CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Note

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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Tech Tips

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


PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET RH


    1. B006GTKC02
      *a Lot No.
      B006AHR Engine Front

      Place the cylinder head gasket RH on the cylinder block sub-assembly RH surface with the Lot No. stamp upward.

      Note


      • Be careful of the installation direction.

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

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

    Tech Tips

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



    1. Place the cylinder head sub-assembly RH on the cylinder block sub-assembly.

      Note

      Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly RH.

      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. B006FRVC04
      B006AHR Bolt Length 140 mm (5.51 in.)
      B006EC9 Bolt Length 150 mm (5.90 in.)

      Step 1:


      1. Using a 12 mm socket wrench, install and uniformly tighten the 8 cylinder head set bolts with the plate washers in several steps and in the sequence shown in the illustration.

        Torque:
        90 N*m  { 918 kgf*cm, 66 ft.*lbf }

    4. Step 2:


      1. Mark the front side of each cylinder head set bolt head with paint.

      2. Tighten the cylinder head set bolts another 90°.

    5. Step 3:


      1. Tighten the cylinder head set bolts an additional 90°.

      2. Check that the paint marks are now at a 180° angle to the front.

  3. INSTALL CYLINDER HEAD GASKET LH


    1. B006GOHC02
      *a Lot No.
      B006AHR Engine Front

      Place the cylinder head gasket sub-assembly LH on the cylinder block sub-assembly surface with the Lot No. stamp upward.

      Note


      • Be careful of the installation direction.

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

  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

    Tech Tips

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



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

      Note

      Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly 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. B0069HCC04
      B006AHR Bolt Length 140 mm (5.51 in.)
      B006EC9 Bolt Length 150 mm (5.90 in.)

      Step 1:


      1. Using a 12 mm socket wrench, install and uniformly tighten the 8 cylinder head set bolts with the plate washers in several steps in the sequence shown in the illustration.

        Torque:
        90 N*m  { 918 kgf*cm, 66 ft.*lbf }

    4. Step 2:


      1. Mark the front side of each cylinder head set bolt head with paint.

      2. Tighten the cylinder head set bolts another 90°.

    5. Step 3:


      1. Tighten the cylinder head set bolts an additional 90°.

      2. Check that the paint marks are now at a 180° angle to the front.

  5. INSTALL VALVE STEM CAP


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

    2. Install the 24 valve stem caps to the cylinder head sub-assembly.

      Note

      Install the valve stem cap to the same place it was removed from.

  6. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assembly.

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    2. Install the 24 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

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

  7. INSTALL VALVE ROCKER ARM SUB-ASSEMBLY


    1. Apply engine oil to the valve lash adjuster assembly tips and valve stem cap ends.

    2. B006FPKC01
      *1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly

      Install the 24 valve rocker arm sub-assemblies as shown in the illustration.

      Note

      Install the valve rocker arm sub-assembly to the same place it was removed from.

  8. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY LH


    1. Apply a light coat of engine oil to the intake camshaft sub-assembly LH journals and camshaft housing sub-assembly LH.

    2. Install the intake camshaft sub-assembly LH to the camshaft housing sub-assembly LH.

  9. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY LH


    1. Apply a light coat of engine oil to the exhaust camshaft sub-assembly LH journals and camshaft housing sub-assembly LH.

    2. Install the No. 2 chain sub-assembly to the intake camshaft sub-assembly LH and exhaust camshaft sub-assembly LH.

    3. B006AS5C02
      *a Timing Mark
      *b Mark Plate
      *c Intake Side
      *d Exhaust Side

      Align the mark plates (Pink) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    4. Install the exhaust camshaft sub-assembly LH to the camshaft housing sub-assembly LH.

  10. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. Apply engine oil to the camshaft bearing caps.

    2. Make sure on the camshaft bearing caps and place each in the proper position and direction.

    3. B006D4CE04

      Install and tighten the 6 bolts in the order shown in the illustration.

