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Installation [10/2015 - ]: 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 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.)
      Front of Engine
      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 10 minutes applying seal packing.
    3. Place the cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
      NOTE:
      • Remove any oil from the contact surface.
      • Make sure that the cylinder head gasket is installed in the correct orientation.
      • 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 [10/2015 - 10/2018] , or refer to INITIALIZATION [10/2018 - 11/2019] , or refer to INITIALIZATION [11/2019 - ]

    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 bolt holes.
      • Make sure there is no oil on the contact 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 plate washers to the 10 cylinder head set bolts.
      NOTE:
      • Install the cylinder head set bolts to the same place they were removed from.
      • Be careful not to drop the plate washers into the cylinder head sub-assembly.

      HINT: 

      The cylinder head set bolts are tightened in 3 progressive steps.

    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 order shown in the illustration.

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

        Fig 1: Cylinder Head Set Bolts Tightening Sequence
        GTY653056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Step 2:
      1. Mark the front 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 of the engine.
        NOTE:

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

  3. INSTALL VALVE STEM CAP 

    See step  18

  4. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    See step  19

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

    See step  20

  6. INSTALL NO. 3 WATER BY-PASS PIPE 

    See step  27

  7. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    See step  28

  8. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    See step  30

  9. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    See step  31

  10. ADD ENGINE OIL 

    See step  33

  11. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    See step  34

  12. INSTALL CHAIN SUB-ASSEMBLY 

    See step  35

  13. INSTALL CHAIN TENSIONER SLIPPER 

    See step  36

  14. INSTALL TIMING CHAIN GUIDE 

    See step  38

  15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    See step  37

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    See step  20

  17. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  18. INSTALL TIMING CHAIN COVER OIL SEAL 

    See step  1

  19. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  20. INSTALL CRANKSHAFT PULLEY ASSEMBLY 

    See step  49

  21. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 

    See step  18

  22. INSTALL IDLER PULLEY SUB-ASSEMBLY 

    See step  19

  23. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 1

  24. INSTALL WATER OUTLET SUB-ASSEMBLY 

    See step  42

  25. INSTALL AIR CLEANER BRACKET 

    See step  16

  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    See step  32

  27. INSTALL NO. 6 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 11

  28. INSTALL CYLINDER HEAD COVER GASKET 

    See step  47

  29. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    See step  48

  30. CONNECT NO. 3 VENTILATION HOSE 

    See step  22

  31. INSTALL NO. 1 TURBO WATER PIPE 

    See step  21

  32. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  33. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  34. INSTALL FUEL PUMP ASSEMBLY (for High Pressure) 

    Refer to INSTALLATION [10/2015 - ]

  35. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to INSTALLATION [10/2015 - ]

  36. INSTALL TURBOCHARGER SUB-ASSEMBLY 

    Refer to INSTALLATION [10/2015 - ]

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