CYLINDER HEAD GASKET INSTALLATION

PROCEDURE

  1. INSPECT CYLINDER HEAD SET BOLT

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  2. INSTALL CYLINDER HEAD GASKET

    1. A325595C01

      *a

      Seal Packing

      *b

      23.0 to 27.0 mm (0.906 to 1.06 in.)

      *c

      1.0 to 3.0 mm (0.0394 to 0.118 in.)

      *d

      28.0 mm (1.10 in.)

      *e

      13.0 mm (0.512 in.)

      *f

      28.0 to 32.0 mm (1.10 to 1.26 in.)

      *g

      4.0 mm (0.157 in.)

      Apply 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

      Note:

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

      • Apply seal packing to the edge of the cylinder head gasket.

    2. Place the cylinder head gasket on the cylinder block sub-assembly.

      Note:

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

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Note:

    Place the cylinder head sub-assembly gently in order not to damage the gasket.

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

    2. Install the 8 plate washers to the cylinder head sub-assembly.

      Note:

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

    3. A320135

      Apply engine oil to the threads and seating surface of each cylinder head set bolt.

    4. A278665N01

      Using an 8 mm bi-hexagon wrench, uniformly install and tighten the 8 cylinder head set bolts in several steps in the order shown in the illustration.

      32 N*m

      326 kgf*cm

      24 ft.*lbf

    5. A118683C05

      *a

      Paint Mark

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

    6. Tighten the cylinder head set bolts by an additional 180° as shown in the illustration.

    7. Check that the paint marks are now at a 180° angle from the front.

    8. A249628C02

      *a

      Direction to wipe off

      *b

      Before wiping off

      *c

      After wiping off

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

      Note:

      • Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.

      • Be sure to avoid clogging the bolt holes when wiping off the seal packing.

  4. INSTALL NO. 2 CAMSHAFT

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  5. INSTALL CAMSHAFT

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  6. INSTALL OIL CONTROL VALVE FILTER

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  7. INSTALL CAMSHAFT BEARING CAP

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  8. INSTALL CAMSHAFT TIMING SPROCKET ASSEMBLY

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  9. INSTALL BRACKET

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  10. INSTALL TIMING CHAIN GUIDE

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  11. INSTALL CRANKSHAFT TIMING SPROCKET

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  12. INSTALL CHAIN SUB-ASSEMBLY

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  13. INSTALL TIMING CHAIN TENSION ARM

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  14. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  15. INSTALL TIMING CHAIN COVER OIL SEAL

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  16. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  17. INSTALL CRANKSHAFT PULLEY

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  18. INSTALL OIL PAN SUB-ASSEMBLY

    1. Remove any old seal packing remaining on the sealing surfaces before applying seal packing.

    2. Clean the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly, and confirm that no oil, moisture or other foreign matter on the surfaces.

    3. A327444C03

      *a

      Continuous Line Area (3.0 to 4.0 mm (0.118 to 0.157 in.))

      *b

      Dashed Line Area (5.0 to 6.0 mm (0.197 to 0.236 in.))

      *c

      39.5 mm (1.56 in.)

      Apply seal packing to the oil pan sub-assembly as shown in the illustration.

      Seal Packing

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

      Note:

      • Apply seal packing to the contact surfaces between the timing chain cover sub-assembly and cylinder block sub-assembly, and between the rear engine oil seal retainer and cylinder block sub-assembly.

      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

    4. A324419N01

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

      24 N*m

      245 kgf*cm

      18 ft.*lbf

    5. A324420C03

      *a

      Nut

      Install the 7 bolts and 2 nuts.

      Bolt (A)

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      Bolt (B), Nut

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  19. INSTALL WATER BY-PASS PIPE

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  20. INSTALL CYLINDER HEAD COVER GASKET

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  21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  22. INSTALL NO. 1 IGNITION COIL

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  23. INSTALL CRANKSHAFT POSITION SENSOR

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  24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

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  25. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

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  26. INSTALL EXHAUST MANIFOLD (TWC: Catalyst)

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  27. INSTALL MANIFOLD STAY

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  28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  29. INSTALL ENGINE OIL LEVEL DIPSTICK

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  30. INSTALL OIL LEVEL GAUGE GUIDE OIL HOSE

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  31. INSTALL WATER BY-PASS HOSE ASSEMBLY

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  32. INSTALL ENGINE HANGER

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  33. REMOVE ENGINE FROM ENGINE STAND

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