Toyota Yaris: Cylinder Head / Reassembly

Toyota Yaris XP210 (2020-2024) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (engine Mechanical) / Cylinder Head / Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL SPARK PLUG TUBE

HINT:

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

(a) 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.

*a

Adhesive

*b

Application Width

*c

Distance

(b) Using a wooden block and hammer, tap in the 4 spark plug tubes to the specified protrusion height.

Standard Protrusion Height:

70.5 to 71.5 mm (2.78 to 2.81 in.)

NOTICE:

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

*a

Protrusion Height

2. INSTALL STUD BOLT

NOTICE:

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

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

Torque:

19.5 N·m {199 kgf·cm, 14 ft·lbf}

*a

45.5 mm (1.79 in.)

*b

15 mm (0.591 in.)

*c

64 mm (2.52 in.)

*d

30.5 mm (1.201 in.)

*e

13 mm (0.512 in.)

*f

46.9 mm (1.85 in.)

(b) Using an E8 "TORX" socket wrench, install the 2 stud bolts.

*a

27 mm (1.06 in.)

*b

13 mm (0.512 in.)

*c

80 mm (3.15 in.)

3. INSTALL STRAIGHT PIN

(a) Using a plastic hammer, tap in 2 new straight pins to the cylinder head sub-assembly.

Standard Protrusion Height:

3.0 to 5.0 mm (0.118 to 0.197 in.)

*a

8.0 mm (0.315 in.)

*b

5.0 mm (0.197 in.)

*c

Protrusion Height

4. INSTALL NO. 2 STRAIGHT SCREW PLUG

HINT:

If coolant leaks from a No. 2 straight screw plug or a plug is corroded, replace it.

(a) Apply adhesive to the No. 2 straight screw plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

Install the No. 2 straight screw plug within 3 minutes of applying adhesive.

(b) Using a 10 mm straight hexagon wrench, install the No. 2 straight screw plug to the cylinder head sub-assembly.

Torque:

135 N·m {1377 kgf·cm, 100 ft·lbf}

5. INSTALL NO. 1 STRAIGHT SCREW PLUG

HINT:

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

(a) Apply adhesive to the 3 No. 1 straight screw plugs.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

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

(b) Using a 6 mm straight hexagon wrench, install the 3 No. 1 straight screw plugs to the cylinder head sub-assembly.

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

6. INSTALL VALVE SPRING SEAT

(a) Install the 12 valve spring seats to the cylinder head sub-assembly.

7. INSTALL VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to 12 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.

*a

Intake Valve Stem Oil Seal

*b

Exhaust Valve Stem Oil Seal

*c

Gold

*d

Gray

(b) Using SST, push in the 12 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.

*a

Correct

*b

Incorrect

8. INSTALL INTAKE VALVE

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

*a

30 mm (1.18 in.) or more

(b) Install the 6 intake valves, 6 compression springs and 6 valve spring retainers to the cylinder head sub-assembly.

NOTICE:

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

(c) Using SST, compress each compression spring and install the 6 valve spring retainer locks.

SST: 09202-70020

09202-01010

09202-01020

SST: 09202-00021

(d) 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.

9. INSTALL EXHAUST VALVE

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

*a

30 mm (1.18 in.) or more

(b) Install the 6 exhaust valves, 6 compression springs and 6 valve spring retainers to the cylinder head sub-assembly.

NOTICE:

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

(c) Using SST, compress each compression spring and install the 6 valve spring retainer locks.

SST: 09202-70020

09202-01010

09202-01020

SST: 09202-00021

(d) 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.

    Replacement

    REPLACEMENT PROCEDURE 1. REPLACE INTAKE VALVE GUIDE BUSH (a) Heat the cylinder head sub-assembly to between 80 and 100°C (176 to 212°F). (b) Place the cylinder head sub-assembly on wooden blocks...

    Repair

    REPAIR PROCEDURE 1. REPAIR INTAKE VALVE SEAT NOTICE: While repairing the intake valve seat, make sure to constantly check the valve seat width and valve seating position...

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