CYLINDER HEAD GASKET INSTALLATION


  1. INSPECT CYLINDER HEAD SET BOLT

    A00XE0FE01

    1. Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

      Text in Illustration
      *a Measurement Length
      Standard length
      141.3 to 142.7 mm (5.56 to 5.62 in.)
      Maximum length
      143.7 mm (5.66 in.)

      If the length is more than the maximum, replace the cylinder head set bolt.

    2. A00XDSG

      Using a vernier caliper, measure the diameter of the elongated thread at the narrowest visible area.

      Standard diameter
      10.73 to 10.97 mm (0.422 to 0.432 in.)
      Minimum diameter
      10.40 mm (0.409 in.)

      If the diameter is less than the minimum, replace the cylinder head set bolt.

      Tech Tips

      If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.

  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. A00954GE01
      Text in Illustration
      *A Cylinder Block Side
      *B Intake Side
      *C Exhaust Side

      Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder block sub-assembly and manifolds.

      Standard Warpage
      Item Specified Condition
      Cylinder block side 0.05 mm (0.00197 in.)
      Intake side 0.08 mm (0.00315 in.)
      Exhaust side 0.08 mm (0.00315 in.)
      Maximum Warpage
      Item Specified Condition
      Cylinder block side 0.10 mm (0.00394 in.)
      Intake side 0.10 mm (0.00394 in.)
      Exhaust side 0.10 mm (0.00394 in.)

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

    2. 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. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head or cylinder block.

    2. A00JW8ZE01
      Text in Illustration
      *1 Seal Packing
      *2 Gasket

      Apply 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 diameter
      2.5 to 3.0 mm (0.0984 to 0.118 in.)
      Seal Packing Application Range
      A 10 to 15 mm (0.394 to 0.591 in.)
      B 1.25 to 1.5 mm (0.0492 to 0.0591 in.)

      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.

      • Do not add engine oil within 2 hours of installation.

    3. A00JZMGE01
      Text in Illustration
      *1 Lot No.
      A00JWY4 Engine Front

      Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

      Note

      Make sure that the gasket is installed facing the proper direction.

  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. Place the cylinder head on the cylinder block.

      Note


      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

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

      Tech Tips

      The cylinder head 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 bolts.

    3. Step 1:


      1. A00K1C3E02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head 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. Step 2:


      1. Mark the front side of each cylinder head bolt head with paint.

      2. Tighten the cylinder head bolts another 90°.

    5. Step 3:


      1. Tighten the cylinder head bolts an additional 90°.

      2. Check that the paint mark is now at a 180° angle to the front.

        Note

        Thoroughly wipe clean any seal packing.

  5. INSTALL NO. 2 CYLINDER HEAD GASKET


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head or cylinder block.

    2. A00JZ61E01
      Text in Illustration
      *1 Seal Packing
      *2 Gasket

      Apply 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 diameter
      2.5 to 3.0 mm (0.0984 to 0.118 in.)
      Seal Packing Application Range
      A 10 to 15 mm (0.394 to 0.591 in.)
      B 1.25 to 1.5 mm (0.0492 to 0.0591 in.)

      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.

      • Do not add engine oil within 2 hours of installation.

    3. A00JU0YE01
      Text in Illustration
      *1 Lot No.
      A00JWY4 Engine Front

      Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

      Note

      Make sure that the gasket is installed facing the proper direction.

  6. INSTALL CYLINDER HEAD LH


    1. Place the cylinder head on the cylinder block.

      Note


      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

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

      Tech Tips

      The cylinder head 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 bolts.

    3. Step 1:


      1. A00JZ8OE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head 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. Step 2:


      1. Mark the front side of each cylinder head bolt head with paint.

      2. Tighten the cylinder head bolts another 90°.

    5. Step 3:


      1. Tighten the cylinder head bolts an additional 90°.

      2. Check that the paint mark is now at a 180° angle to the front.

    6. A00JWFIE02

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

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

      Note

      Thoroughly wipe clean any seal packing.

  7. INSTALL REAR WATER BY-PASS JOINT


    1. A00XFKME04
      Text in Illustration
      *1 New O-Ring
      *2 New Gasket

      Apply soapy water to a new O-ring and install it to the water outlet pipe. Then install 2 new gaskets to the water ports LH and RH.

    2. A00XGLEE01

      Install the rear water by-pass joint with the 2 bolts and 4 nuts.

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

  8. INSTALL VALVE STEM CAP


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

    2. Install the 24 valve stem caps to the cylinder head.

  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster Click here.

