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Cylinder Head, Intake Manifold, Exhaust Manifold: Installation

  1. INSPECT CYLINDER HEAD SET BOLT 
    1. Using vernier calipers, measure the tension portion diameter of the bolt.

      Standard outside diameter: 

      8.95 to 9.05 mm (0.3524 to 0.3563 in.) 

      Minimum outside diameter: 

      8.75 mm (0.3445 in.) 

      If the diameter is less than the minimum, replace the bolt.

      Fig 1: Identifying Tension Portion Diameter Of Bolt
      G05200424Courtesy 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 the gasket in the correct direction.
      • Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
        Fig 2: Identifying Cylinder Block With L Mark Upward
        G05200425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL CYLINDER HEAD LH 
    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 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.

      SST 09011-38121 

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

      Fig 3: Identifying Cylinder Head Bolt With Tighten Sequence
      G05129311Courtesy 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 step (c).
    6. Check that each painted mark is now at 90° angle to the front.
      Fig 4: Identifying Cylinder Head Bolt
      G05129312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a socket hexagon wrench 8 mm, install the hexagon bolt.

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

      Fig 5: Installing Hexagon Bolt
      G05129546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using several steps, install and tighten the 2 bolts and intake air connector bracket No.2 uniformly in the sequence shown in the illustration.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

    9. Connect the ground cable with the 2 bolts.

      Torque: Nut A 

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

      Nut B 

      11 N*m (112 kgf*cm, 97 in.*lbf) 

      Fig 6: Locating Bolts And Intake Air Connector Bracket
      G05200429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO.4 CAMSHAFT SUB-ASSEMBLY (See  INSTALLATION   ) 
  5. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY (See  INSTALLATION   ) 
  6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (See  ADJUSTMENT   ) 
  7. INSTALL WATER INLET PIPE  (See INSTALLATION )
  8. INSTALL OIL LEVEL GAUGE GUIDE 
    1. Install a new O-ring to the oil level gauge guide.
    2. Apply soapy water to the O-ring.
    3. Push in the oil level gauge guide end into the guide hole of the cylinder block.
    4. Install the oil level gauge guide with the bolt.

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

    5. Install the oil level gauge.
      Fig 7: Locating Oil Level Gauge Guide With Bolt
      G05200420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2 
    1. Install a new gasket as shown in the illustration.
      Fig 8: Installing Gasket
      G05200431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold converter No.2 with the 6 nuts and bolt. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
      Fig 9: Locating Exhaust Manifold Converter, Nuts And Bolt
      G05200432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Retighten nuts 1 and 2 shown in the illustration.
  10. CONNECT COOLING FAN ECU 
    1. Connect the 2 bolts and cooling fan ECU.

      Torque: 2.6 N*m (26 kgf*cm, 23 in.*lbf) 

  11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 
    1. Install the 2 bolts and exhaust manifold heat insulator No.2.

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

      Fig 10: Locating Bolts And Exhaust Manifold Heat Insulator
      G05200433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL MANIFOLD CONVERTER INSULATOR NO.3 
    1. Install the bolt, nut and manifold converter insulator No.3.

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

      Fig 11: Locating Manifold Converter Insulator, Bolt And Nut
      G05200417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 the gasket in the correct direction.
      • Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
        Fig 12: Identifying Cylinder Block With R Mark Upward
        G05129543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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.

      SST 09011-38121 

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

      Fig 13: Identifying Cylinder Head Bolts Tightening Sequence
      G05200436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
      Fig 14: Identifying Cylinder Head Bolt
      G05129312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
    6. Check that each painted mark is now at 90° angle to the front.
    7. Using a socket hexagon wrench 8 mm, install the hexagon bolt.
      Fig 15: Identifying Cylinder Head Bolts Tightening Sequence
      G05129264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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) 

  15. INSTALL NO.2 CAMSHAFT (See  INSTALLATION   ) 
  16. INSTALL CAMSHAFT (See  INSTALLATION   ) 
  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See  ADJUSTMENT   ) 
  18. INSTALL IGNITION COIL ASSEMBLY 

    Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf) 

  19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Install a new gasket as shown in the illustration.
      Fig 16: Installing Gasket
      G05200439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
      Fig 17: Identifying Gasket And Exhaust Manifold RH With Nuts
      G05200440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Retighten nuts 1 and 2 shown in the illustration.
  20. INSTALL MANIFOLD STAY 
    1. Temporarily install the manifold stay to the exhaust manifold and transaxle.
    2. Fully tighten the 2 bolts.

