CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly or cylinder head sub-assembly.

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PROCEDURE


  1. INSPECT CYLINDER HEAD BOLT

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  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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  3. INSTALL CYLINDER HEAD GASKET


    1. A0028EUC13
      *1 Cylinder Head Gasket
      *2 Cylinder Block Sub-assembly
      *a Lot No.
      *b 3.0 mm or more
      *c 20 mm or more
      B003ZIE Seal Packing
      B003Z8F Front

      Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

    2. 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
      Standard Seal Dimension
      3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) or thicker

      Tech Tips

      Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block sub-assembly.

      Note


      • Remove any oil from the contact surfaces.

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

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

      Note

      Pay attention to the installation direction.

  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 4 progressive steps.


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

      Note


      • Ensure that no oil is on the contact surface of the cylinder head sub-assembly.

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

    2. Install the 10 plate washers to the 10 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. A00270QN19

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the order shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

        Note

        Do not drop the plate washers for the cylinder head bolts into the cylinder head sub-assembly.

    5. Step 2:


      1. Check that the cylinder head bolts are tightened to the specified torque.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    6. Step 3:


      1. A002ACHC03
        *a Paint Mark
        B003ZIE Front

        Mark each cylinder head bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head bolts by 90° in the order shown in step 1.

    7. Step 4:


      1. Tighten the cylinder head bolts by another 90° in the order shown in step 1.

      2. Check that the paint marks are now facing rearward.

        Note


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

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

        • After installation, if the seal packing has seeped out, wipe it off.

        Tech Tips

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

        Click here

  5. INSTALL VALVE STEM CAP


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

  6. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

    When installing the camshaft timing gear assembly, release the lock pin and set the camshaft timing gear assembly to the advanced position before installation.


    1. A00278JC26
      *a Advanced Position
      *b Retarded Position
      *c Knock Pin Hole
      *d Alignment Mark

      Check the camshaft timing gear assembly position.

      Note


      • If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

      • If the camshaft timing gear assembly has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear assembly to the most advanced position before tightening the bolt of the camshaft timing gear assembly.

    2. A0027FQC55
      *a Knock Pin
      *b Pin Hole

      Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    3. A002BAAC74
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

      Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

    4. Secure the camshaft in place by hand, and then install the bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    5. Release the lock pin.

      A0028GAC21
      *a Retard Side Path *b Advance Side Path
      *c Open *d Close
      *e Rubber Piece *f Vinyl Tape
      *g Knock Pin - -

      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug 3 of the paths with rubber pieces.

      3. Make a hole at the port (A) shown in the illustration.

      4. A002CB8

        While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips


        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      5. Remove the vinyl tape and rubber pieces from the camshaft.

    6. Remove the bolt and camshaft timing gear assembly.

      Note

      Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

  7. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the 16 valve lash adjuster assemblies before installing them.

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    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.

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


    1. A002BKVC37
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

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

  9. INSTALL NO. 2 CAMSHAFT BEARING

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  10. INSTALL NO. 1 CAMSHAFT BEARING

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  11. INSTALL OIL CONTROL VALVE FILTER

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  12. INSTALL CAMSHAFT


    1. Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    3. Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft.

      Click here

  13. INSTALL CAMSHAFT BEARING CAP


    1. A002BDZ

      Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.

    2. A0029QRN14

      Install the 11 bolts in the order shown in the illustration.

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

      Note

      Make sure that the camshaft and No. 2 camshaft rotate smoothly after installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps.

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A002BNTC20
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Incorrect
      *b Correct

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

    2. A002A4LC05
      *a Dashed Line
      *b Groove

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

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Apply Seal Packing as Follows
      Area Seal Packing Diameter Application Position
      Continuous Line 3.0 to 4.0 mm (0.118 to 0.157 in.) Distance from edge of camshaft housing sub-assembly to center of seal packing: 3.5 to 4.0 mm (0.138 to 0.157 in.)
      Dashed Line Distance from outside edge of groove to center of seal packing: 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

    3. A002C1JC12
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin

      Position the knock pins of the camshaft and No. 2 camshaft as shown in the illustration.

    4. A002BGFN11

      Install the camshaft housing sub-assembly, and then install the 20 bolts in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

      Note


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

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

      • After installation, if the seal packing has seeped out, wipe it off.

  15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A0029FHC12
      *a Knock Pin Hole
      *b Alignment Mark

      Check the camshaft timing gear assembly position.

      If the camshaft timing gear assembly is not set to the advanced position, release the lock pin and reset the camshaft timing gear assembly. (Refer to the "Set Camshaft Timing Gear Assembly" procedures.)

    2. A0027FQC56
      *a Knock Pin
      *b Pin Hole

      Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    3. A002BAAC75
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

      Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

    4. A002APYC12
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

      Click here

  16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A0028SAC27
      *a Knock Pin
      *b Pin Hole

      Align and fit the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

    2. A002BAAC76
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 No. 2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

      Check that there is no gap between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

    3. A0028XIC12
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

      Click here

  17. ADD ENGINE OIL


    1. A00283P

      Add 50 cc (3.1 cu.in.) of engine oil into the oil hole shown in the illustration.

      Note


      • Engine oil must be added if the lash adjusters were removed.

      • Make sure that the low pressure chamber and oil paths of the lash adjusters are full of engine oil.

  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A0027VRN04

      Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.

    3. A002AEIC09
      *a Approximately 7°
      *b Approximately 32°
      *c Timing Mark

      Check that the timing marks of the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  19. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A0026Y9N02

      Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.

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

  20. INSTALL CHAIN SUB-ASSEMBLY


    1. Place the chain sub-assembly onto the camshaft timing exhaust gear assembly and camshaft timing gear assembly and crankshaft timing sprocket.

      Tech Tips


      • Make sure the mark plate of the chain sub-assembly faces away from the engine.

      • It is not necessary to install the chain sub-assembly to the teeth of the gears and sprocket.

    2. A0028WXC11
      *a Mark Plate
      *b Timing Mark

      Align the mark plate (yellow or gold) of the chain sub-assembly with the timing mark of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

    3. A002B5WC18
      *a Mark Plate
      *b Timing Mark

      Align the mark plate (pink or gold) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.

    4. A002AMD

      Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.

    5. A0027NZC11
      *a Mark Plate
      *b Timing Mark

      Using a wrench, hold the hexagonal portion of the camshaft and rotate the camshaft counterclockwise to align the timing mark of the camshaft timing gear assembly with the mark plate (yellow or gold) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    6. A002AC1

      Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.

      Note

      Make sure the chain sub-assembly is secure.

  21. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

    2. Remove the pin from the stopper plate.

  23. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  24. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A0026UUC17
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.

    3. Check that the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  25. INSTALL INTAKE MANIFOLD

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  26. INSTALL FUEL DELIVERY PIPE

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  27. CONNECT UNION TO VACUUM TUBE HOSE

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  28. CONNECT NO. 2 VENTILATION HOSE

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  29. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

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  30. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  31. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)

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  32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  33. INSTALL NO. 2 MANIFOLD STAY

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  34. INSTALL MANIFOLD STAY

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  35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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