. Clean the valves.
  1. Using a gasket scraper, chip off any carbon from the valve head.
  2. Using a wire brush, thoroughly clean the valve.
  Fig 10: Cleaning Valves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of the valve stem.
  Valve stem diameter:
  
  5.470 - 5.485 mm (0.2154 - 2.2159 in.)
  
  Fig 11: Measuring Valve Stem Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the valve face angle.
  1. Grind the valve enough to remove pits and carbon.
  2. Check that the valve is ground to the correct valve face angle.
  Valve face angle: 44.5°
  
  Fig 12: Checking Valve Face Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the valve head margin thickness.
  Standard margin thickness: 1.0 mm (0.039 in.)
  
  Minimum margin thickness: 0.5 mm (0.020 in.)
  
  If the margin thickness is less than minimum, replace the valve.
  
  Fig 13: Checking Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the valve overall length.
  Standard overall length:
  
  94.80 - 95.30 mm (3.7323 - 3.7520 in.)
  
  Minimum overall length: 94.55 mm (3.7224 in.)
  
  If the overall length is less than minimum, replace the valve.
  
  Fig 14: Checking Valve Overall Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check the surface of the valve stem tip for wear.
  If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.
  
  NOTE: Do not grind off more than minimum.
Fig 15: Resurfacing Valve Stem Tip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST VALVE
1. Clean the valves.
  1. Using a gasket scraper, chip off any carbon from the valve head.
  2. Using a wire brush, thoroughly clean the valve.
  Fig 16: Cleaning Exhaust Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of the valve stem.
  Valve stem diameter:
  
  5.465 - 5.480 mm (0.2152 - 2.2157 in.)
  
  Fig 17: Measuring Valve Stem Diameter (Exhaust Valve)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the valve face angle.
  1. Grind the valve enough to remove pits and carbon.
  2. Check that the valve is ground to the correct valve face angle.
  Valve face angle: 44.5°
  
  Fig 18: Grinding Valve Face Angle (Exhaust Valve)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the valve head margin thickness.
  Standard margin thickness: 1.0 mm (0.039 in.)
  
  Minimum margin thickness: 0.5 mm (0.020 in.)
  
  If the margin thickness is less than minimum, replace the valve.
  
  Fig 19: Checking Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the valve overall length. Standard overall length:
  94.85 - 95.35 mm (3.7342 - 3.7539 in.)
  
  Minimum overall length: 94.60 mm (3.7244 in.)
  
  If the overall length is less than minimum, replace the valve.
  
  Fig 20: Checking Valve Overall Length (Exhaust Valve)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check the surface of the valve stem tip for wear.
  If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.
  
  NOTE: Do not grind off more than minimum.
Fig 21: Resurfacing Valve Stem Tip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INNER COMPRESSION SPRING
[ 13711B / 98-12 ]
1. Using a steel square, measure the deviation of the spring.
  Maximum deviation: 2.0 mm (0.079 in.)
  
  If the deviation is greater than maximum, replace the spring.
  
  Fig 22: Measuring Valve Spring Deviation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using vernier calipers, measure the free length of the spring.
  Free length: 54.05 - 54.15 mm (2.1279 - 2.1319 in.)
  
  If the free length is not as specified, replace the spring.
  
  Fig 23: Measuring Valve Spring Free Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a spring tester, measure the tension of the valve spring at the specified installed length.
  Installed tension:
  
  210 - 226 N (20.8 - 23.0 kgf, 45.9 - 50.7 lbf)
  
  at 35.04 mm (1.3795 In.)
If the installed tension is not as specified, replace the valve spring.

Fig 24: Measuring Valve Spring Tension
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTAKE VALVE GUIDE BUSH
1. Using a caliper gauge, measure the inside diameter of the guide bush.
  Bush inside diameter:
  
  5.510 - 5.530 mm (0.2169 - 0.2177 in.)
2. Subtract the valve stem diameter measurement (See step 6) from the guide bush inside diameter measurement.
  Standard oil clearance:
  
  0.025 - 0.060 mm (0.0010 - 0.0024 in.)
  
