Cylinder Head: Installation

WARNING: This page is about a different car, the 2007 Lexus GS 430. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
  NOTE: Be careful of the installation direction.
  
  Fig 1: Identifying Cylinder Head Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the heat insulator with the 4 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
Fig 2: Locating Heat Insulator With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
  NOTE: Be careful of the installation direction.
  
  Fig 3: Identifying Cylinder Head Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the heat insulator with the 4 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
Fig 4: Identifying No. 1 Exhaust Manifold Heat Insulator With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CYLINDER HEAD GASKET
1. Place a new cylinder head gasket in position on the cylinder block.
  HINT:
  
  The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3L" mark is on the LH bank's gasket.
  
  NOTE: Be careful of the installation direction.
Fig 5: Placing Cylinder Head Gasket In Position On Cylinder Block
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD LH
1. 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.
2. Install the cylinder head together with the exhaust manifold to the cylinder block.
3. Apply a light coat of engine oil on the threads and under the head of the cylinder head bolts.
4. Put the washer on the bolt, and insert the bolt with washer into the cylinder head.
  NOTE: Be careful not to drop washers into the cylinder head.
  
  Fig 6: Checking Timing Mark Of Crankshaft Timing Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration.
  Torque: 59 N*m (601 kgf*cm, 44 ft.*lbf)
  
  Fig 7: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Mark the front of the cylinder head bolt's head with paint.
7. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
8. Check that the painted mark is now at a 90° angle to the front.
Fig 8: Checking Painted Mark 90° Angle To Front
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD GASKET
1. Place a new cylinder head gasket in position on the cylinder block.
  HINT:
  
  The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3R" mark is on the RH bank's gasket.
  
  NOTE: Be careful of the installation direction.
Fig 9: Identifying Cylinder Head Gasket In Position On Cylinder Block
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY
1. 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.
2. Install the cylinder head together with the exhaust manifold to the cylinder block.
3. Apply a light coat of engine oil on the threads and under the head of the cylinder head bolts.
4. Put the washer on the bolt, and insert the bolt with washer into the cylinder head.
  NOTE: Be careful not to drop washers into the cylinder head.
  
  Fig 10: Checking Timing Mark Of Crankshaft Timing Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install and uniformly tighten the 10 cylinder head bolts, and plate washers in the sequence shown in the illustration.
  Torque: 59 N*m (601 kgf*cm, 44 ft.*lbf)
  
  Fig 11: Identifying Installing Sequence Of Cylinder Head Bolt (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Mark the front of the cylinder head bolt's head with paint.
7. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
8. Check that the painted mark is now at a 90° angle to the front.
INSTALL FRONT WATER BYPASS JOINT
1. Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
2. Connect the ECT connector.
Fig 13: Identifying Water Bypass Joint With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER INLET HOUSING
1. Install a new O-ring to the water inlet housing.
2. Apply soapy water on the O-ring.
3. Apply seal packing to the sealing groove of the inlet housing as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
  
  Seal diameter:
  
  2 to 3 mm (0.08 to 0.12 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the water inlet housing within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
4. Install the water inlet and housing with the 2 bolts. Alternately tighten the bolts.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
Fig 14: Applying Seal Packing To Sealing Groove Of Inlet Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR WATER BYPASS JOINT
1. Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL INTAKE MANIFOLD ASSEMBLY
1. Installation procedure (see INSTALLATION ).
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION )
INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

Fig 15: Identifying Water Bypass Joint With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
2. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the No. 3 and No. 4 camshafts.
3. Set the timing mark (2 dot marks each) of the camshaft drive and driven main gears at an angle of approximately 10°.
  
  Fig 16: Aligning Timing Marks Of Camshaft Drive And Driven Main Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply seal packing to the camshaft housing plug.
  - Remove the old packing (FIPG) material.
  - Apply seal packing to the housing plug as shown in the illustration.
    Seal packing:
    
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Fig 17: Applying Seal Packing To Camshaft Housing Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the camshaft housing plug to the cylinder head as shown in the illustration.
6. Install the oil control valve filter to the cylinder head.
  NOTE: Be careful of the installation direction.
  
  Fig 18: Identifying Camshaft Housing Plug And Oil Control Valve Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Apply seal packing to the front bearing cap.
  - Remove any old packing (FIPG) material.
  - Apply seal packing to the bearing cap as shown in the illustration.
    Seal packing:
    
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
    
    Seal width:
    
    1.5 to 2.0 mm (0.059 to 0.079 in.)
  NOTE: Do not apply seal packing to the front bearing cap grooves.
  
