Installation

2AZ-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION

INSTALLATION

1. INSTALL CYLINDER HEAD GASKET






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

NOTICE:
- Remove any oil from contact surface.
- Be careful of the installation direction.
- Place the cylinder head gently in order to avoid damaging the gasket.

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





(a) Apply a light coat of engine oil to the threads and under the heads of the cylinder set head bolts.
(b) 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: 78.5 Nm (800 kgf-cm, 58 ft-lbf)






(c) Mark the front of the cylinder head bolts with paint.
(d) Retighten the cylinder head bolts by 90° as shown in the illustration.
(e) Check that the paint mark is now at a 90° angle to the front.






(f) Connect the ground cable with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(g) Connect the camshaft position sensor connector.
(h) Connect the engine coolant temperature sensor connector.
(i) Connect the engine oil pressure switch connector.
(j) Connect the radio setting condenser connector.
(k) Connect the heater water inlet hose.
(l) Connect the radiator hose inlet.
3. INSTALL NO. 2 CAMSHAFT BEARING






(a) Clean the contact surfaces of the bearing and the cylinder head.
(b) Install the No. 2 camshaft bearing onto the cylinder head.
NOTE: Do not apply engine oil to the bearing its contact surface.

4. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY






(a) Put the camshaft timing gear and camshaft together with the straight pin off the key groove.
(b) 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.
NOTE: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

(c) Check that the there is no clearance between the gear fringe and camshaft.
(d) Tighten the flange bolt with the camshaft timing gear fixed in pace.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
(e) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
5. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET






(a) Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTE: Do not to damage the camshaft.

6. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the camshaft.






(b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.






(c) Examine the front marks and numbers and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
(d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.






(e) Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.
Torque: 29.5 Nm (301 kgf-cm, 22 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

NOTICE:
- Tighten the bolts after deciding the position in the thrust direction of the camshaft by the No. 1 and No. 2 bearing caps.
- Install the camshaft with the timing mark of the camshaft timing gear on top.

7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
8. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
(a) Install a new gasket onto the cylinder head.
(b) Temporarily tighten the exhaust manifold converter with the 5 nuts.






(c) Tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)
9. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR






(a) Install the exhaust manifold heat insulator with the 3 bolts and nut.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
10. INSTALL NO. 2 MANIFOLD STAY






(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
11. INSTALL MANIFOLD STAY






(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
12. INSTALL OIL DIPSTICK GUIDE






(a) Apply a light coat of engine oil to a new O-ring and install it onto the guide.
(b) Install the guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
13. INSTALL OIL DIPSTICK
(a) Apply a light coat of engine oil to the O-ring.
(b) Install the dipstick to the guide.
14. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation

15. INSTALL CHAIN SUB-ASSEMBLY
16. INSTALL CHAIN TENSIONER SLIPPER Installation

17. INSTALL TIMING CHAIN GUIDE Installation

18. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE Installation

19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

20. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation

21. INSTALL CRANKSHAFT PULLEY Installation

22. INSTALL OIL PAN SUB-ASSEMBLY Installation

23. INSTALL CRANKSHAFT POSITION SENSOR Installation

24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation

25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation

26. INSTALL IGNITION COIL ASSEMBLY Installation

27. INSTALL ENGINE MOUNTING INSULATOR RH Installation

28. INSTALL VANE PUMP ASSEMBLY
29. INSTALL GENERATOR ASSEMBLY Installation

30. INSTALL FAN AND GENERATOR V BELT Installation

31. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

32. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR Installation

33. INSTALL INTAKE MANIFOLD Installation

34. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

35. INSTALL THROTTLE BODY ASSEMBLY Installation

36. INSTALL AIR CLEANER ASSEMBLY Installation

37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
38. ADD ENGINE COOLANT Testing and Inspection

39. ADD ENGINE OIL Replacement

40. CHECK FOR FUEL LEAKAGE Testing and Inspection

41. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for the engine coolant leaks Testing and Inspection.
42. CHECK FOR ENGINE OIL LEAKS
43. CHECK FOR EXHAUST GAS LEAKS
44. CHECK IGNITION TIMING Engine

45. INSPECT ENGINE IDLING SPEED Engine

46. INSPECT COMPRESSION Engine

47. INSPECT CO/HC Engine

48. INSTALL COWL BODY MOUNTING BRACKET LOWER LH
49. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
50. INSTALL WIPER LINK ASSEMBLY Installation

51. INSTALL COWL TOP VENTILATOR LOUVER LH
52. INSTALL HOOD TO COWL TOP SEAL
53. INSTALL FRONT WIPER ARM LH Installation

54. INSTALL FRONT WIPER ARM RH Installation

55. INSTALL FRONT WIPER ARM HEAD CAP
56. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

57. INSTALL FRONT FENDER APRON SEAL RH
58. INSTALL ENGINE UNDER COVER LH
59. INSTALL ENGINE UNDER COVER RH
60. INSTALL FRONT WHEEL RH Installation

61. INSTALL HOOD SUB-ASSEMBLY
(a) Install and adjust the hood Adjustments.
62. PERFORM INITIALIZATION
(a) Perform initialization Testing and Inspection.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.