  Maximum oil clearance: 0.08 mm (0.0031 in.)
If the clearance is greater than maximum, replace the valve and guide bush (See steps 11and 13).

Fig 25: Measuring Inside Diameter Of Guide Bush (Intake Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST VALVE GUIDE BUSH
1. Using a caliper gauge, measure the inside diameter of the guide bush.
  Bush inside diameter:
  
  5.510 - 5.530 mm (0.2169 - 0.2177 in.)
2. Subtract the valve stem diameter measurement, see step 7 from the guide bush inside diameter measurement.
  Standard oil clearance:
  
  0.030 - 0.065 mm (0.0012 - 0.0026 in.)
  
  Maximum oil clearance: 0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and guide bush, see steps 12 and 14.

Fig 26: Measuring Inside Diameter Of Guide Bush (Exhaust Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTAKE VALVE GUIDE BUSH
1. Gradually heat the cylinder head to 80 - 100°C (176 - 212°F).
  
  Fig 27: Heating Cylinder Head (Intake Valve)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the guide bush.
  SST 09201-01055, 09950-70010 (09951-07100)
Fig 28: Removing Guide Bush (Intake Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST VALVE GUIDE BUSH
1. Gradually heat the cylinder head to 80 - 100°C (176 - 212°F).
  
  Fig 29: Heating Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the guide bush.
  SST 09201-01055, 09950-70010 (09951-07100)
Fig 30: Removing Guide Bush (Exhaust Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INTAKE VALVE GUIDE BUSH

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Select a new guide bush (STD or O/S 0.05).

GUIDE BUSH SPECIFICATIONS (INTAKE VALVE)

Bush Bore Diameter	Bush Size
10.285 - 10.306 mm (0.4049 - 0.4057 in.)	Use STD
10.335 - 10.356 mm (0.4068 - 0.4077 in.)	Use O/S 0.05

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to this dimension of 10.335 - 10.356 mm (0.4068 - 0.4077 in.).

If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

Fig 31: Measuring Cylinder Head Bush Bore Diameter (Intake Valve)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Different sized bushes are used for the intake and exhaust.

Fig 32: Identifying Intake And Exhaust Valve Guide Bushes

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Gradually heat the cylinder head to 80 - 100°C (176 - 212°F).
Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)

Protrusion height (H): 9.2 - 9.8 mm (0.362 - 0.386 in.)

Fig 33: Installing New Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance (See step 9) between the guide bush and valve stem.

Fig 34: Reaming Guide Bush

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL EXHAUST VALVE GUIDE BUSH

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Select a new guide bush (STD or O/S 0.05).

GUIDE BUSH SPECIFICATIONS (EXHAUST VALVE)

Bush Bore Diameter	Bush Size
10.285 - 10.306 mm (0.4049 - 0.4057 in.)	Use STD
10.335 - 10.356 mm (0.4068 - 0.4077 in.)	Use O/S 0.05

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to this dimension of 10.335 - 10.356 mm (0.4068 - 0.4077 in.).

If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

Fig 35: Measuring Cylinder Head Bush Bore Diameter (Exhaust Valve)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Different sized bushes are used for the intake and exhaust.

Fig 36: Identifying Intake And Exhaust Valve Guide Bushes

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Gradually heat the cylinder head to 80 - 100°C (176 - 212°F).
Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)

Protrusion height (H): 8.2 - 8.8 mm (0.323 - 0.346 in.)

Fig 37: Installing Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance (See step 10) between the guide bush and valve stem.

Fig 38: Identifying Reamer Dimensions

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT INTAKE VALVE SEAT
1. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.
  
