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Cylinder Head, Intake Manifold, Exhaust Manifold: Installation

  1. INSTALL CYLINDER HEAD GASKET 
    1. Place a new cylinder head gasket on the cylinder block with the R mark upward.
    NOTE:
    • Remove any oil from the contact surface.
    • Be careful to install of the installing orientation.
    • Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
    Fig 1: Placing New Cylinder Head Gasket On Cylinder Block With R Mark Upward
    G04087723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL CYLINDER HEAD GASKET NO. 2 
    1. Place a new cylinder head gasket on the cylinder block with the L mark upward.
    NOTE:
    • Remove any oil from the contact surface.
    • Be careful to install of the installing orientation
    • Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
    Fig 2: Placing New Cylinder Head Gasket On Cylinder Block With L Mark Upward
    G04087724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY 
    NOTE: The cylinder head bolts are tightened in 2 successive steps.
    1. Apply a light coat of engine oil to the threads of the cylinder head bolts.
    2. Install the plate washers to the cylinder head bolts.
    3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration (procedure "A").

      Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf) 

      Fig 3: Identifying Cylinder Head Bolts Tightening Sequence
      G04087725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
    5. Retighten the cylinder head bolts by 90° in the same sequence as procedure "A".
    6. Check that each painted mark is now at 90° angle to the front.
      Fig 4: View Of 90 Degree Turn Using Paint Mark Reference
      G04111409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a socket hexagon wrench 8, install the hexagon bolt.

      Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) 

    8. Connect the engine wire harness clamp with the nut.

    Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

    4. Fig 5: Installing Hexagon Bolt
    G04087727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CYLINDER HEAD LH 
    NOTE: The cylinder head bolts are tightened in 2 successive steps.
    1. Apply a light coat of engine oil on the threads of the cylinder head bolts.
    2. Install the plate washer to the cylinder head bolt.
    3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration (Procedure "B").

      Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf) 

      Fig 6: Identifying Hexagon Bolt
      G04111406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
    5. Retighten the cylinder head bolts by 90° in the same sequence as procedure "B".
    6. Check that each painted mark is now at 90° angle to the front.
      Fig 7: View Of 90 Degree Turn Using Paint Mark Reference
      G04111409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a socket hexagon wrench 8, install the hexagon bolt.

      Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) 

    8. Install the bolt holding the water inlet to the cylinder head. (TMMWV MADE)

      Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) 

    9. Install the wire harness clamp bracket with the bolt.

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

    10. Connect the ground cable with the bolts.
    Fig 8: Identifying Hexagon Bolt
    G04111410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  5. INSTALL NO. 2 CAMSHAFT 
    1. Install the No. 2 camshaft (See INSTALLATION  ).
  6. INSTALL CAMSHAFT 
    1. Install the camshaft (See INSTALLATION  ).
  7. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. Install the No. 4 camshaft sub-assembly (See INSTALLATION  ).
  8. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 
    1. Install the No. 3 camshaft sub-assembly (See INSTALLATION  ).
  9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install the cylinder head cover sub-assembly (See ADJUSTMENT  ).
  10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Install the cylinder head cover sub-assembly (See ADJUSTMENT  ).
  11. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the ignition coil assembly (See ADJUSTMENT  ).
  12. INSTALL WATER INLET PIPE 
    1. Install the water inlet pipe (TMC made) (See INSTALLATION ).
  13. INSTALL OIL LEVEL GAGE GUIDE 
    1. Install a new O-ring to the oil level gage guide.
    2. Apply soapy water to the O-ring.
    3. Push in the oil level gage guide end into the guide hole of the cylinder block.
    4. Install the oil level gage guide with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    5. Install the oil level gage.
    Fig 9: Installing O-Ring To Oil Level Gage Guide
    G04087731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY 
    1. Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

    2. Retighten nuts 1 and 2 shown in the illustration.
      3. Fig 10: Identifying Exhaust Manifold RH Bolts Tightening Sequence
      G04087732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL MANIFOLD STAY 

    Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

  16. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 

    Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  17. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3 

    Refer to INSTALLATION

  18. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY NO. 2 
    1. Install a new gasket and the exhaust manifold converter No. 2 with the 6 nuts and bolt. Using several steps, tighten the nuts uniformly in the sequence in the illustration.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

    2. Retighten nuts 1 and 2 shown in the illustration.
      3. Fig 11: Identifying Exhaust Manifold Converter No 2 Bolts Tightening Sequence
      G04087733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2 

    Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  20. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3 

    Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  21. INSTALL EXHAUST PIPE ASSEMBLY FRONT 
    1. Install the exhaust pipe assembly front (See INSTALLATION ).
  22. INSTALL PROPELLER SHAFT (for 4WD) 
    1. Install the propeller shaft (See INSTALLATION ).
  23. INSTALL VANE PUMP ASSEMBLY 
    1. Install the vane pump assembly (See INSTALLATION  ).
  24. INSTALL TIMING BELT NO. 3 COVER 
    1. Install the timing belt No. 3 cover (See INSTALLATION  ).
  25. INSTALL CAMSHAFT TIMING PULLEY 

