TOYOTA PRODEMAND Corolla LE Cylinder Head Gasket Installation Guide

TOYOTA PRODEMAND Corolla LE Cylinder Head Gasket

Product Information

• Engine: 1.8L Eng.
• VIN: JTDBL40E399027625
• License: May 21, 2023
• Odometer:

Product Usage Instructions: Cylinder Head Gasket Installation

1. Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward. Ensure that the gasket is installed in the correct direction and remove any oil from the contact surface.
2. Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.
3. Install the bolts and plate washers to the cylinder head. Do not drop the washers into the cylinder head.
4. Using several passes, 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: 49 Nm (500 kgfcm, 36 ft.*lbf)
5. Install No. 1 camshaft bearing, followed by No. 2 camshaft bearing, No. 2 camshaft, camshaft, camshaft bearing cap, camshaft housing sub-assembly, camshaft timing gear assembly, camshaft timing exhaust gear assembly, and No. 1 chain vibration damper.
6. Install No. 2 chain vibration damper, followed by chain sub-assembly.
7. Check that the No. 1 cylinder is at TDC/compression and temporarily tighten the crankshaft pulley bolt.
8. Turn the crankshaft counterclockwise to position the timing gear key to the top and remove the crankshaft pulley bolt.
9. Check that the timing marks on each camshaft timing gear are aligned as shown in the illustration.
10. Align the mark plate (orange) with the timing mark of the No. 2 camshaft as shown in the illustration and install the chain.
11. Place the chain on the crankshaft without passing it around the shaft.
12. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark.
13. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise to tension the chain, slowly turning it to prevent the chain from being misaligned.

CYLINDER HEAD GASKET > INSTALLATION

1. INSTALL CYLINDER HEAD GASKET

   • Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.
     NOTE
   1. Remove any oil from the contact surface.
   2. Make sure that the gasket is installed in the correct direction.
      Fig 1: Identifying Cylinder Block Surface With Lot No. Stamp Facing Upward

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
   HINT: The cylinder head bolts are tightened in 2 progressive steps.

3. Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.

4. Install the bolts and plate washers to the cylinder head.
   NOTE: Do not drop the washers into the cylinder head.

5. Using several passes, uniformly install and tighten the 10 cylinder head set bolts and plate washer swish a 10 mm bi-hexagon wrench in the order shown in the illustration.
   Torque: 49 Nm (500 kgfcm, 36 ft.*lbf)
   Fig 2: Identifying Cylinder Head Bolts Tightening Sequence

6. Mark the front side of the cylinder head bolts with paint.

7. Retighten the cylinder head bolts an additional 90°, then once more 45° as shown in the illustration.

8. Check that the paint mark is now at a 135° angle to the front.

9. INSTALL VALVE LASH ADJUSTER ASSEMBLY(See REASSEMBLY)

10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY(See REASSEMBLY)
    Fig 3: Identifying Cylinder Head Bolts Tightening Angle

11. INSTALL NO. 1 CAMSHAFT BEARING (See INSTALLATION)

12. INSTALL NO. 2 CAMSHAFT BEARING (See INSTALLATION )

13. INSTALL NO. 2 CAMSHAFT (See INSTALLATION)

14. INSTALL CAMSHAFT (See INSTALLATION )

15. INSTALL CAMSHAFT BEARING CAP (See INSTALLATION)

16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (See INSTALLATION )

17. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY ( See INSTALLATION )

18. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (See INSTALLATION )

19. INSTALL NO. 1 CHAIN VIBRATION DAMPER

20. Install the No. 1 chain vibration damper with the 2 bolts.
    Torque: 21 Nm (214 kgfcm, 16 ft.*lbf)

21. INSTALL NO. 2 CHAIN VIBRATION DAMPER (See INSTALLATION)

22. INSTALL CHAIN SUB-ASSEMBLY

23. Check that the No. 1 cylinder is at TDC/compression. Temporarily tighten the crankshaft pulley bolt.

24. Turn the crankshaft counterclockwise to position the timing gear key to the top.
    Fig 4: Identifying Timing Gear Key

25. Remove the crankshaft pulley bolt.

26. Check that the timing marks on each camshaft timing gear are aligned as shown in the illustration.
    Fig 5: Identifying Camshaft Timing Gear Timing Marks

27. Align the mark plate (orange) with the timing mark of the No. 2 camshaft as shown in the illustration and install the chain.
    Fig 6: Aligning Mark Plate (Orange) With Timing Mark Of No. 2 Camshaft
    HINT:

  * Be sure to position the mark plate at the front of the engine.
  * The mark plate on the camshaft side is colored orange.
  * Do not pass the chain around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
  * Pass the chain through the No. 1 vibration damper.
  * Place the chain on the crankshaft without passing it around the shaft.  

