CYLINDER HEAD GASKET INSTALLATION

Tech Tips

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

  1. INSPECT CYLINDER HEAD BOLT

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

      A011SGOE15
      Text in Illustration
      *a 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. 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. Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block and manifold.

      A011V42E05
      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.)
      Text in Illustration
      *a Cylinder Head Lower Side
      *b Intake Manifold Side
      *c Exhaust Manifold Side

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

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

      If cracked, replace the cylinder head.

      A011RMH

  3. INSTALL CYLINDER HEAD GASKET

    1. Clean the cylinder block and cylinder head with solvent.

      A011UIIE01
      Text in Illustration
      *1 Cylinder Head Gasket
      *2 Cylinder Block
      *a Lot No.
      *b 3.0 mm or more
      *c 20 mm or more
      A011T1X Seal Packing
      A011V7Q 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.) 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.

      Note

      • Remove any oil from the contact surface.

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

    3. Place a new cylinder head gasket on the cylinder block surface with the front face of 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 on the cylinder block.

      Note

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

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

    2. Install the plate washers to the 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. 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.

        A011QM2E02
        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. Mark each cylinder head bolt head with paint as shown in the illustration.

        A011TQIE05
        Text in Illustration
        A011V7Q 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.

        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 ends.

    2. Install the 16 valve stem caps to the cylinder head.

      Note

      Do not drop the valve stem caps into the cylinder head.

  6. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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

    1. Check the camshaft timing gear position.

      A011QR6E04
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark
      *a Advanced Position:
      *b Retarded Position:

      Note

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

      If the camshaft timing gear rotates to the retarded position, release the lock pin and set the camshaft timing gear to the advanced position.

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

      A011T73E02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

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

      A011SR5E11
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 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 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.

      A011UG2E04
      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. 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).

        A011SO9

        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

        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • 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.

      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 before installing it Click here.

    2. Install the 16 lash adjusters to the cylinder head.

      Note

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

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

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

      A011UNKE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

    2. Install the 16 valve rocker arms as shown in the illustration.

  9. INSTALL NO. 2 CAMSHAFT BEARING

    1. Clean the No. 2 camshaft bearing.

    2. Install the camshaft bearing to the camshaft housing.

    3. Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

      A011SCOE04
      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)
      Text in Illustration
      *1 Vernier Caliper

  10. INSTALL NO. 1 CAMSHAFT BEARING

    1. Clean the No. 1 camshaft bearing.

      A011RLZE03
      Text in Illustration
      *1 Vernier Caliper

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

    3. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the 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. Install the oil control valve filter to the No. 1 camshaft bearing cap.

      A011T4Z

  12. INSTALL CAMSHAFT

    1. Clean the camshaft journals, camshaft housing and bearing caps.

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

    3. Install the camshaft and No. 2 camshaft to the camshaft housing.

      Tech Tips

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

  13. INSTALL CAMSHAFT BEARING CAP

    1. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

      A011UMO

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

      A011SZ9E02
      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      Make sure that the camshaft rotates smoothly after installing the bearing caps.

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    1. Check that the valve rocker arms are installed as shown in the illustration.

      A011TP9E03
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster
      *a INCORRECT
      *b CORRECT

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

      A011UVRE01
      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 surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

      A011U2EE02
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

    4. Install the camshaft housing, and then install the 20 bolts in the order shown in the illustration.

      A011TH3E02
      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

      Note

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

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

      • Thoroughly wipe clean any seal packing.

  15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    1. Check the camshaft timing gear position.

      A011TWOE02
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark

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

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

      A011T73E02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

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

      A011SR5E11
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

      A011RJ8E01
      Text in Illustration
      *a Hold
      *b Turn
      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      • Be careful not to damage the cylinder head 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. Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

      A011RG6E02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

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

      A011SR5E11
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

      A011QW7E01
      Text in Illustration
      *a Hold
      *b Turn
      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      • Be careful not to damage the cylinder head 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. Add 50 cc (3.1 cu. in) of engine oil into the oil hole shown in the illustration.

      A011U4G

      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. Temporarily install the crankshaft pulley bolt.

      A011UA7E01

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

    3. Check that the timing marks of the camshaft timing gears are as shown in the illustration.

      A011V3LE03
      Text in Illustration
      *1 Timing Mark
      *a Approximately 7°
      *b Approximately 32°

      Tech Tips

      "A" is not a timing mark.

  19. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    1. Install the chain vibration damper with the 2 bolts.

      A011R86
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  20. INSTALL CHAIN SUB-ASSEMBLY

    1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

      Tech Tips

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

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

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

      A011V93E02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

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

      A011UOUE02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

    4. Tie a string above the crankshaft timing sprocket so that the chain is secure.

      A011RHA

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

      A011UH7E02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      Tech Tips

      Hold the intake camshaft in place with a wrench until the chain tensioner is installed.

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

      A011SGN

      Note

      Make sure the chain is secure.

  21. INSTALL CHAIN TENSIONER SLIPPER

    1. Install the chain tensioner slipper with the bolt.

      A011QSZ
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. Install a new gasket and the chain tensioner with the 2 bolts.

      A011S8X
      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.

      A011U2T
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  24. CHECK NO. 1 CYLINDER AT TDC/COMPRESSION

    1. Temporarily install the crankshaft pulley bolt.

      A011S1XE03
      Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Key

    2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears 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 with the bolt.

      A011UPG
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

      A011UV4E03
      Text in Illustration
      *a Black

    3. Check the tumble control valves.

      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 actuator to operate the motor and close the valves Click here.

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

    5. Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration.

      A011T1NE01
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    6. Connect the intake air control actuator connector and 2 wire harness clamps.

      A011SEI

    7. Install the wire harness clamp with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    8. Install the wire harness clamp bracket with the bolt.

      A011V5I
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    9. Connect the 3 wire harness clamps and connector.

    10. Connect the fuel vapor feed hose.

    11. Install the 2 wire harness clamp brackets with the 2 bolts.

      A011RLU
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  26. CONNECT NO. 2 VENTILATION HOSE

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

  27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    1. Install 4 new injector vibration insulators to the cylinder head.

      A011TK9E01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *a Fuel Delivery Pipe Side
      *b Cylinder Head Side

    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 sub-assembly 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 injectors when installing the fuel delivery pipe sub-assembly.

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

  28. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

    1. Install the vacuum switching valve assembly 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 connector tube hose and wire harness clamp.

  29. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Install a new exhaust manifold to head gasket onto the cylinder head.

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

    3. Tighten the 5 nuts in the sequence shown in the illustration (except PZEV).

      A011TIME05
      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    4. Tighten the 5 nuts in the sequence shown in the illustration (for PZEV).

      A011U79E01
      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  31. INSTALL EGR INLET EXHAUST MANIFOLD PLATE (for PZEV)

    1. Install the EGR inlet exhaust manifold plate with the bolt.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV)

    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