Installation
2AZ-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION
INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
(a) Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.
NOTICE:
- Remove any oil from the contact surfaces.
- Make sure that the gasket is installed in the correct direction.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Install the cylinder head on the cylinder block.
HINT: The cylinder head bolts are tightened in 2 progressive steps.
(b) Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.
(c) Install the bolts and plate washers to the cylinder head.
NOTICE: Do not drop the washers into the cylinder head.
(d) 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 Nm (714 kgf-cm, 52ft-lbf)
(e) Mark the front side of the cylinder head bolt with paint.
(f) Retighten the cylinder head bolts 90° in the sequence shown in the illustration.
(g) Check that the paint mark is now at a 90° angle to the front.
3. CONNECT ENGINE WIRE
(a) Connect the ground cable with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74in-lbf)
(b) Connect the camshaft position sensor connector.
(c) Connect the engine coolant temperature sensor connector.
(d) Connect the engine oil pressure switch connector.
(e) Connect the radio setting condenser connector.
4. CONNECT RADIATOR HOSE INLET Installation
5. INSTALL NO. 2 CAMSHAFT BEARING
(a) Install the No. 2 camshaft bearing.
6. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
7. INSTALL CAMSHAFTS
(a) Apply a light coat of engine oil to the camshaft journals.
(b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.
(c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
(d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
(e) Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.
No. 1 and No. 2 bearing caps - Torque: 30 Nm (301 kgf-cm, 22ft-lbf)
No. 3 bearing cap - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
8. INSTALL CHAIN SUB-ASSEMBLY
HINT: Installation.
9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Installation
10. INSTALL NO. 2 MANIFOLD STAY Installation
11. INSTALL MANIFOLD STAY Installation
12. INSTALL OIL LEVEL GAUGE GUIDE Installation
13. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
14. INSTALL GENERATOR ASSEMBLY Installation
15. INSTALL V-RIBBED BELT Installation
16. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH Installation
17. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY Installation
18. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation
19. INSTALL FRONT EXHAUST PIPE ASSEMBLY
HINT: Installation.
20. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR Installation
21. INSTALL INTAKE AIR CONTROL VALVE (For PZEV) Installation
22. INSTALL INTAKE MANIFOLD Installation
23. INSTALL FUEL DELIVERY PIPE WITH INJECTOR Installation
24. CONNECT FUEL TUBE SUB-ASSEMBLY Installation
25. INSTALL THROTTLE BODY ASSEMBLY Installation
26. INSTALL BATTERY Installation
27. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
28. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
29. INSTALL AIR CLEANER INLET ASSEMBLY Installation
30. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY Installation
31. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
HINT: Installation.
32. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Installation
33. ADD ENGINE OIL
34. INSPECT FOR FUEL LEAK Testing and Inspection
35. ADD COOLANT Testing and Inspection
36. INSPECT FOR COOLANT LEAK Testing and Inspection
37. INSPECT FOR ENGINE OIL LEAK
38. INSPECT FOR EXHAUST GAS LEAK
39. INSPECT IGNITION TIMING Engine
40. INSPECT IDLE SPEED Engine
41. INSPECT COMPRESSION Engine
42. INSPECT CO/HC Engine
43. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
44. INSTALL FRONT FENDER APRON SEAL RH
45. INSTALL ENGINE UNDER COVER LH
46. INSTALL ENGINE UNDER COVER RH
47. INSTALL FRONT WHEEL RH Installation