Installation
1AR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: INSTALLATION
1. INSPECT CYLINDER HEAD BOLT Engine Unit
2. INSPECT CYLINDER HEAD SUB-ASSEMBLY Testing and Inspection
3. INSTALL CYLINDER HEAD GASKET
(a) Clean the cylinder block and cylinder head with solvent.
Text in Illustration
(b) Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal dimension:
3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) thick
HINT
Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block.
NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
(c) Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
NOTICE:
Pay attention to the installation direction.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY
HINT
The cylinder head bolts are tightened in 4 progressive steps.
(a) Place the cylinder head on the cylinder block.
NOTICE:
* Ensure that no oil is on the mounting surface of the cylinder head.
* Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.
(b) Install the plate washers to the cylinder head bolts.
(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(d) 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 : 36 Nm (367 kgf-cm, 27 ft-lbf)
NOTICE:
Do not drop the plate washer for the cylinder head bolt into the cylinder head.
(e) Step 2:
(1) Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.
Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)
(f) Step 3:
(1) Mark each cylinder head bolt head with paint as shown in the illustration.
Text in Illustration
(2) Tighten the cylinder head bolts 90° in the sequence shown in step 1.
(g) Step 4:
(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.
NOTICE:
* Do not apply oil for at least 4 hours after the installation.
* Do not start the engine for at least 4 hours after the installation.
* After the installation, if the seal packing has seeped out, wipe it off.
5. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem ends.
(b) Install the 16 valve stem caps to the cylinder head.
NOTICE:
Do not drop the valve stem caps into the cylinder head.
6. SET CAMSHAFT TIMING GEAR ASSEMBLY Installation
7. INSTALL VALVE LASH ADJUSTER ASSEMBLY Installation
8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Installation
9. INSTALL NO. 2 CAMSHAFT BEARING Reassembly
10. INSTALL NO. 1 CAMSHAFT BEARING Reassembly
11. INSTALL OIL CONTROL VALVE FILTER Reassembly
12. INSTALL CAMSHAFT Installation
13. INSTALL CAMSHAFT BEARING CAP Installation
14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY Installation
15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation
16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Installation
17. ADD ENGINE OIL Installation
18. SET NO. 1 CYLINDER TO TDC / COMPRESSION Installation
19. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
20. INSTALL CHAIN SUB-ASSEMBLY Installation
21. INSTALL CHAIN TENSIONER SLIPPER Installation
22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
23. INSTALL TIMING CHAIN GUIDE Installation
24. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION Installation
25. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
26. INSTALL ENGINE MOUNTING BRACKET RH Installation
27. INSTALL TIMING CHAIN COVER OIL SEAL Installation
28. INSTALL CRANKSHAFT PULLEY Reassembly
29. INSTALL CRANKSHAFT POSITION SENSOR Installation
30. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Reassembly
31. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly
32. INSTALL IGNITION COIL ASSEMBLY Installation
33. INSTALL FUEL INJECTOR ASSEMBLY Installation
34. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
35. INSTALL INTAKE MANIFOLD Installation
36. INSTALL UNION TO CONNECTOR TUBE HOSE Installation
37. CONNECT VACUUM SWITCHING VALVE HOSE ASSEMBLY Installation
38. INSTALL NO. 2 FUEL VAPOR FEED HOSE ASSEMBLY Installation
39. INSTALL EXHAUST MANIFOLD TO HEAD GASKET Installation
40. INSTALL EXHAUST MANIFOLD Installation
41. INSTALL NO. 2 MANIFOLD STAY Installation
42. INSTALL MANIFOLD STAY Installation
43. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Installation