Installation

1GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: INSTALLATION

1. INSPECT CYLINDER HEAD SET BOLT Engine Unit

2. INSPECT CYLINDER HEAD SUB-ASSEMBLY Testing and Inspection

3. INSTALL CYLINDER HEAD GASKET

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head or cylinder block.

(b) Apply 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 diameter:

2.5 to 3.0 mm (0.0984 to 0.118 in.)

Seal Packing Application Range

Text in Illustration

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.
* Do not add engine oil within 2 hours of installation.

(c) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

NOTICE:
Make sure that the gasket is installed facing the proper direction.

Text in Illustration

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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

NOTICE:
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
* Make sure that no oil is on the mounting surface 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 front side of each cylinder head bolt head with paint.

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

(e) Step 3:

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

(2) Check that the paint mark is now at a 180° angle to the front.

NOTICE:
Thoroughly wipe clean any seal packing.

5. INSTALL NO. 2 CYLINDER HEAD GASKET

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head or cylinder block.

(b) Apply 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 diameter:

2.5 to 3.0 mm (0.0984 to 0.118 in.)

Seal Packing Application Range

Text in Illustration

NOTICE:
Make sure that the gasket is installed facing the proper direction.

Text in Illustration

6. INSTALL CYLINDER HEAD LH

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

NOTICE:
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
* Make sure that no oil is on the mounting surface 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 : 30 Nm (306 kgf-cm, 22 ft-lbf)

NOTICE:
Thoroughly wipe clean any seal packing.

7. INSTALL VALVE STEM CAP Reassembly

8. INSTALL VALVE LASH ADJUSTER ASSEMBLY Reassembly

9. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Reassembly

10. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Reassembly

11. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Reassembly

12. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Reassembly

13. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Reassembly

14. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Reassembly

15. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) Reassembly

16. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Reassembly

17. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) Reassembly

18. INSTALL NO. 1 CHAIN VIBRATION DAMPER Reassembly

19. INSTALL NO. 2 CHAIN VIBRATION DAMPER Reassembly

20. INSTALL CRANKSHAFT TIMING SPROCKET Reassembly

21. INSTALL NO. 1 IDLE GEAR SHAFT Reassembly

22. INSTALL CHAIN SUB-ASSEMBLY Reassembly

23. INSTALL CHAIN TENSIONER SLIPPER Reassembly

24. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly

25. INSPECT VALVE TIMING Reassembly

26. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Install the timing chain cover Installation.