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CYLINDER HEAD GASKET INSTALLATION

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Info Added 2017-08-02

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CAUTION / NOTICE / HINT

Tip:

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

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PROCEDURE


  1. Click here

    INSPECT CYLINDER HEAD BOLT

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  2. Click here

    INSPECT CYLINDER HEAD SUB-ASSEMBLY

    Click here

  3. Click here

    INSTALL CYLINDER HEAD GASKET


    1. A00054OE03

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

      Table 1. Text in Illustration
      *1 Cylinder Head Gasket
      *2 cylinder block Sub-assembly
      *a Lot No.
      *b 3.0 mm or more
      *c 20 mm or more
      A0005GR Seal Packing
      A0009JS Front

    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 more thick
      Tip:

      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 cylinder head bolts within 15 minutes after applying seal packing.

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

      Note:

      Pay attention to the installation direction.

  4. Click here

    INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tip:

    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 part 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. A00071XE01

        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.

        36 N*m 367 kgf*cm 27 ft.*lbf
        Note:

        Do not drop the plate washer for the cylinder head bolt into the cylinder head sub-assembly.

    5. Step 2:


      1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

        36 N*m 367 kgf*cm 27 ft.*lbf

    6. Step 3:


      1. A00072IE05

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

        Table 2. Text in Illustration
        A0009JS Front
        *a Painted Mark

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

    7. Step 4:


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

        Tip:

        Perform "Inspection After Repair" after replacing the cylinder head sub-assembly (Click here).

  5. Click here

    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. Click here

    SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tip:

    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. A00040EE04

      Check the camshaft timing gear assembly position.

      Table 3. Text in Illustration
      *a Advance Position
      *b Retard Position
      *c Knock Pin Hole
      *d Alignment Mark
      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 rotates to the retarded position, release the lock pin and set the camshaft timing gear assembly to the advanced position.

    2. A0004EBE05

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

      Table 4. Text in Illustration
      *1 Knock Pin
      *a Pin Hole
    3. A0005GCE46

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

      Table 5. Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

    4. Secure the camshaft in place by hand, and then install the installation 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. A0009GTE04
      A0008S9E05

      Release the lock pin.

      Table 6. Text in Illustration
      *1 Rubber
      *2 Vinyl Tape
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      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.

        Tip:

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

      3. Open a hole at port A shown in the illustration.

      4. A0004K5

        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.

        Tip:

        • 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. Click here

    INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assemblies before installing them (Click here).

    2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note:

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

  8. Click here

    INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A00093AE14

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

      Table 7. Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

  9. Click here

    INSTALL NO. 2 CAMSHAFT BEARING

    Click here

  10. Click here

    INSTALL NO. 1 CAMSHAFT BEARING

    Click here

  11. Click here

    INSTALL OIL CONTROL VALVE FILTER

    Click here

  12. Click here

    INSTALL CAMSHAFT


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

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

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

      Tip:

      Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft (Click here).

  13. Click here

    INSTALL CAMSHAFT BEARING CAP


    1. A0007NNE05

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

    2. A00095BE10

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

      16 N*m 163 kgf*cm 12 ft.*lbf
      Note:

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

  14. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A0008IXE03

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

      Table 8. Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a INCORRECT
      *b CORRECT
    2. A0009EEE05
      Table 9.
      *1 3.0 to 4.0 mm

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 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 after applying seal packing.

    3. A0006PTE02

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

      Table 10. Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°
    4. A00086IE10

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

      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. Click here

    INSTALL CAMSHAFT TIMING SPROCKET


    1. A000986E02

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

      Table 11. Text in Illustration
      *a Hold
      *b Turn
      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.

  16. Click here

    INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A00073FE02

      Check the camshaft timing gear assembly position.

      Table 12. Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark

      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" procedure).

    2. A0004EBE05

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

      Table 13. Text in Illustration
      *1 Pin Hole
      *2 Knock Pin
    3. A0005GCE46

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

      Table 14. Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance
    4. A00046DE02

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

      Table 15. Text in Illustration
      *a Hold
      *b Turn
      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.

      Tip:

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly (Click here).

  17. Click here

    ADD ENGINE OIL


    1. A0009CT

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

      Note:

      • 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. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A0005VYE05

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

      21 N*m 214 kgf*cm 15 ft.*lbf
  19. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A0007U3E04

      Temporarily install the crankshaft pulley bolt.

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

    3. A00043LE04

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

      Table 16. Text in Illustration
      *a Timing Mark
      *b Approximately 7°
      *c Approximately 32°
      Tip:

      "A" is not a timing mark.

  20. Click here

    INSTALL CHAIN SUB-ASSEMBLY


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

      Tip:

      • 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 camshaft timing gear assembly, camshaft timing sprocket and crankshaft timing sprocket.

    2. A00086TE02

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

      Table 17. Text in Illustration
      *a Mark Plate
      *b Timing Mark
    3. A0007OBE17

      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.

      Table 18. Text in Illustration
      *1 Mark Plate
      *2 Timing Mark
    4. A0003TL

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

    5. A0008P6E02

      Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench, 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.

      Table 19. Text in Illustration
      *a Mark Plate
      *b Timing Mark
      Tip:

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

    6. A000599

      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. Click here

    INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  22. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


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

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Remove the pin from the stopper plate.

  23. Click here

    INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  24. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A0007YDE06

      Temporarily install the crankshaft pulley bolt.

      Table 20. Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Crankshaft Pulley Key

    2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket, camshaft timing gear assembly and camshaft timing sprocket are as shown in the illustration.

      Tip:

      "A" is not a timing mark.

    3. Remove the crankshaft pulley bolt.

  25. Click here

    INSTALL FUEL DELIVERY PIPE

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  26. Click here

    INSTALL INTAKE MANIFOLD

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  27. Click here

    INSTALL NO. 1 WATER BY-PASS PIPE

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  28. Click here

    INSTALL NO. 3 WATER BY-PASS PIPE

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  29. Click here

    INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  30. Click here

    INSTALL MANIFOLD STAY

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  31. Click here

    INSTALL NO. 2 MANIFOLD STAY

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  32. Click here

    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  33. Click here

    INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

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  34. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    (Click here)