Cylinder Head, Intake Manifold, Exhaust Manifold: Installation

1. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

Fig 1: Identifying Lot No. On Stamp Cylinder Head Gasket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

The cylinder head bolts should be tightened in 2 successive steps.

1. Apply a light coat of engine oil to the threads of the cylinder head bolts.
2. Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration (Procedure "A").

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

   Fig 2: Identifying Cylinder Head Sub-Assembly Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mark the front of the cylinder head bolts with paint.
4. Retighten the cylinder head bolts 90° in the same sequence as procedure "A".
5. Check that the paint mark of each bolt is at a 90° angle to the front.
6. Install the water bypass pipe No. 1 with the bolt.

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

7. Connect the heater inlet water hose.
8. Connect the radiator hose inlet.
9. Connect the engine wire.
   Fig 3: Tightening Cylinder Head Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Connect the heated oxygen sensor connector.
   2. Install the clamp onto the clamp bracket.
   3. Connect the 2 engine earth.

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

   4. Connect the radio setting condenser connector.
   5. Connect the engine coolant temperature sensor connector.
   6. Connect the camshaft position sensor connector.
   7. Connect the knock sensor connector.
   8. Connect the crankshaft position sensor connector.
   9. Connect the oil pressure switch connector.
   10. Connect the 4 fuel injector connectors.

1. Connect the fuel tube sub-assembly (See INSTALLATION ).

1. Apply a light coat of engine oil to the camshaft journals.
2. Place the 2 camshafts on the cylinder head as shown in the illustration.
   Fig 4: Identifying Camshafts On Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then tighten the bolts.

   Torque: Bearing cap No. 1 

   23 N*m (235 kgf*cm, 17 ft.*lbf) 

   Bearing cap No. 3 

   13 N*m (133 kgf*cm, 10 ft.*lbf) 

   Fig 5: Checking Sequence Order Of Bearing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Bearing cap No. 1 is used for bearings numbered from 9 to 11 in the illustration.
   • Bearing cap No. 3 is used for bearings numbered from 1 to 8 in the illustration.

1. Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.
2. Install the camshaft timing oil control valve with the bolt.

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

1. Install a new gasket onto the intake manifold.
   Fig 6: Locating Camshaft Timing Oil Control Valve Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the intake manifold and throttle body with the 2 brackets, 4 bolts and 2 nuts.

   Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

3. Connect the union to check valve hose to the intake manifold.
4. Connect the water bypass hose No. 2 to the throttle body.
5. Connect the water bypass hose to the throttle body.
6. Connect the throttle control motor connector.
7. Install the 2 clamps of the engine wire onto the clamp bracket.

Fig 7: Locating Intake Manifold And Throttle Body Bolts And Nuts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the air cleaner hose No. 1 with the 2 hose clamp bolts.
2. Connect the fuel vapor feed hose No. 3 to the VSV.
3. Connect the fuel vapor feed hose No. 1 to the VSV.
4. Install the clamp of the engine wire.
5. Connect the VSV connector.

1. Install the chain vibration damper No. 1 (See INSTALLATION ).

1. Install the chain sub-assembly (See )REMOVAL .

   SST 09223-22010 

1. Install the chain tensioner slipper (See INSTALLATION ).

1. Install the crankshaft position sensor plate No. 1 (See INSTALLATION ).

1. Install the timing chain or belt cover oil seal (See INSTALLATION ).

   SST 09223-22010 

1. Install the timing chain or belt cover sub-assembly (See INSTALLATION ).

1. Install the chain tensioner assembly No. 1 (See INSTALLATION ).

1. Install the crankshaft pulley (See INSTALLATION ).

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

1. Install the crankshaft position sensor (See INSTALLATION ).

1. Install the water pump assembly (See INSTALLATION ).

1. Install the engine mounting bracket RH (See INSTALLATION ).

1. Install the V-ribbed belt tensioner assembly (See INSTALLATION ).

1. Install the cylinder head cover sub-assembly (See INSTALLATION ).

1. Install the ignition coil assembly (See INSTALLATION ).

1. Install the engine mounting insulator RH (See INSTALLATION ).

1. Install the generator assembly (See INSTALLATION ).

1. Install the vane pump assembly (See INSTALLATION ).

1. Install the manifold stay (See REMOVAL ).

1. Install the exhaust pipe assembly front (See INSTALLATION ).

1. Add the engine coolant (See ON-VEHICLE INSPECTION ).

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

1. Check for the engine coolant leaks (See ON-VEHICLE INSPECTION ).

1. Inspect the ignition timing (See ENGINE ).

   SST 09843-18040 

1. Inspect the engine idling speed (See ENGINE ).

1. Inspect the compression (See ENGINE ).

   SST 09992-00500 

1. Inspect the CO/HC (See ENGINE ).

1. Install the cylinder head cover No. 2 (See INSTALLATION ).

Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)