CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. 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.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

   Tip:

   The cylinder head set bolts are tightened in 2 progressive steps.

   1. Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the plate washers.

   2. Place the cylinder head sub-assembly on the cylinder block sub-assembly, and set the cylinder head set bolts and plate washers to the cylinder head sub-assembly.

      Note:

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

   3. 

      Using a 10 mm bi-hexagon wrench, uniformly install and tighten the 10 cylinder head set bolts and 10 plate washers in several steps and in the order shown in the illustration.

      49 N*m

      500 kgf*cm

      36 ft.*lbf

   4. 

      *a	Paint Mark
      	Engine Front

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

   5. Tighten the cylinder head set bolts an additional 90° and then another 45° as shown in the illustration.

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

   7. 

      *a	Before wiping off
      *b	After wiping off

      Wipe off any seal packing seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly.

      Tip:

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

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3. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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5. INSTALL NO. 1 CAMSHAFT BEARING

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6. INSTALL NO. 2 CAMSHAFT BEARING

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7. INSTALL NO. 2 CAMSHAFT

   1. Clean the camshaft journals.

   2. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

   3. 

      Install the No. 2 camshaft to the camshaft housing sub-assembly.

8. INSTALL CAMSHAFT

   1. Clean the camshaft journals.

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

   3. 

      Install the camshaft to the camshaft housing sub-assembly.

9. INSTALL CAMSHAFT BEARING CAP

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10. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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11. INSTALL CHAIN SUB-ASSEMBLY

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