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Installation [08/2015 - ]: Procedure

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  1. INSTALL CYLINDER HEAD GASKET 
    1. Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
    2. Apply a seal packing to a new cylinder head gasket as shown in the illustration.
      GTY656799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Gasket
      *a Lot No.
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 152.5 mm (6.00 in.)
      *d 38 mm (1.50 in.)
      *e 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *f 5.0 to 7.0 mm (0.197 to 0.276 in.)
      Engine Front
      Seal Packing Application Area

      Seal packing

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head gasket within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
    3. Place a new cylinder head gasket on the cylinder block sub-assembly surface with the front face of the Lot No. stamp upward.
      NOTE:
      • Remove any oil from the contact surface.
      • Pay attention to the installation direction.
      • Do not damage the cylinder head gasket.
  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    HINT: 

    Perform "Inspection After Repair" after replacing the cylinder head sub-assembly.

    Refer to INITIALIZATION [08/2015 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2019] , or refer to INITIALIZATION [09/2019 - ]

    1. Clean the cylinder head sub-assembly with solvent.
    2. Place the cylinder head sub-assembly on the cylinder block sub-assembly.
      NOTE:
      • Check and clean the cylinder head set bolts and their installation holes.
      • Make sure that no oil is on the mounting surface of the cylinder head sub-assembly.
      • Gently place the cylinder head sub-assembly in order not to damage the cylinder head gasket.
    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
    4. Install the 10 cylinder head set plate washers to the 10 cylinder head set bolts.
      NOTE:
      • Install the cylinder head set bolt to the same place it was removed from.
      • Be careful not to drop the cylinder head set plate washers into the cylinder head sub-assembly.
    5. Step 1:
      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps, in the sequence shown in the illustration.

        Torque: 85 N.m (867 kgf/cm, 63 ft.lbf) 

        Fig 1: Cylinder Head Bolts Loosening Sequence
        GTY653056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Step 2:
      GTY640003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 90°
      Engine Front
      1. Mark the front side of each cylinder head set bolt head with paint.
      2. Tighten the cylinder head set bolts an additional 90°.
    7. Step 3:
      1. Tighten the cylinder head set bolts an additional 90°.
      2. Check that the paint marks are now at a 180° angle to the front.
        NOTE:

        After installing the cylinder head sub-assembly, wipe off any excess seal packing within 5 minutes.

  3. INSTALL VALVE STEM CAP 

    Refer to PROCEDURE - Step 18

  4. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 19

  5. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 20

  6. INSTALL NO. 3 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 27

  7. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 28

  8. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 30

  9. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 31

  10. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 32

  11. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 34

  12. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 35

  13. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 36

  14. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 37

  15. INSTALL TIMING CHAIN GUIDE 

    Refer to PROCEDURE - Step 38

  16. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 39

  17. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to INSTALLATION [08/2015 - ]

  18. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to INSTALLATION [08/2015 - ]

  19. INSTALL TURBOCHARGER SUB-ASSEMBLY 

    Refer to INSTALLATION [08/2015 - ]

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