CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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

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PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. B003SX5C01
      *1 Cylinder Head Gasket
      *a 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *d 38.6 mm (1.52 in.)
      *e 142.7 mm (5.62 in.)

      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

      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. B003WI0C03
      *a Lot No.
      B003WAF 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 sub-assembly on the cylinder block.

      Note

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

      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. B003WNNE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 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. B003TVMC12
      *1 Paint Mark
      *a 90°

      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. B003TXWC01
      *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. B003U60C01
      *1 No. 2 Cylinder Head Gasket
      *a 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *d 39.3 mm (1.55 in.)
      *e 111.3 mm (4.38 in.)

      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

      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. B003V6PC03
      *a Lot No.
      B003WAF 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. B003WKCE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 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. B003TVMC12
      *1 Paint Mark
      *a 1st

      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. B003X1NE03

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

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. B003TXWC01
      *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

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  6. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)

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  7. INSTALL FUEL DELIVERY PIPE RH

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  8. INSTALL FUEL DELIVERY WITH SENSOR PIPE ASSEMBLY LH

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  9. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

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  10. INSTALL REAR WATER BY-PASS JOINT

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  11. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the 24 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 assembly.

      Click here

    2. Install the 24 valve lash adjuster assemblies 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 valve lash adjuster tips and valve stem cap ends.

    2. B003T05C06
      *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-assemlies 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

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  15. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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  16. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


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

    2. Install 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 sub-assembly journals and camshaft housing sub-assembly LH.

    2. Install 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. B003U3P

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

    3. B003WEQE02

      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 NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B003U4LC01
      *a Plunger
      *b Pin
      *c 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 fix the No. 3 chain tensioner assembly in place.

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


    1. B003T79C03
      *a Timing Mark
      *b Mark Plate (yellow)

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

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

  21. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)

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  22. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)

    Click here

  23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B003T5EC11
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
      *a CORRECT
      *b INCORRECT

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

    2. B003V0WC04
      *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.)
      *c Clearance of 4.0 to 6.0 mm (0.158 to 0.236 in.)
      B003V24 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. Install the camshaft housing LH and tighten the 15 bolts in the order shown in the illustration.

      B003V0YC07
      *a Bolt Type *b Tightening Order
      *c Knock Pin *d Intake Side
      *e Exhaust Side - -
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 48 mm (1.89 in.)
      Bolt B 68 mm (2.68 in.)

      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.

      • 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.

    4. B003X8XE01

      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.

  24. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 2)


    1. B003TZ3C04
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of each camshaft, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    2. B003UECC04
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of each camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with the wrench.

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

  25. 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.

  26. 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.

  27. INSTALL FUEL PUMP LIFTER HOUSING


    1. Install the fuel pump lifter housing.

  28. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. B003UE8

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

    3. B003X3YC03
      B003WAF Bolt A
      B003U82 Bolt B

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

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

  29. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003TUJC01
      *a Plunger
      *b Pin
      *c 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 fix the No. 2 chain tensioner assembly in place.

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


    1. B003UQZC03
      *a Timing Mark
      *b Mark Plate

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

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

  31. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)

    Click here

  32. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)

    Click here

  33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B003T5EC11
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *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. B003VQZC04
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.)
      *b Clearance of 4.0 to 6.0 mm (0.158 to 0.236 in.)
      B003V24 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. Install the camshaft housing RH and tighten the 15 bolts in the order shown in the illustration.

      B003TIAC06
      *a Tightening Order *b Types of bolt
      *c Knock Pin *d Exhaust Side
      *e Intake Side *f 45°
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 48 mm (1.89 in.)
      Bolt B 68 mm (2.68 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. B003TMRE01

      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.

  34. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 1)


    1. B003X2HC04
      *a Turn
      *b Hold

      Using a wrench to hold the hexagonal portion of each camshaft, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    2. B003SYPC03
      *a Turn
      *b Hold

      Using a wrench to hold the hexagonal portion of each camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    3. Remove the pin from the No. 2 chain tensioner assembly.

  35. INSTALL CHAIN SUB-ASSEMBLY

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  36. INSTALL CHAIN TENSIONER SLIPPER

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  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  38. INSPECT VALVE TIMING

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  39. INSTALL TIMING CHAIN COVER ASSEMBLY

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