CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the camshaft, No. 2 camshaft or cylinder head sub-assembly Click here.

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. Clean and degrease the contact surfaces of the cylinder head sub-assembly and cylinder block sub-assembly.

    2. A01XES7E04
      Text in Illustration
      *1 Cylinder Head Gasket
      *a 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *b 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *c 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *d 166.25 mm (6.55 in.)
      *e 62.25 mm (2.46 in.)
      *f Side View
      *g View A

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

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

      Note


      • Be sure to clean and degrease the contact surfaces.

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

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

    3. A01XF3YE01
      Text in Illustration
      *a Lot No.
      B001CHY Engine Front

      Place the cylinder head gasket on the cylinder block surface with the lot No. stamp facing upward.

      Note


      • Remove any oil from the contact surface.

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

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


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

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


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

      Note


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

      • Place the cylinder head sub-assembly on the cylinder block gently so as not to damage the gasket with the bottom part of the cylinder head sub-assembly.

    2. Install the plate washers to the cylinder head set bolts.

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

    4. A01XIOOE02

      Step 1:

      Using several steps, install and uniformly tighten the 10 cylinder head set bolts with plate washers in the sequence shown in the illustration.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    5. Mark the front of each cylinder head set bolt head with paint.

    6. Step 2:

      Tighten the cylinder head set bolts 90° in the sequence shown in step 1.

    7. Step 3:

      Tighten the cylinder head set bolts another 90° in the sequence shown in step 1.

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

    9. w/ Oil Cooler:

      Connect the No. 4 water by-pass pipe with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  3. CONNECT ENGINE WIRE


    1. Connect the engine wire to the cylinder head sub-assembly with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  4. 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 sub-assembly.

      Note

      Do not drop the valve stem caps into the cylinder head sub-assembly.

  5. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect each valve lash adjuster assembly before installing it Click here.

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

      Note

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

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


    1. Apply clean engine oil to the valve lash adjuster assembly tips and valve stem cap surfaces.

    2. B001I90E03
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
      *a INCORRECT
      *b CORRECT

      Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note

      Install the valve stem cap, valve lash adjuster assembly and No. 1 valve rocker arm sub-assembly to the same places they were removed from.

  7. INSTALL CAMSHAFTS

    Tech Tips

    Perform "Inspection After Repairs" after replacing the camshaft or No. 2 camshaft Click here.


    1. A01XH82E03

      Apply clean engine oil to the camshaft cams and cylinder head journals.

    2. Position the camshaft and No. 2 camshaft as shown in the illustration.

    3. B001I90E03
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
      *a INCORRECT
      *b CORRECT

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

  8. INSTALL CAMSHAFT BEARING CAP


    1. A01XJOU

      Temporarily install the No. 1 camshaft bearing cap.

    2. Confirm the location for each No. 2 camshaft bearing cap and install each one to the proper location.

    3. Uniformly temporarily install the 20 bolts while keeping the camshaft level.

    4. A01XDSTE03

      Tighten the 20 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 158 kgf*cm, 11 ft.*lbf }

  9. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  10. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  11. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  13. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  14. INSTALL TIMING CHAIN GUIDE

    Click here

  15. INSTALL CYLINDER HEAD COVER CONNECTOR SUB-ASSEMBLY

    Click here

  16. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  17. INSTALL VENTILATION PIPE


    1. Install the ventilation pipe with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Connect the No. 3 water by-pass hose to the cylinder head sub-assembly, and slide the clip to secure the hose.

    3. Connect the No. 3 ventilation hose to the ventilation pipe, and slide the clip to secure the hose.

    4. Connect the No. 1 ventilation hose to the PCV valve sub-assembly, and slide the clip to secure the hose.

    5. Connect the No. 1 water by-pass hose to throttle body with motor assembly, and slide the clip to secure the hose.

  18. INSTALL HEATER HOSE

    Click here

  19. INSTALL EXHAUST MANIFOLD

    Click here

  20. INSTALL AIR SWITCHING VALVE ASSEMBLY

    Click here

  21. INSTALL NO. 4 INTAKE PIPE

    Click here

  22. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  23. INSTALL ENGINE ASSEMBLY

    Click here