CYLINDER HEAD GASKET INSTALLATION

INSTALL CYLINDER HEAD GASKET RH
1. Place a new cylinder head gasket RH on the cylinder block surface with the Lot No. stamp upward.
  Note
  
  Be careful of the installation direction.
  
  Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
1. Place the cylinder head on the cylinder block.
  
  Note
  
  Be careful not to allow oil to adhere to the bottom part 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. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
    
    Torque:
    
    36 N*m { 367 kgf*cm, 27 ft.*lbf }
4. Step 2
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  2. Tighten the cylinder head bolts another 90°.
5. Step 3
  1. Tighten the cylinder head bolts an additional 90°.
  2. Check that the painted mark is now facing rearward.
INSTALL CYLINDER HEAD GASKET LH
1. Place a new cylinder head gasket LH on the cylinder block surface with the Lot No. stamp upward.
  Note
  
  Be careful of the installation direction.
  
  Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
1. Place the cylinder head on the cylinder block.
  
  Note
  
  Be careful not to allow oil to adhere to the bottom part 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. 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 cylinder head bolt head with paint as shown in the illustration.
  2. Tighten the cylinder head bolts another 90°.
5. Step 3
  1. Tighten the cylinder head bolts an additional 90°.
  2. Check that the painted mark is now facing rearward.
6. Tighten the 2 bolts in the order shown in the illustration.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
INSTALL WATER OUTLET
1. Install 2 new gaskets and a new O-ring.
  
  Tech Tips
  
  Apply soapy water to the O-ring.
2. Text in Illustration
  
  *1 Nut
  
  *2 Bolt
  
  Install the water outlet with the 2 bolts and 4 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Note
  
  Be careful that the O-ring does not get caught between the parts.
INSTALL VALVE STEM CAP
1. Install the 24 valve stem caps.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
Note
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.
1. Place the lash adjuster into a container filled with engine oil.
2. 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
3. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed the air.
  
  OK
  
  Plunger moves up and down.
  
  Note
  
  When bleeding air from 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, air will not bleed.
5. After bleeding the air, 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 valve lash adjuster.
6. Install the valve lash adjusters.
  
  Note
  
  Install each valve lash adjuster to the same place it was removed from.

Text in Illustration
*1	Nut
*2	Bolt

OK
Plunger moves up and down.

OK
Plunger is very difficult to move.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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

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

Install the valve rocker arms as shown in the illustration.

INSTALL NO. 3 CAMSHAFT
1. Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH.
2. Install the No. 3 camshaft to the camshaft housing sub-assembly LH.
INSTALL NO. 4 CAMSHAFT
1. Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.
2. Install the No. 4 camshaft to the camshaft housing sub-assembly LH.
INSTALL CAMSHAFT BEARING CAP (for Bank 2)
1. Apply engine oil to the camshaft bearing caps.
2. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
3. Temporarily tighten the 8 bolts in the order shown in the illustration.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

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.

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

3.5 to 4.5 mm (0.138 to 0.177 in.)
Note
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly LH within 3 minutes.
- Do not start the engine for at least 2 hours after installing.
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.
Tighten the 8 bolts in the order shown in the illustration.

Torque:

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

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.
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.
INSTALL CAMSHAFT BEARING CAP (for Bank 1)
1. Apply engine oil to the camshaft bearing caps.
2. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
3. Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

Tech Tips

See the steps from "Install Camshaft Housing Sub-Assembly RH" through "Install Automatic Transaxle Assembly" Click here.