Up to 08/2009

2GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: INSTALLATION

1. INSTALL CYLINDER HEAD GASKET RH

(a) Place a new cylinder head gasket RH on the cylinder block surface with the Lot No. stamp upward.





NOTICE:
* Be careful of the installation direction.
* Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

(a) Place the cylinder head on the cylinder block.

NOTICE:
Be careful not to allow oil to adhere to the bottom part of the cylinder head.

HINT
The cylinder head bolts are tightened in 3 progressive steps.

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

(c) 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 and in the sequence shown in the illustration.





Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

(d) Step 2





(1) Mark the cylinder head bolt head with paint as shown in the illustration.

(2) Tighten the cylinder head bolts another 90°.

(e) Step 3

(1) Tighten the cylinder head bolts an additional 90°.

(2) Check that the painted mark is now facing rearward.

3. INSTALL CYLINDER HEAD GASKET LH

(a) Place a new cylinder head gasket LH on the cylinder block surface with the Lot No. stamp upward.





NOTICE:
* Be careful of the installation direction.
* Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

(a) Place the cylinder head on the cylinder block.

NOTICE:
Be careful not to allow oil to adhere to the bottom part of the cylinder head.

HINT
The cylinder head bolts are tightened in 3 progressive steps.

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

(c) 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 Nm (367 kgf-cm, 27 ft-lbf)

(d) Step 2





(1) Mark the cylinder head bolt head with paint as shown in the illustration.

(2) Tighten the cylinder head bolts another 90°.

(e) Step 3

(1) Tighten the cylinder head bolts an additional 90°.

(2) Check that the painted mark is now facing rearward.

(f) Tighten the 2 bolts in the order shown in the illustration.





Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

5. INSTALL WATER OUTLET Reassembly

6. INSTALL VALVE STEM CAP

(a) Install the 24 valve stem caps.

7. INSTALL VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
* Keep the lash adjuster free of dirt and foreign objects.
* Only use clean engine oil.
(a) Place the lash adjuster into a container filled with engine oil.

(b) 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

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

(d) Check the movement of the plunger and bleed the air.

OK:

Plunger moves up and down.

NOTICE:
When bleeding air from the high-pressure 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 will not bleed.

(e) After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly by hand.

OK:

Plunger is very difficult to move.

(f) If the result is not as specified, replace the valve lash adjuster.

(g) Install the valve lash adjusters.

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

8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Apply engine oil to the lash adjuster tip and valve stem cap end.

(b) Install the valve rocker arms as shown in the illustration.





Text in Illustration





9. INSTALL NO. 3 CAMSHAFT Installation

10. INSTALL NO. 4 CAMSHAFT Installation

11. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation

12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Installation

13. INSTALL CAMSHAFT Installation

14. INSTALL NO. 2 CAMSHAFT Installation

15. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation

16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

HINT
See the steps from "Install Camshaft Housing Sub-Assembly RH" through "Install Automatic Transaxle Assembly" Installation.