  Fig 19: Applying Seal Packing To Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the front bearing cap.
  HINT:
  
  Installing the front bearing cap will determine the thrust portion of the camshaft.
9. Install the other bearing caps in the sequence shown with the arrow mark facing forward.
  
  Fig 20: Identifying Installing Sequence Of Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Push in the camshaft oil seal.
  
  Fig 21: Pushing Camshaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Install 4 new seal washers to the bearing cap bolts (1 to 4).
12. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 to 22).
  NOTE: Do not apply engine oil under the heads of the bearing cap bolts (1 to 4).
13. Install the oil feed pipe and the 22 bearing cap bolts.
14. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
  
  Fig 22: Identifying Tightening Sequence Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 7.5 N*m (76 kgf*cm, 66 ft.*lbf) for bolts 21 and 22
  
  16 N*m (163 kgf*cm, 12 in.*lbf) for other bolts
15. Remove the service bolt.
  
  Fig 23: Identifying Service Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH
1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "L" mark forward.
3. Hold the camshaft with a wrench and install the 4 pulley bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
Fig 24: Identifying Mark On Timing Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
1. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
2. Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the intake and exhaust camshafts.
3. Set the timing mark (1 dot mark each) of the camshaft drive and driven main gears at an angle of approximately 10°.
  
  Fig 25: Aligning Timing Marks Of Camshaft Drive And Driven Main Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply seal packing to the camshaft housing plug.
  - Remove the old packing (FIPG) material.
  - Apply seal packing to the housing plug as shown in the illustration.
    Seal packing:
    
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Fig 26: Applying Seal Packing To Camshaft Housing Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the camshaft housing plug to the cylinder head as shown in the illustration.
6. Install the oil control valve filter to the cylinder head.
  NOTE: Be careful of the installation direction.
  
  Fig 27: Identifying Camshaft Housing Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Apply seal packing to the front bearing cap.
  - Remove any old packing (FIPG) material.
  - Apply seal packing to the bearing cap as shown in the illustration.
    Seal packing:
    
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
    
    Seal width:
    
    1.5 to 2.0 mm (0.059 to 0.079 in.)
  NOTE: Do not apply seal packing to the front bearing cap grooves.
  
  Fig 28: Applying Seal Packing To Front Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the front bearing cap.
  HINT:
  
  Installing the front bearing cap will determine the thrust portion of the camshaft.
9. Install the other bearing caps in the sequence shown with the arrow mark facing forward.
  
  Fig 29: Identifying Installing Sequence Of Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Push in the camshaft oil seal.
  
  Fig 30: Pushing Camshaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Install 4 new seal washers to the bearing cap bolts (1 to 4).
12. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 to 22).
  NOTE: Do not apply engine oil under the heads of the bearing cap bolts (1 to 4).
13. Install the oil feed pipe and the 22 bearing cap bolts.
14. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
  Torque: 7.5 N*m (76 kgf*cm, 66 ft.*lbf) for bolts 21 and 22
  
  16 N*m (163 kgf*cm, 12 in.*lbf) for other bolts
  
  Fig 31: Identifying Tightening Sequence Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Remove the service bolt.
  
  Fig 32: Identifying Service Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH
1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward.
3. Hold the camshaft with a wrench and install the 4 pulley bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
Fig 33: Identifying Timing Pulley's "R" Mark
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
1. Remove any old packing (FIPG) material.
2. Apply seal packing to the cylinder heads as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 5 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
3. Install the gasket to the cylinder head cover.
4. Install the seal washer to the bolt.
5. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
6. Install the wire clamp bracket on the engine wire to the cylinder head.
7. Install the wire clamp bracket on the engine wire to the camshaft bearing cap.
Fig 34: Applying Seal Packing To Cylinder Heads
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Remove any old packing (FIPG) material.
2. Apply seal packing to the cylinder heads as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 5 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
  Fig 35: Applying Seal Packing To Cylinder Heads
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the gasket to the cylinder head cover.
4. Install the seal washer to the bolt.
5. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
6. Install the wire clamp bracket on the engine wire to the cylinder head.
7. Install the wire clamp bracket on the engine wire to the camshaft bearing cap.
INSTALL IGNITION COIL
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL TIMING BELT
1. Install the timing belt (see INSTALLATION ).
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization (see INITIALIZATION ).
  NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.