CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly or cylinder head sub-assembly Click here.

PROCEDURE


  1. INSPECT CYLINDER HEAD BOLT

    Click here

  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY

    Click here

  3. INSTALL CYLINDER HEAD GASKET


    1. A01W4MBE02
      Text in Illustration
      *1 Cylinder Head Gasket
      *2 Cylinder Block Sub-assembly
      *a Lot No.
      *b 3.0 mm or more
      *c 20 mm or more
      B001O8N Seal Packing
      B001OAO Front

      Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

    2. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Dimension
      3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) or thicker

      Tech Tips

      Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block sub-assembly.

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. Place the new cylinder head gasket on the cylinder block sub-assembly surface with the Lot No. stamp facing upward.

      Note

      Pay attention to the installation direction.

  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 4 progressive steps.


    1. Place the cylinder head sub-assembly on the cylinder block sub-assembly.

      Note


      • Ensure that no oil is on the contact surface of the cylinder head sub-assembly.

      • Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the gasket with the bottom part of the head.

    2. Install the 10 plate washers to the 10 cylinder head bolts.

    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    4. Step 1:


      1. A01W2DAE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

        Note

        Do not drop the plate washers for the cylinder head bolts into the cylinder head sub-assembly.

    5. Step 2:


      1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    6. Step 3:


      1. A01W0PXE02
        Text in Illustration
        *a Paint Mark
        B001O8N Front

        Mark each cylinder head bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.

    7. Step 4:


      1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

      2. Check that the paint marks are now facing rearward.

        Note


        • Do not add engine oil for at least 2 hours after installation.

        • Do not start the engine for at least 2 hours after installation.

        • After installation, if the seal packing has seeped out, wipe it off.

        Tech Tips

        Perform "Inspection After Repair" after replacing the cylinder head sub-assembly Click here.

  5. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem ends.

    2. Install the 16 valve stem caps to the cylinder head sub-assembly.

      Note

      Do not drop the valve stem caps into the cylinder head sub-assembly.

  6. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

    When installing the camshaft timing gear assembly, release the lock pin and set the camshaft timing gear assembly to the advanced position before installation.


    1. A01VZEWE03
      Text in Illustration
      *a Advance Position
      *b Retard Position
      *c Knock Pin Hole
      *d Alignment Mark

      Check the camshaft timing gear assembly position.

      Note

      If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

      If the camshaft timing gear assembly rotates to the retarded position, release the lock pin and set the camshaft timing gear assembly to the advanced position.

    2. A01W22RE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and insert the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    3. A01VZE4E47
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d Camshaft Flange
      *e No Clearance

      Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

    4. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    5. A01W3MAE02
      A01VZV9E01

      Release the lock pin.

      Text in Illustration
      *1 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close
      *e Rubber
      *f Vinyl Tape

      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the camshaft journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.

      3. Open a hole at port (A) shown in the illustration.

      4. A01W3JU

        While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the path with a piece of cloth when applying pressure to keep oil from spraying.

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips


        • The camshaft timing gear assembly may turn in the advance direction without assistance by hand.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      5. Remove the vinyl tape and rubber pieces from the camshaft.

    6. Remove the bolt and camshaft timing gear assembly.

      Note

      Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

  7. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assemblies before installing them Click here.

    2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

      Install the valve lash adjuster assembly to the same place it was removed from.

  8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      A01W01WE02
      Text in Illustration
      *A Type A *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap - -

  9. INSTALL NO. 2 CAMSHAFT BEARING

    Click here

  10. INSTALL NO. 1 CAMSHAFT BEARING

    Click here

  11. INSTALL OIL CONTROL VALVE FILTER

    Click here

  12. INSTALL CAMSHAFT


    1. Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journal, camshaft housing sub-assembly and camshaft bearing caps.

    3. Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft Click here.

  13. INSTALL CAMSHAFT BEARING CAP


    1. A01W129

      Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.

    2. A01VZ8BE02

      Install the 11 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      Make sure that the camshaft and No. 2 camshaft rotate smoothly after installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and No. 3 camshaft bearing caps.

