Installation

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

HINT
Check whether the engine is TMC made or not by referring to the following illustration.

Text in Illustration

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.

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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)

(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.

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(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)

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(g) Align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.

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(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.

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(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.

Text in Illustration

SST : 09309-37010

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

Text in Illustration

15. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper with the bolt.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

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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.

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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)

Text in Illustration

Bolt length

(e) Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.

Torque : 22 Nm (220 kgf-cm, 16 ft-lbf)

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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.

Text in 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.

Text in Illustration

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.

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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.

Text in Illustration

(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)

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(e) Place a 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 (for TMC Made Engine) Reassembly

25. INSTALL CRANKSHAFT POSITION SENSOR (except TMC Made Engine) Installation

26. INSTALL IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley with the 2 bolts.

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf)

27. 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)

28. 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)

Text in Illustration

HINT
Install the bolt which is used to secure the front engine mounting bracket.

29. 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.

30. 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)

31. INSTALL NO. 2 MANIFOLD STAY

(a) Install the stay with the bolt and nut.

Torque : 44 Nm (449 kgf-cm, 33 ft-lbf)

32. INSTALL MANIFOLD STAY

(a) Install the stay with the bolt and nut.

Torque : 44 Nm (449 kgf-cm, 33 ft-lbf)

33. INSTALL INTAKE MANIFOLD INSULATOR

34. INSTALL INTAKE MANIFOLD Installation

35. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation

36. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

37. CONNECT FUEL MAIN TUBE Installation

38. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

39. INSTALL OIL DIPSTICK

40. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation

41. INSTALL SPARK PLUG Installation

42. INSTALL IGNITION COIL ASSEMBLY Installation

43. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Installation

44. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH NO. 1 AIR CLEANER HOSE Installation

45. INSTALL RADIATOR RESERVE TANK ASSEMBLY

(a) Install the radiator reservoir with the 2 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

46. INSTALL GENERATOR ASSEMBLY Installation

47. INSTALL FAN AND GENERATOR V BELT Installation

48. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

49. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation

50. INSTALL OUTER COWL TOP PANEL Installation

51. INSTALL FRONT WIPER MOTOR AND LINK Installation

52. INSTALL COWL TOP VENTILATOR LOUVER LH Installation

53. INSTALL COWL TOP VENTILATOR LOUVER RH Installation

54. INSTALL HOOD TO COWL TOP SEAL Installation

55. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

56. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

57. INSTALL WINDSHIELD WIPER ARM COVER Installation

58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

59. ADD ENGINE OIL Replacement

60. ADD ENGINE COOLANT Service and Repair

61. INSPECT FOR FUEL LEAK

Fuel System

62. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection

63. INSPECT FOR ENGINE OIL LEAK

64. INSPECT FOR EXHAUST GAS LEAK

65. INSPECT IGNITION TIMING On-Vehicle Inspection

66. INSPECT ENGINE IDLING SPEED On-Vehicle Inspection

67. INSPECT COMPRESSION On-Vehicle Inspection

68. INSPECT CO/HC On-Vehicle Inspection

69. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

70. INSTALL NO. 1 ENGINE UNDER COVER

71. INSTALL REAR ENGINE UNDER COVER RH

72. INSTALL FRONT WHEEL RH

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

73. INSTALL HOOD

(a) Temporarily install the hood with the 4 bolts.

(b) Connect the washer hose.

74. INSPECT HOOD Adjustments

75. ADJUST HOOD Adjustments