Cylinder Head Gasket (for Bank 1)

CYLINDER HEAD GASKET (for Bank 1)

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
^ After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and setting. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
^ Some systems need to be initialized after the cable is reconnected.

3. DRAIN ENGINE OIL
4. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) for Regular cab standard deck, refer to the following procedures.
(b) except Regular cab standard deck, refer to the following procedures.
5. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Remove the windshield wiper motor.
6. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY
7. REMOVE TIMING BELT
(a) Remove the timing belt.
8. DISCONNECT VACUUM HOSE ASSEMBLY
9. REMOVE NO. 2 WATER BY-PASS PIPE
10. DISCONNECT FUEL MAIN TUBE
11. DISCONNECT FUEL RETURN TUBE
12. REMOVE FRONT FENDER APRON SEAL LH
13. REMOVE NO. 2 AIR HOSE
14. REMOVE NO. 3 AIR TUBE
15. REMOVE AIR SWITCHING VALVE ASSEMBLY (for Bank 1)
16. REMOVE INTAKE MANIFOLD
17. REMOVE WATER INLET HOUSING

18. REMOVE FRONT WATER BY-PASS JOINT
(a) Remove the 4 nuts, water by-pass joint and 2 gaskets.

19. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Remove the bolt and pull out the water by-pass pipe.
(b) Remove the O-ring from the water by-pass pipe.

20. REMOVE REAR WATER BY-PASS JOINT
(a) Disconnect the air hose and remove the 4 nuts, water by-pass joint and 2 gaskets.
21. REMOVE IGNITION COIL ASSEMBLY
22. REMOVE SPARK PLUG

23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove the 9 bolts, cylinder head cover and gasket.
24. REMOVE CAMSHAFT POSITION SENSOR ASSEMBLY

25. REMOVE CAMSHAFT TIMING PULLEY LH
(a) Hold the hexagonal portion of the camshaft with a wrench and remove the 4 bolts indicated by the arrows in the illustration and timing pulley.

NOTICE:
^ Do not loosen or remove the 4 bolts that are not indicated by the arrows in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one.
^ Be careful not to damage the cylinder head with the wrench.

26. REMOVE REAR NO. 1 TIMING BELT PLATE LH
(a) Remove the 2 bolts, No. 1 timing belt plate and No. 2 timing belt plate.
27. REMOVE CAMSHAFT SUB-ASSEMBLY LH

NOTICE:
^ As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out.

(a) Bring the service bolt hole of the sub-gear upward by turning the hexagonal portion of the exhaust camshaft with a wrench.
(b) Secure the sub-gear to the main gear with a service bolt.

Recommended Service Bolt:

HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

(c) Using a wrench, turn the camshaft so that the timing marks (2 dot marks each) on the camshaft drive and driven main gears are aligned, as shown in the illustration.

(d) Uniformly loosen and remove the 22 bearing cap bolts in several steps, in the order shown in the illustration.

(e) Remove the cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and camshafts.

NOTICE:
^ Do not forcibly pry the camshaft with a tool.
^ Do not damage the reception part of the thrust on the cylinder head side.

HINT: Arrange the bearing caps in the correct order.

28. REMOVE VALVE LIFTER
(a) Remove the valve lifters and shims from the cylinder head.

HINT: Arrange the removed parts in the correct order.

29. REMOVE CYLINDER HEAD LH
(a) Uniformly loosen the 10 cylinder head bolts on the cylinder head in several passes, in the sequence shown in the illustration.
(b) Remove the bolts and plate washers.

NOTICE:
^ Cylinder head warpage or cracking could result from removing bolts in the incorrect order.
^ Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(c) Remove the cylinder head by prying between the cylinder block and cylinder head with a screwdriver.

NOTICE:
^ Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
^ The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.

30. REMOVE CYLINDER HEAD GASKET LH
31. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY

INSTALLATION
1. INSPECT CYLINDER HEAD SET BOLT
2. INSPECT CYLINDER HEAD

3. INSTALL CYLINDER HEAD GASKET LH
(a) Clean the cylinder block and cylinder head with solvent.
(b) Place a new cylinder head gasket in position on the cylinder block.

HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH sides, a "2R" mark for the RH side and a "2L" mark for the LH side.

NOTICE: Be careful of the installation direction.

4. INSTALL CYLINDER HEAD LH
(a) Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.
(b) Install the cylinder head with the exhaust manifold to the cylinder block.

NOTICE: Ensure that no oil is on the mounting surface of the cylinder head.

(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(d) Step 1:
(1) Set the plate washer to the cylinder head bolt.

(2) Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration.
Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

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

NOTICE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(e) Step 2:
(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
(f) Step 3:
(1) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
(2) Check that the painted marks are now facing rearward.
5. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil to the valve lifters and shims.
(b) Install the valve lifters and shims to the cylinder head.
(c) Check that the valve lifter rotates smoothly by hand.
6. INSTALL CAMSHAFT SETTING OIL SEAL
7. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY
8. INSTALL CAMSHAFT SUB-ASSEMBLY LH

NOTICE:
^ As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out.

^ Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration.

(a) Apply a light coat of engine oil to the cam lobe and gear of the camshaft and also the journal of the cylinder head.

(b) Using a wrench, align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and set the No. 3 and No. 4 camshafts in place.

(c) Install the bearing cap.
(1) Apply seal packing to the camshaft housing plug groove.

HINT: Remove any old packing (FIPG) material before applying new seal packing.

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

(2) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

NOTICE:
^ Be careful of the installation direction.
^ Remove any oil from the contact surface.

(3) Apply seal packing to the No. 1 bearing cap as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter: 1.5 to 2.0 mm (0.0591 to 0.0787 in.)

NOTICE:
^ Do not apply seal packing to the front bearing cap grooves.
^ Install the No. 1 bearing cap and housing plug within 3 minutes.

(4) Install 4 new seal washers to the bearing cap bolts (A and B).
(5) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (C to E).

NOTICE: Do not apply engine oil to the bearing cap bolts (A and B).

(6) Temporarily install the oil feed pipe and bearing caps with the 22 bolts, as shown in the illustration.

Bolt length:

(7) Push in the camshaft setting oil seal.

(8) Uniformly tighten the 22 bearing cap bolts in several steps, in the sequence shown in the illustration.
Torque:
for bolt 21, 22 7.5 N*m (76 kgf*cm, 66 in.*lbf)
for other bolt 16 N*m (163 kgf*cm, 12 ft.*lbf)

(d) Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.
(e) Remove the service bolt.
9. INSTALL REAR NO. 1 TIMING BELT PLATE LH
(a) Install the No. 1 timing belt plate and No. 2 timing plate with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

10. INSTALL CAMSHAFT TIMING PULLEY LH
(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
(b) Temporarily install the 4 bolts of the camshaft timing pulley.
(c) Hold the hexagonal portion of the camshaft with a wrench.
(d) Using a 5 mm hexagon wrench, tighten the 4 bolts.
Torque: 8.1 N*m (83 kgf*cm, 72 in.*lbf)
11. INSTALL CAMSHAFT POSITION SENSOR ASSEMBLY
12. INSTALL TIMING BELT
13. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION
14. INSPECT VALVE CLEARANCE
(a) Inspect the valve clearance. If the result is not as specified, adjust the valve clearance.

15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Apply seal packing to the semicircular plug grooves.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
(b) Install the 2 semicircular plugs to the cylinder heads.
(c) Install the gasket to the cylinder head cover.

(d) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes after applying seal packing.

(e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
16. INSTALL SPARK PLUG
17. INSTALL IGNITION COIL ASSEMBLY

18. INSTALL REAR WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts and connect the air hose.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

HINT: With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine rear side.

19. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Apply soapy water to a new O-ring and install it to the water by-pass pipe.
(b) Push in the water by-pass pipe end into the pipe hole of the water pump.
(c) Install the water by-pass pipe with the bolt.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

20. INSTALL FRONT WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

HINT: With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine front side.

21. INSTALL WATER INLET HOUSING
22. INSTALL INTAKE MANIFOLD
23. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 1)
24. INSTALL NO. 3 AIR TUBE
25. INSTALL NO. 2 AIR HOSE
26. INSTALL FRONT FENDER APRON SEAL LH
27. CONNECT FUEL MAIN TUBE
28. CONNECT FUEL RETURN TUBE
29. INSTALL NO. 2 WATER BY-PASS PIPE
30. CONNECT VACUUM HOSE ASSEMBLY
31. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
32. INSTALL NO. 1 TIMING BELT COVER
33. INSTALL CRANKSHAFT PULLEY
34. INSTALL FAN BRACKET SUB-ASSEMBLY
35. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
36. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY
37. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH
38. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH
39. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
40. INSTALL OIL COOLER PIPE
41. CONNECT COOLER COMPRESSOR ASSEMBLY
42. INSTALL GENERATOR ASSEMBLY
43. CONNECT VANE PUMP ASSEMBLY
44. INSTALL FLUID COUPLING ASSEMBLY
45. INSTALL FAN AND GENERATOR V BELT
46. INSTALL RADIATOR HOSE OUTLET
47. INSTALL RADIATOR HOSE INLET
48. INSTALL AIR CLEANER ASSEMBLY
49. INSTALL AIR CLEANER HOSE ASSEMBLY
50. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY
51. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY
52. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Install the windshield wiper motor.
53. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) for Regular cab standard deck, refer to the following procedures.
(b) except Regular cab standard deck, refer to the following procedures.
54. ADD ENGINE OIL
55. ADD ENGINE COOLANT
56. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE: Some systems need to be initialized after the cable is reconnected.

57. INSPECT FOR OIL LEAK
58. INSPECT FOR COOLANT LEAK
59. INSPECT FOR FUEL LEAK
60. INSPECT FOR EXHAUST GAS LEAK
61. CHECK ENGINE OIL LEVEL
62. INSPECT IGNITION TIMING
63. INSPECT ENGINE IDLE SPEED
64. INSTALL NO. 1 ENGINE UNDER COVER