  Fig 39: Resurfacing Valve Seats (Intake Valve)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the valve seating position.
  1. Apply a light coat of prussian blue (or white lead) to the valve face.
  2. Lightly press the valve against the seat. Do not rotate valve.
3. Check the valve face and seat for the following:
  1. If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
    
    Fig 40: Checking Valve Seating Position (Intake Valve)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
  3. Check that the seat contact is in the middle of the valve face with these width:
  Width: 1.0 - 1.4 mm (0.039 - 0.055 in.)
INSPECT EXHAUST VALVE SEAT
1. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.
  
  Fig 41: Resurfacing Valve Seats (Exhaust Valve)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the valve seating position.
  1. Apply a light coat of prussian blue (or white lead) to the valve face.
  2. Lightly press the valve against the seat. Do not rotate valve.
3. Check the valve face and seat for the following:
  1. If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
  2. If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
  3. Check that the seat contact is in the middle of the valve face with these width:
  Width: 1.0 - 1.4 mm (0.039 - 0.055 in.)
Fig 42: Checking Valve Seating Position (Exhaust Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPAIR INTAKE VALVE SEAT
1. If the seating is too high on the valve face: Use 30° and 45° cutters to correct the seat.
  
  Fig 43: Identifying Valve Seat Repairing Angle (Intake Valve) (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the seating is too low on the valve face: Use 60° and 45° cutters to correct the seat.
  
  Fig 44: Identifying Valve Seat Repairing Angle (Intake Valve) (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Hand-lap the valve and valve seat with an abrasive compound.
4. After hand-lapping, clean the valve and valve seat.
Fig 45: Cleaning Valve And Valve Seat (Intake Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPAIR EXHAUST VALVE SEAT
1. If the seating is too high on the valve face: Use 30° and 45° cutters to correct the seat.
  
  Fig 46: Identifying Valve Seat Repairing Angle (Exhaust Valve) (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the seating is too low on the valve face: Use 60° and 45° cutters to correct the seat.
  
  Fig 47: Identifying Valve Seat Repairing Angle (Exhaust Valve) (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Hand-lap the valve and valve seat with an abrasive compound.
4. After hand-lapping, clean the valve and valve seat.
Fig 48: Cleaning Valve And Valve Seat (Exhaust Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE LIFTER
1. Using a micrometer, measure the lifter diameter at the 12.5 +/- 2.0 mm (0.492 +/- 0.079 in.) from the top surface.
  
  Fig 49: Measuring Lifter Diameter From Top Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Lifter diameter:
  
  30.968 - 30.976 mm (1.2192 - 1.2195 in.)
2. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
  
  Fig 50: Measuring Cylinder Head Lifter Bore Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Lifter bore diameter:
  
  31.000 - 31.016 mm (1.2205 - 1.2211 in.)
3. Subtract the lifter diameter measurement from the lifter bore diameter measurement.
  Standard oil clearance:
  
  0.024 - 0.048 mm (0.0009 - 0.0018 in.)
  
  Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.

If necessary, replace the cylinder head.

INSPECT CAMSHAFT

Inspect the circle runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Fig 51: Measuring Circle Runout At Center Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maximum circle runout: 0.08 mm (0.0031 in.)

If the circle runout is greater than maximum, replace the camshaft.
Using a micrometer, measure the cam lobe height.

Fig 52: Measuring Cam Lobe Height
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard cam lobe height:

42.610 - 42.710 mm (1.6776 - 1.6815 in.)

Minimum cam lobe height: 42.46 mm (1.6717 in.)

If the cam lobe height is less than minimum, replace the camshaft.
Inspect the journal diameter of the camshaft.
1. Using a micrometer, measure the journal diameter of the camshaft for the camshaft bearing.
  
  Fig 53: Measuring Journal Diameter Of Camshaft For Camshaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Journal diameter:
  
  26.954 - 26.970 mm (1.0612 - 1.0618 in.)
  
  If the journal diameter is not as specified, check the oil clearance.
2. Using a micrometer, measure the journal diameter for the camshaft timing tube.
  
