Installation

CYLINDER HEAD

INSTALLATION
1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.

(b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)

2. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.

(b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

LH Bank:

5. INSTALL NO. 2 CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket in position on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3L" mark is on the LH bank's gasket.

NOTICE: Be careful of the installation direction.

6. INSTALL CYLINDER HEAD LH

(a) Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.
(b) Install the cylinder head together with the exhaust manifold to the cylinder block.
(c) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(d) Put the washer on the bolt, and insert the bolt with washer into the cylinder head.

NOTICE: Be careful not to drop the washers into the cylinder head.

LH Bank:

(e) Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration.
Torque: 59 N*m (602 kgf*cm, 44 ft.*lbf)

RH Bank:

7. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket in position on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3R" mark is on the RH bank's gasket.

NOTICE: Be careful of the installation direction.

8. INSTALL CYLINDER HEAD SUB-ASSEMBLY

RH Bank:

(e) Install and uniformly tighten the 10 cylinder head bolts, and plate washers in the sequence shown in the illustration.
Torque: 59 N*m (602 kgf*cm, 44 ft.*lbf)

(f) Mark the front of each cylinder head bolt's head with paint.
(g) Tighten the cylinder head bolts another 90° in the sequence shown in the illustration.
(h) Check that the painted mark is now at a 90° angle to the front.

9. INSTALL CAMSHAFT

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Set the crankshaft position.
(1) Using the crankshaft pulley bolt, turn the crankshaft, and set the set key of the crankshaft to 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.

NOTICE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.

(b) Apply MP grease to the thrust portion of the camshafts.

(c) Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the 2 camshafts.
(d) Set the timing marks (1 dot mark each) of the camshaft drive and driven main gears at an approximately 10° angle.

(e) Apply seal packing to the camshaft housing plug.
(1) Remove the old packing (FIPG) material.
(2) Apply seal packing to the housing plug as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(f) Install the camshaft housing plug to the cylinder head as shown in the illustration.
(g) Install the oil control valve filter to the cylinder head.

NOTICE: Be careful of the installation direction.

(h) Apply seal packing to the front bearing cap.
(1) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
(2) Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 1.5 to 2.0 mm (0.059 to 0.079 in.)

NOTICE: Do not apply seal packing to the front bearing cap grooves.

(i) Install the front bearing cap.

HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

(j) Install the other bearing caps in the sequence shown, with the arrow marks facing forward.

(k) Push in the camshaft setting oil seal.

(l) Install new seal washers to the bearing cap bolts A and B.
(m) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts D and E.

NOTICE: Do not apply engine oil under the heads of the bearing cap bolts A, B and C.
Bolt length:
94 mm (3.70 in.) for A with seal washer
72 mm (2.83 in.) for B with seal washer
25 mm (0.98 in.) for C
52 mm (2.05 in.) for D
38 mm (1.50 in.) for E

(n) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.

(o) Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque: 7.5 N*m (76 kgf*cm, 66 ft.*lbf) for bolts 21 and 22
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) for other bolts

(p) Remove the service bolt.

10. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Check that the set key of the crankshaft is at a position 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.

NOTICE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.

(b) Apply MP grease to the thrust portion of the camshafts.

LH Bank:

(d) Apply seal packing to the camshaft housing plug.
(1) Remove the old packing (FIPG) material.
(2) Apply seal packing to the housing plug as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(e) Install the camshaft housing plug to the cylinder head as shown in the illustration.
(f) Install the oil control valve filter to the cylinder head.

NOTICE: Be careful of the installation direction.

(g) Apply seal packing to the front bearing cap.
(1) Remove any old packing (FIPG) material.
(2) Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 1.5 to 2.0 mm (0.059 to 0.079 in.)

NOTICE: Do not apply seal packing to the front bearing cap grooves.

(h) Install the front bearing cap.

HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

(i) Install the other bearing caps in the sequence shown, with the arrow marks facing forward.

(j) Push in the camshaft setting oil seal.

(k) Install new seal washers to the bearing cap bolts A and B.
(l) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts D and E.

NOTICE: Do not apply engine oil under the heads of the bearing cap bolts A, B and C.
Bolt length:
94 mm (3.70 in.) for A with seal washer
72 mm (2.83 in.) for B with seal washer
25 mm (0.98 in.) for C
52 mm (2.05 in.) for D
38 mm (1.50 in.) for E

(m) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.

(n) Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque: 7.5 N*m (76 kgf*cm, 66 ft.*lbf) for bolts 21 and 22
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) for other bolts

(o) Remove the service bolt.

11. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH
12. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH

13. INSTALL REAR TIMING BELT PLATE RH
(a) Install the timing belt plate with the bolt and stud bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

14. INSTALL REAR NO. 2 TIMING BELT PLATE RH
(a) Install the timing belt plate with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

15. INSTALL REAR TIMING BELT PLATE LH
(a) Install the timing belt plate with the bolt and stud bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

16. INSTALL REAR NO. 2 TIMING BELT PLATE LH
(a) Install the timing belt plate with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

17. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH
(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
(b) Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward.
(c) Hold the camshaft with a wrench and install the 4 pulley bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

18. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH
(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
(b) Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "L" mark forward.
(c) Hold the camshaft with a wrench and install the 4 pulley bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

19. INSTALL VVT SENSOR
20. INSTALL CAMSHAFT POSITION SENSOR
21. INSTALL OIL DIPSTICK AND GUIDE
22. INSTALL NO. 2 ENGINE HANGER
23. INSTALL NO. 1 ENGINE HANGER
24. INSTALL CATALYST CONVERTER ASSEMBLY
25. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
26. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
27. INSTALL REAR WATER BY-PASS JOINT
28. INSTALL FRONT WATER BY-PASS JOINT
29. INSTALL WATER INLET HOUSING
30. INSTALL INTAKE MANIFOLD ASSEMBLY
31. INSTALL THROTTLE BODY ASSEMBLY
32. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY

33. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 5 minutes after applying seal packing.
^ Do not start the engine within 2 hours after applying seal packing.

(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
(f) Install the wire clamp bracket on the engine wire to the cylinder head.
(g) Install the wire clamp bracket on the engine wire to the camshaft bearing cap.

34. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 5 minutes after applying seal packing.
^ Do not start the engine within 2 hours after applying seal packing.

(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
(f) Install the wire clamp bracket on the engine wire to the cylinder head.
(g) Install the wire clamp bracket on the engine wire to the camshaft bearing cap.

35. INSTALL IGNITION COIL
36. INSTALL TIMING BELT
(a) Install the timing belt.

37. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL
38. CHECK FOR FUEL LEAKS
39. PERFORM INITIALIZATION
(a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.