CYLINDER HEAD GASKET INSTALLATION

Tech Tips

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly RH or cylinder head sub-assembly LH Click here.


  1. INSTALL CYLINDER HEAD GASKET RH


    1. A01G9PGE02
      Text in Illustration
      *a Lot No.
      A01G8AH Engine Front

      Place a new cylinder head gasket RH on the cylinder block sub-assembly surface with the lot No. stamp facing upward.

      Note

      Be careful of the installation direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


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

      Note


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

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

      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. A01G45IE02

        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 }
    4. A01G4GEE05
      Text in Illustration
      *a Turn 90°
      *b Painted Mark
      A01G8AH Engine Front

      Step 2


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

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

    5. Step 3


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

      2. Check that the painted mark is now facing rearward.

        Tech Tips

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

  3. INSTALL CYLINDER HEAD GASKET LH


    1. A01G9DPE02
      Text in Illustration
      *a Lot No.
      A01G8AH Engine Front

      Place a new cylinder head gasket LH on the cylinder block sub-assembly surface with the lot No. stamp facing upward.

      Note

      Be careful of the installation direction.

  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH


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

      Note


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

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

      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. A01G9FBE02

        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 }
    4. A01G4GEE05
      Text in Illustration
      *a Turn 90°
      *b Painted Mark
      A01G8AH Engine Front

      Step 2


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

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

    5. Step 3


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

      2. Check that the painted mark is now facing rearward.

    6. A01G6L7E02

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

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

      Tech Tips

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

  5. INSTALL WATER OUTLET


    1. A01G5DK

      Install 2 new gaskets and a new O-ring.

      Tech Tips

      Apply soapy water to the O-ring.

    2. A01G6G6E02
      Text in Illustration
      *A w/ Oil Cooler
      *B w/o Oil Cooler
      *1 Nut
      *2 Bolt

      Install the water outlet with the 2 bolts and 4 nuts.

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

      Note

      Be careful that the O-ring does not get caught between the parts.

  6. INSTALL VALVE STEM CAP


    1. Install the 24 valve stem caps.

  7. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the lash adjuster free of dirt and foreign matter.

    • Only use clean engine oil.


    1. Place the valve lash adjuster assembly into a container filled with engine oil.

    2. A01G7QRE17
      Text in Illustration
      *1 Tapered Part
      *2 Plunger
      *3 Check Ball
      *a Correct
      *b Incorrect
      *c Low Pressure Chamber
      *d High Pressure Chamber

      Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed the air.

      OK
      Plunger moves up and down.

      Note

      When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

    5. After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly by hand.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster assembly.

    6. Install the valve lash adjuster assemblies.

      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. Apply engine oil to the valve lash adjuster assembly tip and valve stem cap end.

    2. A01G4JOE06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

  9. INSTALL NO. 3 CAMSHAFT


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

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the No. 3 camshaft Click here.

  10. INSTALL NO. 4 CAMSHAFT


    1. Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the No. 4 camshaft Click here.

  11. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01G9BW

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

    3. A01G6DVE01

      Temporarily tighten the 8 bolts in the order shown in the illustration.

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

  12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01G4JOE06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

      Make sure that the valve rocker arm is installed as shown in the illustration.

    2. A01G9KCE01
      Text in Illustration
      *a

      Seal packing diameter

      (3.5 to 4.5 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
      3.5 to 4.5 mm (0.138 to 0.177 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts.

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

    3. A01G5KSE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

      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, valve contact with a piston at TDC 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. A01G9RTE02

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

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

  13. 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.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft Click here.

  14. 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.

      Tech Tips

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

  15. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01G63O

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

    3. A01G799E01

      Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.

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

  16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here