Cylinder Head: Installation

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INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Place a new gasket on the cylinder head.
  NOTE: Be careful of the installation direction.
  
  Fig 1: Placing Gasket On Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold to the cylinder head with 8 new nuts in the order shown in Fig 2.
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
  
  Fig 2: Installing Exhaust Manifold To Cylinder In Ordered Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the heat insulator with the 4 bolts in the order shown in Fig 3.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 3: Installing Heat Insulator In Ordered Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Place a new gasket on the cylinder head.
  NOTE: Be careful of the installation direction.
  
  Fig 4: Placing Gasket On Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold with 8 new nuts in the order shown in Fig 5.
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
  
  Fig 5: Installing Exhaust Manifold In Ordered Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the heat insulator with the 4 bolts in the order shown in Fig 6.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 6: Installing Heat Insulator In Ordered Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD GASKET LH
1. Place a new cylinder head gasket in position on the cylinder block.
  HINT:
  
  The rear side of the cylinder head gasket has marks so that the bank 1 and bank 2 can be distinguished. A "L" mark is on the bank 1 gasket.
  
  NOTE: Be careful of the installation direction.
  
  Fig 7: Installing Cylinder Head Gasket LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD LH
1. Check that the timing mark of the crankshaft timing pulley is in the position shown in Fig 8, and that the piston is below the TDC/compression.
  
  Fig 8: Checking Timing Mark Is In Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cylinder head together with the exhaust manifold to the cylinder block.
3. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
4. Put the washers on the bolts, and insert the bolts with washers into the cylinder head.
  NOTE: Be careful not to drop washers into the cylinder head.
5. Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in Fig 9.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
  
  Fig 9: Tightening Cylinder Head Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Mark the front of the cylinder head bolt's head with paint.
  
  Fig 10: Marking Front Of Cylinder Head Bolt With Paint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Retighten the cylinder head bolts by 90° in the numerical order shown in Fig 9 .
8. Retighten the cylinder head bolts by an additional 90°.
9. Check that the painted mark is now at a 180° angle to the front.
INSTALL CYLINDER HEAD GASKET RH
1. Place a new cylinder head gasket in position on the cylinder block.
  HINT:
  
  The rear side of the cylinder head gasket has marks so that the bank 1 and bank 2 can be distinguished. A "R" mark is on the bank 2 gasket.
  
  NOTE: Be careful of the installation direction.
  
  Fig 11: Installing Cylinder Head Gasket RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD RH
1. Check that the timing mark of the crankshaft timing pulley is in the position shown in Fig 12, and that the piston is below the TDC/compression.
  
  Fig 12: Checking Timing Mark Of Crankshaft Timing Pulley Is In Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cylinder head together with the exhaust manifold to the cylinder block.
3. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
4. Put the washers on the bolts, and insert the bolts with washers into the cylinder head.
  NOTE: Be careful not to drop washers into the cylinder head.
5. Install and uniformly tighten the 10 cylinder head bolts, and plate washers in the sequence shown in Fig 13.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
  
  Fig 13: Tightening Cylinder Head Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Mark the front of the cylinder head bolt's head with paint.
  
  Fig 14: Marking Front Of Cylinder Head With Paint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Retighten the cylinder head bolts by 90° in the numerical order shown in Fig 13 .
8. Retighten the cylinder head bolts by an additional 90°.
9. Check that the painted mark is now at a 180° angle to the front.
INSTALL CAMSHAFT (for Bank 1)
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
1. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
2. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the No. 3 and No. 4 camshafts.
  
  Fig 15: Aligning Timing Marks Of Camshaft Drive & Driven Main Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing to the camshaft housing plug.
  - Remove the old packing (FIPG) material.
  - Apply seal packing to the housing plug as shown in Fig 16.
    Seal packing: Part No. 08826-00080 or equivalent
    
    Fig 16: Applying Seal Packing To Camshaft Housing Plug
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the camshaft housing plug to the cylinder head as shown in Fig 17.
  
