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Cylinder Head, Intake Manifold, Exhaust Manifold: Installation

  1. INSTALL CYLINDER HEAD GASKET 
    1. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.
      NOTE:
      • Remove any oil from contact surface.
      • Be careful of the installation direction.
      • Place the cylinder head gently in order to avoid damaging the gasket.
    2. Fig 1: Identifying Cylinder Block Surface With Lot Number
    G04865510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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 and under the heads of the cylinder set head 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: 78.5 N*m (800 kgf*cm, 58 ft.*lbf) 

      Fig 2: Identifying Cylinder Set Head Bolts Tighten Sequence
      G04865511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mark the front of the cylinder head bolts with paint.
    4. Retighten the cylinder head bolts by 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 Paint Mark
      G04865512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the ground cable with the bolt.

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

    7. Connect the camshaft position sensor connector.
    8. Connect the engine coolant temperature sensor connector.
    9. Connect the engine oil pressure switch connector.
    10. Connect the radio setting condenser connector.
    11. Connect the heater water inlet hose.
    12. Connect the radiator hose inlet.
      Fig 4: Locating Engine Coolant Temperature Sensor Connector
      G04865463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean the contact surfaces of the bearing and the cylinder head.
    2. Install the No. 2 camshaft bearing onto the cylinder head.
      NOTE: Do not apply engine oil to the bearing its contact surface.
      Fig 5: Identifying Camshaft Bearing Onto Cylinder Head
      G04865461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Put the camshaft timing gear and camshaft together with the straight pin off the key groove.
    2. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
      NOTE: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).
      Fig 6: Turning Camshaft Timing Gear
      G04865515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the there is no clearance between the gear fringe and camshaft.
    4. Tighten the flange bolt with the camshaft timing gear fixed in pace.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

    5. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
  5. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET 
    1. Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      NOTE: Do not to damage the camshaft.
    Fig 7: Installing Camshaft Timing Sprocket With Bolt
    G04865516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL CAMSHAFT 
    1. Apply a light coat of engine oil to the journal portion of the camshaft.
    2. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.
      Fig 8: Identifying Cam Lobes Facing Directions
      G04865517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Examine the front marks and numbers and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
    4. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
      Fig 9: Inspecting Camshaft Bearing Caps
      G04865518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.

      Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf) for No. 1 and No. 2 bearing cap 

      9.0 N*m (92 kgf*cm, 80 in.*lbf) for No. 3 bearing cap 

      NOTE:
      • Tighten the bolts after deciding the position in the thrust direction of the camshaft by the No. 1 and No. 2 bearing caps.
      • Install the camshaft with the timing mark of the camshaft timing gear on top.
      Fig 10: Identifying Bearing Cap Bolts In Sequence
      G04865519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
  8. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 
    1. Install a new gasket onto the cylinder head.
    2. Temporarily tighten the exhaust manifold converter 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 11: Locating Exhaust Manifold Converter Nuts Sequence
      G04865520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the exhaust manifold heat insulator with the 3 bolts and nut.

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

    2. Connect the air fuel ratio sensor connector.
      Fig 12: Locating Exhaust Manifold Heat Insulator With Bolts And Nut
      G04865447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 2 MANIFOLD STAY 
    1. Install the stay with the bolt and nut.

      Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

      Fig 13: Locating Stay With Bolt And Nut
      G04865445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL MANIFOLD STAY 
    1. Install the stay with the bolt and nut.

      Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

      Fig 14: Locating Manifold Stay
      G04865444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL OIL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring and install it onto the guide.
    2. Install the guide with the bolt.

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

      3. Fig 15: Locating O-Ring And Guide
      G04865524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL OIL DIPSTICK 
    1. Apply a light coat of engine oil to the O-ring.
    2. Install the dipstick to the guide.
  14. INSTALL NO. 1 CHAIN VIBRATION DAMPER (See  INSTALLATION  )
  15. INSTALL CHAIN SUB-ASSEMBLY 
  16. INSTALL CHAIN TENSIONER SLIPPER (See  INSTALLATION  )
  17. INSTALL TIMING CHAIN GUIDE (See  INSTALLATION  )
  18. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (See  INSTALLATION  )
  19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See  INSTALLATION  )
  20. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See  INSTALLATION  )
  21. INSTALL CRANKSHAFT PULLEY (See  INSTALLATION  )
  22. INSTALL OIL PAN SUB-ASSEMBLY (See  INSTALLATION  )
  23. INSTALL CRANKSHAFT POSITION SENSOR (See  REMOVAL  ) 
  24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See  INSTALLATION  )
  25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See  INSTALLATION  )
  26. INSTALL IGNITION COIL ASSEMBLY (See  REMOVAL  ) 
  27. INSTALL ENGINE MOUNTING INSULATOR RH (See  INSTALLATION  )
  28. INSTALL VANE PUMP ASSEMBLY 
  29. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
  30. INSTALL FAN AND GENERATOR V BELT (See  REMOVAL  )
  31. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See  DISASSEMBLY  ) 
  32. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR (See  INSPECTION  ) 
  33. INSTALL INTAKE MANIFOLD (See  INSTALLATION  ) 
  34. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (See  INSTALLATION  ) 
  35. INSTALL THROTTLE BODY ASSEMBLY (See  INSPECTION  ) 
  36. INSTALL AIR CLEANER ASSEMBLY (See  INSTALLATION  )
  37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  38. ADD ENGINE COOLANT (See  COOLANT  ) 
  39. ADD ENGINE OIL (See  REPLACEMENT  ) 
  40. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION  ) 
  41. CHECK FOR ENGINE COOLANT LEAKS 
    1. Check for the engine coolant leaks (see COOLING SYSTEM ).
  42. CHECK FOR ENGINE OIL LEAKS 
  43. CHECK FOR EXHAUST GAS LEAKS 
  44. CHECK IGNITION TIMING (See  ON-VEHICLE INSPECTION  )
  45. INSPECT ENGINE IDLING SPEED (See  ON-VEHICLE INSPECTION  )
  46. INSPECT COMPRESSION (See  ON-VEHICLE INSPECTION  )
  47. INSPECT CO/HC (See  ON-VEHICLE INSPECTION  )
  48. INSTALL COWL BODY MOUNTING BRACKET LOWER LH 
  49. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 
  50. INSTALL WIPER LINK ASSEMBLY (See  INSTALLATION  ) 
  51. INSTALL COWL TOP VENTILATOR LOUVER LH 
  52. INSTALL HOOD TO COWL TOP SEAL 
  53. INSTALL FRONT WIPER ARM LH (See  INSTALLATION  ) 
  54. INSTALL FRONT WIPER ARM RH (See  INSTALLATION  ) 
  55. INSTALL FRONT WIPER ARM HEAD CAP 
  56. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See  INSTALLATION  )
  57. INSTALL FRONT FENDER APRON SEAL RH 
  58. INSTALL ENGINE UNDER COVER LH 
  59. INSTALL ENGINE UNDER COVER RH 
  60. INSTALL FRONT WHEEL RH (See  INSTALLATION  ) 
  61. INSTALL HOOD SUB-ASSEMBLY 
    1. Install and adjust the hood (see HOOD ).
  62. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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