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

  21. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 
    1. Install the 3 bolts and exhaust manifold heat insulator No. 1.
      Fig 18: Locating Exhaust Manifold Heat Insulator And Bolts
      G05200412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  22. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3 (See  INSTALLATION   ) 
  23. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See  INSTALLATION   ) 
  24. INSTALL TIMING BELT NO.3 COVER (See  INSTALLATION   ) 
  25. INSTALL CAMSHAFT TIMING PULLEY (See  INSTALLATION   ) 
  26. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2 (See  INSTALLATION   ) 
  27. INSPECT TIMING BELT (See  INSTALLATION   ) 
  28. INSTALL TIMING BELT (See  INSTALLATION   ) 
  29. INSTALL CHAIN TENSIONER ASSEMBLY NO.1 (See  INSTALLATION   ) 
  30. INSTALL TIMING BELT GUIDE NO.2 (See  INSTALLATION   ) 
  31. INSTALL ENGINE MOUNTING BRACKET RH (See  INSTALLATION   ) 
  32. INSTALL TIMING BELT NO.2 COVER (See  INSTALLATION   ) 
  33. INSTALL TIMING BELT NO.1 COVER (See  INSTALLATION   ) 
  34. INSTALL CRANKSHAFT PULLEY (See  INSTALLATION   ) 
  35. INSTALL ENGINE MOUNTING STAY NO.2 RH (See  INSTALLATION   ) 
  36. INSTALL ENGINE MOVING CONTROL ROD (See  INSTALLATION   ) 
  37. INSTALL AIR CLEANER BRACKET (See  INSTALLATION   ) 
  38. INSTALL RESERVOIR BRACKET (See  INSTALLATION   ) 
  39. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (See  INSTALLATION   ) 
  40. INSTALL WATER OUTLET 
    1. Install 2 new gaskets to the 2 cylinder heads.
    2. Install the water outlet together with water bypass 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.
  41. CONNECT 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.
      Fig 19: Identifying Intake Manifold Bolts, Nuts And Washers
      G05200442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
  43. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1 (See  INSTALLATION   ) 
  44. INSTALL INTAKE AIR SURGE TANK  (See INSTALLATION )
  45. INSTALL EMISSION CONTROL VALVE SET  (See INSTALLATION )
  46. INSTALL W/ CONVERTER INVERTER ASSEMBLY 

    (See INSTALLATION )

  47. INSTALL AIR CLEANER CASE W/ RESONATOR  (See INSTALLATION )
  48. INSTALL AIR CLEANER CAP W/ INLET (See  INSTALLATION   ) 
  49. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER (See  INSTALLATION   ) 
  50. INSTALL BATTERY CARRIER SUB-ASSEMBLY (See  INSTALLATION   ) 
  51. INSTALL BATTERY (See  INSTALLATION   ) 
  52. INSTALL SERVICE PLUG GRIP  (See INSTALLATION )
  53. INSTALL ENGINE UNDER COVER NO.2 (See  INSTALLATION   ) 
  54. INSTALL FRONT FENDER APRON SEAL RH (See  INSTALLATION   ) 
  55. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See  INSTALLATION   ) 
  56. INSTALL ENGINE UNDER COVER NO.1 (See  INSTALLATION   ) 
  57. INSTALL FRONT WHEEL RH 
  58. ADD ENGINE OIL 
  59. CHECK FOR FUEL LEAKS  (See ON-VEHICLE INSPECTION )
  60. ADD COOLANT (Hybrid side)  (See COOLANT )
  61. ADD COOLANT (Engine side)  (See COOLANT )
  62. INSPECT FOR OIL LEAK 
  63. INSPECT FOR ENGINE COOLANT LEAK (Hybrid Side) 
  64. INSPECT FOR ENGINE COOLANT LEAK (Engine side)  (See COOLING SYSTEM )
  65. INSPECT FOR EXHAUST GAS LEAK 
  66. INSPECT IGNITION TIMING (See  ON-VEHICLE INSPECTION   ) 
  67. INSPECT ENGINE IDLE SPEED (See  ON-VEHICLE INSPECTION   ) 
  68. INSPECT COMPRESSION (See  ON-VEHICLE INSPECTION   ) 
  69. INSPECT CO/HC (See  ON-VEHICLE INSPECTION   ) 
  70. PERFORM INITIALIZATION 
    1. Some system need initialization when reconnecting the cable from the battery terminal. (See INITIALIZATION )
  71. INSTALL ENGINE ROOM SIDE LH COVER NO.2 (See  INSTALLATION   ) 
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