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. A01EXQFE15
      Text in Illustration
      *a Measurement Point

      Using a vernier caliper, measure the diameter of the threads at the 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. A01EYBNE05
      Text in Illustration
      *a Cylinder Head Lower Side
      *b Intake Manifold Side
      *c Exhaust Manifold Side

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

      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.)

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

    2. A01EYM4

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

      If cracked, replace the cylinder head.

  3. INSTALL CYLINDER HEAD GASKET


    1. A01ESU3E02
      Text in Illustration
      *1 Cylinder Head Gasket
      *2 Cylinder Block
      *a Front
      *b Lot No.
      *c Seal Packing
      *d 20mm or more

      Clean the cylinder block and cylinder head with solvent.

    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.

      • 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. A01EU6JE02

        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.

        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.

    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. A01EXP3E05
        Text in Illustration
        A01ETOA Front
        *a Painted Mark

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

      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 4 hours after installation.

        • Do not start the engine for at least 4 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. A01EX0RE04
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark
      *a Advanced Position:
      *b Retarded Position:

      Check the camshaft timing gear 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. A01EVVOE02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    3. A01ET3ZE11
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

    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. A01EVENE04

      Release the lock pin.

      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. A01EVFG

        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).

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

        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. A01EU1CE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

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

    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. A01EWCGE04
      Text in Illustration
      *1 Vernier Caliper

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

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  10. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01EYOQE03
      Text in Illustration
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

    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. A01EWXX

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  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 camshafts 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. A01EVOQ

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

    2. A01EXYCE02

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

      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. A01EWTKE03
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster
      *a INCORRECT
      *b CORRECT

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

    2. A01EXM8E01

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

      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. A01ETOTE02
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

      Position the knock pin of the No. 1 and No. 2 camshafts as shown in the illustration.

    4. A01EYLQE02

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

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

      Note


      • Do not apply oil for at least 4 hours after the installation.

      • Do not start the engine for at least 4 hours after the installation.

      • Thoroughly wipe clean any seal packing.

  15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EVGVE02
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark

      Check the camshaft timing gear position.

      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. A01EVVOE02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    3. A01ET3ZE11
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

    4. A01EXRX

      Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the bolt.

      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.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly Click here.

  16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01EYISE02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.

    2. A01ET3ZE11
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

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

    3. A01EX6Q

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

      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.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly Click here.

  17. ADD ENGINE OIL


    1. A01EV4U

      Add 50 cc (3.1 cu. in) of engine oil into the oil hole shown in the illustration.

      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. A01ET7RE01

      Temporarily install the crankshaft pulley bolt.

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

    3. A01EVE6E03
      Text in Illustration
      *1 Timing Mark
      *a Approximately 7°
      *b Approximately 32°

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

      Tech Tips

      "A" is not a timing mark.

  19. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01EUB3

      Install the chain vibration damper with the 2 bolts.

      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. A01ETW5E02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      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.

    3. A01EX09E02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      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.

    4. A01EV8R

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

    5. A01EX5NE02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

      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.

      Tech Tips

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

    6. A01EUKR

      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.

      Note

      Make sure the chain is secure.

  21. INSTALL CHAIN TENSIONER SLIPPER


    1. A01EYU8

      Install the chain tensioner slipper with the bolt.

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

  22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01EXZH

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

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

    2. Remove the pin from the stopper plate.

  23. INSTALL TIMING CHAIN GUIDE


    1. A01EV0O

      Install the timing chain guide with the bolt.

      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.

      A01ETOLE03
      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. A01EYEZ

      Install the wire harness clamp bracket with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. A01EX7HE03
      Text in Illustration
      *a Black

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

    3. Check the tumble control valves (w/ TCV).

      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. A01ETJYE01

      Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/ TCV).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    6. A01ETCBE01

      Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration (w/o TCV).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    7. A01EY87E01

      Connect the intake air control actuator connector and 2 wire harness clamps (w/ TCV).

    8. Connect the 2 wire harness clamps (w/o TCV).

    9. Install the wire harness clamp with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Text in Illustration
      *A w/ TCV
      *B w/o TCV
    10. A01EUH1

      Install the wire harness clamp bracket with the bolt.

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

    11. Connect the 3 wire harness clamps and connector.

    12. Connect the fuel vapor feed hose.

    13. A01EW2L

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

      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. A01EVW6E01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *a Fuel Delivery Pipe Side
      *b Cylinder Head Side

      Install 4 new injector vibration insulators to the cylinder head.

    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 hose clamp with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    2. Install the vacuum switching valve assembly with the bolt.

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

    3. Connect the 2 vacuum hoses and connector.

    4. Connect the union to connector tube hose and wire harness clamp.

  29. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY


    1. Install a new gasket to the intake manifold.

    2. Install the fuel tube bracket with the bolt.

      Torque:
      13 N*m  { 132 kgf*cm, 10 ft.*lbf }

    3. Install the throttle with motor body assembly with the 4 bolts.

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

    4. Connect the throttle body connector.

    5. Connect the fuel tube to the clamp.

    6. Connect the No. 2 water by-pass hose to the throttle with motor body assembly.

    7. Connect the water by-pass hose to the throttle with motor body assembly.

  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. A01EVVIE05

      Tighten the 5 nuts in the sequence shown in the illustration.

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

  31. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  32. 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 }

  33. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the bolt and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  34. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here