CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

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

   Click here

2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

   Click here

3. INSPECT CYLINDER HEAD SET BOLT

   Click here

4. INSPECT CYLINDER HEAD

   Click here

5. INSTALL CYLINDER HEAD GASKET

   
   
   1. 

      *1	Cylinder Block Sub-assembly
      	Engine Front

      Apply seal packing (diameter 4.0 mm (0.157 in.)) to the cylinder block sub-assembly as shown in the illustration.

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

      Note

      Remove any oil from the cylinder block sub-assembly.

   2. 

      *a	Lot No.
      	Engine Front

      Place a new cylinder head gasket on the cylinder block sub-assembly with the lot No. stamp facing upward.

      Note

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

   3. 

      *1	Cylinder Head Gasket
      	Engine Front

      Apply seal packing (diameter 4.0 mm (0.157 in.)) to the new cylinder head gasket as shown in the illustration.

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

      Note

      
      

      • Remove any oil from the cylinder head gasket and cylinder head sub-assembly.

      • Install the cylinder head gasket 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.

   
   

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

      Note

      
      

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

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

   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. 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 sub-assembly.

   5. 

      *a	Paint Mark
      	Front

      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. 

      *a	Before wiping off
      *b	After wiping off

      After tightening the cylinder head bolts, wipe off any seal packing material that seeped out from the contact surfaces between the cylinder head and cylinder block sub-assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the cylinder head sub-assembly.

      Click here

7. INSTALL VALVE STEM CAP

   Click here

8. INSTALL VALVE LASH ADJUSTER ASSEMBLY

   Click here

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

   Click here

10. INSTALL NO. 1 WATER BY-PASS PIPE

    Click here

11. INSTALL EXHAUST MANIFOLD

    Click here

12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

13. INSTALL FUEL INJECTOR ASSEMBLY

    Click here

14. INSTALL NO. 1 DELIVERY PIPE SPACER

    Click here

15. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

16. INSTALL FUEL TUBE SUB-ASSEMBLY

    Click here

17. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here