  Fig 54: Measuring Journal Diameter For Camshaft Timing Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Journal diameter:

30.984 - 31.000 mm (1.2198 - 1.2205 in.)
Inspect the journal diameter of the camshaft timing tube.
1. Using a micrometer, measure the journal diameter.
  
  Fig 55: Measuring Journal Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Journal diameter:

39.955 - 39.964 mm (1.5730 - 1.5734 in.)

If the journal diameter is not as specified, check the oil clearance.
Install the camshaft timing tube to the camshaft, and check the timing tube turn smoothly.
If necessary, replace the timing tube and camshaft.

Fig 56: Installing Camshaft Timing Tube To Camshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the oil clearance.

Install the camshaft timing tube to the camshaft, see OVERHAUL .
Clean the bearing caps and journals.
Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cylinder head as a set.
Place the camshaft on the cylinder head.
Lay a strip of Plastigage across each of the journals.

Fig 57: Inserting Strip Of Plastigage To Camshaft Journals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the bearing caps, see OVERHAUL .
NOTE: Do not turn the camshaft.
Remove the bearing caps.

Measure the Plastigage at its widest point.

Standard oil clearance:

STANDARD OIL CLEARANCE SPECIFICATIONS

Camshaft journal	0.030 - 0.067 mm (0.0012 - 0.0026 in.)
Camshaft timing tube journal	0.036 - 0.057 mm (0.0014 - 0.0022 in.)

Maximum oil clearance:

MAXIMUM OIL CLEARANCE SPECIFICATIONS

Camshaft journal	0.100 mm (0.0039 in.)
Camshaft timing tube journal	0.075 mm (0.0030 in.)

If the oil clearance is greater than maximum, replace the camshaft and timing tube. If necessary, replace the bearing caps and cylinder head as a set.

Completely remove the Plastigage.

Fig 58: Measuring Plastigage At Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the camshaft.
Remove the camshaft timing tube from the camshaft.

Check the thrust clearance.
1. Install the camshaft timing tube to the camshaft, see OVERHAUL .
2. Install the camshaft, see OVERHAUL .
3. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
  Standard thrust clearance:
  
  0.060 - 0.100 mm (0.0024 - 0.0039 in.)
  
  Maximum thrust clearance: 0.13 mm (0.0051 in.)
  
  If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
4. Remove the camshaft.
5. Remove the camshaft timing tube from the camshaft.
Fig 59: Measuring Thrust Clearance While Moving Camshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check the gear backlash.
1. Install the drive gear to the camshaft timing tube, see OVERHAUL .
2. Install the camshaft timing tube to the camshaft, see OVERHAUL .
3. Install the camshaft and No. 2 camshaft without installing the camshaft sub-gear and front bearing cap, see OVERHAUL .
4. Using a dial indicator, measure the backlash.
Fig 60: Measuring Backlash
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard backlash:

0.020 - 0.200 mm (0.0008 - 0.0079 in.)

Maximum backlash: 0.30 mm (0.0188 in.)

If the backlash is greater than maximum, replace the drive gear and No. 2 camshaft.
Remove the camshaft and No. 2 camshaft.
Remove the camshaft timing tube from the camshaft.
Remove the drive gear from the camshaft timing tube.

INSPECT NO.2 CAMSHAFT
1. Inspect the circle runout.
  1. Place the camshaft on V-blocks.
  2. Using a dial indicator, measure the circle runout at the center journal.
    
    Fig 61: Measuring Circle Runout At Center Journal (No.2 Camshaft)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  Maximum circle runout: 0.08 mm (0.0031 in.)
  
  If the circle runout is greater than maximum, replace the No. 2 camshaft.
2. Using a micrometer, measure the cam lobe height.
  
  Fig 62: Measuring Cam Lobe Height (No.2 Camshaft)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard cam lobe height:
  
  42.630 - 42.730 mm (1.6783 - 1.6823 in.)
  
