INSTALLATION

CAUTION / NOTICE / HINT

HINT:

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

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PROCEDURE

1. INSTALL CYLINDER HEAD GASKET

(a) Remove any oil from the contact surfaces.

(b) Apply seal packing to the cylinder block sub-assembly as shown in the illustration.

*a	Cylinder Block Sub-assembly
*b	2.0 to 4.0 mm (0.0787 to 0.157 in.)
*c	10 to 15 mm (0.394 to 0.591 in.)
*d	Diameter 4.0 mm (0.157 in.)
	Front of Engine

Seal Packing:

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

NOTICE:

Install the cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying seal packing.

(c) Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.

*a	Lot No.
	Front of Engine

NOTICE:

Make sure to install the cylinder head gasket in the correct direction.

(d) Apply seal packing to the cylinder head gasket as shown in the illustration.

*a	Cylinder Head Gasket
*b	0 to 2.0 mm (0 to 0.0787 in.)
*c	10 to 15 mm (0.394 to 0.591 in.)
*d	Diameter 4.0 mm (0.157 in.)
	Front of Engine

Seal Packing:

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

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT:

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

(a) Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

(b) Place the cylinder head sub-assembly on the cylinder block sub-assembly.

(c) Install the 10 cylinder head set plate washers to the 10 cylinder head set bolts.

(d) Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

(e) Step 1: (1) Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration. Torque: 49 N·m {500 kgf·cm, 36 ft·lbf} NOTICE: Do not drop the cylinder head set plate washers for the cylinder head set bolts into the cylinder head sub-assembly.

(f) Step 2:

*a	Paint Mark
	Front of Engine

(1) Mark each cylinder head set bolt head with paint as shown in the illustration.

(2) Tighten the cylinder head set bolts 90° in the order shown in step 1.

(g) Step 3:

(1) Tighten the cylinder head set bolts another 45° in the order shown in step 1.

(h) Check that the paint marks are now at a 135° angle.

NOTICE:

Do not add engine oil for at least 2 hours after installing the cylinder head sub-assembly.

(i) After tightening the cylinder head set bolts, wipe off any seal packing that seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly. NOTICE: Be sure to wipe off the seal packing from inside to outside, parallel to the joint line. Be sure to avoid clogging the bolt holes when wiping off the seal packing.

*a Before Wiping Off *b After Wiping Off

3. INSTALL NO. 1 WATER BY-PASS PIPE

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4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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