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Cylinder Head, Intake Manifold, Exhaust Manifold: Installation

WARNING: This page is about a different car, the 2002 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using Valve Stem Oil Seal Replacer (09201-41020), install valve stem oil seals onto valve guides. Install valves, valve spring seats, valve springs, spring retainers and keepers.
    2. NOTE: When installing exhaust manifold gasket, ensure White paint mark on gasket faces manifold.
  2. Install NEW exhaust manifold gaskets on cylinder head, so White paint mark on gasket faces exhaust manifold. Install exhaust manifolds. Install NEW exhaust manifold nuts and tighten to specification. See TORQUE SPECIFICATIONS . Install heat insulators.
  3. Rear side of cylinder head gaskets are marked "3R" and "3L" to distinguish right and left banks. Install NEW cylinder head gasket on correct side of cylinder block. Position cylinder heads on cylinder block over locating dowels in block.
  4. Apply light coat of oil to threads and underside of cylinder head bolts. Install washers on cylinder head bolts. Install cylinder head bolts and tighten to specification in 2 steps, in sequence. See Fig 1. See TORQUE SPECIFICATIONS .
  5. Install body ground leads to rear of cylinder heads. Install wiring harness brackets to cylinder heads. Connect 2 heated oxygen sensor harness connectors. Install valve lifters and adjusting shims.
  6. Install camshafts. See CAMSHAFT . To avoid valve/piston interference, position crankshaft pulley timing mark with center of crankshaft pulley bolt and center of No. 2 timing belt idler pulley bolt. See Figure. Check and adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT  under ADJUSTMENTS.
    NOTE: There are 2 half-circular camshaft plugs for each cylinder head. Ensure both half-circular plugs are installed in each cylinder head.
  7. Apply a continuous bead of silicone sealant to mating surface of all 4 half-circular camshaft plugs before installation. Install plugs to cylinder head.
  8. Apply silicone sealant to outer edges of front camshaft bearing caps at cylinder head. Install NEW gaskets onto valve covers. Install valve covers. Install seal washers and valve cover bolts. Tighten bolts evenly to specification, in several passes. See TORQUE SPECIFICATIONS .
  9. Install wiring harness clamp bracket to right front camshaft bearing cap. Install engine hangers, VVT sensors, and camshaft timing oil control valve. Install engine and transmission oil dipstick guide tubes.
  10. Using NEW gaskets, install front and rear water manifolds. Tighten nuts alternately to specification. See TORQUE SPECIFICATIONS . Connect coolant hoses to water manifolds. Connect engine coolant temperature sensor. Using a NEW "O" ring, install water by-pass pipe to water pump. Connect heater hose to water by-pass pipe.
  11. Using NEW gaskets and nuts, install both TWCs to exhaust manifolds. Install front exhaust pipe to both TWCs. Install power steering pump. Install timing belt rear plates to cylinder heads. Install camshaft position sensor. Install camshaft sprockets. Install timing belt. See TIMING BELT REPLACEMENT - 4.3L article.
  12. Install NEW intake manifold gaskets onto cylinder heads, with White paint mark on gaskets facing upward. Ensure holes in gasket align with holes in cylinder head. Install intake manifold assembly onto cylinder heads. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
  13. Connect 8 injector harness connectors. Install wiring harness retainers. Connect EVAP hoses. Connect all wiring harness connectors, emission, coolant and vacuum hoses removed. Connect fuel lines. Install throttle body. Connect and adjust accelerator cable.
  14. Install radiator assembly. Install intake air duct and air cleaner assembly. Fill engine with coolant. Check engine oil level. Connect negative battery cable. Start engine and check for coolant and fuel leaks. Bleed cooling system. See COOLING SYSTEM BLEEDING  under ADJUSTMENTS.
  15. Install engine under cover. Install engine "V" bank and side covers.
Fig 1: Identifying Cylinder Head Bolt Tightening Sequence
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