CYLINDER HEAD GASKET INSTALLATION

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. B0076KDC02
      *a Seal Packing
      *b Cylinder Head Gasket
      B0073AQ Application Area

      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
      Seal Diameter
      2.5 to 3.0 mm (0.0984 to 0.118 in.)
      Seal Packing Application Specification
      (A) 10 to 15 mm (0.394 to 0.591 in.)
      (B) 1.25 to 1.50 mm (0.0492 to 0.0591 in.)

      Note


      • Remove any oil from the contact surfaces.

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

      • Do not add engine oil for at least 2 hours after installation.

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

    2. B00754ZC02
      *a Lot No.
      B0073AQ Engine Front

      Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp facing upward.

      Note

      Be sure to place the gasket in the correct orientation.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


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

      Note


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

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

      • Check and clean the cylinder head set bolts and bolt holes.

      • Clean the installation surface.

      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. B0074W4N06

      Step 1:


      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head set bolts with the 8 plate washers in several steps in the order shown in the illustration.

        Note


        • Be careful not to drop the plate washers into the cylinder head sub-assembly RH.

        • Install the cylinder head set bolts to their original locations.

        • When reusing the cylinder head set bolts, inspect the diameter of the threads. If the diameter is less than the minimum, replace the cylinder head set bolts with new ones.

          Click here

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

    4. Step 2:


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

      2. B0075TZC09
        *a 90°
        *b 90°
        *c Paint Mark
        B0073AQ Engine Front

        Tighten the cylinder head set bolts another 90°.

    5. Step 3:


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

      2. Check that the paint marks are now at a 180° angle to the front.

    6. B0073R7C01
      *1 Cylinder Head Sub-assembly RH
      *2 Cylinder Head Gasket
      *3 Cylinder Block Sub-assembly
      *a Wipe clean

      Thoroughly wipe off any seal packing that has seeped out onto the front side of the engine.

  3. INSTALL NO. 2 CYLINDER HEAD GASKET


    1. B00763VC02
      *1 Seal Packing
      *2 No. 2 Cylinder Head Gasket
      B0073AQ Application Area

      Apply a continuous line of seal packing to a new No. 2 cylinder head gasket as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Diameter
      2.5 to 3.0 mm (0.0984 to 0.118 in.)
      Seal Packing Application Specification
      (A) 10 to 15 mm (0.394 to 0.591 in.)
      (B) 1.25 to 1.50 mm (0.0492 to 0.0591 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the No. 2 cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying the seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    2. B0074BCC02
      *a Lot No.
      B0073AQ Engine Front

      Place the No. 2 cylinder head gasket on the cylinder block surface with the Lot No. stamp facing upward.

      Note

      Be sure to place the gasket in the correct orientation.

  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH


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

      Note


      • Gently place the cylinder head sub-assembly LH in order not to damage the No. 2 cylinder head gasket with the bottom part of the cylinder head sub-assembly LH.

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

      • Check and clean the cylinder head set bolts and bolt holes.

      • Clean the installation surface.

      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. B0073QIN06

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head set bolts with the 8 plate washers in several steps in the order shown in the illustration.

        Note


        • Be careful not to drop plate washers into the cylinder head sub-assembly LH.

        • Install the cylinder head set bolts to their original locations.

        • When reusing the cylinder head set bolts, inspect the diameter of the threads. If the diameter is less than the minimum, replace the cylinder head set bolts with new ones.

          Click here

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

    4. Step 2:


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

      2. B0075TZC10
        *a 90°
        *b 90°
        *c Paint Mark
        B0073AQ Engine Front

        Tighten the cylinder head set bolts another 90°.

    5. Step 3:


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

      2. Check that the paint marks are now at a 180° angle to the front.

    6. B00773RN06

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

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. B0073R7C01
      *1 Cylinder Head Sub-assembly LH
      *2 No. 2 Cylinder Head Gasket
      *3 Cylinder Block Sub-assembly
      *a Wipe clean

      Thoroughly wipe off any seal packing that has seeped out onto the front side of the engine.

  5. INSTALL FUEL INJECTOR SEAL

    Click here

  6. INSTALL REAR WATER BY-PASS JOINT

    Click here

  7. 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 intake valves and exhaust valves.

      Note

      Install each valve stem cap to the same place it was removed from.

  8. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assembly.

