LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2017 >> IS 300 F Sport >> Repair and Diagnosis >> External Pages >> Different car >> Section 66 (Engine Mechanical System (2GR-FKS) - Service Information (1 Of 2)) >> Cylinder Head Gasket >> Installation [10/2017 - ] >> Procedure

Installation [10/2017 - ]: Procedure

WARNING: This page does not describe the selected car, but rather 14 other vehicles, including the 2024 Lexus IS 350, 2024 Lexus IS 300, 2023 Lexus IS 350, 2023 Lexus IS 300, and 2022 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL CYLINDER HEAD GASKET 
    1. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.
      GTY826249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Gasket
      *a 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *d 38.6 mm (1.52 in.)
      *e 142.7 mm (5.62 in.)

      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 after applying the seal packing.
      • Do not apply engine oil within 2 hours of installation.
    2. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
      GTY776085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lot No.
      Engine Front
      NOTE:
      • Be careful of the installation direction.
      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    HINT: 

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

    Refer to INITIALIZATION [10/2017 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]

    1. Place the cylinder head sub-assembly on the cylinder block.
      NOTE:

      Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly.

      HINT: 

      The cylinder head bolts are tightened in 3 progressive steps.

    2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
    3. Step 1:
      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 bolts with the 8 plate washers in several steps and in the sequence shown in the illustration.
        Fig 1: Cylinder Head Sub-Assembly Tightening Sequence (1 Of 2)
        GTY571794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 36 N.m (367 kgf/cm, 27 ft.lbf) 

    4. Step 2:
      Fig 2: Cylinder Head Sub-Assembly Tightening Sequence (2 Of 2)
      GTY830689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Paint Mark
      *a 90°
      1. Mark the front side of each cylinder head bolt head with paint.
      2. Tighten the cylinder head bolts another 90°.
    5. Step 3:
      1. Tighten the cylinder head bolts an additional 90°.
      2. Check that the paint marks are now at a 180° angle to the front.
    6. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
      GTY838455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head
      *2 Cylinder Head Gasket
      *3 Cylinder Block
      *a Wipe Clean
  3. INSTALL NO. 2 CYLINDER HEAD GASKET 
    1. Apply a continuous line of seal packing to a new No. 2 cylinder head gasket as shown in the illustration.
      GTY820260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Cylinder Head Gasket
      *a 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *d 39.3 mm (1.55 in.)
      *e 111.3 mm (4.38 in.)

      Seal packing

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the No. 2 cylinder head gasket within 3 minutes after applying the seal packing.
      • Do not start the engine for at least 2 hours after installation.
    2. Place the No. 2 cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
      GTY787850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lot No.
      Engine Front
      NOTE:
      • Be careful of the installation direction.
      • Gently place the cylinder head LH in order not to damage the gasket with the bottom part of the head.
  4. INSTALL CYLINDER HEAD LH 

    HINT: 

    Perform "Inspection After Repairs" after replacing the cylinder head LH.

    Refer to INITIALIZATION [10/2017 - 09/2018] , or refer to INITIALIZATION [09/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]

    1. Place the cylinder head LH on the cylinder block.
      NOTE:

      Be careful not to allow oil to adhere to the bottom part of the cylinder head LH.

      HINT: 

      The cylinder head bolts are tightened in 3 progressive steps.

    2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
    3. Step 1:
      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 bolts with the 8 plate washers in several steps in the sequence shown in the illustration.
        Fig 3: Cylinder Head LH Tightening Sequence (1 Of 2)
        GTY548071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 36 N.m (367 kgf/cm, 27 ft.lbf) 

    4. Step 2:
      Fig 4: Cylinder Head LH Tightening Sequence (2 Of 2)
      GTY830689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Paint Mark
      *a 90°
      1. Mark the front side of each cylinder head bolt head with paint.
      2. Tighten the cylinder head bolts another 90°.
    5. Step 3:
      1. Tighten the cylinder head bolts an additional 90°.
      2. Check that the paint marks are now at a 180° angle to the front.
    6. Tighten the 2 bolts in the order shown in the illustration.
      Fig 5: Cylinder Head Bolts Tightening Sequence
      GTY809713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N.m (306 kgf/cm, 22 ft.lbf) 

    7. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
      GTY838455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head LH
      *2 No. 2 Cylinder Head Gasket
      *3 Cylinder Block
      *a Wipe Clean
  5. INSTALL FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 1

  6. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 2

  7. INSTALL FUEL DELIVERY PIPE RH 

    Refer to PROCEDURE - Step 3

  8. INSTALL FUEL DELIVERY WITH SENSOR PIPE ASSEMBLY LH 

    Refer to PROCEDURE - Step 4

  9. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  10. INSTALL REAR WATER BY-PASS JOINT 

    Refer to PROCEDURE - Step 63

  11. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the 24 valve stem caps.
    2. Install the 24 valve stem caps to the cylinder head.
      NOTE:

      Install the valve stem cap to the same place it was removed from.

  12. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Inspect the valve lash adjuster assembly.

      Refer to PROCEDURE - Step 2

    2. Install the 24 valve lash adjuster assemblies to the cylinder head.
      NOTE:

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

  13. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the valve lash adjuster tips and valve stem cap ends.
    2. Install the 24 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
      NOTE:

      Install the No. 1 valve rocker arm to the same place it was removed from.

