CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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

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PROCEDURE


  1. INSPECT VALVE LASH ADJUSTER ASSEMBLY

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  2. INSPECT NO. 1 VALVE ROCKER ARM 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. A01OB2WC06
      *1 Cylinder Head Gasket
      *a Lot No.
      *b Front of Engine
      *c Seal Packing
      *d View (A)
      *e 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *f 38 mm (1.50 in.)
      *g 152.5 mm (6.00 in.)
      *h 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *i 5.0 to 7.0 mm (0.197 to 0.276 in.)

      Apply 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 cylinder head bolts within 15 minutes of applying seal packing.

    3. Place the cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.

      Note


      • Remove any oil from the contact surfaces.

      • Pay attention to the installation direction.

      • Do not damage the cylinder head gasket.

  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


      • Check and clean the cylinder head set bolts and bolt holes.

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

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

    4. Step 1:


      1. A01ODL8N04

        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


        • Install the cylinder head set bolts to the same place they were removed from.

        • Be careful not to drop the plate washers 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. A01OBL5C01
        *a Paint Mark
        *b 90°
        B004FMB Front of Engine

        Mark the front side of each cylinder head set bolt head with paint.

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

    7. Step 4:


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

      2. Check that the paint marks are now at a 180° angle to the front of the engine.

        Note

        After installing the cylinder head sub-assembly, wipe off any seal packing that has seeped out within 5 minutes.

  5. INSTALL VALVE STEM CAP


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

    2. Install the 16 valve stem caps to the valve stem ends.

      Note


      • Install the valve stem caps to the same place they were removed from.

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

  6. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster assembly free from dirt and foreign matter.

    • Only use clean engine oil.

    • If the valve lash adjuster assembly is tilted after bleeding, oil will leak. Make sure to bleed the valve lash adjuster assembly again.


    1. Bleed the valve lash adjuster assembly.

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    2. If the plunger moves, bleed the valve lash adjuster assembly again.

    3. Place the valve lash adjuster assembly into a container filled with new engine oil, and then fill the low pressure chamber with engine oil.

    4. Apply engine oil to the outer surface of the valve lash adjuster body and the tip of the plunger, and then install the valve lash adjuster assembly while turning it.

      Note

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

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


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

    2. A01OC38C28
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

      Note

      Install the No. 1 valve rocker arm sub-assemblies to the same place they were removed from.

  8. INSTALL SPARK PLUG

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  9. CONNECT NO. 9 WATER BY-PASS HOSE


    1. A01OAHQC01
      *a Paint Mark
      *b Up

      Connect the No. 9 water by-pass hose to the cylinder head sub-assembly and slide the clip to secure.

      Note


      • Engage the clip so that it is positioned as shown in the illustration.

      • Connect the No. 9 water by-pass hose with the paint mark facing upward.

  10. CONNECT NO. 2 WATER BY-PASS PIPE


    1. Install the No. 2 water by-pass pipe to the cylinder head sub-assembly with the 2 bolts.

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

  11. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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  12. INSTALL FUEL INJECTOR SET

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  13. INSTALL FUEL INJECTOR ASSEMBLY

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  14. INSTALL EGR COOLER ASSEMBLY

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