    2. Install the 24 valve lash adjusters to the cylinder head.

      Note

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

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


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

    2. A00XI8XE01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Install the 24 valve rocker arms as shown in the illustration.

  11. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing.

    3. A00XKD1

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

    4. A00XG0CE01

      Temporarily install 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. A00XI8XE01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. A00XJ5DE01
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      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 within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A00XI9EE01
      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 with a piston at TDC, valve contact 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.

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

    4. A00XD0YE02

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

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

      Note

      Thoroughly wipe clean any seal packing.

  13. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

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

    3. A00XHMD

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

    4. A00XKHXE01

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

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

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A00XI8XE01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. A00XCVME01
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      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 within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A00XG34E01
      Text in Illustration
      *1 Knock Pin
      *a Front View

      Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing RH, 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 with a piston at TDC, valve contact will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces and reapply seal packing.

      • If the camshaft housing sub-assembly RH 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.

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

    4. A00XFYRE02

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

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

      Note

      Thoroughly wipe clean any seal packing.

  15. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A00XFMQE01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      Install the No. 3 chain tensioner assembly with the bolt.

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

    2. Push in the tensioner and insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the tensioner.

  16. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)


    1. A00XDV7E01
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.

    4. A00XD14E01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 3 chain tensioner assembly.

  17. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A00XC6ME01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      Install the No. 2 chain tensioner assembly with the bolt.

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

    2. Push in the No. 2 chain tensioner assembly and insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the tensioner.

  18. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)


    1. A00XKKUE01
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

    4. A00XCT3E01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 2 chain tensioner assembly.

  19. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A00XDN9

      Install the No. 1 chain vibration damper with the 2 bolts.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

  20. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. A00XC1I

      Install the 2 No. 2 chain vibration dampers.

  21. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A00XETCE02
      Text in Illustration
      *a Inward

      Align the key groove of the timing sprocket with the timing sprocket set key.

    2. Install the timing sprocket to the crankshaft with the sprocket facing inward as shown in the illustration.

  22. INSTALL NO. 1 IDLE GEAR SHAFT


    1. Apply a light coat of engine oil to the sliding surface of the No. 1 idle gear shaft.

    2. A00XITZE01
      Text in Illustration
      *1 Knock Pin

      Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

      Note

      Make sure that the idle gear is installed facing the proper direction.

    3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

    4. Remove the bar from the chain tensioner.

  23. INSTALL CHAIN SUB-ASSEMBLY


    1. A00XGYDE01
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      Align the mark plate and timing marks as shown in the illustration and install the chain.

      Tech Tips

      The camshaft mark plates are orange.

    2. A00XGVS

      Do not pass the chain around the crankshaft, just temporarily place it on the crankshaft.

    3. A00XHREE01
      Text in Illustration
      *1 Chain Plate
      *a When idle sprocket is reused
      *b Mark
      *c Align
      A00XHOQ Turn

      Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks.

      Note

      When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been when tightening the chain between the banks.

    4. A00XD4VE01
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      Align the mark plate and timing marks as shown in the illustration and install the chain to the crankshaft timing sprocket.

      Tech Tips

      The crankshaft mark plate is yellow.

    5. Temporarily install the pulley set bolt.

    6. A00XGG4E01
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

      Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

  24. INSTALL CHAIN TENSIONER SLIPPER


    1. A00XCU0

      Install the chain tensioner slipper.

  25. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00XCQZE01
      Text in Illustration
      *1 Stopper Plate
      *a Push

      Turn the stopper plate of the tensioner clockwise and push in the plunger of the tensioner as shown in the illustration.

    2. Turn the stopper plate of the tensioner counterclockwise and insert a pin of φ1.27 mm (0.0500 in.) into the holes on the stopper plate and tensioner to fix the stopper plate in place.

    3. A00XDIFE02

      Install the chain tensioner with the 2 bolts.

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

    4. Remove the pin from the No. 1 chain tensioner.

  26. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

    2. Check that each camshaft timing mark is positioned as shown in the illustration.

      A00XGF1E01
      Text in Illustration
      *1 Timing Mark - -
      *a Viewpoint - -

      Tech Tips

      for Intake Camshaft:

      Be sure to check mark A at the point when marks B, C and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      A00XH1ME01

    3. If the valve timing is misaligned, reinstall the timing chain.

    4. Remove the pulley set bolt.

  27. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Install the timing chain cover Click here.