      GTY778828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
  14. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 39

  15. INSTALL NO. 2 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 40

  16. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to the No. 3 camshaft sub-assembly journals and camshaft housing sub-assembly LH.
    2. Install the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH.
  17. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to the No. 4 camshaft sub-assembly journals and camshaft housing sub-assembly LH.
    2. Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH.
  18. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 
    1. Apply engine oil to the camshaft bearing caps.
    2. Make sure of the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.
      GTY826335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install and tighten the 8 bolts in the order shown in the illustration.
      Fig 6: Camshaft Bearing Cap (For Bank 2) Tightening Sequence
      GTY795350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 3 chain tensioner assembly with the bolt.
      GTY828570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Plunger
      *c Push

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    2. While pushing in the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix the No. 3 chain tensioner assembly in place.
  20. TEMPORARILY INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) 
    1. Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.
      GTY819991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate (yellow)
    2. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.
  21. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 

    See step  8

  22. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 

    See step  9

  23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 
    1. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.
      GTY793019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
      *a CORRECT
      *b INCORRECT
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY776199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.)
      *b Diameter 4.0 to 4.5 mm (0.158 to 0.177 in.)
      *c Clearance of 4.0 to 6.0 mm (0.158 to 0.236 in.)
      Seal Packing

      Seal packing

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the camshaft housing LH within 3 minutes.
      • Do not start the engine for at least 2 hours after installation.
    3. Install the camshaft housing LH and tighten the 15 bolts in the order shown in the illustration.
      Fig 7: Camshaft Housing LH Tightening Sequence (1 Of 2)
      GTY821030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Type *b Tightening order
      *c Knock Pin *d Intake Side
      *e Exhaust Side - -

      Torque: 28 N.m (286 kgf/cm, 21 ft.lbf) 

      Bolt Length

      Item Length
      Bolt A 48 mm (1.89 in.)
      Bolt B 68 mm (2.68 in.)
      NOTE:
      • When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing sub-assembly LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
    4. Tighten the 8 bolts in the order shown in the illustration.
      Fig 8: Camshaft Housing LH Tightening Sequence (2 Of 2)
      GTY664828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

    5. Remove any protruding seal packing black.
  24. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 2) 
    1. Using a wrench to hold the hexagonal portion of each camshaft, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.
      GTY810006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold

      Torque: 95 N.m (969 kgf/cm, 70 ft.lbf) 

      NOTE:

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    2. Using a wrench to hold the hexagonal portion of each camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.
      GTY796897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold

      Torque: 95 N.m (969 kgf/cm, 70 ft.lbf) 

      NOTE:

      Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with the wrench.

    3. Remove the pin from the No. 3 chain tensioner assembly.
  25. INSTALL CAMSHAFT 
    1. Apply a light coat of engine oil to the camshaft journals and camshaft housing RH.
    2. Install the camshaft to the camshaft housing RH.
  26. INSTALL NO. 2 CAMSHAFT 
    1. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing RH.
    2. Install the No. 2 camshaft to the camshaft housing RH.
  27. INSTALL FUEL PUMP LIFTER HOUSING 
    1. Install the fuel pump lifter housing.
  28. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 
    1. Apply engine oil to the camshaft bearing caps.
    2. Make sure of the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.
      GTY826338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install and tighten the 9 bolts in the order shown in the illustration.
      Fig 9: Camshaft Bearing Cap (For Bank 1) Tightening Sequence
      GTY806828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt A
      Bolt B

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      Bolt Length

      Item Length
      Bolt A 40 mm (1.57 in.)
      Bolt B 58 mm (2.28 in.)
  29. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 2 chain tensioner assembly with the bolt.
      GTY779102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
      *b Pin
      *c Push

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    2. While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix the No. 2 chain tensioner assembly in place.
  30. TEMPORARILY INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) 
    1. Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.
      GTY779210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    2. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.
  31. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 

    See step  21

  32. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 

    See step  22

  33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    1. Make sure that the No. 1 valve rocker arm is installed as shown in the illustration.
      GTY793019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
      *a CORRECT
      *b INCORRECT
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY789240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.)
      *b Clearance of 4.0 to 6.0 mm (0.158 to 0.236 in.)
      Seal Packing

      Seal packing

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the camshaft housing RH within 3 minutes.
      • Do not start the engine for at least 2 hours after installation.
    3. Install the camshaft housing RH and tighten the 15 bolts in the order shown in the illustration.
      Fig 10: Camshaft Housing RH Tightening Sequence (1 Of 2)
      GTY829052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Type *b Tightening order
      *c Knock Pin *d Exhaust Side
      *e Intake Side *f 45°

      Torque: 28 N.m (286 kgf/cm, 21 ft.lbf) 

      Bolt Length

      Item Length
      Bolt A 48 mm (1.89 in.)
      Bolt B 68 mm (2.68 in.)
      NOTE:
      • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration.

        Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing RH, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
    4. Tighten the 9 bolts in the order shown in the illustration.
      Fig 11: Camshaft Housing RH Tightening Sequence (2 Of 2)
      GTY637982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

    5. Remove any protruding seal packing black.
  34. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 1) 
    1. Using a wrench to hold the hexagonal portion of each camshaft, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.
      GTY793511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold

      Torque: 95 N.m (969 kgf/cm, 70 ft.lbf) 

      NOTE:

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    2. Using a wrench to hold the hexagonal portion of each camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.
      GTY829690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold

      Torque: 95 N.m (969 kgf/cm, 70 ft.lbf) 

      NOTE:

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

    3. Remove the pin from the No. 2 chain tensioner assembly.
  35. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 43

  36. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 44

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 45

  38. INSPECT VALVE TIMING 

    Refer to PROCEDURE - Step 46

  39. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to INSTALLATION [08/2015 - ]

scientia non olet · About LEMON Manuals