Complete valve job including cylinder head removal, valve grinding/lapping, valve guide and seat reconditioning, and reassembly with new seals and gaskets.

Warnings

Tools required

Parts

• Valve stem seals (set of 16) × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Cylinder head bolts (set of 10) × 1 — TTY bolts - Use OEM specification
• Spark plugs (set of 4) × 1 — Use OEM specification
• Timing chain tensioner gasket × 1 — Use OEM specification
• VVT-i oil control valve gasket × 1 — Use OEM specification
• Anti-seize compound × 1 — Copper-based
• RTV silicone sealant × 1 — Toyota Genuine FIPG or equivalent

Fluids

• Toyota Super Long Life Coolant (Pink) — 7.5 qt
• Toyota Genuine 0W-20 — 4.5 qt

Preparation

1. Disconnect negative battery cable and wait 90 seconds for airbag system to discharge
2. Drain engine coolant completely from radiator drain and engine block drain plugs
3. Drain engine oil and remove oil filter
4. Remove engine cover and plastic trim pieces from top of engine
5. Remove air intake assembly from throttle body to air filter box
6. Label and disconnect all vacuum hoses, electrical connectors, and wiring harness clips from cylinder head area
7. Support engine from below with jack and wood block or install engine support fixture across fender rails
8. Rotate engine to TDC on cylinder #1 compression stroke and verify timing marks align
9. Take photos of timing chain routing, cam sprocket alignment, and all electrical connections

Procedure

1. 1

   Remove exhaust manifold and intake manifold
   Disconnect oxygen sensor connectors. Remove exhaust manifold heat shield. Remove exhaust manifold nuts working from the center outward to prevent warping. Remove intake manifold bolts and lift away manifold with throttle body attached. Inspect manifold mating surfaces for damage.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)

   Intake Manifold Bolts25 Nm (18 lb-ft)
2. 2

   Remove valve cover and timing components
   Remove ignition coils and spark plugs. Remove valve cover bolts in reverse of tightening sequence and lift off valve cover. Remove right engine mount to access timing cover. Remove timing cover bolts in reverse sequence and carefully pry off timing cover. Verify timing marks are aligned on crankshaft and both camshaft sprockets.
   ⚠Paint or scribe alignment marks on timing chain and cam sprockets before removal - chain links should align with dots on sprockets
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
3. 3

   Remove camshaft sprockets and timing chain
   Install timing chain tensioner locking pin or compress tensioner and lock with pin. Hold exhaust camshaft with wrench on hex section and remove camshaft sprocket bolt. Hold intake camshaft and remove its sprocket bolt. Remove both sprockets with chain attached as an assembly. Secure chain to prevent it from falling into timing case.
   Torque spec

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
4. 4

   Remove camshafts
   Mark camshaft bearing caps with their position and orientation. Loosen camshaft cap bolts in reverse sequence (outward from center) in multiple passes, 1/4 turn at a time to gradually release valve spring pressure. Remove bearing caps and lift out both camshafts. Keep camshafts identified as intake and exhaust. Store bearing caps in order.
   ⚠Loosen cam cap bolts gradually and evenly - uneven loosening can bind and damage camshaft or caps
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)
5. 5

   Remove cylinder head
   Disconnect coolant hoses from cylinder head. Remove cylinder head bolts in reverse of tightening sequence in multiple passes. Carefully lift cylinder head straight up - do not pry or tilt. Place head on clean wooden blocks with combustion chambers facing up. Remove and discard old head gasket. Clean and inspect block surface for damage or warping.
   ℹ️Head is heavy (approximately 40 lbs) - use assistant or hoist to prevent dropping
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
6. 6

   Disassemble valvetrain from cylinder head
   Flip head to position combustion chambers down. Using valve spring compressor, compress first valve spring and remove keeper locks. Release compressor and remove retainer and spring. Remove valve from combustion chamber side. Mark valve position (intake/exhaust and cylinder number). Remove valve stem seal with pliers. Repeat for all 16 valves. Keep valves in numbered order if reusing.
   ⚠Ensure spring compressor is centered and secure before removing keepers - spring can launch retainer if compressor slips
7. 7

   Inspect and measure valve components
   Clean all carbon from valves using wire wheel or chemical cleaner. Inspect each valve face, stem, and margin for burning, pitting, or excessive wear. Measure valve stem diameter with micrometer - exhaust should be 5.465-5.475mm, intake 5.475-5.485mm. Measure valve margin thickness - minimum is 0.5mm. Measure valve spring free length and squareness. Check valve guides for wear using dial indicator - maximum runout is 0.05mm. Record all measurements.
8. 8

   Recondition valve seats and guides
   If valve guides are worn beyond spec (>0.05mm runout), ream guides oversize and install oversize stem seals, or have guides replaced by machine shop. Using valve seat cutter or grinding stones, cut valve seats to 45-degree angle with proper width (1.0-1.5mm for intake, 1.2-1.7mm for exhaust). Cut narrow top and bottom angles to position seat properly on valve face. Ensure seat is concentric with guide - maximum runout 0.03mm.
   ℹ️Valve seat cutting requires specialized equipment and skill - consider machine shop service if inexperienced
9. 9

