Cylinder Head Gasket Installation

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head LH or cylinder block.

Apply seal packing to a new No. 2 cylinder head gasket as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.5 to 3.0 mm (0.0984 to 0.118 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the No. 2 cylinder head gasket within 3 minutes after applying the seal packing.
   
3. Do not add engine oil within 2 hours of installation.
   

Place the No. 2 cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

Text in Illustration

*1	Lot No.
	Engine Front

NOTICE:

Make sure that the gasket is installed facing the proper direction.

Seal packing will seep out from the front side of engine. Thoroughly wipe off the seal packing that seeps out.

Place the cylinder head LH on the cylinder block.

NOTICE:

1. Gently place the cylinder head LH in order not to damage the gasket with the bottom part of the head.
   
2. Make sure that no oil is on the mounting surface of the cylinder head LH.
   

HINT:

The cylinder head bolts are tightened in 2 progressive steps.

1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
   

Step 1:

1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
   

   Torque:

   36 N*m{367 kgf*cm, 27 ft.*lbf}

   NOTICE:

   Do not drop the washers into the cylinder head LH.

Step 2:

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

2. Tighten the cylinder head bolts another 180°.
   

3. Check that the paint marks are now at a 180° angle to the front.
   

Install the 2 bolts in the order shown in the illustration.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

NOTICE:

Thoroughly wipe clean any seal packing.

Place the 2 camshafts onto the cylinder head with the cam lobes of the No. 2 cylinder oriented as shown in the illustration.

Set the 8 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Uniformly install the 16 bolts in several steps in the order shown in the illustration.

Torque:

for 10 mm head bolt:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

for 12 mm head bolt:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Text in Illustration

*A	for Bank 2
	10 mm Head Bolt
	12 mm Head Bolt

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head or cylinder block.

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

Standard seal diameter:

2.5 to 3.0 mm (0.0984 to 0.118 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head gasket within 3 minutes after applying the seal packing.
   
3. Do not add engine oil within 2 hours of installation.
   

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

Text in Illustration

*1	Lot No.
	Engine Front

NOTICE:

Make sure that the gasket is installed facing the proper direction.

Place the cylinder head RH on the cylinder block.

NOTICE:

1. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
   
2. Make sure that no oil is on the mounting surface of the cylinder head.
   

HINT:

The cylinder head bolts are tightened in 2 progressive steps.

1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
   

Step 1:

1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
   

   Torque:

   36 N*m{367 kgf*cm, 27 ft.*lbf}

   NOTICE:

   Do not drop the washers into the cylinder head.

Step 2:

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

2. Tighten the cylinder head bolts another 180°.
   

3. Check that the paint marks are now at a 180° angle to the front.
   

Seal packing will seep out from the front side of engine. Thoroughly wipe off the seal packing that seeps out.

Align the bearing claw with the groove of the No. 1 camshaft bearing cap and push in the camshaft bearing.

NOTICE:

1. Install the bearing while aligning it with the oil hole in the No. 1 camshaft bearing cap.
   
2. Clean the backside of the bearing and the bearing surface of the No. 1 camshaft bearing cap and do not allow any oil or grease to contact the parts.
   

Install the No. 2 camshaft bearing to the cylinder head.

NOTICE:

Clean the backside of the bearing and the bearing surface of the cylinder head and do not allow any oil or grease to contact the parts.

Set the crankshaft position.

1. Using the crankshaft pulley set bolt, turn the crankshaft and set the crankshaft set key to the left horizontal position.
   

   Text in Illustration

   *1	Set Key
   *a	Turn

   NOTICE:

   Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.

Apply new engine oil to the thrust portion and journals of the camshafts.

Place the 2 camshafts onto the cylinder head with the cam lobes of the No. 1 cylinder oriented shown in the illustration.

Set the 8 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Uniformly install the 16 bolts in several steps in the order shown in the illustration.

Torque:

for 10 mm head bolt:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

for 12 mm head bolt:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Text in Illustration

*A	for Bank 1
	10 mm Head Bolt
	12 mm Head Bolt

Using a wrench, turn the camshafts clockwise until the camshaft knock pin is at a position 90° to the cylinder head.

While pushing in the tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

Install the No. 2 chain tensioner with the bolt.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Align the mark links of the No. 2 chain with the timing marks (1-dot mark) of the camshaft timing gear and sprocket as shown in the illustration.

Align the timing marks on the camshaft timing gear and sprocket with the timing marks on the bearing caps and install the camshaft timing gear and sprocket together with the No. 2 chain to the camshafts.

Temporarily install the 2 camshaft timing gear bolts.

NOTICE:

Do not forcibly push the camshaft timing gear assembly onto the camshaft when installing it.

Hold the hexagonal portion of the camshaft with a wrench and tighten the 2 bolts.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Remove the pin from the No. 2 chain tensioner.

While pushing in the tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

Install the No. 3 chain tensioner with the bolt.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Align the mark links of the No. 2 chain with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gear and sprocket as shown in the illustration.

Align the timing marks on the camshaft timing gear and sprocket with the timing marks on the bearing caps and install the camshaft timing gear and sprocket together with the No. 2 chain to the camshafts.

Temporarily install the 2 camshaft timing gear bolts.

NOTICE:

Do not forcibly push the camshaft timing gear assembly onto the camshaft when installing it.

Hold the hexagonal portion of the camshaft with a wrench and tighten the 2 bolts.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Remove the pin from the No. 3 chain tensioner.

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

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

While turning the stopper plate of the tensioner counterclockwise, insert a bar with a diameter of 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate in place.

Install the No. 1 chain tensioner with the 2 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Set the No. 1 cylinder to TDC/compression.

1. Align the timing marks of the camshaft timing gears and sprockets with the timing marks of the bearing caps.
   

   Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *1	Timing Mark





2. Install the crankshaft pulley set bolt and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.
   

   Text in Illustration

   *1	Timing Line
   *2	Set Key

Align the mark link with the timing mark of the crankshaft timing gear.

Align the mark links with the timing marks of the camshaft timing gears and install the chain.

Install the 2 No. 2 chain vibration dampers.

Apply a light coat of engine oil to the sliding surface of the No. 1 idle gear shaft.

Temporarily install the No. 1 idle gear shaft and idle gear together with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

Text in Illustration

*1	Knock Pin
	Forward

NOTICE:

Make sure that the idle gear is installed facing the proper direction.

Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

Torque:

60 N*m{612 kgf*cm, 44 ft.*lbf}

Remove the bar from the No. 1 chain tensioner.

Turn the crankshaft pulley and align its groove with the "0" timing mark of the timing chain cover.

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

Apply soapy water to a new O-ring and install it to the No. 1 water outlet pipe. Then install 2 new gaskets to the water ports LH and RH.

Install the rear water by-pass joint with the 2 bolts and 4 nuts.

Torque:

for bolt:

10 N*m{102 kgf*cm, 7 ft.*lbf}

for nut:

9.0 N*m{92 kgf*cm, 80 in.*lbf}