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Installation [10/2014 - ]: Procedure

  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.
      GTY516132Courtesy 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
      NOTE:
      • 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.
    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 [10/2014 - 05/2019] , or refer to INITIALIZATION [05/2019 - ]

    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 Sub-Assembly Tightening Sequence
        GTY497583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Step 2:
      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 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 18 [09/2015 - ]

  4. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 19 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 19 [09/2015 - ]

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

    Refer to PROCEDURE - Step 20 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 20 [09/2015 - ]

  6. CONNECT NO. 7 WATER BY-PASS HOSE 
    1. Connect the No. 7 water by-pass hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.
  7. INSTALL NO. 3 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 27 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 27 [09/2015 - ]

  8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 28 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 28 [09/2015 - ]

  9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 30 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 30 [09/2015 - ]

  10. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 31 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 31 [09/2015 - ]

  11. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 33 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 33 [09/2015 - ]

  12. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 34 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 34 [09/2015 - ]

  13. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 35 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 35 [09/2015 - ]

  14. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 36 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 36 [09/2015 - ]

  15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 37 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 37 [09/2015 - ]

  16. INSTALL TIMING CHAIN GUIDE 

    Refer to PROCEDURE - Step 38 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 38 [09/2015 - ]

  17. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 33 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 35 [09/2015 - ]

  18. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 7 [10/2014 - ]

  19. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1 [10/2014 - ]

  20. INSTALL TURBOCHARGER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 [10/2014 - ]

  21. CONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5 [10/2014 - ]

  22. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2 [10/2014 - 09/2017] , or refer to PROCEDURE - Step 2 [09/2017 - 05/2018] , or refer to PROCEDURE - Step 2 [05/2018 - ]

  23. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 3 [10/2014 - 09/2017] , or refer to PROCEDURE - Step 3 [09/2017 - 05/2018] , or refer to PROCEDURE - Step 3 [05/2018 - ]

  24. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4 [10/2014 - 09/2017] , or refer to PROCEDURE - Step 4 [09/2017 - 05/2018] , or refer to PROCEDURE - Step 4 [05/2018 - ]

  25. INSTALL FUEL INJECTOR SEAL (for Direct Injection) 

    Refer to PROCEDURE - Step 1 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 1 [09/2015 - ]

  26. INSTALL FUEL INJECTOR SET (for Direct Injection) 

    Refer to PROCEDURE - Step 2 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 2 [09/2015 - ]

  27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 3 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 3 [09/2015 - ]

  28. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection) 

    Refer to PROCEDURE - Step 1 [10/2014 - ]

  29. INSTALL FUEL DELIVERY PIPE (for Port Injection) 

    Refer to PROCEDURE - Step 2 [10/2014 - ]

  30. INSTALL INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY 

    Refer to PROCEDURE - Step 14 [10/2014 - ]

  31. INSTALL PURGE VSV 

    Refer to PROCEDURE - Step 1 [10/2014 - ]

  32. INSTALL NO. 2 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 15 [10/2014 - 09/2015] , or refer to PROCEDURE - Step 15 [09/2015 - ]

  33. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to INSTALLATION [10/2014 - 09/2015] , or refer to INSTALLATION [09/2015 - ]

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