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

      A01W3JGE01
      Text in Illustration
      *A Type A *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly - -
      *a INCORRECT *b CORRECT
    2. A01W020E08
      Text in Illustration
      *a Dashed Line
      *b Groove

      Apply seal packing in a continuous line as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Apply Seal Packing as Follows
      Area Seal Packing Diameter Application Position
      Continuous Line 3.0 to 4.0 mm (0.118 to 0.157 in.) Distance from edge of camshaft housing sub-assembly to center of seal packing: 3.5 to 4.0 mm (0.138 to 0.157 in.)
      Dashed Line Distance from outside edge of groove to center of seal packing: 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

    3. A01W1VRE05
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

      Position the knock pins of the camshaft and No. 2 camshaft as shown in the illustration.

    4. A01W2T4E02

      Install the camshaft housing sub-assembly, and then install the 20 bolts in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

      Note


      • Do not add engine oil for at least 2 hours after installation.

      • Do not start the engine for at least 2 hours after installation.

      • After installation, if the seal packing has seeped out, wipe it off.

  15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01W1HZE01
      Text in Illustration
      *a Knock Pin Hole
      *b Alignment Mark

      Check the camshaft timing gear assembly position.

      If the camshaft timing gear assembly is not set to the advanced position, release the lock pin and reset the camshaft timing gear assembly (Refer to the "Set Camshaft Timing Gear Assembly" procedures).

    2. A01W22RE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and insert the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    3. A01VZE4E47
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d Camshaft Flange
      *e No Clearance

      Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

    4. A01VZCSE01
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly Click here.

  16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01W0E5E04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and insert the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

    2. A01VZE4E47
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d No. 2 Camshaft Flange
      *e No Clearance

      Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

    3. A01W2TAE01
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly Click here.

  17. ADD ENGINE OIL


    1. A01W4GT

      Add 50 cc (3.1 cu. in.) of engine oil into the oil hole shown in the illustration.

      Note


      • Oil must be added if the valve lash adjuster assemblies were removed.

      • Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01W24ZE04

      Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.

    3. A01W4YCE02
      Text in Illustration
      *a Approximately 7°
      *b Approximately 32°
      *c Timing Mark

      Check that the timing marks of the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  19. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01W56IE03

      Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  20. INSTALL CHAIN SUB-ASSEMBLY

    A01W5OYE01

    Tech Tips

    Confirm the color of each mark plate before installing the chain sub-assembly.

    Text in Illustration
    *a for Intake Side
    *b for Exhaust Side
    *c for Crankshaft
    Type of Chain Sub-assembly for Exhaust Side for Intake Side for Crankshaft
    Type A Yellow Yellow Pink
    Type B Gold Gold Gold
    Type C Orange Orange Yellow

    1. Place the chain sub-assembly onto the camshaft timing exhaust gear assembly, camshaft timing gear assembly and crankshaft timing sprocket.

      Tech Tips


      • Make sure the mark plate of the chain sub-assembly faces away from the engine.

      • It is not necessary to install the chain sub-assembly to the teeth of the camshaft timing exhaust gear assembly, camshaft timing gear assembly and crankshaft timing sprocket.

    2. A01W0LUE08
      Text in Illustration
      *a Mark Plate (for Exhaust Side)
      *b Timing Mark

      Align the mark plate (for Exhaust Side) of the chain sub-assembly with the timing mark of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

    3. A01W4CFE16
      Text in Illustration
      *a Mark Plate (for Crankshaft)
      *b Timing Mark

      Align the mark plate (for Crankshaft) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.

    4. A01W3VU

      Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.

    5. A01W4TVE06
      Text in Illustration
      *a Mark Plate (for Intake Side)
      *b Timing Mark

      Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear assembly with the mark plate (for Intake Side) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    6. A01W4TX

      Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.

      Note

      Make sure the chain sub-assembly is secure.

  21. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Remove the pin from the stopper plate.

  23. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  24. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01W3TWE02
      Text in Illustration
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.

    3. Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    4. Remove the crankshaft pulley bolt.

  25. INSTALL INTAKE MANIFOLD

    Click here

  26. INSTALL FUEL DELIVERY PIPE

    Click here

  27. CONNECT UNION TO VACUUM TUBE HOSE (for LHD)

    Click here

  28. CONNECT UNION TO CHECK VALVE HOSE (for RHD)

    Click here

  29. CONNECT NO. 2 VENTILATION HOSE

    Click here

  30. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

    Click here

  31. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  32. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  33. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  34. INSTALL NO. 2 MANIFOLD STAY

    Click here

  35. INSTALL MANIFOLD STAY

    Click here

  36. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here