Installation

1NZ-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION

INSTALLATION

1. INSTALL INJECTOR VIBRATION INSULATOR
(a) Install 4 new injector vibration insulators onto the cylinder head.

2. INSTALL DELIVERY PIPE NO. 1 SPACER
(a) Install the 2 delivery pipe No. 1 spacers onto the cylinder head.
NOTE: Install the delivery pipe No. 1 spacer in the correct direction.

3. INSTALL FUEL INJECTOR ASSEMBLY Installation
4. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Provisionally install the fuel delivery pipe sub-assembly with the 4 fuel injectors using the 3 bolts.
NOTICE:
- Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
- Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub-assembly.

(b) Tighten the 3 bolts to the specified torque.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

5. INSTALL HARNESS BRACKET
(a) Install the harness bracket with the bolt.
Torque: 13 Nm (131 kgf-cm, 9.5 ft-lbf)

6. INSTALL WATER BY-PASS HOSE
(a) Install the water by-pass hose.

7. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Provisionally install the engine coolant temperature sensor through a new gasket.
(b) Using SST, tighten the engine coolant temperature sensor.
SST: 09817-33190
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)

8. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring on the camshaft position sensor.
(b) Install the camshaft position sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
NOTE: Do not twist the O-ring.

9. INSTALL BOOSTER VACUUM TUBE
(a) Install the booster vacuum tube with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

10. INSTALL HARNESS BRACKET
(a) Install the harness bracket with the bolt.
Torque: 13 Nm (131 kgf-cm, 9.5 ft-lbf)

11. INSTALL EXHAUST MANIFOLD
(a) Using several steps, install a new exhaust manifold gasket and the exhaust manifold with the 3 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)

12. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
(a) Install exhaust manifold heat insulator No. 1 with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)

13. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
NOTICE:
- Remove any oil from the contact surfaces.
- Check the mounting orientation of the cylinder head gasket.
- Place the cylinder head on the cylinder head gently in order not to damage the gasket.

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

(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.

(b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench, in the sequence shown in the illustration.
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
(c) Mark the front of the cylinder head bolt with paint.

(d) Retighten the cylinder head bolts 90° and then an additional by 90° as shown in the illustration.
(e) Check that the paint mark is now at a 180° angle from the front.

(f) Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 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 pump assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.

15. INSTALL CAMSHAFT

(a) Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then provisionally tighten the 19 bolts.

(b) Uniformly tighten the bolts in several steps in the sequence shown in the illustration and install camshaft bearing cap No. 1 and camshaft bearing cap No. 2.
Camshaft bearing cap No. 1 - Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
Camshaft bearing cap No. 2 - Torque: 13 Nm (129 kgf-cm, 9.4 ft-lbf)
NOTE: Tighten each bolt uniformly while keeping the camshaft level.

16. INSTALL CHAIN SUB-ASSEMBLY Installation
17. INSTALL CHAIN TENSIONER SLIPPER Installation
18. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 Installation
19. INSTALL OIL PUMP SEAL Replacement
20. INSTALL OIL PUMP ASSEMBLY Installation
21. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Installation
22. INSTALL WATER PUMP ASSEMBLY Installation
23. INSTALL WATER PUMP PULLEY Installation
24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
25. INSTALL CRANKSHAFT POSITION SENSOR Installation
26. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY Installation
27. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH Installation
28. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
29. INSTALL VENTILATION HOSE NO. 2 Installation
30. INSTALL VENTILATION HOSE Installation
31. INSTALL IGNITION COIL NO. 1 Installation
32. INSTALL GENERATOR ASSEMBLY Installation
33. INSTALL FAN AND GENERATOR V BELT Installation
34. ADJUST FAN AND GENERATOR V BELT Installation
35. INSPECT FAN AND GENERATOR V BELT Installation

36. INSTALL MANIFOLD SUPPORT BRACKET
(a) Install the manifold support bracket with the 3 bolts.
Torque: 44 Nm (449 kgf-cm, 33 ft-lbf)
37. INSTALL EXHAUST PIPE ASSEMBLY FRONT

(a) Using vernier calipers, measure the free length of the compression spring.
Minimum length:
40.5 mm (1.594 in.)
If the length is not as specified, replace the compression spring.

