Removal and Replacement

CYLINDER HEAD

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE TIMING BELT
(a) Remove the timing belt.

4. REMOVE IGNITION COIL

5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
(a) Remove the bolt, and disconnect the wire clamp bracket from the camshaft bearing cap.
(b) Remove the bolt, and disconnect the engine wire protector from the cylinder head cover.
(c) Remove the 9 bolts, 9 seal washers and cylinder head cover.

6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove the bolt, and disconnect the wire clamp bracket from the camshaft bearing cap.
(b) Remove the 9 bolts, 9 seal washers and cylinder head cover.

7. WORK FOR PISTON AND VALVE DAMAGE PREVENTION
(a) Turn the crankshaft timing pulley counterclockwise by 45° and match the timing mark with the illustrated position.

HINT: When the No. 1 cylinder is positioned at 45° BTDC, the valve and piston do not interfere with each other even when the valve is fully open.

NOTICE: Be sure to match the cut part by turning it counterclockwise.

8. REMOVE CAMSHAFT TIMING PULLEY
(a) Hold the crankshaft with a wrench, and remove the 4 bolts and timing pulley.

9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
10. REMOVE CAMSHAFT

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Bring the service bolt hole of the sub gear upward by turning the hexagon head portion of the No. 2 camshaft with a wrench.
(b) Secure the sub gear to the main gear with a service bolt.
Recommended service bolt

HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

(c) Set a wrench to the hexagon head portion of the No. 2 camshaft. Rotate the wrench so that the timing mark (1 dot mark) on the camshaft main gear is moved approximately 10°, as shown in the illustration.

(d) Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
(e) Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.

NOTICE:
^ Do not forcibly pry the camshaft with a tool.
^ Do not damage the reception part of the thrust on the cylinder head side.

11. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Bring the service bolt hole of the sub gear upward by turning the hexagon head portion of the exhaust camshaft with a wrench.
(b) Secure the sub gear to the main gear with a service bolt.
Recommended service bolt

HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

(c) Set a wrench to the hexagon head portion of the No. 4 camshaft. Rotate the wrench so that the timing marks (2 dot marks each) on the camshaft drive and driven main gears are aligned, as shown in the illustration.

(d) Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
(e) Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.

NOTICE:
^ Do not forcibly pry the camshaft with a tool.
^ Do not damage the reception part of the thrust on the cylinder head side.

12. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY
13. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Removal procedure.

14. REMOVE REAR WATER BY-PASS JOINT
(a) Disconnect the heater inlet hose from the water bypass joint.
(b) Remove the 4 nuts, water by-pass joint and 2 gaskets.

15. REMOVE WATER INLET HOUSING
(a) Remove the 2 bolts and inlet housing.

16. REMOVE FRONT WATER BY-PASS JOINT
(a) Disconnect the ECT sensor connector.
(b) Remove the 4 nuts, water by-pass joint and 2 gaskets.

17. REMOVE FRONT TWC

RH Bank:

18. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Uniformly loosen 10 cylinder head bolts on cylinder head in several passes, in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE: Be careful not to drop washers into the cylinder head.

(b) Remove cylinder head together with the exhaust manifold.

19. REMOVE CYLINDER HEAD GASKET
20. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Remove the 4 bolts and heat insulator.

21. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Remove the 8 nuts, exhaust manifold and gasket.

22. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 in.)
If the warpage is greater than the maximum, replace the manifold.

LH Bank:

23. REMOVE CYLINDER HEAD LH
(a) Uniformly loosen 10 cylinder head bolts on cylinder head in several passes, in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE: Be careful not to drop washers into the cylinder head.

(b) Remove cylinder head together with the exhaust manifold.

24. REMOVE NO. 2 CYLINDER HEAD GASKET
25. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Remove the 4 bolts and heat insulator.

26. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Remove the 8 nuts, exhaust manifold and gasket.

27. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 in.)
If the warpage is greater than the maximum, replace the manifold

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 N*m (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 N*m (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 N*m (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 N*m (76 kgf*cm, 66 in.*lbf)

LH Bank:

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 head 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 washers into the cylinder head.

