CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly Click here.

PROCEDURE


  1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Click here

  3. INSPECT CYLINDER HEAD BOLT

    Click here

  4. INSPECT CYLINDER HEAD

    Click here

  5. INSTALL CYLINDER HEAD GASKET


    1. A0057K1E03
      *1 Seal Packing
      *2 Cylinder Block
      *3 Engine Front

      Apply seal packing to the cylinder block as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal packing diameter
      4.0 mm (0.157 in.)
      Application Specification
      Area Seal Packing Application Length Distance from Edge of Cylinder Block to Center of Seal Packing
      A - 2.0 to 4.0 mm (0.0787 to 0.157 in.)
      B 10 to 15 mm (0.394 to 0.591 in.) -

      Note

      Remove any oil from the cylinder block.

    2. A0054OOE06
      *1 Lot No.
      *2 Engine Front

      Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.

      Note

      Install the cylinder head gasket within 3 minutes after applying seal packing.

    3. A00570YE03
      *1 Seal Packing
      *2 Cylinder Head Gasket
      *3 Engine Front

      Apply seal packing to the cylinder head gasket as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal packing diameter
      4.0 mm (0.157 in.)
      Application Specification
      Area Seal Packing Application Length Distance from Edge of Cylinder Head Gasket to Center of Seal Packing
      A - 2.0 to 4.0 mm (0.0787 to 0.157 in.)
      B 10 to 15 mm (0.394 to 0.591 in.) -

      Note


      • Remove any oil from the cylinder head gasket and cylinder head.

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

  6. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly Click here.


    1. Place the cylinder head on the cylinder block.

      Note


      • Make sure 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. A0058MXE02

      Step 1:


      1. 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:
        49 N*m  { 500 kgf*cm, 36 ft.*lbf }

        Note

        Do not drop the plate washers into the cylinder head.

    5. A0052GWE12
      *1 Front
      *2 Paint Mark

      Step 2:


      1. 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.

    6. Step 3:


      1. Tighten the cylinder head bolts another 45° in the sequence shown in step 1.

    7. Check that the paint mark is now at a 135° angle to the front.

    8. A00535HE04
      *1 Before wiping off
      *2 After wiping off

      After tightening the cylinder head bolts, wipe off the seal packing material that has seeped out from between the contact surfaces of the cylinder head and cylinder block.

  7. INSTALL VALVE STEM CAP

    Click here

  8. INSTALL NO. 1 WATER BY-PASS PIPE

    Click here

  9. INSTALL EXHAUST MANIFOLD

    Click here

  10. INSTALL MANIFOLD STAY

    Click here

  11. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  13. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. Install the camshaft housing sub-assembly Click here.

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine assembly with transaxle Click here.