CYLINDER HEAD GASKET INSTALLATION

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. Clean and degrease the contact surfaces of the cylinder head sub-assembly and cylinder block.

    2. A01WBB0C01
      *1 Cylinder Head Gasket
      *a 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *b 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *c 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *d 166.25 mm (6.55 in.)
      *e 62.25 mm (2.46 in.)
      *f Side View
      *g View A

      Apply seal packing to a new cylinder head gasket as shown in the illustration.

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

      Note


      • Be sure to clean and degrease the contact surfaces.

      • Apply seal packing to the bead on the cylinder head gasket.

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

    3. A01W8COC05
      *a Lot No.
      B0068HS Front

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

      Note


      • Remove any oil from the contact surface.

      • Make sure that the cylinder head gasket is installed in the correct direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


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

      Click here

    • The cylinder head set bolts are tightened in 3 successive steps.


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

      Note


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

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

    2. Install the plate washers to the cylinder head set bolts.

    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

    4. A01W9EHN10

      Step 1:

      Using several steps, install and uniformly tighten the 10 cylinder head set bolts with plate washers in the sequence shown in the illustration.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

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

    6. Step 2:

      Tighten the cylinder head set bolts 90° in the sequence shown in step 1.

    7. Step 3:

      Tighten the cylinder head set bolts another 90° in the sequence shown in step 1.

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

  3. CONNECT ENGINE WIRE


    1. A01W8JEC01
      *a INCORRECT
      *b Do not Allow Wires to Overlap

      Connect the engine wire to the cylinder head sub-assembly with the 3 bolts so that it is within the specified range shown in the illustration.

      Torque:
      for bolt A
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for bolt B
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  4. INSTALL VALVE STEM CAP


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

  5. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect each valve lash adjuster assembly before installing it.

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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.

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


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

    2. B0026HLC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
      *a INCORRECT
      *b CORRECT

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

      Note

      Install the valve stem cap, valve lash adjuster assembly and No. 1 valve rocker arm sub-assembly to the same places they were removed from.

  7. INSTALL CAMSHAFT

    Tech Tips

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

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    1. A01W9LDN01

      Apply clean engine oil to the camshaft cams and cylinder head journals.

    2. Position the camshaft and No. 2 camshaft as shown in the illustration.

    3. B0026HLC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
      *a INCORRECT
      *b CORRECT

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

  8. INSTALL CAMSHAFT BEARING CAP


    1. A01SBR8

      Temporarily install the No. 1 camshaft bearing cap.

    2. Confirm the location for each No. 2 camshaft bearing cap and install each one to the proper location.

    3. Uniformly temporarily install the 20 bolts while keeping the camshaft level.

    4. A01WA99N02

      Tighten the 20 bolts in the order shown in the illustration.

      Torque:
      15.5 N*m  { 158 kgf*cm, 11 ft.*lbf }

  9. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  10. INSTALL CHAIN SUB-ASSEMBLY

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  11. INSTALL CHAIN TENSIONER SLIPPER

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  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  13. INSTALL TIMING CHAIN GUIDE

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  14. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

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  15. INSTALL CYLINDER HEAD COVER CONNECTOR SUB-ASSEMBLY

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  16. INSTALL EXHAUST MANIFOLD

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  17. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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