   Lap valves to seats
   Apply thin coat of fine valve lapping compound to valve face. Insert valve into guide and attach lapping tool to valve head. Rotate valve back and forth with light downward pressure for 30-60 seconds. Clean compound and check contact pattern with Prussian blue - seat should show complete 360-degree contact band on valve face. Pattern should be centered on valve face width. Re-lap if pattern is incomplete. Thoroughly clean all compound residue from valves and seats.
10. 10

    Inspect and resurface cylinder head
    Clean cylinder head mating surface thoroughly. Check head flatness using precision straightedge and feeler gauges at multiple positions - maximum warpage is 0.05mm. If warpage exceeds 0.03mm, have head resurfaced by machine shop. Maximum material removal is 0.2mm. After resurfacing, valve stem height must be checked and corrected if necessary. Clean all coolant passages and oil passages with solvent.
11. 11

    Reassemble valves into cylinder head
    Lubricate valve stems with clean engine oil. Install each valve into its original position from combustion chamber side. Using seal driver, install new valve stem seals onto guides - tap gently until seated. Install valve spring and retainer over valve stem. Compress spring with compressor and install keeper locks in valve stem groove. Release compressor slowly and verify keepers are fully seated. Tap valve tip lightly with plastic hammer to ensure keepers are locked. Repeat for all 16 valves.
12. 12

    Install cylinder head to engine block
    Clean engine block surface thoroughly with solvent and inspect for damage. Verify engine is still at TDC #1. Install new head gasket on block - verify correct orientation with UP mark facing up and front toward timing chain. Carefully lower cylinder head onto block using alignment dowels. Install new cylinder head bolts with light oil on threads. Torque head bolts in proper sequence to 65 Nm, then tighten an additional 90 degrees in sequence, then final 90 degrees in sequence (total 180 degrees additional).
    ⚠️Use only new TTY head bolts - torque sequence is critical for proper clamping and must be followed exactly
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
13. 13

    Install camshafts and bearing caps
    Lubricate camshaft journals and lobes with clean engine oil. Position intake and exhaust camshafts in head with timing marks visible. Verify cam lobes for cylinder #1 are positioned for valve clearance. Apply light coat of RTV to front bearing cap mating surface. Install bearing caps in correct position and orientation. Tighten cam cap bolts in sequence from center outward in three passes: first to 6 Nm, second to 10 Nm, final to 14 Nm.
    Torque spec

    Camshaft Cap Bolts14 Nm (10 lb-ft)
14. 14

    Install timing chain and components
    Verify crankshaft is at TDC. Route timing chain around crankshaft sprocket and up both sides. Install intake cam sprocket with chain aligned to timing mark. Hold intake camshaft with wrench on hex and torque sprocket bolt to 80 Nm. Install exhaust cam sprocket with chain aligned to timing mark. Hold exhaust camshaft and torque sprocket bolt to 80 Nm. Verify all three timing marks align properly. Remove tensioner locking pin to tension chain. Rotate engine two complete revolutions by hand and recheck timing marks.
    ⚠️Double-check timing mark alignment before rotating engine - incorrect timing will cause valve-to-piston contact and catastrophic damage
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)
15. 15

    Install remaining components and test
    Apply thin bead of RTV to timing cover mating surface per factory pattern. Install timing cover and torque bolts to 25 Nm in proper sequence. Install valve cover with new gasket and torque bolts to 10 Nm in sequence. Install intake manifold with new gasket and torque to 25 Nm. Apply anti-seize to exhaust manifold studs, install manifold with new gasket, and torque nuts to 30 Nm working from hot (center) to cold (outer). Install new spark plugs and ignition coils. Reconnect all electrical connectors, vacuum hoses, and coolant hoses. Install right engine mount and torque to specification. Refill cooling system and engine oil. Start engine and check for leaks. Allow engine to reach operating temperature and verify proper operation.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

Reassembly

1. After initial startup, check for oil, coolant, and vacuum leaks at all disturbed connections
2. Allow engine to fully warm up and cool down once before retorquing cylinder head bolts if required by service manual
3. After 500 miles of operation, recheck valve clearances and adjust if necessary
4. Monitor oil consumption and coolant level for first 1000 miles to detect any sealing issues

Verification

• Engine should start easily and idle smoothly without misfires or rough running
• No oil leaks from valve cover, timing cover, or head gasket areas
• No coolant leaks from head gasket or coolant passage connections
• Perform compression test - all cylinders should be within 10% of each other and meet factory specification (approximately 185 psi)
• Perform cylinder leakage test if available - leakage should be less than 10% per cylinder
• No abnormal engine noises such as ticking, knocking, or rattling from valvetrain
• Engine maintains proper oil pressure at idle and under load
• Exhaust emissions should be within normal range - perform smoke test if available
• Scan for diagnostic trouble codes - none should be present related to engine mechanical operation

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