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

      Tech Tips

      Bolt Length 40 mm (1.57 in.)

    4. B006GHSC02
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.)
      B006ECJ Seal Packing

      Apply seal packing in a continuous line 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.

      • Do not start the engine for at least 2 hours after installation.

    5. B0069M6C01
      *1 Valve Stem Cap
      *2 Valve Rocker Arm Sub-assembly
      *3 Valve Lash Adjuster Assembly
      *a CORRECT
      *b INCORRECT

      Make sure that the valve rocker arm sub-assembly is installed as shown in the illustration.

    6. Install the camshaft housing sub-assembly LH to the cylinder head sub-assembly LH.

  11. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Install the fuel pump lifter housing sub-assembly LH.

    2. B006AFKE04

      Install the camshaft housing sub-assembly LH and tighten the 17 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Standard Bolt
      Item Length
      Camshaft housing sub-assembly LH install bolt 40 mm (1.57 in.)
      Bearing cap bolt 65 mm (2.56 in.)

      Note


      • 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.

    3. Remove any protruding seal packing black.

  12. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY RH


    1. Apply a light coat of engine oil to the intake camshaft sub-assembly RH journals and camshaft housing sub-assembly RH.

    2. Install the intake camshaft sub-assembly RH to the camshaft housing sub-assembly RH.

  13. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY RH


    1. Apply a light coat of engine oil to the exhaust camshaft sub-assembly RH journals and camshaft housing sub-assembly RH.

    2. Install the No. 2 chain sub-assembly to the intake camshaft sub-assembly RH and exhaust camshaft sub-assembly RH.

    3. B006GASC02
      *a Timing Mark
      *b Mark Plate
      *c Intake Side
      *d Exhaust Side

      Align the mark plates (Pink) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    4. Install the exhaust camshaft sub-assembly RH to the camshaft housing sub-assembly RH.

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. Apply engine oil to the camshaft bearing caps.

    2. Make sure on the camshaft bearing caps and place each in the proper position and direction.

    3. B006CU2E04

      Install and tighten the 4 bolts in the order shown in the illustration.

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

      Tech Tips

      Bolt Length 40 mm (1.57 in.)

    4. B006E6BC02
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.)
      B006ECJ Seal Packing

      Apply seal packing in a continuous line 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.

      • Do not start the engine for at least 2 hours after installation.

    5. B0069M6C01
      *1 Valve Stem Cap
      *2 No. 1 Valve Rocker Arm Sub-assembly
      *3 Valve Lash Adjuster Assembly
      *a CORRECT
      *b INCORRECT

      Make sure that the valve rocker arm sub-assembly is installed as shown in the illustration.

    6. Install the camshaft housing sub-assembly RH to the cylinder head sub-assembly RH.

  15. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Install the fuel pump lifter housing sub-assembly RH.

    2. B006C0FE04

      Install the camshaft housing sub-assembly RH and tighten the 14 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Standard Bolt
      Item Length
      Camshaft housing sub-assembly RH install bolt 40 mm (1.57 in.)
      Bearing cap bolt 65 mm (2.56 in.)

      Note


      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly RH 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.

    3. Remove any protruding seal packing black.

  16. INSTALL VACUUM PUMP ASSEMBLY

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  17. INSTALL TIMING CHAIN COVER ASSEMBLY

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  18. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

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  19. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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  20. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  21. INSTALL IDLE SPROCKET ASSEMBLY

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  22. INSTALL NO. 1 CHAIN SUB-ASSEMBLY

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  23. INSTALL CHAIN TENSIONER SLIPPER

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  24. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  25. INSPECT VALVE TIMING

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  26. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

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  27. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

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  28. INSTALL NO. 2 TURBOCHARGER SUB-ASSEMBLY

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  29. INSTALL NO. 1 TURBOCHARGER SUB-ASSEMBLY

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  30. INSTALL DIRECT FUEL INJECTOR ASSEMBLY (for Direct Injection)

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  31. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH (for 2WD)

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  32. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION

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