  Fig 17: Installing Camshaft Housing Plug To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the oil control valve filter to the cylinder head.
  NOTE: Be careful of the installation direction.
6. Apply seal packing to the front bearing cap.
  - Remove any old packing (FIPG) material.
  - Apply seal packing to the bearing cap as shown in Fig 18.
    - Seal packing: Part No. 08826-00080 or equivalent
    - Standard seal diameter: 1.5 to 2.0 mm (0.059 to 0.079 in.)
    NOTE: Do not apply seal packing to the front bearing cap grooves.
    
    Fig 18: Applying Seal Packing To Bearing Cap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the front bearing cap.
  HINT:
  
  Installing the front bearing cap will determine the thrust portion of the camshaft.
8. Install the other bearing caps in the sequence shown in Fig 19, with the arrow mark facing forward.
  
  Fig 19: Installing Bearing Caps In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Push in the camshaft oil seal.
  
  Fig 20: Pushing In Camshaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install 4 new seal washers to the bearing cap bolts (1 to 4).
11. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 to 22).
  NOTE: Do not apply engine oil under the heads of the bearing cap bolts (1 to 4).
12. Install the oil feed pipe and the 22 bearing cap bolts.
13. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in Fig 21 .
  Torque:
  - 7.5 N*m (76 kgf*cm, 66 ft.*lbf) for bolts 21 and 22
  - 16 N*m (163 kgf*cm, 12 in.*lbf) for other bolts
  Fig 21: Installing Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Remove the service bolt.
  
  Fig 22: Removing Service Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR TIMING BELT PLATE LH
1. Install the rear timing belt plate with the bolt.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL REAR NO. 2 TIMING BELT PLATE LH
1. Install the rear timing belt plate with the 2 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL CAMSHAFT TIMING PULLEY LH
1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Temporarily install the 4 bolts of the camshaft timing pulley.
3. Hold the camshaft timing pulley with SST, and tighten the pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Torque: 8.1 N*m (83 kgf*cm, 72 in.*lbf)
  
  Fig 23: Holding Camshaft Timing Pulley With SST & Tightening Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT (for Bank 2)
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
1. Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
2. Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the No. 1 and No. 2 camshafts.
3. Set the timing mark (1 dot mark each) of the camshaft drive and driven main gears at an angle of approximately 10°.
  
  Fig 24: Setting Timing Mark Of Camshaft Drive & Driven Main Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply seal packing to the camshaft housing plug.
  - Remove the old packing (FIPG) material.
  - Apply seal packing to the housing plug as shown in Fig 25.
    Seal packing: Part No. 08826-00080 or equivalent
    
    Fig 25: Applying Seal Packing To Camshaft Housing Plug
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the camshaft housing plug to the cylinder head as shown in Fig 26.
6. Install the oil control valve filter to the cylinder head.
  NOTE: Be careful of the installation direction.
7. Apply seal packing to the front bearing cap.
  - Remove any old packing (FIPG) material.
  - Apply seal packing to the bearing cap as shown in Fig 27.
    Seal packing: Part No. 08826-00080 or equivalent
    
    Standard seal diameter: 1.5 to 2.0 mm (0.059 to 0.079 in.)
    
    NOTE: Do not apply seal packing to the front bearing cap grooves.
  Fig 27: Applying Seal Packing To Front Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the front bearing cap.
  HINT:
  
  Installing the front bearing cap will determine the thrust portion of the camshaft.
9. Install the other bearing caps in the sequence shown in Fig 28, with the arrow mark facing forward.
  
  Fig 28: Installing Bearing Caps In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Push in the camshaft oil seal.
  
  Fig 29: Pushing In Camshaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Install 4 new seal washers to the bearing cap bolts (1 to 4).
  
  Fig 30: Installing Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 to 22).
  NOTE: Do not apply engine oil under the heads of the bearing cap bolts (1 to 4).
13. Install the oil feed pipe and the 22 bearing cap bolts.
14. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in Fig 30 .
  Torque:
  - 7.5 N*m (76 kgf*cm, 66 ft.*lbf) for bolts 21 and 22
  - 16 N*m (163 kgf*cm, 12 in.*lbf) for other bolts
15. Remove the service bolt.
Fig 31: Removing Service Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR TIMING BELT PLATE RH
1. Install the rear timing belt plate with the bolt.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL REAR NO. 2 TIMING BELT PLATE RH
1. Install the rear timing belt plate with the 2 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL CAMSHAFT TIMING PULLEY RH
1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Temporarily install the 4 bolts of the camshaft timing pulley.
3. Hold the camshaft timing pulley with SST, and tighten the pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Torque: 8.1 N*m (83 kgf*cm, 72 in.*lbf)
  
