CYLINDER HEAD GASKET INSTALLATION

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. B0075J4C03
      *1 Cylinder Head Gasket
      *a 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *d 38.6 mm (1.52 in.)
      *e 142.7 mm (5.62 in.)

      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

      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 seal packing.

    2. B0074IEC03
      *a Lot No.
      B0073AQ Front of Engine

      Place the cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.

      Note


      • Remove any oil from the contact surfaces.

      • Make sure to install the cylinder head gasket in the correct direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly.



    1. Place the cylinder head sub-assembly onto the cylinder block sub-assembly.

      Note


      • Do not allow oil to adhere to the bottom of the cylinder head sub-assembly.

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

      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. B00762OE02

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

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    4. B0075TZC15
      *a Turn 90°
      *b Paint Mark
      B0073AQ Front of Engine

      Step 2:


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

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

    5. Step 3:


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

      2. Check that the paint marks are now facing rearward.

    6. B00762ZC01
      *1 Cylinder Head Sub-assembly
      *2 Cylinder Head Gasket
      *3 Cylinder Block Sub-assembly
      *a Wipe Off

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

  3. INSTALL NO. 2 CYLINDER HEAD GASKET


    1. B0072W3C01
      *1 No. 2 Cylinder Head Gasket
      *a 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *d 39.3 mm (1.55 in.)
      *e 111.3 mm (4.38 in.)

      Apply 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

      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 seal packing.

    2. B0072V6C03
      *a Lot No.
      B0073AQ Front of Engine

      Place the No. 2 cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.

      Note


      • Remove any oil from the contact surfaces.

      • Make sure to install the No. 2 cylinder head gasket in the correct direction.

  4. INSTALL CYLINDER HEAD LH

    Tech Tips

    Perform "Inspection After Repairs" after replacing the cylinder head LH.



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

      Note


      • Do not allow oil to adhere to the bottom of the cylinder head LH.

      • Gently lower the cylinder head LH in order not to damage the No. 2 cylinder head gasket with the bottom of the cylinder head LH.

      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. B0072PAE02

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

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    4. B0075TZC16
      *a Turn 90°
      *b Paint Mark
      B0073AQ Front of Engine

      Step 2:


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

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

    5. Step 3:


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

      2. Check that the paint marks are now facing rearward.

    6. B007486E03

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

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. B00762ZC01
      *1 Cylinder Head LH
      *2 No. 2 Cylinder Head Gasket
      *3 Cylinder Block Sub-assembly
      *a Wipe Off

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

  5. INSTALL FUEL INJECTOR SEAL

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  6. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)

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  7. INSTALL FUEL DELIVERY PIPE RH

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  8. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

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  9. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

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  10. INSTALL REAR WATER BY-PASS JOINT

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  11. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the 24 valve stem caps.

    2. Install the 24 valve stem caps.

      Note

      Install each part to its original position.

  12. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assembly.

      Click here

    2. Install the 24 valve lash adjuster assemblies.

      Note

      Install each part to its original position.

  13. 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. B007582C06
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

      Note

      Install each part to its original position.

  14. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  15. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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  16. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

    Tech Tips

    Perform Inspection After Repair after replacing the 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. Install the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH.

  17. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY

    Tech Tips

    Perform Inspection After Repair after replacing the 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. Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH.

  18. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the 5 camshaft bearing caps.

    2. B0075DN

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

    3. B0075GWE02

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

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

  19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B0076SOC03
      *a Pin
      *b Plunger
      *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 1.0 mm (0.0394 in.) diameter pin into the hole to secure it.

  20. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)

    Tech Tips

    Perform Inspection After Repair after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly LH.



    1. B0073ZMC05
      *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. Align the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly with the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH with the No. 2 chain sub-assembly installed.

      Note

      Be careful not to damage the contact surface of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH with the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly.

  21. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)

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  22. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)

    Click here

  23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B0072YJC11
      *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 as shown in the illustration.

    2. B0072NAC04
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)
      *b Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)
      *c Separated by 4.0 to 6.0 mm (0.157 to 0.236 in.)
      B007493 Seal Packing

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes of applying 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. Install the camshaft housing sub-assembly LH and tighten the 15 bolts in the order shown in the illustration.

      B0073HNC09
      *a Types of bolt *b Tightening order
      *c Intake Side *d Exhaust Side
      *e Knock Pin - -
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing sub-assembly LH, 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, valve contact with a piston at TDC may occur.

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

      • If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.

      • If it is necessary to remove the camshaft housing sub-assembly LH during installation, make sure that the previously applied seal packing does not enter any oil passages.

      Bolt Length
      Item Length
      Bolt (A) 48 mm (1.89 in.)
      Bolt (B) 68 mm (2.68 in.)
    4. B0077G6E01

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

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

    5. Remove any protruding seal packing.

      Note

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

  24. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)


    1. B0075RZC02
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with the wrench.

  25. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)


    1. B0075LTC02
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with the wrench.

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

  26. INSTALL CAMSHAFT

    Tech Tips

    Perform Inspection After Repair after replacing the 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.

  27. INSTALL NO. 2 CAMSHAFT

    Tech Tips

    Perform Inspection After Repair after replacing the 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.

  28. INSTALL FUEL PUMP LIFTER HOUSING


    1. Install the fuel pump lifter housing.

  29. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the 5 camshaft bearing caps.

    2. B0077TP

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

    3. B0075LJC03
      B0073AQ Bolt (A)
      B0077IM Bolt (B)

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt Length
      Item Length
      Bolt (A) 40 mm (1.57 in.)
      Bolt (B) 58 mm (2.28 in.)

  30. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B0075W4C01
      *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 1.0 mm (0.0394 in.) diameter pin into the hole to secure it.

  31. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)

    Tech Tips

    Perform Inspection After Repair after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly RH.



    1. B0075FBC03
      *a Timing Mark
      *b Mark Plate

      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. Align the straight pins of the camshaft and No. 2 camshaft with the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH with the No. 2 chain sub-assembly installed.

      Note

      Be careful not to damage the contact surface of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH with the straight pins of the camshaft and No. 2 camshaft.

  32. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)

    Click here

  33. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)

    Click here

  34. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B0072YJC11
      *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 as shown in the illustration.

    2. B0075VPC04
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)
      *b Separated by 4.0 to 6.0 mm (0.157 to 0.236 in.)
      B007493 Seal Packing

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes of applying 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. Install the camshaft housing sub-assembly RH and tighten the 15 bolts in the order shown in the illustration.

      B00759ZC08
      *a Types of bolt *b Tightening order
      *c Exhaust Side *d Intake Side
      *e Knock Pin - -
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing sub-assembly RH, 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, valve contact with a piston at TDC may occur.

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

      • If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.

      • If it is necessary to remove the camshaft housing sub-assembly RH during installation, make sure that the previously applied seal packing does not enter any oil passages.

      Bolt Length
      Item Length
      Bolt (A) 48 mm (1.89 in.)
      Bolt (B) 68 mm (2.68 in.)
    4. B0075LCE01

      Tighten the 9 bolts in the order shown in the illustration.

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

    5. Remove any protruding seal packing.

      Note

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

  35. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)


    1. B0076NCC02
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly RH or spark plug tube with the wrench.

  36. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)


    1. B00757BC02
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly RH or spark plug tube with the wrench.

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

  37. INSTALL CHAIN SUB-ASSEMBLY

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  38. INSTALL CHAIN TENSIONER SLIPPER

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  39. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  40. INSPECT VALVE TIMING

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  41. INSTALL TIMING CHAIN COVER ASSEMBLY

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