Installation

2AZ-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: INSTALLATION

INSTALLATION

1. INSTALL CYLINDER HEAD GASKET

(a) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp facing upward.

NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Place the cylinder head on the cylinder head gasket.
NOTE: Place the cylinder head gently in order to avoid damaging the cylinder head gasket.

(b) 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 Nm (714 kgf-cm, 52 ft-lbf)

(c) Mark the front of the cylinder head bolts with paint.
(d) Further tighten the cylinder head bolts 90° as shown in the illustration.
(e) Check that the paint mark is now at a 90° angle to the front.
3. INSTALL NO. 1 CAMSHAFT BEARING Reassembly
4. INSTALL NO. 2 CAMSHAFT BEARING Reassembly
5. INSTALL CAMSHAFT Reassembly
6. INSTALL NO. 2 CAMSHAFT Reassembly
7. CONNECT INLET HEATER WATER HOSE Installation
8. CONNECT OUTLET HEATER WATER HOSE Installation
9. CONNECT NO. 1 RADIATOR HOSE Installation
10. CONNECT ENGINE WIRE

(a) Connect the ground cable with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74 in-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.
(f) Connect the inlet heater water hose.
11. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

(a) Set the crankshaft key in the position as shown in the illustration.

(b) Turn the cutout of the drive shaft so that it faces upward.
(c) Align the yellow mark links with the timing marks of each gear as shown in the illustration.
(d) Install the sprockets onto the crankshaft and oil pump shaft with the chain placed on the gears.
(e) Temporarily tighten the oil pump drive shaft sprocket with the nut.

(f) Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)

(g) Align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.
(h) Insert a bar of 4 mm in diameter into the adjusting hole on the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
Torque: 30 Nm (301 kgf-cm, 22 ft-lbf)
12. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Install the crankshaft timing gear or sprocket to the crankshaft.
13. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
14. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to TDC/compression.

(1) Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks on the camshaft timing gear with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.

(2) Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.

(b) Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

(d) Align the gold or yellow links with the timing marks located on the camshaft timing gear and sprocket, then install the chain.
15. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
16. INSTALL TIMING CHAIN GUIDE

(a) Install the timing chain guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
17. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Install the sensor plate with the "F" mark facing forward.
18. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Installation
19. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Release the ratchet pawl, then fully push in the plunger and set the hook to the pin so that the plunger is in the position shown in the illustration.

(b) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.

20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Except spring type V-ribbed belt tensioner:

(1) Install the V-ribbed belt tensioner assembly with the bolt and nut.
Torque: 60 Nm (607 kgf-cm, 44 ft-lbf)
(b) Spring type V-ribbed belt tensioner:

(1) Install the V-ribbed belt tensioner to the engine by first tightening the bolt and then tightening the nut.
Torque: 60 Nm (607 kgf-cm, 44 ft-lbf)
NOTE: When replacing the V-ribbed belt tensioner with a new one, do not pull out the pin.

21. INSTALL CRANKSHAFT PULLEY

(a) Using SST, secure the pulley in place and tighten the bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 180 Nm (1835 kgf-cm, 133 ft-lbf)

(b) Turn the crankshaft counterclockwise, then disconnect the hook from the pin.

(c) Turn the crankshaft clockwise, then check that the plunger is extended.
22. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

(b) Apply a continuous bead of seal packing (Diameter 4.0 to 4.5 mm (0.158 to 0.177 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
- Remove any oil from the contact surfaces.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the oil pan.

(c) Install the oil pan onto the cylinder block.

(d) Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

(e) Place a wooden block between a floor jack and the engine, then support the engine using the floor jack.
(f) Remove the chain block and sling device.
(g) Remove the 2 bolts and engine hangers.
23. INSTALL CRANKSHAFT POSITION SENSOR Installation
24. INSTALL IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley sub-assembly with the 2 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
25. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

(a) Install the engine mounting insulator sub-assembly RH with the 4 bolts and 2 nuts.
Bolt A - Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
Bolt B - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Nut A - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Nut B - Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
26. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
(a) Install a new gasket onto the cylinder head sub-assembly.
(b) Temporarily tighten the exhaust manifold converter sub-assembly with the 5 nuts.

(d) Connect the air fuel ratio sensor connector.
27. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
28. INSTALL NO. 2 MANIFOLD STAY Installation
29. INSTALL MANIFOLD STAY Installation
30. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR Installation
31. INSTALL INTAKE MANIFOLD Installation
32. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
33. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
34. CONNECT FUEL MAIN TUBE Installation
35. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
(a) Apply a light coat of engine oil to a new O-ring and install it onto the engine oil level dipstick guide.

(b) Install the engine oil level dipstick guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
36. INSTALL ENGINE OIL LEVEL DIPSTICK
37. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
38. INSTALL SPARK PLUG Installation
39. INSTALL IGNITION COIL ASSEMBLY Installation
40. INSTALL THROTTLE BODY ASSEMBLY Installation
41. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE Installation
42. INSTALL RADIATOR RESERVE TANK ASSEMBLY Installation
43. INSTALL GENERATOR ASSEMBLY Installation
44. INSTALL V-RIBBED BELT
(a) When a tensioner except spring type V-ribbed belt tensioner is used or the spring type V-ribbed belt tensioner is reused:
(1) Install the V-ribbed belt Installation.
(b) When the spring type V-ribbed belt tensioner is replaced:

(1) Using SST, slowly turn the V-ribbed belt tensioner clockwise.
SST: 09216-42010
09216-04010
(2) Pull out the pin with the V-ribbed belt tensioner being compressed in a clockwise direction.
(3) Slowly return the V-ribbed belt tensioner.
NOTICE:
- Make sure that SST and other tools are set to the tensioner securely.
- When compressing the V-ribbed belt tensioner, slowly turn the tensioner.
(4) Install the V-ribbed belt Installation.
45. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
46. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2WD) Installation
47. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 4WD) Installation
48. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
49. ADD ENGINE OIL Replacement
50. ADD ENGINE COOLANT Service and Repair
51. INSPECT FOR FUEL LEAK Testing and Inspection
52. INSPECT FOR COOLANT LEAK Testing and Inspection
53. INSPECT FOR OIL LEAK
54. INSPECT FOR EXHAUST GAS LEAK
55. INSPECT IGNITION TIMING Engine
56. INSPECT ENGINE IDLING SPEED Engine
57. INSPECT COMPRESSION Engine
58. INSPECT CO/HC Engine
59. INSTALL SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar) Installation
60. INSTALL OUTER COWL TOP PANEL Installation
61. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
62. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
63. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
64. INSTALL HOOD TO COWL TOP SEAL Installation
65. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
66. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
67. INSTALL FRONT WIPER ARM HEAD CAP Installation
68. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
69. INSTALL ENGINE UNDER COVER LH
70. INSTALL ENGINE UNDER COVER RH
71. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)