  Minimum cam lobe height: 42.48 mm (1.6724 in.)
  
  If the cam lobe height is less than minimum, replace the No. camshaft.
3. Using a micrometer, measure the journal diameter.
  Journal diameter:
  
  26.954 - 26.970 mm (1.0612 - 1.0618 in.)
  
  If the journal diameter is not as specified, check the oil clearance.
  
  Fig 63: Measuring Journal Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the oil clearance.
  1. Clean the bearing caps and journals.
  2. Check that bearings for flaking and scoring.
    If the bearings are damaged, replace the bearing caps and cylinder head as a set.
  3. Place the No. 2 camshaft on the cylinder head.
  4. Lay a strip of Plastigage across each of the journals.
  5. Install the bearing caps, see OVERHAUL .
    NOTE: Do not turn the No. 2 camshaft.
    
    Fig 64: Using Plastigage To Measure Journal Clearance
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove the bearing caps.
  7. Measure the Plastigage at its widest point.
    Standard oil clearance:
    
    Fig 65: Measuring Plastigage At Widest Point
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    0.030 - 0.067 mm (0.0012 - 0.0026 in.)
    
    Maximum oil clearance: 0.100 mm (0.0039 in.)
    
    If the oil clearance is greater than maximum, replace the No. 2 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
  8. Completely remove the Plastigage.
  9. Remove the No. 2 camshaft.
5. Check the thrust clearance.
  1. Install the camshaft, see OVERHAUL .
  2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
    
    Fig 66: Using Dial Indicator To Measure Camshaft Thrust Clearance
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard thrust clearance:
    
    0.030 - 0.075 mm (0.0012 - 0.0030 in.)
    
    Maximum thrust clearance: 0.12 mm (0.0047 in.)
    
    If the thrust clearance is greater than maximum, replace the No. 2 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
  3. Remove the No. 2 camshaft.

INSPECT NO. 3 CAMSHAFT SUB-ASSEMBLY

Inspect the circle runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.08 mm (0.0031 in.)

If the circle runout is greater than maximum, replace the No. 3 camshaft.

Fig 67: Measuring Circle Runout At Center Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a micrometer, measure the cam lobe height.

Fig 68: Measuring Cam Lobe Height
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard cam lobe height:

42.610 - 42.710 mm (1.6776 - 1.6815 in.)

Minimum cam lobe height: 42.46 mm (1.6717 in.)

If the cam lobe height is less than minimum, replace the No. 3 camshaft.
Inspect the journal diameter of the camshaft.
1. Using a micrometer, measure the journal diameter of the No. 3 camshaft for the camshaft bearing.
  
  Fig 69: Measuring Journal Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Journal diameter:
  
  26.954 - 26.970 mm (1.0612 - 1.0618 in.)
  
  If the journal diameter is not as specified, check the oil clearance.
2. Using a micrometer, measure the journal diameter for the camshaft timing tube.
  
  Fig 70: Measuring Journal Diameter For Camshaft Timing Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Journal diameter:

30.984 - 31.000 mm (1.2198 - 1.2205 in.)
Inspect the journal diameter of the camshaft timing tube.
1. Using a micrometer, measure the journal diameter.
  
  Fig 71: Measuring Camshaft Timing Tube Journal Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Journal diameter:
  
  39.955 - 39.964 mm (1.5730 - 1.5734 in.)
If the journal diameter is not as specified, check the oil clearance.
Install the timing tube to the No. 3 camshaft, and check the timing tube turn smoothly.
If necessary, replace the timing tube and No. 3 camshaft.

Fig 72: Installing Timing Tube To Camshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the oil clearance.

Install the camshaft timing tube to the No. 3 camshaft, see OVERHAUL .
Clean the bearing caps and journals.
Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and under head as a set.
Place the No. 3 camshaft on the cylinder head.
Lay a strip of Plastigage across each of the journals.
Install the bearing caps, see OVERHAUL .

