Cylinder Head, Intake Manifold, Exhaust Manifold: Installation

1. Install 4 new injector vibration insulators onto the cylinder head.
   Fig 1: Identifying Injector Vibration Insulators Onto Cylinder Head

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1. Install the 2 delivery pipe No. 1 spacers onto the cylinder head.
   NOTE: Install the delivery pipe No. 1 spacer in the correct direction.
   Fig 2: Identifying Delivery Pipe No. 1 Spacers Onto Cylinder Head

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1. Provisionally install the fuel delivery pipe sub-assembly with the 4 fuel injectors using the 3 bolts.
   NOTE:

   • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
   • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub-assembly.
     Fig 3: Locating Fuel Delivery Pipe Sub-Assembly With Fuel Injectors

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2. Tighten the 3 bolts to the specified torque.

   Torque: 19 N*m (194 kgf*cm, 14 ft.lbf) for bolt A 

   9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt B 

   Fig 4: Locating Fuel Delivery Pipe Sub-Assembly And Bolts

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1. Install the harness bracket with the bolt.

   Torque: 13 N*m (131 kgf*cm, 9.5 ft.*lbf) 

   Fig 5: Locating Harness Bracket With Bolt

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1. Install the water bypass hose.
   Fig 6: Locating Water Bypass Hose

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1. Provisionally install the engine coolant temperature sensor through a new gasket.
2. Using SST, tighten the engine coolant temperature sensor.

   SST 09817-33190 

   Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

   Fig 7: Identifying Engine Coolant Temperature Sensor Connector With SST

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1. Apply a light coat of engine oil to the O-ring on the camshaft position sensor.
2. Install the camshaft position sensor with the bolt.

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

   NOTE: Do not twist the O-ring.
   Fig 8: Locating Camshaft Position Sensor And Bolt

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1. Install the booster vacuum tube with the 2 bolts.

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

   Fig 9: Locating Booster Vacuum Tube And Bolt

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1. Install the harness bracket with the bolt.

   Torque: 13 N*m (131 kgf*cm, 9.5 ft.*lbf) 

   Fig 10: Locating Harness Bracket And Bolt

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1. Using several steps, install a new exhaust manifold gasket and the exhaust manifold with the 3 bolts and 2 nuts in the sequence shown in the illustration.

   Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

   Fig 11: Locating Exhaust Manifold With Bolts And Nuts

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1. Install exhaust manifold heat insulator No. 1 with the 4 bolts.

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

   Fig 12: Locating Exhaust Manifold Heat Insulator With Bolt

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

   • Remove any oil from the contact surfaces.
   • Check the mounting orientation of the cylinder head gasket.
   • Place the cylinder head on the cylinder head gently in order not to damage the gasket.
     Fig 13: Locating Cylinder Block With Lot No

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HINT:

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. Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench, in the sequence shown in the illustration.

   Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

3. Mark the front of the cylinder head bolt with paint.
   Fig 14: Identifying Cylinder Head Bolt Sequence

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4. Retighten the cylinder head bolts 90° and then an additional by 90° as shown in the illustration.
5. Check that the paint mark is now at a 180° angle from the front.
   Fig 15: Identifying Paint Mark Angle From Front

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6. Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as shown in the illustration.

   Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent 

   NOTE:

   • Remove any oil from the contact surfaces.
   • Install the oil pump assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.
     Fig 16: Identifying Cylinder Head Gasket Dimension

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1. Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then provisionally tighten the 19 bolts.
   Fig 17: Identifying Camshaft Tightening Sequence

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2. Uniformly tighten the bolts in several steps in the sequence shown in the illustration and install camshaft bearing cap No. 1 and camshaft bearing cap No. 2.

   Torque: Camshaft bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf) Camshaft bearing cap No. 2 13 N*m (129 kgf*cm, 9.4 ft.*lbf) 

   NOTE: Tighten each bolt uniformly while keeping the camshaft level.

1. Install the manifold support bracket with the 3 bolts.

   Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) 

   Fig 19: Locating Manifold Support Bracket

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1. Using vernier calipers, measure the free length of the compression spring.

   Minimum length: 40.5 mm (1.594 in.) 

   If the length is not as specified, replace the compression spring.

   Fig 20: Measuring Free Length Of Compression Spring

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2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.
   NOTE:

   • Install the exhaust pipe gasket in the correct direction.
   • Do not damage the outer surface of the exhaust pipe gasket.
   • Do not reuse the exhaust pipe gasket.
   • Do not push in the gasket with the exhaust pipe when installing.
     Fig 21: Identifying Wooden Block And Gasket

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3. Install the exhaust front pipe assembly with the 2 compression springs and 2 bolts.

   Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

   Fig 22: Locating Exhaust Pipe Assembly With Bolt

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1. Connect the wire harness with the 2 bolts.

   Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

   Fig 23: Locating Wire Harness Bolt

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1. Install water bypass pipe No. 1 with the bolt.

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

   Fig 24: Locating Separate Water Bypass Pipe With Bolt

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1. Connect heater water inlet hose A.
   Fig 25: Locating Heater Water Inlet Hose

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1. Connect the heated oxygen sensor connector.
2. Install the sensor bracket with the bolt.
   Fig 26: Locating Heated Oxygen Sensor Connector

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1. Connect the engine coolant temperature sensor connector.
   Fig 27: Locating Engine Coolant Temperature Sensor Connector

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1. Connect the camshaft position sensor connector.
   Fig 28: Locating Camshaft Position Sensor Connector

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1. Connect the booster vacuum tube.

1. Apply engine oil to a new O-ring.
2. Install the oil level gauge guide with the bolt through a new O-ring.

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

3. Install the wire harness.

1. Install a new gasket onto the intake manifold.
   Fig 30: Locating Wire Harness Clamp And Bolt

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2. Install the intake manifold with the 3 bolts and 2 nuts.

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

   Fig 31: Locating Intake Manifold Bolts And Nuts

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3. Connect the 3 wire harness clamps shown in the illustration.

1. Connect the union to connector tube hose.
   Fig 33: Locating Union To Connector Tube Hose

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1. Connect the ventilation hose.
   Fig 34: Identifying Ventilation Hose

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1. Install the throttle with motor body connector bracket with the nut.

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

2. Connect the throttle with motor body connector.
3. Connect the wire harness clamp.
   Fig 35: Locating Throttle With Motor Body Connector

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1. Connect the water bypass hose.
   Fig 36: Locating Water Bypass Hose

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1. Connect water bypass hose No. 2.
   Fig 37: Locating Water Bypass Hose

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1. Install the water filler sub-assembly with the 2 nuts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

2. Connect radiator hose No. 1 to the cylinder head.
   Fig 38: Locating Water Filler Sub-Assembly

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1. Connect the reserve tank hose.
   Fig 39: Locating Reserve Tank Hose

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1. Connect radiator hose No. 3.