Cylinder Head Gasket Installation

Clean and degrease the contact surfaces of the cylinder head sub-assembly and cylinder block sub-assembly.

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

Seal Packing:

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

NOTICE:

1. Be sure to clean and degrease the contact surfaces.
   
2. Apply seal packing to the bead on the cylinder head gasket.
   
3. Install the cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes after applying seal packing.
   

Place the cylinder head gasket on the cylinder block surface with the lot No. stamp facing upward.

Text in Illustration

*a	Lot No.
	Engine Front

NOTICE:

1. Remove any oil from the contact surface.
   
2. Make sure that the cylinder head gasket is installed in the correct direction.
   

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

NOTICE:

1. Make sure that no oil is on the mounting surface of the cylinder head sub-assembly.
   
2. Place the cylinder head sub-assembly on the cylinder block gently so as not to damage the gasket with the bottom part of the cylinder head sub-assembly.
   

Install the plate washers to the cylinder head set bolts.

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

Step 1:
Using several steps, install and uniformly tighten the 10 cylinder head set bolts with plate washers in the sequence shown in the illustration.

Torque:

39 N*m{398 kgf*cm, 29 ft.*lbf}

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

Step 2:
Tighten the cylinder head set bolts 90° in the sequence shown in step 1.

Step 3:
Tighten the cylinder head set bolts another 90° in the sequence shown in step 1.

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

w/ Oil Cooler:
Connect the No. 4 water by-pass pipe with the bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the engine wire to the cylinder head sub-assembly with the 3 bolts.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

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

Install the 16 valve stem caps to the cylinder head sub-assembly.

NOTICE:

Do not drop the valve stem caps into the cylinder head sub-assembly.

Inspect each valve lash adjuster assembly before installing it (LandCruiser RM00000447K00SX_01_0017.html).

Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

NOTICE:

Install each valve lash adjuster assembly to the same place it was removed from.

Apply clean engine oil to the valve lash adjuster assembly tips and valve stem cap surfaces.

Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

NOTICE:

Install the valve stem cap, valve lash adjuster assembly and No. 1 valve rocker arm sub-assembly to the same places they were removed from.

Apply clean engine oil to the camshaft cams and cylinder head journals.

Position the camshaft and No. 2 camshaft as shown in the illustration.

Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

Temporarily install the No. 1 camshaft bearing cap.

Confirm the location for each No. 2 camshaft bearing cap and install each one to the proper location.

Uniformly temporarily install the 20 bolts while keeping the camshaft level.

Tighten the 20 bolts in the order shown in the illustration.

Torque:

16 N*m{158 kgf*cm, 11 ft.*lbf}

Install the No. 1 chain vibration damper with the bolt and nut.

Torque:

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

As shown in the illustration, install the chain sub-assembly to the camshaft timing exhaust gear assembly and camshaft timing gear assembly with the mark plates aligned with the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly.

HINT:

1. The camshaft mark plate is pink.
   
2. The crankshaft mark plate is yellow.
   

Use a rope to tie the chain sub-assembly of the crankshaft timing gear or sprocket. Tie the rope near the crankshaft timing gear or sprocket.

NOTICE:

After the chain tensioner has been installed, the rope must be removed.

HINT:

The rope is tied so that the chain sub-assembly will not jump a tooth.

Install the chain tensioner slipper with the bolt.

Torque:

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

Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

Install a new gasket and the No. 1 chain tensioner assembly with the bolt and nut.

Torque:

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

Remove the hexagon wrench from the No. 1 chain tensioner assembly and release the plunger.

Check that the No. 1 cylinder is set to TDC/compression.

1. Rotate the crankshaft two full rotations, and then check that all timing marks are in the position shown in the illustration.
   If the timing marks do not match, set the chain sub-assembly again.
   

   Text in Illustration

   *1	Crankshaft Pulley Set Key
   *a	Timing Mark
   *b	Approximately 13°
   *c	Approximately 30°

Install a new O-ring to the No. 1 camshaft bearing cap.

Install the timing chain guide with the 2 bolts.

Torque:

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

Install a new No. 2 camshaft bearing cap oil hole gasket and 3 new No. 3 camshaft bearing cap oil hole gaskets to the No. 1 camshaft bearing cap.

Install the cylinder head cover connector sub-assembly with the 2 bolts.

Torque:

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

Install the ventilation pipe with the bolt.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Connect the No. 3 water by-pass hose to the cylinder head sub-assembly, and slide the clip to secure the hose.

Connect the No. 3 ventilation hose to the ventilation pipe, and slide the clip to secure the hose.

Connect the No. 1 ventilation hose to the PCV valve sub-assembly, and slide the clip to secure the hose.

Connect the No. 1 water by-pass hose to throttle body with motor assembly, and slide the clip to secure the hose.

Install the 2 heater hoses to the No. 1 water by-pass pipe and No. 2 water by-pass pipe, and slide the 2 clips to secure the hoses.

Set the No. 1 exhaust manifold heat insulator in place.

Install the air switching valve with 2 new nuts.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Connect the connector.

Connect the vacuum hose.

Install 2 new gaskets and the No. 4 intake pipe with 4 new nuts in the order shown in the illustration. Tighten the nuts labeled 1 and 3 to the torque specification again.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Check that the nuts are tightened to the torque specification.

Install the No. 1 exhaust manifold heat insulator with the 5 bolts.

Torque:

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