Lexus ES: Reassembly

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / 2gr-fks (engine Mechanical) / Cylinder Head / Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

Use the same procedure for bank 1 and bank 2.
The following procedure is for bank 2.

PROCEDURE

1. INSTALL SPARK PLUG TUBE

HINT:

When using a new cylinder head LH, 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 3.0 mm (0.0394 to 0.118 in.)

NOTICE:

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

*a	Application Width
*b	9.0 to 15.0 mm (0.354 to 0.591 in.)

(b) Using a hammer and wooden block, tap in the 3 spark plug tubes to the specified protrusion height.

Standard Protrusion Height:

73 mm (2.87 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 let adhesive drip into the cylinder head LH.

*a	Wooden Block
*b	Protrusion Height
*c	Cylinder Head LH Top Surface

2. INSTALL NO. 3 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon socket wrench, install 4 new cylinder head screw plug gaskets and the 4 No. 3 straight screw plugs to the cylinder head LH.

Torque:

65 N·m {663 kgf·cm, 48 ft·lbf}

NOTICE:

Do not apply adhesive to the No. 3 straight screw plug.
The cylinder head screw plug gasket for the No. 3 straight screw plug is not the same as the water hole gasket for the No. 1 straight screw plug.

3. INSTALL NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, install a new cylinder head screw plug gasket and the No. 2 straight screw plug to the cylinder head LH.

Torque:

80 N·m {816 kgf·cm, 59 ft·lbf}

4. INSTALL NO. 1 STRAIGHT SCREW PLUG

(a) Apply adhesive to the 2 No. 1 straight screw plugs.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

Install the 2 No. 1 straight screw plugs within 3 minutes of applying adhesive.

(b) Using a 10 mm hexagon socket wrench, install 2 new water hole gaskets and the 2 No. 1 straight screw plugs to the cylinder head LH.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

5. INSTALL VALVE SPRING SEAT

(a) Install the 12 valve spring seats to the cylinder head LH.

6. INSTALL INTAKE VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to a new intake valve stem oil seal.

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 gray and the exhaust valve stem oil seals are black.

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

(b) Using SST, push in the 6 intake valve stem oil seals to the intake valve guide bush.

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 seal at an angle.

*1	Valve Stem Oil Seal
*a	Correct
*b	Incorrect

7. INSTALL EXHAUST VALVE STEM OIL SEAL

HINT:

Use the same procedure as for the intake side.

8. 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 inner compression springs and 6 valve spring retainers to the cylinder head LH.

*1	Valve Spring Retainer
*2	Inner Compression Spring
*3	Cylinder Head LH
	Top Side

NOTICE:

Install the inner 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.

(c) Using SST and wooden blocks, compress the inner compression spring and install the 6 valve spring retainer locks to the valve spring retainer.

SST: 09202-70020

09202-01010

09202-01020

SST: 09202-00021

NOTICE:

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

*a	Wooden Block

(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.

*a	Plastic Hammer
*b	Wooden Block

9. 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 inner compression springs and 6 valve spring retainers to the cylinder head LH.

*1	Valve Spring Retainer
*2	Inner Compression Spring
*3	Cylinder Head LH
	Top Side

NOTICE:

Install the inner 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.

(c) Using SST and wooden blocks, compress the inner compression spring and install the 6 valve spring retainer locks to the valve spring retainer.

SST: 09202-70020

09202-01010

09202-01020

SST: 09202-00021

NOTICE:

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

*a	Wooden Block

(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.

*a	Plastic Hammer
*b	Wooden Block

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Lexus ES: Reassembly

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