CYLINDER HEAD GASKET INSTALLATION


  1. INSPECT CYLINDER HEAD BOLT


    1. A01EM73E13

      Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard diameter
      10.85 to 11.00 mm (0.427 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)
      Measurement point (distance from the seat)
      106 mm (4.17 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage.

      • If there is any thread deformation, replace the cylinder head bolt with a new one.

  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. A01EL66E02
      Text in Illustration
      *1 Cylinder Head Lower Side:
      *2 Intake Manifold Side:
      *3 Exhaust Manifold Side:

      Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block and manifold.

      Maximum Warpage
      Item Specified Condition
      Cylinder head lower side 0.05 mm (0.00197 in.)
      Intake manifold side 0.10 mm (0.00394 in.)
      Exhaust manifold side 0.10 mm (0.00394 in.)

      If the warpage is more than the maximum, replace the cylinder head.

    2. A01EIQV

      Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.

      If cracked, replace the cylinder head.

  3. INSTALL CYLINDER HEAD GASKET


    1. A01EJ0ZE01

      Clean the cylinder block and cylinder head 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.) thick

      Tech Tips

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

      Note


      • Remove any oil from the contact surface.

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

    3. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp 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 on the cylinder block.

      Note


      • Ensure that no oil is on the mounting surface of the cylinder head.

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

    2. Install the plate washers to the 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. A01EJ20E02

        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 washer for the cylinder head bolt into the cylinder head.

    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. A01EKM7E03

        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 painted marks are now facing rearward.

        Note


        • Do not apply oil for at least 4 hours after the installation.

        • Do not start the engine for at least 4 hours after the installation.

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

  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.

      Note

      Do not drop the valve stem caps into the cylinder head.

  6. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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


    1. A01EKS7E02
      Text in Illustration
      *1 Advanced Position:
      *2 Knock Pin Hole
      *3 Alignment Mark
      *4 Retarded Position:

      Check the camshaft timing gear position.

      Note

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

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

    2. A01EKOME02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    3. A01ELO9E05
      Text in Illustration
      *1 INCORRECT
      *2 Camshaft Timing Gear
      *3 Clearance
      *4 Flange
      *5 CORRECT
      *6 No Clearance

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

    4. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear 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. A01EKR1E01

      Release the lock pin.


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

      2. Cover the 4 oil paths of the cam 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. A01EKGU

        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 paths with a piece of cloth when applying pressure to keep oil from splashing.

        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 be turned in the advance direction without applying any force.

        • 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.

      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 before installing it Click here.

    2. Install the 16 lash adjusters to the cylinder head.

      Note

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

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


    1. A01EKLEE04
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

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

    2. Install the 16 valve rocker arms as shown in the illustration.

  9. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. Install the camshaft bearing to the camshaft housing.

    3. A01EJNBE01

      Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  10. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01EKZYE01

      Clean the No. 1 camshaft bearing.

    2. Install the camshaft bearing to the No. 1 camshaft bearing cap.

    3. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  11. INSTALL OIL CONTROL VALVE FILTER


    1. A01EM6ZE01

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  12. INSTALL CAMSHAFT


    1. Clean the camshaft journals, camshaft housing and bearing caps.

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

    3. Install the No. 1 and No. 2 camshafts to the camshaft housing.

  13. INSTALL CAMSHAFT BEARING CAP


    1. A01ELZO

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    2. A01ELKUE02

      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 rotates smoothly after installing the bearing caps.

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01EK4EE02
      Text in Illustration
      *1 INCORRECT
      *2 Valve Rocker Arm
      *3 Valve Stem Cap
      *4 Valve Lash Adjuster
      *5 CORRECT

      Check that the valve rocker arms are installed as shown in the illustration.

    2. A01ELT1E01

      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 within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

    3. A01EKM5E01

      Position the knock pin of the No. 1 and No. 2 camshafts as shown in the illustration.

    4. A01EMJOE02

      Install the camshaft housing, 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 apply oil for at least 4 hours after the installation.

      • Do not start the engine for at least 4 hours after the installation.

      • Thoroughly wipe clean any seal packing.

  15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EKD9E02
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark

      Check the camshaft timing gear position.