      Click here

    2. Install the 24 valve lash adjuster assemblies to the cylinder head sub-assembly RH and cylinder head sub-assembly LH.

      Note

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

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


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

    2. B0075E2C01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
      *a Correct
      *b Incorrect

      Install the 24 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note


      • Make sure that the No. 1 valve rocker arm sub-assemblies are installed correctly as shown in the illustration.

      • Install each No. 1 valve rocker arm sub-assembly to the same place it was removed from.

  10. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  11. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    Click here

  12. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


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

    2. Place the No. 3 camshaft sub-assembly onto the camshaft housing sub-assembly LH.

  13. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY


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

    2. Place the No. 4 camshaft sub-assembly onto the camshaft housing sub-assembly LH.

  14. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. B0073HEC03
      *1 No. 3 Camshaft Bearing Cap
      *2 No. 4 Camshaft Bearing Cap
      *3 No. 8 Camshaft Bearing Cap
      *4 No. 7 Camshaft Bearing Cap

      Confirm the marks and numbers on the camshaft bearing caps and place each camshaft bearing cap in the proper position and direction.

    3. B0074YSN03

      Temporarily install and uniformly tighten the 8 bolts in the order shown in the illustration.

  15. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B0075E2C01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
      *a Correct
      *b Incorrect

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

    2. B0075QQC03
      *a 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
      Range (A)
      4.0 to 4.5 mm (0.157 to 0.177 in.)
      except Range (A)
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Check and clean the bolts and bolt holes.

      • Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    3. B0073K2C04
      *a Knock Pin
      *b Intake
      *c Exhaust
      B0073AQ Bolt (A)
      B0077IM Bolt (B)

      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, make sure to correctly position the camshafts as shown in the illustration.

        Failure to do so 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.

      • Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed.

      • 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.

      Bolt Length:
      Item Specified Condition
      Bolt (A) 68 mm (2.68 in.)
      Bolt (B) 48 mm (1.89 in.)
    4. B007717N09

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

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

    5. Thoroughly wipe clean any seal packing.

      Note

      Be careful not to drop seal packing into the cylinder head sub-assembly LH.

  16. 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.

  17. 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.

  18. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. B00735GC02
      *1 No. 6 Camshaft Bearing Cap
      *2 No. 7 Camshaft Bearing Cap
      *3 No. 5 Camshaft Bearing Cap
      *4 No. 1 Camshaft Bearing Cap
      *5 No. 2 Camshaft Bearing Cap

      Confirm the marks and numbers on the camshaft bearing caps and place each camshaft bearing cap in the proper position and direction.

    3. B0073ZYN01

      Temporarily install and uniformly tighten the 9 bolts in the order shown in the illustration.

  19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B0075E2C01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
      *a Correct
      *b Incorrect

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

    2. B007535C02
      *a 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 4.0 mm (0.138 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Check and clean the bolts and bolt holes.

      • Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    3. B0074TJC04
      *a Knock Pin
      *b Exhaust
      *c Intake
      *d 45°
      B0073AQ Bolt (A)
      B0077IM Bolt (B)

      Install the camshaft housing sub-assembly RH and tighten the 14 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, make sure to correctly position the camshafts as shown in the illustration.

        Failure to do so 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.

      • Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed.

      • 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.

      Bolt Length:
      Item Specified Condition
      Bolt (A) 68 mm (2.68 in.)
      Bolt (B) 48 mm (1.89 in.)
    4. B0074JPN06

      Fully tighten the 9 bolts in the order shown in the illustration.

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

    5. Thoroughly wipe clean any seal packing.

      Note

      Be careful not to drop seal packing into the cylinder head sub-assembly RH.

  20. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B0077Z2C10
      *a Plunger
      *b Pin
      *c Push

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

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

    2. While pushing in the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to secure it.

  21. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)


    1. B0077IIC03
      *a Timing Mark
      *b Mark Plate (yellow)

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH as shown in the illustration.

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

    3. Align the knock pin of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly with the pin hole of the camshaft timing exhaust gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH with the No. 2 chain sub-assembly installed.

    4. B0073G3C01
      *a Turn
      *b Hold

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

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

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

  22. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B0074ATC14
      *a Plunger
      *b Pin
      *c Push

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

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

    2. While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to secure it.

  23. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)


    1. B0072LMC06
      *a Timing Mark
      *b Mark Plate (yellow)

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH as shown in the illustration.

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

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

    4. B007578C01
      *a Turn
      *b Hold

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

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

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

  24. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  25. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  26. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  27. INSPECT VALVE TIMING

    Click here

  28. POUR ENGINE OIL

    Click here

  29. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here