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 SET BOLT

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  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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  3. INSTALL CYLINDER HEAD GASKET


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

    2. A01W03YE02
      Text in Illustration
      *1 Cylinder Head Gasket
      *a Lot No.
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 152.5 mm (6.00 in.)
      *d 38 mm (1.50 in.)
      *e 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *f 5.0 to 7.0 mm (0.197 to 0.276 in.)
      B001O8N Front
      B001OAO Seal Packing

      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

      Note


      • Remove any oil from the contact surfaces.

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

    3. Place the cylinder head gasket on the cylinder block sub-assembly 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 set 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 cylinder head gasket with the bottom of the cylinder head sub-assembly.

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

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

    4. Step 1:


      1. A01W08JE04

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps, in the order 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 set bolts into the cylinder head sub-assembly.

    5. Step 2:


      1. Check that the cylinder head set bolts 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 set bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head set bolts by 90° in the order shown in step 1.

    7. Step 4:


      1. Tighten the cylinder head set bolts by another 90° in the order shown in step 1.

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

        Note


        • Do not apply 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

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  6. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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  8. INSTALL NO. 1 CAMSHAFT BEARING

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  9. INSTALL NO. 2 CAMSHAFT BEARING

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  10. INSTALL OIL CONTROL VALVE FILTER

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  11. INSTALL CAMSHAFT

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  12. INSTALL NO. 2 CAMSHAFT

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  13. INSTALL CAMSHAFT BEARING CAP

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  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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  15. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  16. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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  17. ADD ENGINE OIL

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  18. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  19. INSTALL CHAIN SUB-ASSEMBLY

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  20. INSTALL CHAIN TENSIONER SLIPPER

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  21. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  22. INSTALL TIMING CHAIN GUIDE

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  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  24. INSTALL VACUUM PUMP ASSEMBLY

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  25. INSTALL FUEL INJECTOR SEAL

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  26. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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  27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  28. INSTALL NO. 5 ENGINE WIRE

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  29. INSTALL INTAKE MANIFOLD

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  30. INSTALL THROTTLE BODY GASKET

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  31. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  32. INSTALL PORT FUEL INJECTOR ASSEMBLY

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  33. INSTALL INJECTOR VIBRATION INSULATOR

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  34. INSTALL FUEL DELIVERY SPACER

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  35. INSTALL FUEL DELIVERY PIPE

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  36. CONNECT FUEL TUBE SUB-ASSEMBLY

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  37. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)

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  38. INSTALL NO. 2 MANIFOLD STAY

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  39. INSTALL MANIFOLD STAY

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  40. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  41. INSTALL EGR VALVE WITH COOLER ASSEMBLY

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  42. INSTALL TIMING CHAIN COVER ASSEMBLY

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