CYLINDER HEAD GASKET

INSPECT CYLINDER HEAD SET BOLT

INSPECT CYLINDER HEAD SUB-ASSEMBLY

INSTALL CYLINDER HEAD GASKET

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

*1	Cylinder Head Gasket
*a	Lot No.
*b	Front of Engine
*c	Seal Packing
*d	3.0 to 5.0 mm (0.118 to 0.197 in.)
*e	38 mm (1.50 in.)
*f	152.5 mm (6.00 in.)
*g	7.0 to 9.0 mm (0.276 to 0.354 in.)
*h	5.0 to 7.0 mm (0.197 to 0.276 in.)

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 cylinder head bolts within 15 minutes of applying seal packing.

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.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

Tech Tips

The cylinder head bolts are tightened in 4 progressive steps.

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.
Install the 10 plate washers to the 10 cylinder head bolts.
Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
Step 1:
1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head 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 washer for the cylinder head bolt into the cylinder head sub-assembly.
Step 2:
1. Check that the cylinder head bolts are tightened to the specified torque.
  
  Torque:
  
  36 N*m { 367 kgf*cm, 27 ft.*lbf }
Step 3:
1. *a Paint Mark
  
  Front of Engine
  
  Mark each cylinder head bolt head with paint as shown in the illustration.
2. Tighten the cylinder head bolts 90° in the order shown in step 1.
Step 4:
1. Tighten the cylinder head bolts another 90° in the order shown in step 1.
2. Check that the paint marks are now facing rearward.
  Note
  - Do not install the timing chain cover sub-assembly for at least 2 hours after installation.
  - Do not start the engine for at least 2 hours after installation.
  - Thoroughly wipe off any seal packing that has seeped out onto the front side of the engine.
  Tech Tips
  
  Perform inspection after repair after replacing the cylinder head sub-assembly.
  
  Click here

INSTALL VALVE STEM CAP

Apply a light coat of engine oil to the valve stem cap ends.
Install the 16 valve stem caps to the cylinder head sub-assembly.

Note

Be careful not to drop the valve stem caps into the cylinder head sub-assembly.

INSTALL VALVE LASH ADJUSTER ASSEMBLY

Inspect the 16 valve lash adjuster assemblies before installing them.

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

Tech Tips

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

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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

*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.

INSTALL NO. 2 CAMSHAFT BEARING

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INSTALL NO. 1 CAMSHAFT BEARING

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INSTALL OIL CONTROL VALVE FILTER

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INSTALL NO. 2 CAMSHAFT

Tech Tips

Perform inspection after repair after replacing the No. 2 camshaft.

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Clean the camshaft journals and camshaft housing sub-assembly.
Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.
Install the No. 2 camshaft to the camshaft housing sub-assembly.

INSTALL CAMSHAFT

Tech Tips

Perform inspection after repair after replacing the camshaft.

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Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
Install the camshaft to the camshaft housing sub-assembly.

INSTALL CAMSHAFT BEARING CAP

Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps in their correct locations.
Uniformly tighten the 11 bolts in several steps in the order shown in the illustration.

Torque:

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

Note

Make sure that the camshaft rotates smoothly after installing the camshaft bearing caps.
Check the torque of each bolt again.

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Stem Cap
*3	Valve Lash Adjuster Assembly
*a	Incorrect
*b	Correct

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

*a	Seal Packing
*b	2.5 to 3.5 mm (0.0984 to 0.138 in.)
*c	3.5 to 4.0 mm (0.138 to 0.157 in.)

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

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard seal diameter
3.0 to 4.0 mm (0.118 to 0.157 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.

*a	Approximately 17°
*b	Approximately 2°
*c	Knock Pin

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

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.

INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

Tech Tips

Perform inspection after repair after replacing the camshaft timing gear assembly.

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*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.
*a Knock Pin Hole

*b Knock Pin

Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

*1	Camshaft Timing Gear Assembly
*2	Camshaft Flange
*a	Incorrect
*b	Correct
*c	Gap
*d	No Gap

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

Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing gear assembly with 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

INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Tech Tips

Perform inspection after repair after replacing the camshaft timing exhaust gear assembly.

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Secure the No. 2 camshaft in a vise by clamping the hexagonal part between aluminum plates.

Note

Do not damage the No. 2 camshaft by tightening the vise excessively.
*a Knock Pin Hole

*b Knock Pin

Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.

*1	Camshaft Timing Exhaust Gear Assembly
*2	Camshaft Flange
*a	Incorrect
*b	Correct
*c	Gap
*d	No Gap

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

*a Hold

*b Turn

Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing exhaust gear assembly with 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.

ADD ENGINE OIL

Add 50 cc (3.1 cu. in) of engine oil into the oil hole shown in the illustration.
Note
- Engine oil must be added if the valve lash adjusters were removed.
- Make sure that the low pressure chamber and oil paths of the valve lash adjusters are full of engine oil.

SET NO. 1 CYLINDER TO TDC/COMPRESSION

Temporarily install the crankshaft pulley bolt.
*1 Crankshaft Pulley Key

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

INSTALL NO. 1 CHAIN VIBRATION DAMPER

Install the No. 1 chain vibration damper with the 2 bolts.

Torque:

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

INSTALL CHAIN SUB-ASSEMBLY

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 paint mark of the chain sub-assembly is facing away from the engine assembly.
- It is not necessary to install the chain sub-assembly to the teeth of the gears and sprocket.
*a Paint Mark (Orange)

*b Timing Mark

Align the paint mark (orange) 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.
*a Paint Mark (Yellow)

*b Timing Mark

Align the paint mark (yellow) 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.
Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.
*a Paint Mark (Orange)

*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 paint mark (orange) 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.
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 securely installed.

INSTALL CHAIN TENSIONER SLIPPER

Install the chain tensioner slipper with the bolt.

Torque:

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

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

*a Pin

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 }
Remove the pin from the stopper plate.