Cylinder Head Gasket Installation

Turn the roller by hand to check that it turns smoothly.
If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

Place the lash adjuster into a container full of new engine oil.

Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

SST

09276-75010

Squeeze SST and the valve lash adjuster together to move the plunger up and down 5 to 6 times.

Check the movement of the plunger and bleed the air.

OK:

Plunger moves up and down.

NOTICE:

When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air bleeding is not possible.

After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

OK:

Plunger can be pressed 3 times.

Using a vernier caliper, measure the length of the cylinder head bolt from the seat to the end.

Standard length:

146.8 to 148.2 mm (5.78 to 5.83 in.)

Maximum length:

149.2 mm (5.87 in.)

Using a vernier caliper, measure the diameter of the elongated thread at the measuring area.

Distance:

115 mm (4.53 in.)

Standard diameter:

9.77 to 9.96 mm (0.385 to 0.392 in.)

Minimum diameter:

9.4 mm (0.370 in.)

HINT:

If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.

Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block and manifolds.

Maximum Warpage:

Item	Specified Condition
Cylinder Block Side	0.05 mm (0.00197 in.)
Intake Manifold Side	0.10 mm (0.00394 in.)
Exhaust Manifold Side	0.10 mm (0.00394 in.)

Apply seal packing to the cylinder block as shown in the illustration.

Seal packing:

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

Standard seal packing diameter:

4.0 mm (0.157 in.)

Application Specification:

Area	Seal Packing Application Length	Distance from Edge of Cylinder Block to Center of Seal Packing
A	-	2.0 to 4.0 mm (0.0787 to 0.157 in.)
B	10 to 15 mm (0.394 to 0.591 in.)	-

NOTICE:

Remove any oil from the cylinder block.

Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.

NOTICE:

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

Apply seal packing to the cylinder head gasket as shown in the illustration.

Seal packing:

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

Standard seal packing diameter:

4.0 mm (0.157 in.)

Application Specification:

Area	Seal Packing Application Length	Distance from Edge of Cylinder Head Gasket to Center of Seal Packing
A	-	2.0 to 4.0 mm (0.0787 to 0.157 in.)
B	10 to 15 mm (0.394 to 0.591 in.)	-

NOTICE:

1. Remove any oil from the cylinder head gasket and cylinder head.
   
2. Install the cylinder head within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
   

Place the cylinder head on the cylinder block.

NOTICE:

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

Install the plate washers to the cylinder head bolts.

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 10 cylinder head bolts in several steps, in the sequence shown in the illustration.
   

   Torque:

   49 N*m{500 kgf*cm, 36 ft.*lbf}

   NOTICE:

   Do not drop the plate washers into the cylinder head.

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.
   

Step 3:

1. Tighten the cylinder head bolts another 45° in the sequence shown in step 1.
   

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

After tightening the cylinder head bolts, wipe off the seal packing material that has seeped out from between the contact surfaces of the cylinder head and cylinder block.

Apply a light coat of engine oil to the valve stem ends.

Install the 16 valve stem caps to the cylinder head.

NOTICE:

Do not drop the valve stem caps into the cylinder head.

Install the water by-pass pipe with the 2 bolts.

Torque:

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

Install a new exhaust manifold gasket.

Install the exhaust manifold with the 5 nuts.

Torque:

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

Temporarily install the manifold stay with the 3 bolts.

While pushing the manifold stay toward the exhaust manifold, tighten the 2 bolts labeled 1.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Tighten the bolt labeled 2.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Install the heat insulator with the 3 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Install the camshaft housing sub-assembly (RAV4_ACA30 RM0000027I901JX.html).

Install the engine assembly with transaxle (RAV4_ACA30 RM000003PXK003X.html).