    SST 09960-10010 (09962-01000, 09963-01000),09249-63010 

    1. Install the camshaft timing pulley (See INSTALLATION  ).
  26. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2 
    1. Install the timing belt idler sub-assembly No. 2 (See INSTALLATION  ).
  27. INSPECT TIMING BELT 
    1. Inspect the timing belt (See page INSPECTION  ).
  28. INSTALL TIMING BELT 
    1. Install the timing belt (See INSPECTION  ).
  29. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 
    1. Install the chain tensioner assembly No. 1 (See INSPECTION  ).
  30. INSTALL TIMING BELT GUIDE NO. 2 
    1. Install the timing belt guide No. 2 (See INSPECTION  ).
  31. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket RH (See INSPECTION  ).
  32. INSTALL TIMING BELT NO. 2 COVER 
    1. Install the timing belt No. 2 cover (See INSPECTION  ).
  33. INSTALL TIMING BELT NO. 1 COVER 
    1. Install the timing belt No. 1 cover (See INSPECTION  ).
  34. INSTALL CRANKSHAFT PULLEY 

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

    1. Install the crankshaft pulley (See INSPECTION  ).
  35. INSTALL GENERATOR BRACKET NO. 2 
    1. Install the generator bracket No. 2 (See INSPECTION  ).
  36. INSTALL ENGINE MOUNTING STAY NO. 2 RH 
    1. Install the engine mounting stay No. 2 RH (See INSPECTION  ).
  37. INSTALL ENGINE MOVING CONTROL ROD 
    1. Install the engine moving control rod (See INSPECTION  ).
  38. INSTALL VANE PUMP V-BELT 
    1. Install the vane pump V-belt (See INSTALLATION  ).
  39. INSTALL V-(COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 
    1. Install the V-(cooler compressor to crankshaft pulley) belt No. 1 (See INSTALLATION  ).
  40. INSTALL DRIVE BELT DEFLECTION AND TENSION 
    1. Install the drive belt deflection and tension (reference) ( See DRIVE BELT  ).
  41. INSTALL WATER OUTLET 
    1. Install 2 new gaskets to the 2 cylinder heads.
    2. Install the water outlet together with water by-pass hose No. 1 and unlock the hose clamp.
    3. Tighten the 2 bolts, 2 nuts and 2 washers.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

    4. Install the clamp.
    5. Connect the engine coolant temperature sensor connector.
    6. Connect the radiator hose inlet.
  42. INSTALL INTAKE MANIFOLD 
    1. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

    2. Retighten the water outlet mounting bolts and nuts.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

    3. Install the ground cable with the nut.

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

    4. Connect the heater inlet water hose.
      5. Fig 12: Identifying Intake Manifold Bolts Tightening Sequence
      G04087734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1 
    1. Connect the fuel pipe sub-assembly No. 1 (See FUEL SYSTEM ).
  44. INSTALL INTAKE AIR SURGE TANK 
    1. Install the intake air surge tank (See ADJUSTMENT  ).
  45. INSTALL EMISSION CONTROL VALVE SET 
    1. Install the emission control valve set (See ADJUSTMENT  ).
  46. INSTALL AIR CLEANER CASE 
    1. Install the air cleaner case (See INSTALLATION ).
  47. INSTALL AIR CLEANER INLET NO. 2 
    1. Install the air cleaner inlet No. 2 (See INSTALLATION ).
  48. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 
    1. Install the air cleaner cap sub-assembly (See INSTALLATION ).
  49. CONNECT VACUUM HOSE 
    1. Connect the vacuum hose (See INSTALLATION  ).
  50. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Install the V-bank cover sub-assembly (See ADJUSTMENT  ).
  51. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER 
    1. Install the cowl top panel sub-assembly outer (See INSTALLATION ).
  52. INSTALL WINDSHIELD WIPER LINK ASSEMBLY 
    1. Install the windshield wiper link assembly (See INSTALLATION ).
  53. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY 
    1. Install the cowl top ventilator louver sub-assembly (See INSTALLATION ).
  54. INSTALL FR WIPER ARM LH 
    1. Install the FR wiper arm LH (See INSTALLATION ).
  55. INSTALL FR WIPER ARM RH 
    1. Install the FR wiper arm RH (See INSTALLATION ).
  56. INSTALL FRONT WHEEL RH 
    1. Install the front wheel RH (See INSTALLATION  ).
  57. ADD ENGINE OIL 
    1. Add engine oil (See REPLACEMENT ).
  58. ADD ENGINE COOLANT 
    1. Add engine coolant (See COOLANT ).
  59. CHECK FOR ENGINE OIL LEAKS 
  60. CHECK FOR ENGINE COOLANT LEAKAGE 
    1. Check the engine coolant leakage (See COOLING SYSTEM ).
  61. INSPECT FUEL LEAKAGE 
  62. CHECK FOR EXHAUST GAS LEAKAGE 
  63. INSPECT IGNITION TIMING 

    SST 09843-18040 

    1. Inspect the ignition timing (See ON-VEHICLE INSPECTION  ).
  64. INSPECT ENGINE IDLE SPEED 

    SST 09843-18040 

    1. Inspect the engine idle speed (See ON-VEHICLE INSPECTION  ).
  65. INSPECT COMPRESSION 

    SST 09992-00500 

    1. Inspect the compression (See ON-VEHICLE INSPECTION  ).
  66. INSPECT CO/HC 
    1. Inspect the CO/HC (See ON-VEHICLE INSPECTION  ).
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