Fig 73: Using Plastigage To Check Bearing Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not turn the camshaft.
Remove the bearing caps.

Measure the Plastigage at its widest point.

Standard oil clearance:

STANDARD OIL CLEARANCE SPECIFICATIONS

Camshaft journal	0.030 - 0.067 mm (0.0012 - 0.0026 in.)
Camshaft timing tube journal	0.036 - 0.057 mm (0.0014 - 0.0022 in.)

Maximum oil clearance:

MAXIMUM OIL CLEARANCE SPECIFICATIONS

Camshaft journal	0.100 mm (0.0039 in.)
Camshaft timing tube journal	0.075 mm (0.0030 in.)

If the oil clearance is greater than maximum, replace the No. 3 camshaft and timing tube. If necessary, replace the bearing caps and cylinder head as a set.

Completely remove the Plastigage.
Remove the camshaft.
Remove the camshaft timing tube from the No. 3 camshaft.

Fig 74: Measuring Plastigage At Widest Point

Check the thrust clearance.
1. Install the camshaft timing tube to the No. 3 camshaft, see OVERHAUL .
2. Install the No. 3 camshaft, see OVERHAUL .
3. Using a dial indicator, measure the thrust clearance while moving the No. 3 camshaft back and forth.
  
  Fig 75: Using Dial Indicator To Check Camshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance:
  
  0.060 - 0.100 mm (0.0024 - 0.0039 in.)
  
  Maximum thrust clearance: 0.13 mm (0.0051 in.)
  
  If the thrust clearance is greater than maximum, replace the No. 3 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
4. Remove the No. 3 camshaft.
5. Remove the camshaft timing tube from the No. 3 camshaft.
Check the gear backlash.
1. Install the drive gear to the camshaft timing tube, see OVERHAUL .
2. Install the camshaft timing tube to the No. 3 camshaft, see OVERHAUL .
3. Install the No. 3 camshaft and No. 4 camshaft without installing the camshaft sub-gear and front bearing cap, see OVERHAUL .
4. Using a dial indicator, measure the backlash.
Fig 76: Measuring Backlash
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard backlash:

0.020 - 0.200 mm (0.0008 - 0.0079 in.)

Maximum backlash: 0.30 mm (0.0188 in.)

If the backlash is greater than maximum, replace the drive c and No. 4 camshaft.
Remove the No. 3 camshaft and No. 4 camshaft.
Remove the camshaft timing tube from the No. 3 camshaft.
Remove the drive gear from the camshaft timing tube.

INSPECT NO.4 CAMSHAFT SUB-ASSEMBLY
1. Inspect the circle runout.
  1. Place the camshaft on V-blocks.
  2. Using a dial indicator, measure the circle runout at the center journal.
    
    Fig 77: Measuring Circle Runout At Center Journal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  Maximum circle runout: 0.08 mm (0.0031 in.)
  
  If the circle runout is greater than maximum, replace the No. 4 camshaft.
2. Using a micrometer, measure the cam lobe height.
  
  Fig 78: Measuring Cam Lobe Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard cam lobe height:
  
  42.630 - 42.730 mm (1.6783 - 1.6823 in.)
  
  Minimum cam lobe height: 42.48 mm (1.6724 in.)
  
  If the cam lobe height is less than minimum, replace the N camshaft.
3. Using a micrometer, measure the journal diameter.
  
  Fig 79: Measuring Journal Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Journal diameter:
  
  26.954 - 26.970 mm (1.0612 - 1.0618 in.)
  
  If the journal diameter is not as specified, check the oil clearance.
4. Check the oil clearance.
  1. Clean the bearing caps and journals.
  2. Check that bearings for flaking and scoring.
    If the bearings are damaged, replace the bearing caps and cylinder head as a set.
  3. Place the No. 4 camshaft on the cylinder head
  4. Lay a strip of Plastigage across each of the journals.
  5. Install the bearing caps, see OVERHAUL .
    NOTE: Do not turn the No. 4 camshaft.
    
