Cylinder Head Gasket Installation

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

Text in Illustration

*1	Lot No.
	Front

NOTICE:

Make sure that the cylinder head gasket is installed so that it is facing in the correct direction.

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 so as 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:
Using several steps, install and uniformly tighten the 10 cylinder head 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 bolt head with paint.

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

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

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

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.

Inspect each valve lash adjuster before installing it (HILUX_TGN26 RM00000447K00LX_01_0017.html).

Install the 16 valve lash adjusters to the cylinder head.

NOTICE:

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

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

Install the 16 valve rocker arms as shown in the illustration.

NOTICE:

Install the valve stem cap, lash adjuster and valve rocker arm 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.

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.

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

Temporarily install the oil delivery pipe.

Install the 21 bolts and tighten them in the order shown in the illustration.

Torque:

for bolt A:

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

except bolt A:

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

Install the 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 to the sprocket and gear with the mark plates aligned with the timing marks on the sprocket and gear.

HINT:

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

Use a rope to secure the chain of the crankshaft timing sprocket. Tie the rope near the sprocket.

NOTICE:

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

HINT:

The rope is used to prevent the chain from jumping a tooth.

Install the 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 chain tensioner with the bolt and nut.

Torque:

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

Install a new O-ring to the camshaft bearing cap.

Install the timing chain guide with the 2 bolts.

Torque:

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