CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. A000SQ5E02
      Text in Illustration
      *1 Seal Packing
      *2 Gasket

      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
      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 1.50 mm (0.0492 to 0.0591 in.)

      Note


      • Remove any oil from the contact surface.

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

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

    2. A000N2XE02
      Text in Illustration
      *1 Lot No.
      B002B6O Engine Front

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

      Note


      • Be careful of the installation direction.

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

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

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


    1. Place the cylinder head on the cylinder block.

      Note

      Be careful not to allow oil to adhere to the bottom part 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. A000NSQE04

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and 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. A000SFQE01
      Text in Illustration
      *1 Cylinder Head
      *2 Cylinder Head Gasket
      *3 Cylinder Block
      *a Wipe Clean

      Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

  3. INSTALL NO. 2 CYLINDER HEAD GASKET


    1. A000SWWE02
      Text in Illustration
      *1 Seal Packing
      *2 Gasket

      Apply a continuous line of seal packing to a new No. 2 cylinder head gasket as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      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 1.50 mm (0.0492 to 0.0591 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 cylinder head gasket within 3 minutes after applying the seal packing.

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

    2. A000OQPE02
      Text in Illustration
      *1 Lot No.
      B002B6O Engine Front

      Place the No. 2 cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

      Note


      • Be careful of the installation direction.

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

  4. INSTALL CYLINDER HEAD LH

    Tech Tips

    Perform "Inspection After Repairs" after replacing the cylinder head LH Click here.


    1. Place the cylinder head LH on the cylinder block.

      Note

      Be careful not to allow oil to adhere to the bottom part of the cylinder head LH.

      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. A000P45E04

        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. A000PC1E04

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

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. A000SFQE01
      Text in Illustration
      *1 Cylinder Head LH
      *2 No. 2 Cylinder Head Gasket
      *3 Cylinder Block
      *a Wipe Clean

      Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

  5. INSTALL FUEL INJECTOR SEAL

    Click here

  6. INSTALL FUEL INJECTOR ASSEMBLY

    Click here

  7. INSTALL FUEL DELIVERY PIPE RH

    Click here

  8. INSTALL FUEL DELIVERY PIPE LH

    Click here

  9. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  10. INSTALL REAR WATER BY-PASS JOINT

    Click here

  11. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem caps.

    2. Install the 24 valve stem caps to the cylinder head.

      Note

      Install the valve stem cap to the same place it was removed from.

  12. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster Click here.

    2. Install the 24 valve lash adjusters to the cylinder head.

      Note

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

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


    1. Apply engine oil to the lash adjuster tips and valve stem cap ends.

    2. A000NP6E04
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Install the 24 No. 1 valve rocker arms as shown in the illustration.

      Note

      Install the No. 1 valve rocker arm to the same place it was removed from.

  14. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  15. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    Click here

  16. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing LH.

    2. Install the No. 3 camshaft to the camshaft housing LH.

  17. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing LH.

    2. Install the No. 4 camshaft to the camshaft housing LH.

  18. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A000O7W

      Make sure of the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.

    3. A000N9DE02

      Temporarily install and tighten the 8 bolts in the order shown in the illustration.

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

  19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A000P90E04
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
      *a CORRECT
      *b INCORRECT

      Make sure that the No. 1 valve rocker arm is installed as shown in the illustration.

    2. A000NXEE02
      Text in Illustration
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.)
      *b Diameter 4.0 to 4.5 mm (0.158 to 0.177 in.)
      B002B9H Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing LH within 3 minutes.

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

    3. A000Q23E03
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX
      B002B6O Bolt A
      B002BBR Bolt B

      Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Standard Bolt
      Item Length
      A 68 mm (2.68 in.)
      B 48 mm (1.89 in.)

      Note


      • When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing LH, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

    4. A000PNDE05

      Tighten the 8 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    5. Remove any protruding seal packing black.

  20. INSTALL CAMSHAFT


    1. Apply a light coat of engine oil to the camshaft journals and camshaft housing RH.

    2. Install the camshaft to the camshaft housing RH.

  21. INSTALL NO. 2 CAMSHAFT


    1. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing RH.

    2. Install the No. 2 camshaft to the camshaft housing RH.

  22. INSTALL FUEL PUMP LIFTER HOUSING


    1. Install the fuel pump lifter housing.

  23. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A000N17

      Make sure of the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.

    3. A000PS7E02

      Temporarily install and tighten the 9 bearing cap bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard Bolt
      Item Length
      A 40 mm (1.57 in.)
      B 58 mm (2.28 in.)
      Text in Illustration
      B002B6O Bolt A
      B002BBR Bolt B

  24. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A000P90E04
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
      *a CORRECT
      *b INCORRECT

      Make sure that the No. 1 valve rocker arm is installed as shown in the illustration.

    2. A000OCNE01
      Text in Illustration
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.)
      B002B9H Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing RH within 3 minutes.

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

    3. A000QMLE03
      Text in Illustration
      *1 Knock Pin
      *a EX
      *b IN
      B002B6O Bolt A
      B002BBR Bolt B

      Install the camshaft housing RH and tighten the 15 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Standard Bolt
      Item Length
      A 68 mm (2.68 in.)
      B 48 mm (1.89 in.)

      Note


      • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration.

        Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing RH, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

    4. A000P74E03

      Tighten the 9 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    5. Remove any protruding seal packing black.

  25. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A000R0XE02
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

      Install the No. 3 chain tensioner with the bolt.

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

    2. While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix the tensioner in place.

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


    1. A000QITE01
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain installed.

    4. A000P3FE06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 3 chain tensioner.

  27. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A000R8PE02
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

      Install the No. 2 chain tensioner with the bolt.

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

    2. While pushing in the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix the tensioner in place.

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


    1. A000NO6E01
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

    4. A000SWAE03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 2 chain tensioner.

  29. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  30. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  31. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  32. INSPECT VALVE TIMING

    Click here

  33. POUR ENGINE OIL

    Click here

  34. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here