CYLINDER HEAD GASKET INSTALLATION

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. B003W0PC06
      *1 Seal Packing
      *2 Cylinder Head Gasket
      B003WAF Application Area

      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 and tighten the cylinder head set bolts within 15 minutes after applying the seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    2. B003U8XC02
      *1 Lot No.
      B003WAF Engine Front

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

      Note

      Be careful of the installation direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY


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

      Note


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

      • Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly.

      • Check the cylinder head set bolts and bolt holes, and clean them.

      • Clean and degrease the installation surface.

      Tech Tips

      The cylinder head set 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 set bolts.

    3. B003W4CN03

      Step 1:


      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head set 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 }

        Note


        • Be careful not to drop plate washers into the cylinder head sub-assembly.

        • Install the cylinder head set bolts in their original locations.

        • When reusing the cylinder head set bolts, inspect the diameter of the threads. If the diameter is less than the minimum, replace the cylinder head set bolts with new ones.

          Click here

    4. Step 2:


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

      2. B003TVMC06
        *1 Point Mark
        *a 90°
        B003WAF Engine Front

        Tighten the cylinder head set bolts another 90°.

    5. Step 3:


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

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

    6. B003THSC01
      *1 Cylinder Head Sub-assembly
      *2 Cylinder Head Gasket
      *3 Cylinder Block Sub-assembly
      *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. B003TOIC02
      *1 Seal Packing
      *2 No. 2 Cylinder Head Gasket
      B003WAF Application Area

      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 and tighten the cylinder head set bolts within 15 minutes after applying the seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    2. B003VZFC02
      *1 Lot No.
      B003WAF Engine Front

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

      Note

      Be careful of the installation direction.

  4. INSTALL CYLINDER HEAD LH


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

      Note


      • Gently place the cylinder head LH in order not to damage the No. 2 cylinder head gasket with the bottom part of the cylinder head LH.

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

      • Check the cylinder head set bolts and bolt holes, and clean them.

      • Clean and degrease the installation surface.

      Tech Tips

      The cylinder head set 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 set bolts.

    3. Step 1:


      1. B003WLBN01

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head set 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 }

        Note


        • Be careful not to drop plate washers into the cylinder head LH.

        • Install the cylinder head set bolts in their original locations.

        • When reusing the cylinder head set bolts, inspect the diameter of the threads. If the diameter is less than the minimum, replace the cylinder head set bolts with new ones.

          Click here

    4. Step 2:


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

      2. B003TVMC06
        *1 Point Mark
        *a 90°
        B003WAF Engine Front

        Tighten the cylinder head set bolts another 90°.

    5. Step 3:


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

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

    6. B003VOIN07

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

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. B003THSC01
      *1 Cylinder Head LH
      *2 No. 2 Cylinder Head Gasket
      *3 Cylinder Block Sub-assembly
      *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 SUB-ASSEMBLY

    Click here

  8. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

  9. INSTALL NO. 3 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 intake valves and exhaust valves.

      Note

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

  12. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assembly.

      Click here

    2. Install the 24 valve lash adjuster assemblies to the cylinder head sub-assembly and cylinder head LH.

      Note

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

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


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

    2. B003VDXC19
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

      Install the 24 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note


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

      • Install the No. 1 valve rocker arm sub-assembly at 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 sub-assembly LH.

    2. Set the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly 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 sub-assembly LH.

    2. Set the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH.

  18. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. B003TJZC04
      *1 No. 3 Camshaft Bearing Cap
      *2 No. 4 Camshaft Bearing Cap
      *3 No. 8 Camshaft Bearing Cap
      *4 No. 7 Camshaft Bearing Cap

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

    3. B003W0ZN03

      Uniformly and temporarily tighten the 8 bolts in the order shown in the illustration.

  19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B003TJLC03
      *1 Valve Stem Cap
      *2 No. 1 Valve Rocker Arm Sub-assembly
      *3 Valve Lash Adjuster Assembly
      *4 Valve Stem
      *a CORRECT
      *b INCORRECT

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

    2. B003WFUC01
      *1 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
      Seal diameter
      3.5 to 4.0 mm (0.138 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Check the bolts and bolt holes, and clean them.

      • Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    3. B003T3EC01
      *1 Knock Pin
      *a IN
      *b EX
      B003WAF Bolt A
      B003U82 Bolt B

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

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing sub-assembly 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.

      • Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed.

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

      • If the camshaft housing sub-assembly 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.

      Bolt Length:
      Item Specified Condition
      Bolt A 68 mm (2.68 in.)
      Bolt B 48 mm (1.89 in.)
    4. B003UMQN09

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

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

    5. Thoroughly wipe clean any seal parking.

      Note

      Be careful not to drop seal packing into the cylinder head LH.

  20. INSTALL CAMSHAFT


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

    2. Install the camshaft to the camshaft housing sub-assembly RH.

  21. INSTALL NO. 2 CAMSHAFT


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

    2. Install the No. 2 camshaft to the camshaft housing sub-assembly RH.

  22. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. B003WT7C03
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap
      *3 No. 5 Camshaft Bearing Cap
      *4 No. 7 Camshaft Bearing Cap
      *5 No. 6 Camshaft Bearing Cap

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

    3. B003TONN01

      Uniformly and temporarily tighten the 9 camshaft bearing cap bolts in the order shown in the illustration.

  23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B003TJLC04
      *1 Valve Stem Cap
      *2 No. 1 Valve Rocker Arm Sub-assembly
      *3 Valve Lash Adjuster Assembly
      *4 Valve Stem
      *a CORRECT
      *b INCORRECT

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

    2. B003UMCC01
      *1 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
      Seal diameter
      3.5 to 4.0 mm (0.138 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Check the bolts and bolt holes, and clean them.

      • Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    3. B003UEQC01
      *1 Knock Pin
      *a EX
      *b IN
      *c 45°
      B003WAF Bolt A
      B003U82 Bolt B

      Install the camshaft housing sub-assembly RH and tighten the 14 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      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.

      • Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed.

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

      • If the camshaft housing sub-assembly 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.

      Bolt Length:
      Item Specified Condition
      Bolt A 68 mm (2.68 in.)
      Bolt B 48 mm (1.89 in.)
    4. B003U6JN06

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

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

    5. Thoroughly wipe clean any seal packing.

      Note

      Be careful not to drop seal packing into the cylinder head sub-assembly.

  24. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B003W4YC03
      *1 Plunger
      *2 Pin
      *a Push

      Install the No. 3 chain tensioner assembly with the bolt.

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

    2. While pushing in the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

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


    1. B003UGRC02
      *1 Timing Mark
      *2 Mark Plate (yellow)

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH 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 LH with the No. 2 chain sub-assembly installed.

      Note

      Do not forcefully press the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly or camshaft timing exhaust gear assembly LH, leading to poor sealing.

    4. B003VQXC01
      *a Turn
      *b Hold

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

  26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003UN6C05
      *1 Plunger
      *2 Pin
      *a Push

      Install the No. 2 chain tensioner assembly with the bolt.

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

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

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


    1. B003TZZC02
      *1 Timing Mark
      *2 Mark Plate (yellow)

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH 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 RH with the No. 2 chain sub-assembly installed.

      Note

      Do not forcefully press the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly or camshaft timing exhaust gear assembly RH, leading to poor sealing.

    4. B003UXRC01
      *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 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 assembly.

  28. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  29. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  31. INSPECT VALVE TIMING

    Click here

  32. POUR ENGINE OIL

    Click here

  33. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

    Click here