LH Bank:

(e) Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration.
Torque: 59 N*m (601 kgf*cm, 44 ft.*lbf)

(f) Mark the front of the cylinder head bolt's head with paint.
(g) Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
(h) Check that the painted mark is now at a 90° angle to the front.

RH Bank:

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

RH Bank:

(e) Install and uniformly tighten the 10 cylinder head bolts, and plate washers in the sequence shown in the illustration.
Torque: 59 N*m (601 kgf*cm, 44 ft.*lbf)

10. INSTALL FRONT WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(b) Connect the ECT connector.

11. INSTALL WATER INLET HOUSING
(a) Install a new O-ring to the water inlet housing.
(b) Apply soapy water on the O-ring.
(c) Apply seal packing to the sealing groove of the inlet housing as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Seal diameter: 2 to 3 mm (0.08 to 0.12 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the water inlet housing within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

(d) Install the water inlet and housing with the 2 bolts. Alternately tighten the bolts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

12. INSTALL REAR WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

13. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Installation procedure.

14. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY
15. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
(b) Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the No. 3 and No. 4 camshafts.
(c) Set the timing mark (2 dot marks each) of the camshaft drive and driven main gears at an angle of approximately 10°.

(d) Apply seal packing to the camshaft housing plug.
^ Remove the old packing (FIPG) material.
^ Apply seal packing to the housing plug as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(e) Install the camshaft housing plug to the cylinder head as shown in the illustration.
(f) Install the oil control valve filter to the cylinder head.

NOTICE: Be careful of the installation direction.

(g) Apply seal packing to the front bearing cap.
^ Remove any old packing (FIPG) material.
^ Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width: 1.5 to 2.0 mm (0.059 to 0.079 in.)

NOTICE: Do not apply seal packing to the front bearing cap grooves.

(h) Install the front bearing cap.

HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

(i) Install the other bearing caps in the sequence shown with the arrow mark facing forward.

(j) Push in the camshaft oil seal.

(k) Install 4 new seal washers to the bearing cap bolts (1 to 4).
(l) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (5 to 22).

NOTICE: Do not apply engine oil under the heads of the bearing cap bolts (1 to 4).

(m) Install the oil feed pipe and the 22 bearing cap bolts.
(n) Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque:
7.5 N*m (76 kgf*cm, 66 ft.*lbf) for bolts 21 and 22
16 N*m (163 kgf*cm, 12 in.*lbf) for other bolts

(o) Remove the service bolt.

16. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

17. INSTALL CAMSHAFT TIMING PULLEY SUBASSEMBLY LH
(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
(b) Attach the timing pulley to the camshaft timing tube.
Face the timing pulley's "L" mark forward.
(c) Hold the camshaft with a wrench and install the 4 pulley bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

18. INSTALL CAMSHAFT

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Apply engine oil to the cam and gear of the camshaft and also the journal of the cylinder head.
(b) Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the intake and exhaust camshafts.
(c) Set the timing mark (1 dot mark each) of the camshaft drive and driven main gears at an angle of approximately 10°.

(j) Push in the camshaft oil seal.

(o) Remove the service bolt.

19. INSTALL INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

20. INSTALL CAMSHAFT TIMING PULLEY SUBASSEMBLY RH
(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
(b) Attach the timing pulley to the camshaft timing tube.
Face the timing pulley's "R" mark forward.
(c) Hold the camshaft with a wrench and install the 4 pulley bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads 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 5 minutes after applying seal packing.
^ Do not start the engine within 2 hours after installing.

(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts.
Uniformly tighten the bolts in several passes.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
(f) Install the wire clamp bracket on the engine wire to the cylinder head.
(g) Install the wire clamp bracket on the engine wire to the camshaft bearing cap.

22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads 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 5 minutes after applying seal packing.
^ Do not start the engine within 2 hours after installing.

(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts.
Uniformly tighten the bolts in several passes.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
(f) Install the wire clamp bracket on the engine wire to the cylinder head.
(g) Install the wire clamp bracket on the engine wire to the camshaft bearing cap.

23. INSTALL IGNITION COIL
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

24. INSTALL TIMING BELT
(a) Install the timing belt.

25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
26. PERFORM INITIALIZATION
(a) Perform initialization.

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