Fig 7: Placing Chain On Crankshaft

6. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark.  

HINT:

  1. Be sure to position the mark plate at the front of the engine.
  2. The mark plate on the camshaft side is colored orange.
  3. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.
7.  **HINT:** To tension the chain, slowly turn the camshaft timing gear assembly clockwise to prevent the chain from being misaligned.  

Fig 8: Aligning Mark Plate (Orange) And Timing Mark

8. Align the mark plate (yellow) and timing mark and install the chain to the crankshaft timing gear.  

HINT: The mark plate on the crankshaft side is colored yellow.
Fig 9: Aligning Mark Plate (Yellow) And Timing Mark And To Crankshaft Timing Gear

9. Recheck each timing mark at TDC/compression.  

Fig 10: Identifying Timing Mark Location

16. INSTALL CHAIN TENSIONER SLIPPER

17. Install the chain tensioner slipper.
    Fig 11: Identifying Chain Tensioner Slipper

18. I NSTALL TIMING CHAIN COVER OIL SEAL (See INSPECTION )

19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See INSTALLATION)

20. INSTALL CRANKSHAFT PULLEY (See INSTALLATION )

21. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See step 38)
    Fig 12: Identifying Chain Tensioner Slipper

22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See step 42)

23. INSTALL RADIO SETTING CONDENSER (See step 1)

24. INSRMOSTAT TALL THE (See THERMOSTAT )

25. INSTALL INLET WATER (See ON-VEHICLE INSPECTION )

26. INSTALL INLET WATER HOSE (See REASSEMBLY)

27. INSTALL WATER BY-PASS HOSE (See REASSEMBLY)

28. INSTALL NO. 1 WATER BY-PASS PIPE (See REASSEMBLY)

29. CONNECT NO. 3 WATER BY-PASS HOSE

30. INSTALL VENTILATION HOSE (See REASSEMBLY)

31. INSPECT EXHAUST MANIFOLD (See REASSEMBLY)

32. INSTALL EXHAUST MANIFOLD (See REASSEMBLY)

33. INSTALL MANIFOLD STAY (See REASSEMBLY)

34. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See REASSEMBLY)

35. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY (See REASSEMBLY)

36. INSTALL IGNITION COIL ASSEMBLY (See INSTALLATION)

37. INSTALL FUEL INJECTOR ASSEMBLY (See INSTALLATION)

38. INSTALL NO. 1 DELIVERY PIPE SPACER (See INSTALLATION)

39. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (See INSTALLATION)

40. INSTALL FUEL TUBE SUB-ASSEMBLY (See INSTALLATION )

41. INSTALL INTAKE MANIFOLD (See COMPONENTS )

42. REMOVE ENGINE STAND (See REASSEMBLY)

43. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
    HINT: See INSTALLATION.

FRONT CRANKSHAFT OIL SEAL > REMOVAL

1. REMOVE FRONT WHEEL RH

2. REMOVE ENGINE UNDER COVER RH

3. REMOVE NO. 2 CYLINDER HEAD COVER (See step 10 )

4. REMOVE V-RIBBED BELT
   (See INSTALLATION)

5. REMOVE CRANKSHAFT PULLEY a.

6. Using SST, hold the pulley in place and loosen the pulley bolt. SST 09213-58013, 09330-00021
   NOTE: Check the SST installation positions when installing them to prevent the SST fixing bolts from coming into contact with the timing chain cover sub-assembly.
   Fig 1: Removing Crankshaft Pulley

7. Using SST, remove the crankshaft pulley and pulley bolt. SST 09950-50013 (09951 -05010, 09952-05010, 09953-05020, 09954-05021)
   Fig 2: Removing Crankshaft Pulley And Pulley Bolt

8. REMOVE TIMING CHAIN COVER OIL SEAL

9. Using a knife, cut off the lip of the oil seal.

10. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.
    NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

Reprinted Under License from Toyota Motor Sales, U.S.A., Inc., License Agreement TMS1002

Documents / Resources

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