Installation

3UZ-FE ENGINE MECHANICAL: 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 Nm (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 Nm (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 Nm (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 Nm (76 kgf-cm, 66 in-lbf)

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.





(e) Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration.

Torque : 59 Nm (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.

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





(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.





(e) Install and uniformly tighten the 10 cylinder head bolts, and plate washers in the sequence shown in the illustration.

Torque : 59 Nm (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 Installation

10. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY Installation

11. INSTALL REAR TIMING BELT PLATE RH





(a) Install the timing belt plate with the bolt and stud bolt.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

12. INSTALL REAR NO. 2 TIMING BELT PLATE RH





(a) Install the timing belt plate with the 2 bolts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

13. INSTALL REAR TIMING BELT PLATE LH





(a) Install the timing belt plate with the bolt and stud bolt.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

14. INSTALL REAR NO. 2 TIMING BELT PLATE LH





(a) Install the timing belt plate with the 2 bolts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

15. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH Installation

16. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH Installation

17. INSTALL VVT SENSOR Installation

18. INSTALL CAMSHAFT POSITION SENSOR Installation

19. INSTALL OIL DIPSTICK AND GUIDE [1][2]Installation

20. INSTALL NO. 2 ENGINE HANGER Installation

21. INSTALL NO. 1 ENGINE HANGER Installation

22. INSTALL CATALYST CONVERTER ASSEMBLY Installation

23. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Installation

24. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY Installation

25. INSTALL REAR WATER BY-PASS JOINT Installation

26. INSTALL FRONT WATER BY-PASS JOINT Installation

27. INSTALL WATER INLET HOUSING Installation

28. INSTALL INTAKE MANIFOLD ASSEMBLY Installation

29. INSTALL THROTTLE BODY ASSEMBLY Installation

30. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Installation

31. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH Installation

32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Installation

33. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH Installation

34. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH Installation

35. INSTALL IGNITION COIL Installation

36. INSTALL TIMING BELT

(a) Install the timing belt Installation.

37. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL

38. CHECK FOR FUEL LEAKS Installation

39. PERFORM INITIALIZATION

(a) Perform initialization Testing and Inspection.

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