    Fig 80: Inserting Strip Of Plastigage To Camshaft Journals
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove the bearing caps.
  7. Measure the Plastigage at its widest point.
    
    Fig 81: Measuring Plastigage At Widest Point
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard oil clearance:
    
    0.030 - 0.067 mm (0.0012 - 0.0026 in.)
    
    Maximum oil clearance: 0.100 mm (0.0039 in.)
    
    If the oil clearance is greater than maximum, replace the No. 4 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
  8. Completely remove the Plastigage.
  9. Remove the No. 4 camshaft.
5. Check the thrust clearance.
  1. Install the camshaft, see OVERHAUL .
  2. Using a dial indicator, measure the thrust clearance while moving the No. 4 camshaft back and forth.
    Standard thrust clearance:
    
    0.030 - 0.075 mm (0.0012 - 0.0030 in.)
    
    Maximum thrust clearance: 0.12 mm (0.0047 in.)
    
    If the thrust clearance is greater than maximum, replace the No. 4 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
  3. Remove the No. 4 camshaft.
  Fig 82: Using Dial Indicator To Measure Camshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD SET BOLT
1. Using vernier calipers, measure the thread outside diameter of the bolt.
  Standard outside diameter:
  
  9.770 - 9.960 mm (0.3846 - 0.3921 in.)
  
  Minimum outside diameter: 9.70 mm (0.3819 in.)
  
  If the diameter is less than minimum, replace the bolt.
Fig 83: Measuring Bolt Thread Outside Diameter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG TUBE
NOTE: When using a new cylinder head, spark plug tubes must be installed.
1. Apply adhesive to the end of the spark plug tube.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
  
  Fig 84: Applying Adhesive To End Of Spark Plug Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a wooden block and hammer, tap in a new spark tube until there is 48.4 - 49.6 mm (1.906 - 1.953 in.) protruding from the camshaft bearing cap installation surface of the cylinder head.
NOTE: Avoid tapping a new spark plug tube in too far by measuring the amount of the protrusion while tapping.

Fig 85: Installing Spark Plug Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIGHT PLUG NO. 1
1. Apply adhesive to the end of the spark plug tube.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
2. Using SST and a hammer, tap in a new tight plug as shown in the illustration.
  SST 09950-60010 (0951-00200), 09950-70010 (09951-07100)
Fig 86: Identifying Tight Plug No. 1 Installation Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RING W/HEAD PIN

Fig 87: Identifying Ring With Head Installation Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STUD BOLT

Fig 88: Identifying Stud Bolt Installation Point And Specifications
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE STEM OIL O SEAL OR RING
1. Using SST, push in a new oil seal.
  SST 09201-41020
Fig 89: Installing Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: The oil seal for intake is brown and the oil seal for exhaust is gray.

Fig 90: Identifying Intake And Exhaust Valve Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE VALVE
1. Install the valve, spring seat, compression spring a spring retainer.
2. Using SST, compress the compression spring and place the 2 keepers around the valve stem.
  SST 09202-70020 (09202-00010)
  
  Fig 91: Compressing Compression Spring (Intake Valve)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to assure proper fit.
NOTE: Be careful not do damage the valve stem tip.

Fig 92: Tapping Valve Stem Tip (Intake Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST VALVE
1. Install the valve, spring seat, compression spring and spring retainer.
2. Using SST, compress the compression spring and place the 2 keepers around the valve stem.
  SST 09202-70020 (09202-00010)
  
  Fig 93: Compressing Compression Spring (Exhaust Valve)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to assure proper fit.
NOTE: Be careful not do damage the valve stem tip.

Fig 94: Tapping Valve Stem Tip (Exhaust Valve)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE LIFTER
1. Install the valve lifter and shim.
2. Check that the valve lifter rotates smoothly by hand.