Installation
2ZR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: INSTALLATION
1. 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 surface.
* Pay attention to the mounting orientation of the cylinder head gasket.
* Do not damage the cylinder gasket when installing the cylinder head onto the cylinder block.
2. 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 a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts by additional 90° and one more additional 45° as shown in the illustration.
(e) Check that the paint mark is now at a 135° angle from the front.
3. INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
* Keep the lash adjuster free of dirt and foreign objects.
* Only use clean engine oil.
(a) Place the lash adjuster into a container filled with engine oil.
(b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
SST : 09276-75010
(c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 or 6 times.
(d) Check the movement of the plunger and bleed the air.
OK:
Plunger moves up and down.
NOTICE:
When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.
(e) After bleeding the air, remove the SST. Then, try to press the plunger quickly and firmly with a finger.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
(f) Install the lash adjusters.
NOTICE:
Install the lash adjuster into its original position.
4. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Apply engine oil to the lash adjuster tip and valve stem cap end.
(b) Install the valve rocker arms as shown in the illustration.
5. INSTALL NO. 1 CAMSHAFT BEARING
(a) Clean the both surfaces of the bearing.
(b) Install the 2 No. 1 camshaft bearings.
(c) Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.
Dimension (A - B):
0.7 mm (0.0276 in.) or less
NOTICE:
Position the bearing to the center of the bearing cap by measuring dimension A - B.
6. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean both surfaces of the bearing.
(b) Install the 2 No. 2 camshaft bearings.
(c) Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.
Dimension (A):
1.05 to 1.75 mm (0.042 to 0.068 in.)
NOTICE:
Position the bearing 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 housing and bearing caps.
(b) Check the marks and numbers on the camshaft bearing caps and place them in the 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 line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal 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 RH within 3 minutes of applying the 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 CRANKSHAFT TIMING GEAR OR SPROCKET Reassembly
12. INSTALL NO. 1 CHAIN VIBRATION DAMPER Reassembly
13. INSTALL CHAIN SUB-ASSEMBLY Reassembly
14. INSTALL CHAIN TENSIONER SLIPPER Reassembly
15. INSTALL NO. 2 CHAIN VIBRATION DAMPER Reassembly
16. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL Installation
17. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Reassembly
18. INSTALL CRANKSHAFT PULLEY Reassembly
19. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly
20. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly
21. INSTALL THERMOSTAT Installation
22. INSTALL WATER INLET Installation
23. INSTALL WIRE HARNESS CLAMP BRACKET Installation
24. INSTALL EXHAUST MANIFOLD Installation
25. INSTALL MANIFOLD STAY Installation
26. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
27. INSTALL AIR TUBE ASSEMBLY Installation
28. INSTALL NO. 1 WATER BY-PASS PIPE Installation
29. INSTALL WATER INLET HOSE Installation
30. INSTALL WATER BY-PASS HOSE Installation
31. INSTALL OIL LEVEL GAGE GUIDE Installation
32. INSTALL OIL LEVEL DIPSTICK
33. INSTALL FAN BELT ADJUSTING BAR Installation
34. INSTALL GENERATOR ASSEMBLY Installation
35. INSTALL FUEL INJECTOR Installation
36. INSTALL INJECTOR VIBRATION INSULATOR Installation
37. INSTALL NO. 1 DELIVERY PIPE SPACER Installation
38. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
39. INSTALL INTAKE MANIFOLD Installation
40. INSTALL NO. 1 RADIATOR HOSE Installation
41. INSTALL HEATER WATER HOSE INLET A Installation
42. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) Installation
43. INSTALL NO. 2 VENTILATION HOSE Installation
44. INSTALL RADIO SETTING CONDENSER Installation
45. INSTALL IGNITION COIL ASSEMBLY Installation
46. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) Installation
47. INSTALL TRANSMISSION OIL LEVEL GAGE SUB-ASSEMBLY (for Automatic Transaxle)
48. INSTALL NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) Installation
49. INSTALL NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) Installation
50. INSTALL NO. 2 OIL COOLER TUBE CLAMP (for Automatic Transaxle) Installation
51. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation
52. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation
53. INSTALL FRONT AXLE ASSEMBLY LH Installation
54. INSTALL FRONT AXLE ASSEMBLY RH
HINT
The installation procedure for the RH side is the same as that for the LH side.
55. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH Installation
56. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH
HINT
The installation procedure for the RH side is the same as that for the LH side.
57. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
58. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT
The installation procedure for the RH side is the same as that for the LH side.
59. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation
60. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT
The installation procedure for the RH side is the same as that for the LH side.
61. INSTALL SPEED SENSOR FRONT LH Installation
62. INSTALL SPEED SENSOR FRONT RH
HINT
The installation procedure for the RH side is the same as that for the LH side.
63. INSTALL FRONT AXLE SHAFT LH NUT Installation
64. INSTALL FRONT AXLE SHAFT RH NUT
HINT
The installation procedure for the RH side is the same as that for the LH side.
65. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
66. INSTALL FRONT FLOOR BRACE CENTER Installation
67. INSTALL FRONT CONSOLE BOX Installation
68. INSTALL REAR CONSOLE BOX ASSEMBLY Installation
69. INSTALL CONSOLE BOX CARPET Installation
70. INSTALL CONSOLE BOX COVER REAR Installation
71. INSTALL CONSOLE PANEL UPPER Installation
72. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Installation
73. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation
74. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY Installation
75. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
76. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Installation
77. CONNECT FUEL TUBE SUB-ASSEMBLY Installation
78. CONNECT HEATER WATER HOSE INLET A Installation
79. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) Installation
80. CONNECT ENGINE WIRE Installation
81. INSTALL NO. 1 FUEL VAPOR FEED HOSE Installation
82. INSTALL UNION TO CHECK VALVE HOSE Installation
83. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Installation
84. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Installation
85. INSTALL WITH PULLEY COMPRESSOR ASSEMBLY Installation
86. INSTALL RADIATOR ASSEMBLY Installation
87. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY Installation
88. INSTALL UPPER RADIATOR SUPPORT ABSORBER Reassembly
89. INSTALL NO. 1 COOLER COVER Installation
90. INSTALL HOOD LOCK ASSEMBLY Installation
91. CONNECT NO. 1 RADIATOR HOSE Installation
92. CONNECT NO. 2 OIL COOLER INLET HOSE (for Automatic Transaxle) Installation
93. CONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transaxle) Installation
94. INSTALL NO. 2 RADIATOR HOSE Installation
95. INSTALL FRONT BUMPER COVER Installation
96. INSTALL FAN & GENERATOR V BELT Installation
97. ADJUST FAN & GENERATOR V BELT Installation
98. INSPECT FAN & GENERATOR V BELT Installation
99. INSTALL NO. 2 CYLINDER HEAD COVER Installation
100. INSTALL BATTERY CARRIER Installation
101. INSTALL AIR CLEANER BRACKET Installation
102. INSTALL AIR CLEANER ASSEMBLY Installation
103. INSTALL OUTER COWL TOP PANEL Installation
104. INSTALL FRONT AIR SHUTTER SEAL RH Installation
105. INSTALL FRONT WIPER MOTOR AND LINK Installation
106. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
107. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
108. INSTALL HOOD TO COWL TOP SEAL Installation
109. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
110. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
111. INSTALL FRONT WIPER ARM HEAD CAP Installation
112. INSTALL BATTERY TRAY
113. INSTALL BATTERY Installation
114. ADD ENGINE COOLANT Service and Repair
115. ADD ENGINE OIL Replacement
116. INSPECT FOR FUEL LEAK
117. INSPECT FOR ENGINE OIL LEAK
118. INSPECT FOR EXHAUST GAS LEAK
119. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection
120. INSTALL ENGINE UNDER COVER RH
121. INSTALL ENGINE UNDER COVER LH
122. INSTALL FRONT WHEELS Installation
123. INSPECT IGNITION TIMING Engine
124. INSPECT ENGINE IDLING SPEED Engine
125. INSPECT CO/HC Engine
126. INSPECT FRONT WHEEL ALIGNMENT
Front Wheel Alignment
127. CHECK VSC SENSOR SIGNAL
Test Mode Procedure