CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL CYLINDER HEAD GASKET

   1. Clean the cylinder block and cylinder head with solvent.

   2. 

      *1	Lot No.
      *2	Cylinder Block
      *3	Cylinder Head Gasket
      *a	3.0 to 7.0 mm (0.118 to 0.276 in.)
      *b	20 mm (0.787 in.) or more
      *c	7.0 mm (0.276 in.)
      *d	3.0 mm (0.118 in.) or more
      	Seal Packing
      	Front

      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

      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.

      Tip:

      Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block.

   3. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

      Note:

      Pay attention to the installation direction.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

   Tip:

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

   • w/ Canister Pump Module

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   • w/o Canister Pump Module

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   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.

      Tip:

      The cylinder head bolts are tightened in 4 progressive steps.

   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.

         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.

         36 N*m

         367 kgf*cm

         27 ft.*lbf

   6. Step 3:

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

      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 at a 180° angle to the front.

         Note:

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

3. 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.

4. SET CAMSHAFT TIMING GEAR ASSEMBLY

   Tip:

   • When reusing the camshaft timing gear, release the lock pin and set the camshaft timing gear to the advanced position before installation.

   • If the camshaft timing gear is new or has already been set to the advanced position, install the camshaft timing gear after the camshafts have been installed to the engine.

   1. 

      *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. 

      *1	Pin Hole
      *2	Knock Pin

      Align the knock pin of the camshaft with the pin hole of the camshaft timing gear and attach the gear to the camshaft.

   3. 

      *1	Camshaft Timing Gear
      *2	Clearance
      *3	Camshaft Flange
      *a	INCORRECT
      *b	CORRECT
      *c	No Clearance

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

   4. Fix 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. Release the lock pin.

      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.

         

         *1	Retard Side Path	*2	Advance Side Path
         *3	Port A	*4	Knock Pin
         *a	Open	*b	Closed
         	Rubber		Vinyl Tape

         Tip:

         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. 

         While applying compressed air at approximately 200 kPa (2.0 kgf/ cm², 29 psi) 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.

         Tip:

         • 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 pieces of rubber 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.

5. INSTALL VALVE LASH ADJUSTER ASSEMBLY

   1. Inspect the valve lash adjuster before installing it.

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   2. Install the 16 lash adjusters to the cylinder head.

      Note:

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

6. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

   1. 

      *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.

7. INSTALL NO. 2 CAMSHAFT BEARING

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8. INSTALL NO. 1 CAMSHAFT BEARING

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9. INSTALL OIL CONTROL VALVE FILTER

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10. INSTALL CAMSHAFT

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft.

    • w/ Canister Pump Module

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    • w/o Canister Pump Module

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    1. Clean the camshaft journals, camshaft housing and camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journal, camshaft housing and camshaft bearing caps.

    3. Install the camshaft and No. 2 camshaft to the camshaft housing.

11. INSTALL CAMSHAFT BEARING CAP

    1. 

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

    2. 

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

       16 N*m

       163 kgf*cm

       12 ft.*lbf

       Note:

       Make sure that the camshaft rotates smoothly after installing the bearing caps.

12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    1. 

       *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. 

       *1	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

       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. 

       *1	Knock Pin
       *a	Approximately 17°
       *b	Approximately 2°

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

    4. 

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

       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.

13. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly.

    • w/ Canister Pump Module

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    • w/o Canister Pump Module

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    1. 

       *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. 

       *1	Knock Pin Hole
       *2	Knock Pin

       Align the knock pin of the camshaft with the knock pin hole of the camshaft timing gear and attach the gear to the camshaft.

    3. 

       *1	Camshaft Timing Gear
       *2	Clearance
       *3	Camshaft Flange
       *a	INCORRECT
       *b	CORRECT
       *c	No Clearance

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

    4. 

       *a	Hold
       *b	Turn

       Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

       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.

14. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft timing exhaust gear assembly.

    • w/ Canister Pump Module

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    • w/o Canister Pump Module

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    1. 

       *1	Knock Pin Hole
       *2	Knock Pin

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

    2. 

       *1	Camshaft Timing Exhaust Gear
       *2	Clearance
       *3	Camshaft Flange
       *a	INCORRECT
       *b	CORRECT
       *c	No Clearance

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

    3. 

       *a	Hold
       *b	Turn

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

       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.

15. ADD ENGINE OIL

    1. 

       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.

16. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. 

       Temporarily install the crankshaft pulley bolt.

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

    3. 

       *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.

       Tip:

       "A" is not a timing mark.

    4. Remove the crankshaft pulley bolt.

17. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    1. Install the No. 1 chain vibration damper with the 2 bolts.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

18. INSTALL CHAIN SUB-ASSEMBLY

    1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

       Tip:

       • 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. 

       *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. 

       *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. 

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

    5. 

       *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.

       Tip:

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

    6. 

       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.

19. INSTALL CHAIN TENSIONER SLIPPER

    1. Install the chain tensioner slipper with the bolt.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

20. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. Install a new gasket and the No. 1 chain tensioner with the 2 bolts.

       10 N*m

       102 kgf*cm

       7 ft.*lbf

    2. Remove the pin from the stopper plate.

21. INSTALL TIMING CHAIN GUIDE

    1. Install the timing chain guide with the bolt.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

22. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Temporarily install the crankshaft pulley bolt.

       

       *1	Timing Mark	*2	Key
       *a	Approximately 7°	*b	Approximately 32°

    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.

       Tip:

       "A" is not a timing mark.

    3. Remove the crankshaft pulley bolt.

23. INSTALL TIMING CHAIN COVER ASSEMBLY

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24. INSTALL INTAKE MANIFOLD

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25. CONNECT NO. 2 PCV HOSE

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26. CONNECT WIRE HARNESS

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27. INSTALL FUEL DELIVERY PIPE

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28. CONNECT WIRE HARNESS

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29. CONNECT FUEL TUBE SUB-ASSEMBLY

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30. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

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31. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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32. INSTALL ENGINE AND TRANSAXLE

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