Installation
2ZR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: 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.
NOTICE:
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
(a) Clean both surfaces of the bearings.
(b) Install the 2 No. 2 camshaft bearings.
(c) Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.
Dimension (A):
1.05 to 1.75 mm (0.0413 to 0.0689 in.)
NOTICE:
Position the bearings to the center of the bearing cap by measuring dimension A.
7. INSTALL NO. 2 CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(c) Install the No. 2 camshaft to the camshaft housing.
8. INSTALL CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(c) Install the camshaft to the camshaft housing.
9. INSTALL CAMSHAFT BEARING CAP
(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
HINT
Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
(c) Tighten the 10 bolts in the order shown in the illustration.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
10. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
(a) Make sure that the valve rocker arm is installed as shown in the illustration.
(b) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Bead diameter:
3.5 to 4.0 mm (0.138 to 0.158 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(c) Set the camshaft and No. 2 camshaft as shown in the illustration.
(d) Install the camshaft housing and tighten the 17 bolts in the order shown in the illustration.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
NOTICE:
* After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
* If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
* After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.
11. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check that the knock pin is installed on the camshaft.
(b) Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
NOTICE:
Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear assembly.
(c) Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
NOTICE:
Do not turn the camshaft timing gear in the retard direction (clockwise).
(d) Measure the clearance between the gear and the camshaft flange.
Clearance:
0.1 to 0.4 mm (0.004 to 0.016 in.)
(e) Tighten the flange bolt with the camshaft timing gear secured in place.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(f) Check that the camshaft timing gear can move in the retard direction (clockwise) and is locked in the most retarded position.
12. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Check that the knock pin is installed on the camshaft.
(b) Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
NOTICE:
Be sure not to turn the camshaft timing exhaust gear in the retard direction (clockwise).
(d) Check that there is no clearance between the gear and the camshaft flange.
(e) Tighten the flange bolt with the camshaft timing exhaust gear secured.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(f) Check the camshaft timing exhaust gear lock.
(1) Make sure that the camshaft timing exhaust gear is locked.
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.
(c) Place the chain on the crankshaft without passing it around the shaft.
(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.