CYLINDER HEAD GASKET INSTALLATION

PROCEDURE

1. INSPECT CYLINDER HEAD SET BOLT

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2. INSTALL CYLINDER HEAD GASKET

   
   

   1. Clean and check the cylinder head set bolt holes of the cylinder block sub-assembly.

   2. Clean and degrease the lower surface of the cylinder head sub-assembly and upper surface of the cylinder block sub-assembly.

   3. 

      *a

      Bead

      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

      
      

      • Apply seal packing to the bead center on the cylinder head gasket.

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

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

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

   4. 

      *a	Lot No.
      	Engine Front

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

      Note

      
      

      • Make sure that the cylinder head gasket is installed in the correct direction.

      • Do not damage the cylinder head gasket.

3. INSTALL CYLINDER HEAD SUB-ASSEMBLY

   
   

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

   2. 

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

   3. Temporarily install the 10 cylinder head set bolts and 10 cylinder head set plate washers to the cylinder head sub-assembly.

      Note

      
      

      • Do not drop the cylinder head set plate washers into the cylinder head sub-assembly.

      • Install the same parts to their original positions.

   4. 

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

      Torque:

      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

   5. 

      *a	Paint Mark
      	Engine Front

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

   6. Tighten the cylinder head set bolts 90° in the order shown in the illustration.

   7. Tighten the cylinder head set bolts another 90° in the order shown in the illustration.

      Note

      Do not tighten the same cylinder head set bolt twice consecutively.

   8. Check that the paint mark is now at a 180° angle to the engine front.

   9. 

      *1	Cylinder Head Sub-assembly
      *2	Cylinder Block Sub-assembly
      *3	Cylinder Head Gasket
      *a	Direction to wipe off
      *b	Before wiping off
      *c	After wiping off
      *d	After wiping by cloth
      *e	Seal Packing
      *f	Chamfer of Cylinder Head Sub-assembly
      *g	Chamfer of Cylinder Block Sub-assembly

      After tightening the cylinder head set bolts, wipe off any seal packing material that seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly.

      Note

      
      

      • Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.

      • Be sure to avoid clogging the bolt holes when wiping off the seal packing.

   10. Using a cloth, wipe off any seal packing from the chamfers of the cylinder head sub-assembly and cylinder block sub-assembly.

       Note

       
       

       • Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.

       • Be sure to avoid clogging the bolt holes when wiping off the seal packing.

       • Do not wipe off the seal packing to the extent that the end of the cylinder head gasket is exposed.

       • Do not leave any seal packing on the chamfers of the cylinder block sub-assembly or cylinder head sub-assembly.

4. INSTALL CAMSHAFT

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