(b) Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.
NOTICE:
- Install the exhaust pipe gasket in the correct direction.
- Do not damage the outer surface of the exhaust pipe gasket.
- Do not reuse the exhaust pipe gasket.
- Do not push in the gasket with the exhaust pipe when installing.

(c) Install the exhaust front pipe assembly with the 2 compression springs and 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft-lbf)

38. CONNECT WIRE HARNESS
(a) Connect the wire harness with the 2 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)

39. INSTALL WATER BY-PASS HOSE NO. 1
(a) Install water by-pass pipe No. 1 with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

40. CONNECT HEATER WATER INLET HOSE A
(a) Connect heater water inlet hose A.

41. CONNECT HEATED OXYGEN SENSOR CONNECTOR
(a) Connect the heated oxygen sensor connector.
(b) Install the sensor bracket with the bolt.

42. CONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR
(a) Connect the engine coolant temperature sensor connector.

43. CONNECT CAMSHAFT POSITION SENSOR CONNECTOR
(a) Connect the camshaft position sensor connector.

44. CONNECT BOOSTER VACUUM TUBE
(a) Connect the booster vacuum tube.
45. CONNECT FUEL TUBE SUB-ASSEMBLY Installation

46. INSTALL OIL LEVEL GAUGE GUIDE
(a) Apply engine oil to a new O-ring.
(b) Install the oil level gauge guide with the bolt through a new O-ring.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Install the wire harness.
47. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.

(b) Install the intake manifold with the 3 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)

49. CONNECT UNION TO CONNECTOR TUBE HOSE
(a) Connect the union to connector tube hose.

50. CONNECT VENTILATION HOSE
(a) Connect the ventilation hose.

51. CONNECT THROTTLE WITH MOTOR BODY CONNECTOR
(a) Install the throttle with motor body connector bracket with the nut.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(b) Connect the throttle with motor body connector.
(c) Connect the wire harness clamp.

52. CONNECT WATER BY-PASS HOSE
(a) Connect the water by-pass hose.

53. CONNECT WATER BY-PASS HOSE NO. 2
(a) Connect water by-pass hose No. 2.

54. INSTALL WATER FILLER SUB-ASSEMBLY
(a) Install the water filler sub-assembly with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect radiator hose No. 1 to the cylinder head.

55. CONNECT RESERVE TANK HOSE
(a) Connect the reserve tank hose.

56. CONNECT RADIATOR HOSE NO. 3
(a) Connect radiator hose No. 3.
57. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 Installation
58. INSTALL BATTERY TRAY
59. INSTALL BATTERY
60. ADD ENGINE OIL
61. ADD ENGINE COOLANT Service and Repair
62. CHECK ENGINE OIL LEVEL Testing and Inspection
63. CHECK FOR ENGINE OIL LEAKAGE
64. CHECK FOR ENGINE COOLANT LEAKAGE Testing and Inspection
65. CHECK FOR EXHAUST GAS LEAKAGE
66. CHECK FOR FUEL LEAKAGE Testing and Inspection
67. INSTALL CYLINDER HEAD COVER NO. 2 Installation
68. INSTALL ENGINE UNDER COVER RH
69. INSTALL FRONT WHEEL RH
70. INSTALL COWL TOP PANEL OUTER (for Hatchback) Installation
71. INSTALL COWL TOP PANEL OUTER (for Sedan) Installation
72. INSTALL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 (for Hatchback) Installation
73. INSTALL FRONT AIR SHUTTER SEAL RH (for Sedan) Installation
74. INSTALL FRONT WIPER MOTOR AND LINK (for Hatchback) Installation
75. INSTALL FRONT WIPER MOTOR AND LINK (for Sedan) Installation
76. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback) Installation
77. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback) Installation
78. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan) Installation
79. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) Installation
80. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) Installation
81. INSTALL HOOD TO COWL TOP SEAL (for Hatchback) Installation
82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback) Installation
83. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan) Installation
84. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback) Installation
85. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan) Installation
86. INSTALL FRONT WIPER ARM HEAD CAP (for Hatchback) Installation
87. INSTALL FRONT WIPER ARM HEAD CAP (for Sedan) Installation