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Cylinder Head: Installation

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  1. INSTALL CYLINDER HEAD GASKET 
    1. Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.
      NOTE:
      • Remove any oil from contact surface.
      • Be careful of the installation direction.
  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY 
    1. Place the cylinder head on the head gasket.
      Fig 1: Installing Cylinder Head Gasket
      G04484804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Place the cylinder head gently in order to avoid damaging the gasket.
    2. Install the cylinder head bolts.
      NOTE: The cylinder head bolts are tightened in 2 successive steps.
      1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
      2. Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.

        Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 

        Fig 2: Installing Cylinder Head Bolts
        G04484805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mark the front of the cylinder head bolts with paint.
    4. Retighten the cylinder head bolts by 90° as shown in the illustration.
    5. Check that the paint mark is now at a 90° angle to the front.
      Fig 3: Retightening Cylinder Head Bolts By 90°
      G04484806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
    2. Turn the camshaft timing gear as shown in Fig 4 while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
      NOTE: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).
      Fig 4: Turning Camshaft Timing Gear
      G04484807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that there is no clearance between the gear fringe and camshaft.
    4. Tighten the flange bolt with the camshaft timing gear fixed in place.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

    5. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
  4. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET 
    1. Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      NOTE: Do not damage the camshaft.
      Fig 5: Installing Camshaft Timing Sprocket With Bolt
      G04484808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL CAMSHAFT 
    1. Apply a light coat of engine oil to the journal portion of the camshaft.
    2. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.
      Fig 6: Identifying Cam Lobes Facing Directions For Installation
      G04484809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Examine the front marks and numbers, and check that the order is as shown in Fig 7. Then install the bearing caps onto the cylinder head.
    4. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
      Fig 7: Installing Bearing Caps Onto Cylinder Head
      G04484810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.

      Torque: 

      29.5 N*m (301 kgf*cm, 22 ft.*lbf) for No. 1 and No. 2 bearing cap 

      9.0 N*m (92 kgf*cm, 80 in.*lbf) for No. 3 bearing cap 

      NOTE: Install the camshaft with the timing mark of the camshaft timing gear on top.
      Fig 8: Tightening Bearing Cap Bolts In Sequence
      G04484811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 CHAIN VIBRATION DAMPER (see appropriate step(s) under  INSTALLATION  ) 
  7. INSTALL CHAIN SUB-ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  8. INSTALL CHAIN TENSIONER SLIPPER (see appropriate step(s) under  INSTALLATION  ) 
  9. INSTALL TIMING CHAIN GUIDE (see appropriate step(s) under  INSTALLATION  ) 
  10. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (see appropriate step(s) under  INSTALLATION  ) 
  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  13. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  14. INSTALL ENGINE MOUNTING BRACKET RH (see appropriate step(s) under  INSTALLATION  ) 
  15. INSTALL CRANKSHAFT PULLEY (see appropriate step(s) under  INSTALLATION  ) 
  16. INSTALL OIL PAN SUB-ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  17. INSTALL CRANKSHAFT POSITION SENSOR (see appropriate step(s) under  INSTALLATION  ) 
  18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  19. INSTALL SPARK PLUG (see appropriate step(s) under  ADJUSTMENT  ) 
  20. INSTALL IGNITION COIL ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  21. INSTALL IDLER PULLEY (see appropriate step(s) under  INSTALLATION  ) 
  22. INSTALL ENGINE MOUNTING INSULATOR RH (see appropriate step(s) under  INSTALLATION  ) 
  23. INSTALL RADIATOR RESERVOIR (see appropriate step(s) under  INSTALLATION  ) 
  24. INSTALL GENERATOR ASSEMBLY (see  INSTALLATION  ) 
  25. INSTALL FAN AND GENERATOR V BELT (see appropriate step(s) under  INSTALLATION  ) 
  26. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH (see appropriate step(s) under  INSTALLATION  ) 
  27. CONNECT ENGINE WIRE 
    1. Connect the ground cable with the bolt.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

    2. Connect the camshaft position sensor connector.
    3. Connect the engine coolant temperature sensor connector.
    4. Connect the engine oil pressure switch connector.
    5. Connect the radio setting condenser connector.
    6. Connect the heater water inlet hose.
      Fig 9: Connecting Camshaft Position Sensor Connector
      G04484812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the hose to the cylinder head.
      Fig 10: Connecting Hose To Cylinder Head
      G04484813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 
    1. Install a new gasket onto the cylinder head.
    2. Temporarily tighten the exhaust manifold converter with the 5 nuts.
    3. Tighten the 5 nuts in the sequence shown in the illustration.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

      Fig 11: Tightening Nuts In Sequence
      G04484814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the air-fuel ratio sensor connector.
      Fig 12: Connecting Air-Fuel Ratio Sensor Connector
      G04484815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the exhaust manifold heat insulator with the 4 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      Fig 13: Installing Exhaust Manifold Heat Insulator With Bolts
      G04484816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL NO. 2 MANIFOLD STAY 
    1. Install the stay with the bolt and nut.

      Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

      Fig 14: Installing Stay With Bolt And Nut
      G04484817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL MANIFOLD STAY 
    1. Install the stay with the bolt and nut.

      Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

  34. INSTALL FRONT EXHAUST PIPE (see appropriate step(s) under  INSTALLATION  ) 
  35. INSTALL OIL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring and install it onto the guide.
      Fig 15: Installing Stay With Bolt And Nut
      G04484818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the guide with the bolt.

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

  36. INSTALL OIL DIPSTICK 
  37. INSTALL INTAKE MANIFOLD INSULATOR (see appropriate step(s) under  INSTALLATION  ) 
  38. INSTALL INTAKE MANIFOLD (see appropriate step(s) under  INSTALLATION  ) 
  39. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
    Fig 16: Installing O-Ring
    G04484819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL THROTTLE BODY (see appropriate step(s) under  INSTALLATION  ) 
  41. INSTALL AIR CLEANER CAP (see appropriate step(s) under  INSTALLATION  ) 
  42. ADD ENGINE OIL (see appropriate step(s) under  REPLACEMENT  ) 
  43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  44. CHECK FOR FUEL LEAKS 
  45. ADD ENGINE COOLANT (see appropriate step(s) under  COOLANT  ) 
  46. CHECK FOR ENGINE COOLANT LEAKS 
    1. Check for engine coolant leaks (see appropriate step(s) under COOLING SYSTEM ).
  47. CHECK FOR ENGINE OIL LEAKS 
  48. CHECK FOR EXHAUST GAS LEAKS 
  49. INSPECT IGNITION TIMING (see appropriate step(s) under  ON-VEHICLE INSPECTION  ) 
  50. INSPECT ENGINE IDLING SPEED (see appropriate step(s) under  ON-VEHICLE INSPECTION  ) 
  51. INSPECT COMPRESSION (see appropriate step(s) under  ON-VEHICLE INSPECTION  ) 
  52. INSPECT CO/HC (see appropriate step(s) under  ON-VEHICLE INSPECTION  ) 
  53. INSTALL NO. 1 ENGINE COVER (see appropriate step(s) under  INSTALLATION  ) 
  54. INSTALL FRONT FENDER APRON RH 
  55. INSTALL NO. 1 ENGINE UNDER COVER 
  56. INSTALL FRONT WHEEL RH 
  57. INSTALL RADIATOR SUPPORT OPENING COVER 
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