CYLINDER HEAD GASKET INSTALLATION

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 Click here.


  1. INSPECT CYLINDER HEAD BOLT


    1. A01G7DKE15
      Text in Illustration
      *a Measurement Point

      Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard diameter
      10.85 to 11.00 mm (0.427 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)
      Measurement point (distance from the seat)
      106 mm (4.17 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the cylinder head bolt with a new one. Failure to do so may lead to engine damage.

      • If there is any thread deformation, replace the cylinder head bolt with a new one.

  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. A01G9KUE05
      Text in Illustration
      *a Cylinder Head Lower Side
      *b Intake Manifold Side
      *c Exhaust Manifold Side

      Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head sub-assembly contacts the cylinder block sub-assembly and manifold.

      Maximum Warpage
      Item Specified Condition
      Cylinder head lower side 0.05 mm (0.00197 in.)
      Intake manifold side 0.10 mm (0.00394 in.)
      Exhaust manifold side 0.10 mm (0.00394 in.)

      If the warpage is more than the maximum, replace the cylinder head sub-assembly.

    2. A01G941

      Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.

      If cracked, replace the cylinder head sub-assembly.

  3. INSTALL CYLINDER HEAD GASKET


    1. A01G604E01
      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
      A01G8AH Seal Packing
      A01G47H 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 more thick

      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 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. 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 part of the head.

    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. A01G9SEE02

        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.

        Torque:
        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.

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

    6. Step 3:


      1. A01G7K2E05
        Text in Illustration
        A01G47H Front
        *a Painted Mark

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

      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.

        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. A01G9ENE05
      Text in Illustration
      *a Advance Position:
      *b Retard 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 rotates to the retarded position, release the lock pin and set the camshaft timing gear assembly to the advanced position.

    2. A01G9DKE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

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

    3. A01G959E11
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

    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. A01G8JRE04

      Release the lock pin.

      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.

        Tech Tips

        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. A01G4AY

        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 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. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A01G546E06
      Text in Illustration
      *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


    1. Clean the No. 2 camshaft bearing.

    2. Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

    3. A01G6F4E05
      Text in Illustration
      *1 Vernier Caliper

      Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  10. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01G5ZWE02
      Text in Illustration
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

    2. Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.

    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  11. INSTALL OIL CONTROL VALVE FILTER


    1. A01G5I2

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  12. 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.

      Tech Tips

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

  13. INSTALL CAMSHAFT BEARING CAP


    1. A01G8A9

      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. A01G59JE02

      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 rotates 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. A01G4D4E03
      Text in Illustration
      *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. A01G7VJE01

      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. A01G65ZE02
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

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

    4. A01G84FE02

      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. A01G83WE04
      Text in Illustration
      *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. A01G9DKE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

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

    3. A01G959E11
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

    4. A01G8IIE01
      Text in Illustration
      *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. A01G8E6E04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

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

    2. A01G959E11
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 No. 2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

    3. A01G7F5E01
      Text in Illustration
      *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. A01G9UK

      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. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01G99UE01

      Temporarily install the crankshaft pulley bolt.

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

    3. A01G62JE02
      Text in Illustration
      *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. A01G9DHE01

      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. A01G9NKE03
      Text in Illustration
      *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. A01G5YKE04
      Text in Illustration
      *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. A01G6MN

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

    5. A01G7L9E03
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      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.

      Tech Tips

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

    6. A01G6TC

      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.

      A01G4FEE03
      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 exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    3. Remove the crankshaft pulley bolt.

  25. INSTALL INTAKE MANIFOLD


    1. Install the wire harness clamp bracket to the intake manifold with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01G73TE03
      Text in Illustration
      *a Black

      Connect the 2 vacuum hoses and check that the No. 1 check valve is installed as shown in the illustration.

    3. Check the tumble control valves (w/ TCV).

      Note

      The tumble control valves may be damaged if they are not closed before installing the intake manifold.

      Tech Tips

      Connect the battery to the terminals of the intake air control valve actuator to operate the motor and close the tumble control valves Click here.

    4. Install a new intake manifold gasket to the intake manifold.

    5. A01G8IHE01

      Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/ TCV).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    6. A01G81VE01

      Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/o TCV).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    7. A01G4V9E01

      Connect the intake air control valve actuator connector and 2 wire harness clamps (w/ TCV).

    8. Connect the 2 wire harness clamps (w/o TCV).

    9. Install the wire harness clamp with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Text in Illustration
      *A w/ TCV
      *B w/o TCV
    10. A01G4TD

      Install the wire harness clamp bracket to the intake manifold with the bolt.

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

    11. Connect the 3 wire harness clamps and connector.

    12. Connect the fuel vapor feed hose to the intake manifold.

    13. Install the 2 wire harness clamp brackets to the intake manifold with the 2 bolts.

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

  26. INSTALL FUEL DELIVERY PIPE


    1. A01G6THE01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *a Fuel Delivery Pipe Side
      *b Cylinder Head Side

      Install 4 new injector vibration insulators to the cylinder head.

    2. Install the 2 fuel delivery spacers onto the cylinder head.

      Tech Tips

      Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side.

    3. Install the fuel delivery pipe with the 4 fuel injector assemblies and install the 2 bolts.

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

      Note


      • Do not drop the fuel injector assemblies when installing the fuel delivery pipe.

      • Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe.

  27. CONNECT UNION TO VACUUM TUBE HOSE


    1. Connect the union to vacuum tube hose to the intake manifold.

  28. CONNECT NO. 2 VENTILATION HOSE


    1. Connect the No. 2 ventilation hose to the intake manifold.

  29. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. Install the vacuum switching valve assembly to the intake manifold with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 2 vacuum hoses and connector.

    3. Connect the union to vacuum tube hose and wire harness clamp.

  30. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY


    1. Install a new gasket to the intake manifold.

    2. Install the fuel tube bracket with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    3. Install the throttle with motor body assembly with the 4 bolts.

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

    4. Connect the throttle body connector.

    5. Connect the fuel tube to the fuel tube bracket.

    6. Connect the No. 2 water by-pass hose to the throttle with motor body assembly.

    7. Connect the No. 1 water by-pass hose to the throttle with motor body assembly.

  31. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Set a new gasket to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts.

    3. Temporarily install the No. 2 manifold stay and manifold stay with the 2 bolts and 2 nuts.

    4. A01G7NZE05

      Tighten the 5 nuts in the sequence shown in the illustration.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  33. INSTALL NO. 2 MANIFOLD STAY


    1. Install the No. 2 manifold stay with the bolt and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  34. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the bolt and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here