Installation

2AZ-FXE 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 bolts 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 from 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 CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the camshaft.





(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 cap - Torque: 30 Nm (301 kgf-cm, 22ft-lbf)
No. 1 and No. 2 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 V-RIBBED BELT Installation
15. INSTALL V-RIBBED BELT TENSIONER COVER SUB-ASSEMBLY 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 MANIFOLD Installation
22. INSTALL FUEL DELIVERY PIPE WITH INJECTOR Installation
23. CONNECT FUEL TUBE SUB-ASSEMBLY Installation
24. INSTALL THROTTLE BODY ASSEMBLY Installation
25. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
26. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
27. INSTALL AIR CLEANER INLET ASSEMBLY Installation
28. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY Installation
29. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
30. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
31. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
32. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation
33. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation
34. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
35. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation
37. INSTALL LUGGAGE TRIM SERVICE HOLE COVER
38. ADD ENGINE OIL
39. INSPECT FOR FUEL LEAK Testing and Inspection
40. ADD COOLANT (for Engine) Testing and Inspection
41. INSPECT FOR COOLANT LEAK (for Engine) Testing and Inspection
42. INSPECT FOR ENGINE OIL LEAK
43. INSPECT FOR EXHAUST GAS LEAK
44. INSPECT IGNITION TIMING Engine
45. INSPECT IDLE SPEED Engine
46. INSPECT COMPRESSION Engine
47. INSPECT CO/HC Engine
48. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
49. INSTALL FRONT FENDER APRON SEAL RH
50. INSTALL ENGINE UNDER COVER LH
51. INSTALL ENGINE UNDER COVER RH
52. INSTALL FRONT WHEEL RH Installation
53. PERFORM INITIALIZATION
(a) Perform initialization procedure Repair Instruction - Initialization.
HINT: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.