CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL CYLINDER HEAD GASKET

   1. 

      *1	Cylinder Block Assembly
      *2	Seal Packing
      *a	Distance from Edge of Cylinder Block Assembly to Center of Seal Packing
      *b	Seal Packing Application Length
      	Engine Front

      Apply seal packing to the cylinder block assembly 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

      Distance from Edge of Cylinder Block to Center of Seal Packing	Seal Packing Application Length
      0 to 2.0 mm (0 to 0.0787 in.)	10 to 15 mm (0.394 to 0.591 in.)

      Note:

      Remove any oil from the cylinder block assembly.

   2. 

      *1	Lot No.
      	Engine Front

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

      Note:

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

   3. 

      *1	Cylinder Head Gasket
      *2	Seal Packing
      *a	Distance from Edge of Cylinder Head Gasket to Center of Seal Packing
      *b	Seal Packing Application Length
      	Engine Front

      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

      Distance from Edge of Cylinder Head Gasket to Center of Seal Packing	Seal Packing Application Length
      2.0 to 4.0 mm (0.0787 to 0.157 in.)	10 to 15 mm (0.394 to 0.591 in.)

      Note:

      • Remove any oil from the cylinder head gasket and cylinder head sub-assembly.

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

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

   Tip:

   • The cylinder head bolts are tightened in 3 progressive steps.

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

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

      Note:

      • Make sure that no oil is on the mounting surface of the cylinder head sub-assembly.

      • Place the cylinder head sub-assembly on the cylinder block assembly gently in order not to damage the gasket with the bottom part of the cylinder head sub-assembly.

   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. 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.

         49 N*m

         500 kgf*cm

         36 ft.*lbf

         Note:

         Do not drop the plate washers into the cylinder head sub-assembly.

   5. Step 2:

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

      2. Tighten the cylinder head bolts 90°.

   6. Step 3:

      1. Tighten the cylinder head bolts an additional 45°.

      2. Check that the paint marks are now at a 135° angle to the front.

   7. 

      *a	Before wiping off
      *b	After wiping off

      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 sub-assembly and cylinder block assembly.

3. INSTALL VALVE STEM CAP

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4. CONNECT NO. 1 WATER BY-PASS PIPE

   1. Connect the No. 1 water by-pass pipe to the cylinder head sub-assembly with the 2 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

5. INSTALL EXHAUST MANIFOLD

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6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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