CYLINDER HEAD GASKET INSTALLATION


  1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A01ISJ5

      Turn the roller by hand to check that it turns smoothly.

      If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster free from dirt and foreign matter.

    • Only use clean engine oil.


    1. Place the lash adjuster into a container full of new engine oil.

    2. A01IOR2E02

      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 the valve 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 high-pressure air from the compression 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 bleeding is not possible.

    5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

      OK
      Plunger can be pressed 3 times.

      If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.

  3. INSPECT CYLINDER HEAD BOLT


    1. A01IQATE01

      Using a vernier caliper, measure the length of the cylinder head bolt from the seat to the end.

      Standard length
      146.8 to 148.2 mm (5.78 to 5.83 in.)
      Maximum length
      149.2 mm (5.87 in.)

      If the length is more than the maximum, replace the cylinder head set bolt.

    2. Using a vernier caliper, measure the diameter of the elongated thread at the measuring area.

      Distance
      115 mm (4.53 in.)
      Standard diameter
      9.77 to 9.96 mm (0.385 to 0.392 in.)
      Minimum diameter
      9.4 mm (0.370 in.)

      If the diameter is less than the minimum, replace the cylinder head bolt.

      Tech Tips

      If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.

  4. INSPECT CYLINDER HEAD


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

      Maximum Warpage
      Item Specified Condition
      Cylinder block 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.

  5. INSTALL CYLINDER HEAD GASKET


    1. A01IT1VE01

      Apply seal packing to the cylinder block as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal packing diameter
      4.0 mm (0.157 in.)
      Application Specification
      Area Seal Packing Application Length Distance from Edge of Cylinder Block to Center of Seal Packing
      A - 2.0 to 4.0 mm (0.0787 to 0.157 in.)
      B 10 to 15 mm (0.394 to 0.591 in.) -

      Note

      Remove any oil from the cylinder block.

    2. A01IPVCE04

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

      Note

      Install the cylinder head gasket within 3 minutes after applying seal packing.

    3. A01IOLDE01

      Apply seal packing to the cylinder head gasket as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal packing diameter
      4.0 mm (0.157 in.)
      Application Specification
      Area Seal Packing Application Length Distance from Edge of Cylinder Head Gasket to Center of Seal Packing
      A - 2.0 to 4.0 mm (0.0787 to 0.157 in.)
      B 10 to 15 mm (0.394 to 0.591 in.) -

      Note


      • Remove any oil from the cylinder head gasket and cylinder head.

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

  6. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 3 progressive steps.


    1. Place the cylinder head on the cylinder block.

      Note


      • Make sure 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. A01INZXE02

      Step 1:


      1. 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:
        49 N*m  { 500 kgf*cm, 36 ft.*lbf }

        Note

        Do not drop the plate washers into the cylinder head.

    5. A01IRJXE01

      Step 2:


      1. 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.

    6. Step 3:


      1. Tighten the cylinder head bolts another 45° in the sequence shown in step 1.

    7. Check that the paint mark is now at a 135° angle to the front.

    8. A01IQQRE03

      After tightening the cylinder head bolts, wipe off the seal packing material that has seeped out from between the contact surfaces of the cylinder head and cylinder block.

  7. 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.

  8. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A01IPEK

      Install the water by-pass pipe with the 2 bolts.

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

  9. INSTALL EXHAUST MANIFOLD


    1. Install a new exhaust manifold gasket.

    2. for Nut Type A:


      1. A01IQGQE01
        Text in Illustration
        *A for Nut Type A
        *B for Nut Type B

        Install the exhaust manifold with the 5 nuts.

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

    3. for Nut Type B:


      1. Install the exhaust manifold with 5 new nuts.

        Torque:
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  10. INSTALL MANIFOLD STAY


    1. A01IUFSE01

      Temporarily install the manifold stay with the 3 bolts.

    2. While pushing the manifold stay toward the exhaust manifold, tighten the 2 bolts labeled 1.

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

    3. Tighten the bolt labeled 2.

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

  11. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    A01IMZJ

    1. Install the drive shaft heat insulator sub-assembly with the 2 nuts.

      Torque:
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }

  12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01IUNH

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

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

  13. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. Install the camshaft housing sub-assembly Click here.

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine assembly with transaxle Click here.