CYLINDER HEAD GASKET INSTALLATION

PROCEDURE


  1. INSPECT CYLINDER HEAD SET BOLT

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  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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  3. INSTALL CYLINDER HEAD GASKET


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head or cylinder block.

    2. A01X5QZE04
      Text in Illustration
      *1 Seal Packing
      *2 Gasket

      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
      Standard seal diameter
      2.5 to 3.0 mm (0.0984 to 0.118 in.)
      Seal Packing Application Range
      A 10 to 15 mm (0.394 to 0.591 in.)
      B 1.25 to 1.5 mm (0.0492 to 0.0591 in.)

      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.

      • Do not add engine oil within 2 hours of installation.

    3. A01X92JE01
      Text in Illustration
      *1 Lot No.
      B001XPG Engine Front

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

      Note

      Make sure that the gasket is installed facing the proper direction.

  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. Place the cylinder head on the cylinder block.

      Note


      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

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

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

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

    3. Step 1:


      1. A01X387E09

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    4. Step 2:


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

      2. Tighten the cylinder head bolts another 90°.

    5. Step 3:


      1. Tighten the cylinder head bolts an additional 90°.

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

        Note

        Thoroughly wipe clean any seal packing.

  5. INSTALL NO. 2 CYLINDER HEAD GASKET


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head or cylinder block.

    2. A01X38JE04
      Text in Illustration
      *1 Seal Packing
      *2 Gasket

      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
      Standard seal diameter
      2.5 to 3.0 mm (0.0984 to 0.118 in.)
      Seal Packing Application Range
      A 10 to 15 mm (0.394 to 0.591 in.)
      B 1.25 to 1.5 mm (0.0492 to 0.0591 in.)

      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.

      • Do not add engine oil within 2 hours of installation.

    3. A01XC3VE01
      Text in Illustration
      *1 Lot No.
      B001XPG Engine Front

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

      Note

      Make sure that the gasket is installed facing the proper direction.

  6. INSTALL CYLINDER HEAD LH


    1. Place the cylinder head on the cylinder block.

      Note


      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

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

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

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

    3. Step 1:


      1. A01XA14E08

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    4. Step 2:


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

      2. Tighten the cylinder head bolts another 90°.

    5. Step 3:


      1. Tighten the cylinder head bolts an additional 90°.

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

    6. A01WZCNE02

      Install the 2 bolts in the order shown in the illustration.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Thoroughly wipe clean any seal packing.

  7. INSTALL REAR WATER BY-PASS JOINT

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  8. INSTALL VALVE STEM CAP

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  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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  11. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

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  12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

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  13. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

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  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

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  15. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

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  16. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

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  17. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

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  18. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

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  19. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  20. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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  21. INSTALL CRANKSHAFT TIMING SPROCKET

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  22. INSTALL NO. 1 IDLE GEAR SHAFT

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  23. INSTALL CHAIN SUB-ASSEMBLY

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  24. INSTALL CHAIN TENSIONER SLIPPER

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  25. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  26. INSPECT VALVE TIMING

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  27. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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