CYLINDER HEAD GASKET > INSTALLATION

for Preparation Click here

1. Turn the roller by hand to check that it turns smoothly.
   If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.
   

NOTICE:

1. Keep the valve lash adjuster free from dirt and foreign matter.
   
2. Only use clean engine oil.
   

1. Place the lash adjuster into a container filled with new engine oil.
   

2. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
   

   Text in Illustration 

   *1	Plunger
   *2	Check Ball
   *3	Low Pressure Chamber
   *4	High Pressure Chamber
   *a	CORRECT
   *b	INCORRECT
   *c	Taper Part

   SST

   09276-75010  
   

3. Squeeze SST and the valve lash adjuster together to move the plunger up and down 5 to 6 times.
   

4. 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 bleeding is not possible.

5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.
   

   OK:

   Plunger is very difficult to move.
   

   If the result is not as specified, replace the valve lash adjuster assembly.
   

1. Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.
   

   Text in Illustration 

   *a	Measurement Length
   *b	Measurement Area
   *c	Distance

   Standard length:

   146.8 to 148.2 mm (5.78 to 5.83 in.)
   

   Maximum length:

   149.2 mm (5.87 in.)
   

   HINT:

   1. If the length is greater than the maximum, replace the bolt with a new one. Failure to do so may lead to engine damage.
      
   2. If there is any thread deformation, replace the bolt with a new one.
      

2. Using a vernier caliper, measure the diameter of the threaded portion of the bolt at its thinnest point.
   

   HINT:

   Use a straightedge to determine the thinnest point of the threaded portion of the bolt.

   Measurement point:

   115 mm (4.53 in.)
   

   Standard diameter:

   9.77 to 9.96 mm (0.385 to 0.392 in.)
   

   Minimum diameter:

   9.4 mm (0.370 in.)
   

   HINT:

   1. If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. Failure to do so may lead to engine damage.
      
   2. If there is any thread deformation, replace the cylinder head set bolt with a new one.
      

   HINT:

   If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.

1. Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block and manifold.
   

   Text in Illustration 

   *a	Cylinder Head Lower Side:
   *b	Intake Manifold Side:
   *c	Exhaust Manifold Side:

   Maximum Warpage:

   Item	Specified Condition
   Cylinder block side	0.05 mm (0.00197 in.)
   Intake manifold side	0.10 mm (0.00394 in.)
   Exhaust manifold side	0.10 mm (0.00394 in.)

   If the warpage is more than the maximum, replace the cylinder head.
   

1. Apply seal packing (diameter 4.0 mm (0.157 in.)) to the cylinder block as shown in the illustration.
   

   Text in Illustration 

   *1	Cylinder Block
   	Engine Front

   Seal packing:

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

   NOTICE:

   Remove any oil from the cylinder block.

2. Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
   

   Text in Illustration 

   *a	Lot No.
   	Engine Front

   NOTICE:

   Install the cylinder head gasket within 3 minutes of applying seal packing.

3. Apply seal packing (diameter 4.0 mm (0.157 in.)) to the new cylinder head gasket as shown in the illustration.
   

   Text in Illustration 

   *1	Cylinder Head Gasket
   	Engine Front

   Seal packing:

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

   NOTICE:

   1. Remove any oil from the cylinder head gasket and cylinder head.
      
   2. Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      

4. After tightening the cylinder head bolts, wipe off any seal packing material that seeped out from the contact surfaces between the cylinder head and cylinder block.
   

   Text in Illustration 

   *a	Before wiping off
   *b	After wiping off

HINT:

The cylinder head bolts are tightened in 3 progressive steps.

1. 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 in order not to damage the gasket with the bottom part of the head.
      

2. Install the plate washers to the cylinder head bolts.
   

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

4. 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:

      49 N*m{ 500 kgf*cm , 36 ft.*lbf }

      NOTICE:

      Do not drop the plate washers into the cylinder head.

5. Step 2:
   

   Text in Illustration 

   *a	Paint Mark
   	Engine Front

   
   

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

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

6. Step 3:
   
   

   1. Tighten the cylinder head bolts another 45° in the sequence shown in step 1.
      

7. Check that the paint mark is now at a 135° angle to the front.
   

1. Apply a light coat of engine oil to the valve stem ends.
   

2. Install the 16 valve stem caps to the cylinder head.
   

   NOTICE:

   Do not drop the valve stem caps into the cylinder head.

1. Inspect each valve lash adjuster before installing it (Click here).
   

2. Install the 16 valve lash adjusters to the cylinder head.
   

   NOTICE:

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

1. Apply engine oil to the valve lash adjuster tips and valve stem cap ends.
   

   Text in Illustration 

   *1	Valve Rocker Arm
   *2	Valve Lash Adjuster
   *3	Valve Stem
   *4	Valve Stem Cap

2. Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.
   

1. Install 2 new gaskets and the exhaust manifold with the 7 nuts.
   

   Text in Illustration 

   *A	Nut Type A
   *B	Nut Type B

   Torque:

   Type A:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

   Type B:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

1. Install the manifold stay with the 3 bolts.
   

   Torque:

   43 N*m{ 439 kgf*cm , 32 ft.*lbf }

1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.
   

   Torque:

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