CYLINDER HEAD GASKET

INSTALL CYLINDER HEAD GASKET

Text in Illustration
*a	Lot No.

Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
Note
- Remove any oil from the contact surfaces.
- Check the mounting orientation of the cylinder head gasket.
- Do not damage the cylinder gasket when installing the cylinder head onto the cylinder block.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

Tech Tips

The cylinder head bolts are tightened in 2 successive steps.

Apply a light coat of engine oil to the threads of the cylinder head bolts.
Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench, in the sequence shown in the illustration.

Torque:

29 N*m { 300 kgf*cm, 22 ft.*lbf }
Mark the front of the cylinder head bolt with paint.
Text in Illustration

*a Paint Mark

Further tighten the cylinder head bolts 90° and then an additional 90° as shown in the illustration.
Check that the paint mark is now at a 180° angle from the front.

Text in Illustration
*a	Paint Mark

Text in Illustration
*1	Cylinder Head
*2	Cylinder Head Gasket
*3	Cylinder Block
*a	Diameter
	Seal Packing

Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) 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 oil pump assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.

INSTALL VALVE STEM CAP

Apply a light coat of engine oil to the valve stem ends.
Install the 16 valve stem caps to the cylinder head.

Note

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

INSTALL VALVE LASH ADJUSTER ASSEMBLY

Text in Illustration
*1	Plunger
*2	Low Pressure Chamber
*3	Check Ball
*4	High Pressure Chamber
*a	Correct
*b	Incorrect
*c	Taper Part

Note

Keep the lash adjuster free of dirt and foreign matter.
Only use clean engine oil.

Place the lash adjuster into a container filled with engine oil.
Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

SST

09276-75010
Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.
Check the movement of the plunger and bleed it.

OK

Plunger moves up and down.

Note

When bleeding the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.
After bleeding, remove SST. Then, try to press the plunger quickly and firmly by hand.

OK

Plunger is very difficult to move.

If the result is not as specified, replace the lash adjuster.
Install the lash adjusters.

Note

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

OK
Plunger moves up and down.

OK
Plunger is very difficult to move.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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

Apply engine oil to the lash adjuster tip and valve stem cap end.

Make sure that the valve rocker arms are installed as shown in the illustration.

INSTALL CAMSHAFT

Examine the front marks and numbers and check that the order is as shown in the illustration. Then provisionally tighten the 19 bolts.

Text in Illustration
*1	No. 1 Bearing Cap
*2	No. 2 Bearing Cap

Uniformly tighten the bolts in several steps in the sequence shown in the illustration and install the No. 1 and No. 2 camshaft bearing caps.

Torque:: No. 1 camshaft bearing cap; 23 N*m { 235 kgf*cm, 17 ft.*lbf }; No. 2 camshaft bearing cap; 13 N*m { 129 kgf*cm, 9 ft.*lbf }

Note

Tighten each bolt uniformly while keeping the camshaft level.

INSTALL CHAIN SUB-ASSEMBLY

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INSTALL NO. 1 CHAIN VIBRATION DAMPER

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INSTALL CHAIN TENSIONER SLIPPER

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INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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INSTALL OIL PUMP SEAL

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INSTALL OIL PUMP ASSEMBLY

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INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

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INSTALL WATER PUMP ASSEMBLY

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INSTALL WATER PUMP PULLEY

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INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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INSTALL CRANKSHAFT POSITION SENSOR

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INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

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INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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INSTALL INLET HEATER WATER HOSE A

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INSTALL FUEL VAPOR FEED HOSE ASSEMBLY

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INSTALL VENTILATION HOSE

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INSTALL NO. 1 IGNITION COIL

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INSTALL GENERATOR ASSEMBLY

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INSTALL FAN AND GENERATOR V BELT

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ADJUST FAN AND GENERATOR V BELT

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INSPECT FAN AND GENERATOR V BELT

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INSTALL MANIFOLD SUPPORT BRACKET

Install the manifold support bracket with the 3 bolts.

Torque:

44 N*m { 449 kgf*cm, 33 ft.*lbf }

INSTALL FRONT EXHAUST PIPE ASSEMBLY

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INSTALL NO. 1 OIL PIPE

Install a new gasket and temporarily install the No. 1 oil pipe with the 2 oil pipe unions.
Tighten the oil pipe union.

Torque:

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

CONNECT WIRE HARNESS

Connect the wire harness with the 2 bolts.

Torque:

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

INSTALL NO. 1 WATER BY-PASS PIPE

Install the No. 1 water by-pass pipe with the bolt.

Torque:

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

INSTALL WIRING HARNESS CLAMP BRACKET

Connect the heated oxygen sensor connector.
Install the wiring harness clamp bracket with the bolt.

Torque:

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

CONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR

Connect the engine coolant temperature sensor connector.

CONNECT CAMSHAFT POSITION SENSOR CONNECTOR

Connect the camshaft position sensor connector.

INSTALL BOOSTER VACUUM TUBE

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INSTALL NO. 3 WATER BY-PASS HOSE

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INSTALL NO. 4 WATER BY-PASS HOSE

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INSTALL EGR DELIVERY CHAMBER

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INSTALL OIL LEVEL GAGE GUIDE

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INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY

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INSTALL INTAKE MANIFOLD

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INSTALL EGR VALVE ASSEMBLY

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INSTALL WATER FILLER SUB-ASSEMBLY

Install the water filler sub-assembly with the 2 nuts.

Torque:

7.5 N*m { 76 kgf*cm, 66 in.*lbf }
Connect the No. 1 radiator hose to the cylinder head.

CONNECT OUTLET HEATER WATER HOSE A

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INSTALL UNION TO CHECK VALVE HOSE

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CONNECT FUEL TUBE SUB-ASSEMBLY

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INSTALL NO. 2 FUEL PIPE CLAMP

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CONNECT RESERVE TANK HOSE