Installation

2ZR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: 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 surface.
- Make sure that the gasket is installed in the correct direction.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
HINT: The cylinder head bolts are tightened in 2 progressive steps.

(a) 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.
(b) Install the bolts and plate washers to the cylinder head.
NOTE: Do not drop the washers into the cylinder head.

(c) Using several steps, uniformly install and tighten the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

(d) Mark the front side of the cylinder head bolts with paint.
(e) Retighten the cylinder head bolts an additional 90°, then once more 45° as shown in the illustration.
(f) Check that the paint mark is now at a 135° angle to the front.
3. INSTALL VALVE LASH ADJUSTER ASSEMBLY Reassembly
4. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Reassembly
5. INSTALL NO. 1 CAMSHAFT BEARING Installation
6. INSTALL NO. 2 CAMSHAFT BEARING Installation
7. INSTALL NO. 2 CAMSHAFT Installation
8. INSTALL CAMSHAFT Installation
9. INSTALL CAMSHAFT BEARING CAP Installation
10. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY Installation
11. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation
12. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Installation
13. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)
14. INSTALL NO. 2 CHAIN VIBRATION DAMPER Installation
15. INSTALL CHAIN SUB-ASSEMBLY
(a) Check the No. 1 cylinder TDC/compression.
(1) Temporarily tighten the crankshaft pulley bolt.

(2) Turn the crankshaft counterclockwise to position the timing gear key to the top.
(3) Remove the crankshaft pulley bolt.

(4) Check the timing marks on each camshaft timing gear.

(b) Align the mark plate (orange) with the timing mark of the No. 2 camshaft as shown in the illustration and install the chain.

HINT:
- Be sure to position the mark plate at the front of the engine.
- The mark plate on the camshaft side is colored orange.
- Do not pass the chain around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
- Pass the chain through the No. 1 vibration damper.

(d) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark.

HINT:
- Be sure to position the mark plate at the front of the engine.
- The mark plate on the camshaft side is colored orange.

(e) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.
HINT: To tension the chain, slowly turn the camshaft timing gear assembly clockwise to prevent the chain from being misaligned.

(f) Align the mark plate (yellow) and timing mark and install the chain to the crankshaft timing gear.
HINT: The mark plate on the crankshaft side is colored yellow.

(g) Recheck each timing mark at TDC/compression.

16. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.
17. INSTALL TIMING CHAIN COVER OIL SEAL Reassembly
18. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
19. INSTALL CRANKSHAFT PULLEY Installation
20. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly
21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly
22. INSTALL RADIO SETTING CONDENSER Installation
23. INSTALL THERMOSTAT Installation
24. INSTALL INLET WATER Installation
25. INSTALL INLET WATER HOSE Installation
26. INSTALL WATER BY-PASS HOSE Installation
27. INSTALL NO. 1 WATER BY-PASS PIPE Installation
28. CONNECT NO. 3 WATER BY-PASS HOSE Installation
29. INSTALL VENTILATION HOSE Installation
30. INSPECT EXHAUST MANIFOLD Engine Unit
31. INSTALL EXHAUST MANIFOLD Installation
32. INSTALL MANIFOLD STAY Installation
33. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
34. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY Installation
35. INSTALL IGNITION COIL ASSEMBLY Installation
36. INSTALL FUEL INJECTOR ASSEMBLY Installation
37. INSTALL NO. 1 DELIVERY PIPE SPACER Installation
38. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
39. INSTALL FUEL TUBE SUB-ASSEMBLY Installation
40. INSTALL INTAKE MANIFOLD Installation
41. REMOVE ENGINE STAND Installation
42. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT: Installation.