CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

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

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2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

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3. INSPECT CYLINDER HEAD SET BOLT

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4. INSPECT CYLINDER HEAD

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5. INSTALL CYLINDER HEAD GASKET

   1. 

      *1	Cylinder Block Sub-assembly
      	Engine Front

      Apply seal packing (diameter 4.0 mm (0.157 in.)) to the cylinder block sub-assembly as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note:

      Remove any oil from the cylinder block sub-assembly.

   2. 

      *a	Lot No.
      	Engine Front

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

      Note:

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

   3. 

      *1	Cylinder Head Gasket
      	Engine Front

      Apply seal packing (diameter 4.0 mm (0.157 in.)) to the new cylinder head gasket as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note:

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

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

6. INSTALL CYLINDER HEAD SUB-ASSEMBLY

   Tip:

   The cylinder head bolts are tightened in 3 progressive steps.

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

      Note:

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

      • Place the cylinder head on the cylinder block sub-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. 

      *a	Paint Mark
      	Front

      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. 

      *a	Before wiping off
      *b	After wiping off

      After tightening the cylinder head bolts, wipe off any seal packing material that seeped out from the contact surfaces between the cylinder head and cylinder block sub-assembly.

      Tip:

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

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7. INSTALL VALVE STEM CAP

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8. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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10. INSTALL NO. 1 WATER BY-PASS PIPE

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11. INSTALL EXHAUST MANIFOLD

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12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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13. INSTALL FUEL INJECTOR ASSEMBLY

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14. INSTALL NO. 1 DELIVERY PIPE SPACER

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15. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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16. INSTALL FUEL TUBE SUB-ASSEMBLY

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17. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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