Installation

2AR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: INSTALLATION

1. INSPECT CYLINDER HEAD BOLT Engine Unit

2. INSPECT CYLINDER HEAD SUB-ASSEMBLY Testing and Inspection

3. INSTALL CYLINDER HEAD GASKET

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





(b) Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

Seal packing:

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

Standard seal dimension:

3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) thick

HINT
Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block.

NOTICE:
* 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.
(c) Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

NOTICE:
Pay attention to the installation direction.

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT
The cylinder head bolts are tightened in 4 progressive steps.

(a) Place the cylinder head on the cylinder block.

NOTICE:
* Ensure that no oil is on the mounting surface of the cylinder head.
* Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.
(b) Install the plate washers to the cylinder head bolts.

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

(d) Step 1:

(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.





Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

NOTICE:
Do not drop the plate washer for the cylinder head bolt into the cylinder head.

(e) Step 2:

(1) Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

(f) Step 3:

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





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

(g) Step 4:

(1) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

(2) Check that the paint marks are now facing rearward.

NOTICE:
* Do not apply oil for at least 4 hours after the installation.
* Do not start the engine for at least 4 hours after the installation.
* After the installation, if the seal packing has seeped out, wipe it off.
5. INSTALL VALVE STEM CAP

(a) Apply a light coat of engine oil to the valve stem ends.

(b) Install the 16 valve stem caps to the cylinder head.

NOTICE:
Do not drop the valve stem caps into the cylinder head.

6. INSTALL CAMSHAFT

(a) Install the camshafts Installation.

7. INSTALL INTAKE MANIFOLD Installation

8. CONNECT NO. 2 VENTILATION HOSE Installation

9. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

10. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for PZEV) Installation

11. INSTALL VACUUM SWITCHING VALVE ASSEMBLY Installation

12. INSTALL THROTTLE BODY ASSEMBLY Installation

13. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Install the exhaust manifold converter Installation.

14. INSTALL ENGINE AND TRANSAXLE

(a) Install the engine and transaxle Installation.