Cylinder Head & Manifolds: Installation

Install NEW cylinder head gaskets on cylinder block. Ensure identification mark is facing upward at lower corner of cylinder block. See Figure. Ensure all holes in cylinder head gaskets align with cylinder block.
Install cylinder head. Apply engine oil on cylinder head bolt threads and cylinder head bolt-to-cylinder head contact surfaces. Install and tighten 12-point cylinder head bolts to specification in sequence using several passes. See Figure. See TORQUE SPECIFICATIONS .
Install recessed cylinder head bolts and tighten to specification. See TORQUE SPECIFICATIONS . Install camshafts using proper procedure. See CAMSHAFTS .
To install remaining components, reverse removal procedure. See Fig 1. If camshaft or cylinder head components are serviced, adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

Fig 1: Intake Manifold Bolt Installation Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If spark plug tube gasket in valve cover requires replacement, bend gasket retaining tabs upward. Push spark plug tube gasket from valve cover. DO NOT scratch valve cover sealing surface.
Using Gasket/Seal Installer (SST 09608-03070), install spark plug tube gasket until it is even with valve cover surface. Bend retaining tabs downward. Coat spark plug tube gasket sealing area with grease.
Apply sealant to grooves of semi-circular plugs and install in cylinder head. See Figure. Using NEW gasket, install camshaft position sensor. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS .
Before installing valve cover and gasket, apply sealant at front and rear areas of cylinder head. See Figure. Using NEW gasket, install valve cover. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
If injector was removed from delivery pipe, coat NEW "O" ring with gasoline. Install NEW grommets and NEW "O" rings on injector. Using twisting motion, install injector in delivery pipe. Ensure injectors rotate smoothly after delivery pipe is installed. If injector does not rotate smoothly, check for damaged "O" rings.
If installing pressure regulator in delivery pipe, coat NEW "O" ring with gasoline and install on pressure regulator. Install pressure regulator. Ensure pressure regulator rotates smoothly in delivery pipe. If pressure regulator does not rotate smoothly, check for damaged "O" rings.
Before installing coolant inlet pipe, apply soapy water solution on "O" ring and then install. If installing intake air control valve in air intake chamber, apply light coat of engine oil on rubber area of the valve and apply sealant at designated areas. See Fig 2.
Use NEW gasket when installing intake air control valve. Tighten nuts to specification. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Adjust fluid levels and control cables.

Fig 2: Identifying Intake Air Control Valve Sealant & Engine Oil Application Areas