  Fig 32: Installing Camshaft Timing Pulley RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT
1. Install the timing belt (see INSTALLATION ).
ADJUST VALVE CLEARANCE
1. Adjust valve the clearance (see VALVE CLEARANCE ).
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Remove any old packing (FIPG) material.
2. Apply seal packing to the cylinder heads as shown in Fig 33.
  Seal packing: Part No. 08826-00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 5 minutes after applying seal packing.
  - Do not start the engine within 2 hours after applying seal packing.
  Fig 33: Applying Seal Packing To Cylinder Heads
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the gasket to the cylinder head cover.
4. Install the 9 seal washers to the bolts.
5. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 34: Tightening Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install a new gasket and the oil filler cap housing with the 2 nuts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 35: Installing Gasket & Oil Filler Cap Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
1. Remove any old packing (FIPG) material.
2. Apply seal packing to the cylinder heads as shown in Fig 36.
  Seal packing: Part No. 08826-00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 5 minutes after applying seal packing.
  - Do not start the engine within 2 hours after applying seal packing.
  Fig 36: Applying Seal Packing to Cylinder Heads
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the gasket to the cylinder head cover.
4. Install the 9 seal washers to the bolts.
5. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 37: Tightening Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG
Torque: 17.5 N*m (178 kgf*cm, 13 ft.*lbf)
INSTALL IGNITION COIL
1. Install the 8 ignition coils with the 8 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL NO. 1 ENGINE HANGER
1. Install the engine hanger with the 2 bolts.
  Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
  
  Fig 38: Installing No. 1 Engine Hanger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 ENGINE HANGER
1. Install the engine hanger with the 2 bolts.
  Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
  
  Fig 39: Installing No. 2 Engine Hanger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL DIPSTICK GUIDE WITH DIPSTICK
1. Install a new O-ring to the dipstick guide.
2. Install the dipstick guide with the bolt.
  Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
INSTALL REAR WATER BY-PASS JOINT
1. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
  
  Fig 40: Installing Rear Water By-Pass Joint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
1. Install a new O-ring to the water by-pass pipe.
2. Apply soapy water to the O-ring.
3. Push in the water by-pass pipe end into the pipe hole of the water pump.
4. Install the water by-pass pipe with the bolt.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL FRONT WATER BY-PASS JOINT
1. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
2. Connect the ECT connector.
  
  Fig 41: Installing Front Water By-Pass Joint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER INLET HOUSING
1. Install a new O-ring to the water inlet housing.
2. Apply soapy water to the O-ring.
3. Apply seal packing to the sealing groove of the inlet housing as shown in Fig 42 .
  Seal packing: Part No. 08826-00100 or equivalent
  
  Standard seal diameter: 2 to 3 mm (0.08 to 0.12 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the water inlet housing within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing it.
  Fig 42: Applying Seal Packing to Sealing Groove of Inlet Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the water inlet and housing with the 2 bolts. Alternately tighten the bolts.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL STARTER ASSEMBLY (See INSTALLATION )
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) (See INSTALLATION )
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) (See INSTALLATION )
INSTALL KNOCK SENSOR (See INSTALLATION )
INSTALL VVT SENSOR (for Bank 1) (See INSTALLATION )
INSTALL VVT SENSOR (for Bank 2) (See INSTALLATION )
INSTALL CAMSHAFT POSITION SENSOR (See INSTALLATION )
INSTALL AIR PUMP ASSEMBLY (See INSTALLATION )
INSTALL AIR SWITCHING VALVE ASSEMBLY (See REASSEMBLY )
INSTALL INTAKE MANIFOLD ASSEMBLY (See INSTALLATION )
INSTALL FRONT EXHAUST PIPE LH (See INSTALLATION )
INSTALL FRONT EXHAUST PIPE RH (See INSTALLATION )
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION )
INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION )
ADD ENGINE COOLANT (See COOLANT )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
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.