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

    2. A01EKOME02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    3. A01ELO9E05
      Text in Illustration
      *1 INCORRECT
      *2 Camshaft Timing Gear
      *3 Clearance
      *4 Flange
      *5 CORRECT
      *6 No Clearance

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

    4. A01EKKD

      Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the bolt.

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

      Note


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

      • Do not disassemble the camshaft timing gear.

  16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01EMSGE02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

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

    2. A01ELO9E05
      Text in Illustration
      *1 INCORRECT
      *2 Camshaft Timing Exhaust Gear
      *3 Clearance
      *4 Flange
      *5 CORRECT
      *6 No Clearance

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

    3. A01EMJ2

      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 or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear.

  17. ADD ENGINE OIL


    1. A01EJP6

      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 lash adjusters were removed.

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

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01EKG4E01

      Temporarily install the crankshaft pulley bolt.

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

    3. A01EIXLE01

      Check that the timing marks of the camshaft timing gears are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  19. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01EM6Y

      Install the chain vibration damper with the 2 bolts.

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

  20. INSTALL CHAIN SUB-ASSEMBLY


    1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

      Tech Tips


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

      • It is not necessary to install the chain to the teeth of the gears and sprocket.

    2. A01ELEKE02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      Align the mark plate (yellow or gold) of the chain with the timing mark of the camshaft timing exhaust gear and install the chain to the camshaft timing exhaust gear.

    3. A01ELZAE02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      Align the mark plate (pink or gold) of the chain with the timing mark of the crankshaft timing sprocket and install the chain to the crankshaft timing sprocket.

    4. A01EJU2

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

    5. A01EJ6PE01

      Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.

      Tech Tips

      Hold the intake camshaft in place with a wrench until the chain tensioner is installed.

    6. A01EJVD

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

      Note

      Make sure the chain is secure.

  21. INSTALL CHAIN TENSIONER SLIPPER


    1. A01EKD5

      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. A01ELLA

      Install a new gasket and the chain tensioner 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. A01ELJY

      Install the timing chain guide with the bolt

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

  24. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01EKWBE01

    2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    3. Remove the crankshaft pulley bolt.

  25. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  26. INSTALL INTAKE MANIFOLD


    1. A01EJ7PE01

      Close the tumble control valves.

      Note

      The tumble control valves may be damaged if they are not closed before installing the intake manifold.

      Tech Tips

      Connect the battery to the terminals of the actuator to operate the motor and close the valves Click here.

    2. A01EJW4

      Install a new gasket to the intake manifold.

    3. A01EKS8E01

      Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01ELNQ

      Connect the intake air control actuator connector.

    5. Attach the 2 clamps to the intake manifold and bracket.

    6. Install the wire harness with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    7. A01EMBJ

      Install the wire harness bracket with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    8. Connect the fuel vapor feed hose, clamp and connector.

    9. A01ELQ2

      Install the 2 wire harness brackets with the 2 bolts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  27. CONNECT NO. 2 VENTILATION HOSE


    1. A01EJBV

      Connect the No. 2 ventilation hose to the intake manifold.

  28. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01EKM3E01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *a Fuel Delivery Pipe Side
      *b Cylinder Head Side

      Install 4 new injector vibration insulators to the cylinder head.

    2. Install the 2 fuel delivery spacers onto the cylinder head.

      Tech Tips

      Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side.

    3. Install the fuel delivery pipe sub-assembly together with the 4 fuel injectors to the cylinder head, and then temporarily install the 2 bolts.

      Note

      Be careful not to drop the fuel injectors when installing the fuel delivery pipe sub-assembly.

    4. Tighten the 2 bolts to the specified torque.

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

      Note


      • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.

      • Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.

  29. INSTALL THROTTLE BODY ASSEMBLY


    1. A01EJ9Y

      Install a new gasket to the intake manifold.

    2. A01EIXM

      Install the fuel tube bracket with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    3. A01EM4T

      Install the throttle body assembly with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A01EKVP

      Connect the 2 water by-pass hoses to the throttle body.

    5. A01EJO9

      Connect the throttle body assembly connector.

    6. Connect the fuel tube to the clamp.

  30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Install the exhaust manifold converter Click here.

  31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine and transaxle Click here.