Cylinder Head Gasket: Installation

1. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp facing upward.
   NOTE:

   • Remove any oil from the contact surface.
   • Be careful of the installation direction.
     Fig 1: Identifying Cylinder Head Gasket Installation Position

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1. Place the cylinder head on the cylinder head gasket.
   NOTE: Place the cylinder head gently in order to avoid damaging the cylinder head gasket.
2. Install the cylinder head bolts.
   NOTE: The cylinder head bolts are tightened in 2 successive steps.
   1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
   2. Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.

      Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 

      Fig 2: Identifying Cylinder Head Set Bolts Tightening Sequence

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3. Mark the front of the cylinder head bolts with paint.
4. Further tighten the cylinder head bolts 90° as shown in the illustration.
5. Check that the paint mark is now at a 90° angle to the front.
Fig 3: Identifying Cylinder Head Bolts Tightening Angle
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1. Connect the ground cable with the bolt.

   Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

2. Connect the camshaft position sensor connector.
3. Connect the engine coolant temperature sensor connector.
4. Connect the engine oil pressure switch connector.
5. Connect the radio setting condenser connector.
6. Connect the inlet heater water hose.

Fig 4: Locating Camshaft Position Sensor Connector

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1. Set the crankshaft key in the position as shown in the illustration.
   Fig 5: Identifying Crankshaft Key Illustration Position

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2. Turn the cutout of the drive shaft so that it faces upward.
3. Align the yellow mark links with the timing marks of each gear as shown in the illustration.
4. Install the sprockets onto the crankshaft and oil pump shaft with the chain placed on the gears.
5. Temporarily tighten the oil pump drive shaft sprocket with the nut.
   Fig 6: Identifying Timing Marks On Timing Chain

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6. Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

   Fig 7: Locating Chain Tensioner Plate With Bolt

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7. Align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.
8. Insert a bar of 4 mm in diameter into the adjusting hole on the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

   Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

   Fig 8: Identifying Adjusting Hole On Oil Pump Drive Shaft Gear To Lock Gear In Position

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1. Install the crankshaft timing gear or sprocket to the crankshaft.

Fig 9: Locating Crankshaft Timing Gear

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1. Install the No. 1 chain vibration damper with the 2 bolts.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Fig 10: Locating No. 1 Chain Vibration Damper With Bolts

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1. Set the No. 1 cylinder to TDC/compression.
   1. Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks on the camshaft timing gear with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.
      Fig 11: Identifying Timing Marks On Camshaft Timing Gear

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   2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
      Fig 12: Identifying Crankshaft Upward Position

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2. Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.
   Fig 13: Aligning Timing Mark On Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, tap in the crankshaft timing sprocket.

   SST 09309-37010 

   Fig 14: Tapping Crankshaft Timing Sprocket

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4. Align the gold or yellow links with the timing marks located on the camshaft timing gear and sprocket, then install the chain.
   Fig 15: Identifying Timing Marks Location

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1. Install the chain tensioner slipper with the bolt.

   Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

   Fig 16: Locating Chain Tensioner Slipper With Bolt

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1. Install the tinning chain guide with the bolt.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Fig 17: Locating Timing Chain Guide And Bolt

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1. Install the sensor plate with the "F" mark facing forward.

1. Release the ratchet pawl, then fully push in the plunger and set the hook to the pin so that the plunger is in the position shown in the illustration.
   Fig 19: Releasing Ratchet Pawl

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2. Install a new gasket and the chain tensioner with the 2 nuts.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
   Fig 20: Identifying Chain Tensioner With Nuts

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1. Except spring type V-ribbed belt tensioner:
   1. Install the V-ribbed belt tensioner assembly with the bolt and nut.

      Torque: 60 N*m (607 kgf*cm, 44 ft.*lbf) 

      Fig 21: Locating V-Ribbed Belt Tensioner Assembly With Bolt And Nut

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2. Spring type V-ribbed belt tensioner:
   1. Install the V-ribbed belt tensioner to the engine by first tightening the bolt and then tightening the nut.

