Installation

2AZ-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: INSTALLATION

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 contact surface.
- Be careful of the installation direction.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Place the cylinder head on the head gasket.
NOTICE: Place the cylinder head gently in order to avoid damaging the gasket.

(b) Install the cylinder head bolts.
NOTICE: The cylinder head bolts are tightened in 2 successive steps.

(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
(2) 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: 70 Nm (714 kgf-cm, 52 ft-lbf)

(c) Mark the front of the cylinder head bolts with paint.
(d) Further tighten 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.
3. INSTALL NO. 1 CAMSHAFT BEARING Reassembly
4. INSTALL NO. 2 CAMSHAFT BEARING Reassembly
5. INSTALL CAMSHAFT Reassembly
6. INSTALL NO. 2 CAMSHAFT Reassembly
7. CONNECT INLET HEATER WATER HOSE
8. CONNECT OUTLET HEATER WATER HOSE
9. CONNECT INLET RADIATOR HOSE Installation
10. CONNECT ENGINE WIRE

(a) Connect the ground cable with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(b) Connect the camshaft position sensor connector.
(c) Connect the engine coolant temperature sensor connector.
(d) Connect the engine oil pressure switch connector.
(e) Connect the radio setting condenser connector.
(f) Connect the heater water inlet hose.
11. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

(a) Set the crankshaft key in the left horizontal position.

(b) Turn the cutout of the drive shaft so that it faces upward.
(c) Align the yellow mark links with the timing marks of each gear as shown in the illustration.
(d) Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears.
(e) Temporarily tighten the oil pump drive shaft sprocket with the nut.

(f) Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)

(g) Align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.
(h) Insert a 4 mm diameter bar into the adjusting hole on the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
Torque: 30 Nm (301 kgf-cm, 22 ft-lbf)

12. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

13. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
14. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to TDC/compression.

(1) Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks on the camshaft timing gear with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.

(2) Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.

(b) Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

(d) Align the gold or yellow links with the timing marks located on the camshaft timing gear and sprocket, then install the chain.
15. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)

16. INSTALL TIMING CHAIN GUIDE
(a) Install the timing chain guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

17. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
(a) Install the sensor plate with the "F" mark facing forward.
18. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

(b) Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) 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 chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.

(c) Apply a continuous bead of seal packing 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 chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.

(d) Install the timing chain cover with the 12 bolts and 2 nuts.
Bolt A - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Bolt B - Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
Bolt C - Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
Nut - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)

(e) Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.
Torque: 22 Nm (219 kgf-cm, 16 ft-lbf)
19. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.

(b) Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: When installing the chain tensioner, set the hook again if the hook releases the plunger.

20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the V-ribbed belt tensioner with the bolt and nut.
Torque: 60 Nm (607 kgf-cm, 44 ft-lbf)
NOTICE: Do not lift the engine more than necessary.

21. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

(a) Install the engine transverse engine engine mounting bracket with the 3 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
22. INSTALL CRANKSHAFT PULLEY

(a) Using SST, fix the pulley in place and tighten the bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 180 Nm (1835 kgf-cm, 133 ft-lbf)

(b) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.

(c) Turn the crankshaft clockwise, then check that the plunger is extended.
23. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

(b) Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) 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 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the oil pan.

(c) Install the oil pan onto the cylinder block.

(d) Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

(e) Place a transmission jack underneath the engine, then put a wooden block on the jack.
(f) Remove the chain block and sling device.
(g) Remove the No. 1 and No. 2 engine hangers.
24. INSTALL CRANKSHAFT POSITION SENSOR Installation

25. INSTALL IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley with the 2 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)

26. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
(a) Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
Bolt - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Nut A - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Nut B - Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
(b) Install the 2 cooler brackets with the 2 bolts and nut.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)

27. INSTALL FRONT ENGINE MOUNTING INSULATOR SUB-ASSEMBLY
(a) Install the front engine mounting insulator with the 2 bolts, through bolt and nut.
Bolt - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Through bolt and Nut - Torque: 145 Nm (1479 kgf-cm, 107 ft-lbf)
HINT: Install the bolt which is used to secure the front engine mounting bracket.

28. 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.

(d) Connect the air-fuel ratio sensor connector.
29. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
30. INSTALL NO. 2 MANIFOLD STAY

(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 33 ft-lbf)
31. INSTALL MANIFOLD STAY

(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 33 ft-lbf)
32. INSTALL INTAKE MANIFOLD INSULATOR
33. INSTALL INTAKE MANIFOLD Installation
34. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
35. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
36. CONNECT FUEL MAIN TUBE Installation
37. 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)
38. INSTALL OIL DIPSTICK
39. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
40. INSTALL SPARK PLUG Installation
41. INSTALL IGNITION COIL ASSEMBLY Installation
42. INSTALL THROTTLE BODY ASSEMBLY Installation
43. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE Installation

44. INSTALL RADIATOR RESERVE TANK ASSEMBLY
(a) Install the radiator reservoir with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
45. INSTALL GENERATOR ASSEMBLY Installation
46. INSTALL FAN & GENERATOR V BELT Installation
47. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
48. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation
49. INSTALL OUTER COWL TOP PANEL Installation
50. INSTALL FRONT WIPER MOTOR AND LINK Installation
51. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
52. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
53. INSTALL HOOD TO COWL TOP SEAL Installation
54. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
55. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
56. INSTALL WINDSHIELD WIPER ARM COVER Installation
57. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
58. ADD ENGINE OIL Replacement
59. ADD ENGINE COOLANT Service and Repair
60. INSPECT FOR FUEL LEAK
Fuel System
61. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection
62. INSPECT FOR ENGINE OIL LEAK
63. INSPECT FOR EXHAUST GAS LEAK
64. INSPECT IGNITION TIMING Engine
65. INSPECT ENGINE IDLING SPEED Engine
66. INSPECT COMPRESSION Engine
67. INSPECT CO/HC Engine
68. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
69. INSTALL NO. 1 ENGINE UNDER COVER
70. INSTALL REAR ENGINE UNDER COVER RH
71. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)
72. INSTALL HOOD

(a) Temporarily install the hood with the 4 bolts.
(b) Connect the washer hose.
73. INSPECT HOOD Adjustments
74. ADJUST HOOD Adjustments