      Torque: 60 N*m (607 kgf*cm, 44 ft.*lbf) 

      NOTE: When replacing the V-ribbed belt tensioner with a new one, do not pull out the pin.
      Fig 22: Locating V-Ribbed Belt Tensioner With Bolts

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1. Using SST, secure the pulley in place and tighten the bolt.

   SST 09213-54015 (91651-60855), 09330-00021 

   Torque: 180 N*m (1835 kgf*cm, 133 ft.*lbf) 

   Fig 23: Tightening Crankshaft Pulley Bolts With SST

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2. Turn the crankshaft counterclockwise, then disconnect the hook from the pin.
   Fig 24: Disconnecting Hook From Pin

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3. Turn the crankshaft clockwise, then check that the plunger is extended.
   Fig 25: Checking Plunger Extension

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1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
2. Apply a continuous bead of seal packing (Diameter 4.0 to 4.5 mm (0.158 to 0.177 in.)) as shown in the illustration.

   Seal packing: 

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

   NOTE:

   • Remove any oil from the contact surfaces.
   • Install the oil pan within 3 minutes of applying seal packing.
   • Do not add engine oil for at least 2 hours after installing the oil pan.
3. Install the oil pan onto the cylinder block.
   Fig 26: Identifying Seal Packing Applying Area

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Fig 27: Identifying Oil Pan Bolts Tightening Sequence

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   Fig 28: Placing Wooden Block Between Floor Jack And Engine

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5. Place a wooden block between a floor jack and the engine, then support the engine using the floor jack.
6. Remove the chain block and sling device.
7. Remove the 2 bolts and engine hangers.

1. Install the idler pulley sub-assembly with the 2 bolts.

   Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) 

   Fig 29: Locating Idler Pulley Sub-Assembly With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the engine mounting insulator sub-assembly RH with the 4 bolts and 2 nuts.

   Torque: Bolt A 

   52 N*m (530 kgf*cm, 38 ft.*lbf) 

   Bolt B 

   95 N*m (969 kgf*cm, 70 ft.*lbf) 

   Nut A 

   95 N*m (969 kgf*cm, 70 ft.*lbf) 

   Nut B 

   52 N*m (530 kgf*cm, 38 ft.*lbf) 

   Fig 30: Locating Engine Mounting Insulator Sub-Assembly RH With Bolts And Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket onto the cylinder head sub-assembly.
2. Temporarily tighten the exhaust manifold converter sub-assembly with the 5 nuts.
3. Tighten the 5 nuts in the sequence shown in the illustration.

   Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

   Fig 31: Identifying Exhaust Manifold Converter Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the air fuel ratio sensor connector.
   Fig 32: Locating Air Fuel Ratio Sensor Connector

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1. Apply a light coat of engine oil to a new O-ring and install it onto the engine oil level dipstick guide.
2. Install the engine oil level dipstick guide with the bolt.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Fig 33: Locating Engine Oil Level Dipstick Guide And O-Ring With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. When a tensioner except spring type V-ribbed belt tensioner is used or the spring type V-ribbed belt tensioner is reused:
   1. Install the V-ribbed belt (See INSTALLATION  ).
2. When the spring type V-ribbed belt tensioner is replaced:
   1. Using SST, slowly turn the V-ribbed belt tensioner clockwise.

      SST 09216-42010 (09216-04010) 

   2. Pull out the pin with the V-ribbed belt tensioner being compressed in a clockwise direction.
   3. Slowly return the V-ribbed belt tensioner.
      NOTE:

      • Make sure that SST and other tools are set to the tensioner securely.
      • When compressing the V-ribbed belt tensioner, slowly turn the tensioner.
   4. Install the V-ribbed belt (See INSTALLATION  ).
      Fig 34: Turning V-Ribbed Belt Tensioner

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)