Cylinder Head (for Bank 2)
CYLINDER HEAD (for Bank 2)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):
COMPONENTS (Part 12):
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE OIL
4. REMOVE ENGINE ASSEMBLY
5. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
6. REMOVE CHAIN SUB-ASSEMBLY
7. REMOVE NO.1 COOL AIR INLET
(a) Remove the 2 bolts, then remove the cool air inlet.
8. REMOVE FRONT NO.2 EXHAUST PIPE ASSEMBLY
9. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts, then remove the exhaust manifold stay.
10. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 6 nuts, then remove the exhaust manifold and gasket.
11. REMOVE INTAKE MANIFOLD
12. REMOVE WATER BY-PASS JOINT RR
13. REMOVE NO.1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts, then remove the chain vibration damper No. 1.
14. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (for Bank 2)
(a) While pushing down the chain tensioner No. 2, insert a pin of [diameter] 10 mm (0.039 inch) into the hole to fix it.
(b) Hold the hexagonal portion of the camshaft with a wrench.
NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench.
(c) Remove the 2 bolts, then remove the camshaft timing gear, camshaft timing gear assembly and timing chain No. 2.
NOTICE: Do not disassemble the camshaft timing gear assembly.
15. REMOVE NO.2 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt, then remove the chain tensioner No. 3.
16. REMOVE CAMSHAFTS
NOTICE: Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.
(a) Using several steps, uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 8 bearing caps and 2 camshafts.
17. REMOVE CYLINDER HEAD LH
(a) Remove the bolt, then separate the ground cable.
(b) Using several steps, remove the 2 cylinder head bolts on the cylinder head in the sequence shown in the illustration.
(c) Using several steps, uniformly loosen the 8 cylinder head bolts on the cylinder head with a 10 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 8 cylinder head bolts and 8 plate washers.
NOTICE:
^ Be careful not to drop the plate washers into the cylinder head.
^ Cylinder head warpage or cracking could result form removing the bolts in the wrong order.
(d) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.
NOTICE: Be careful not to drop the plate washers into the cylinder head.
If the cylinder head is difficult to remove, pry between the cylinder head and cylinder block with a screwdriver.
18. REMOVE NO.2 CYLINDER HEAD GASKET
INSTALLATION
1. INSTALL NO.2 CYLINDER HEAD GASKET
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder head and cylinder block.
(b) Apply a continuous bead of seal packing (diameter 2.5 to 3.0 mm (0.098 to 0.118 inch)) to a new cylinder head gasket as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE: Install the cylinder head within 3 minutes of applying the seal packing. Tighten the cylinder head bolts within 15 minutes of installing the cylinder head. Otherwise, the seal packing must be removed and reapplied.
(c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
NOTICE:
^ Be careful of the installation direction.
^ Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD LH
(a) Place the cylinder head on the cylinder head gasket.
(b) Install the 8 cylinder head bolts.
HINT:
^ The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)).
^ If any cylinder head bolts are broken or deformed, replace them.
(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(2) Install the plate washer onto the cylinder head bolt.
(3) Using several steps, tighten each bolt uniformly with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
If any cylinder head bolts do not meet the torque specification, replace them.
NOTICE: Do not drop the washers into the cylinder head.
(4) Mark the front side of each cylinder head bolt with paint.
(5) Retighten the cylinder head bolts 180° as shown.
(6) Check that the painted marks are now at 180° from the engine front.
(c) Install the 2 cylinder head bolts.
(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(2) Using several steps, uniformly install and tighten the 2 cylinder head bolts in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
(d) Install the ground cables with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
3. INSTALL CAMSHAFTS
NOTICE: Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.
(a) Set the crankshaft position.
(1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key in the left horizontal position.
NOTICE: Installing the crankshaft at the wrong angle could cause the piston head and valve head to come into contact with each other when installing the camshaft. This could cause damage, so always set the crankshaft at the correct angle.
(b) Apply new engine oil to the thrust portion and journal of the camshafts.
(c) Place the 2 camshafts onto the cylinder head with the cam lobes of No. 1 cylinder facing in the directions as shown in the illustration.
(d) Install the 8 bearing caps in the proper locations as shown.
(e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
(f) Using several steps, uniformly install and tighten the 16 bearing cap bolts in the sequence shown in the illustration.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
24 Nm (245 kgf-cm, 18 ft. lbs.) for 12 mm (0.47 inch) head
4. INSTALL NO.2 CHAIN TENSIONER ASSEMBLY
(a) While pushing in the tensioner, insert a pin of [diameter] 1.0 mm (0.039 inch) into the hole to fix it.
(b) Install the chain tensioner No. 2 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
5. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (for Bank 2)
(a) Align the yellow mark links with the timing marks (1 dot mark and 2 dot marks) of camshaft timing gears as shown in the illustration.
(b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain onto the LH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.
NOTICE: Do not push camshaft timing gear assembly onto the camshaft forcibly when installing it.
(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
(e) Remove the pin from the tensioner No. 2.
6. INSTALL NO.1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
7. INSTALL WATER BY-PASS JOINT RR
8. INSTALL INTAKE MANIFOLD
9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Set a new gasket to the LH cylinder head with the oval shape facing forward.
NOTICE: Be careful of the installation direction.
(b) Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)
(c) Connect the air fuel ratio sensor connector.
10. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
11. INSTALL NO.2 EXHAUST FRONT PIPE ASSEMBLY
12. INSTALL NO.1 COOL AIR INLET
(a) Install the cool air inlet with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9.0 ft. lbs.)
13. INSTALL CHAIN TENSIONER SLIPPER
14. INSTALL NO.1 CHAIN TENSIONER ASSEMBLY
15. INSTALL CHAIN SUB-ASSEMBLY
16. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
17. INSTALL ENGINE ASSEMBLY
18. INSTALL BATTERY
19. ADD ENGINE COOLANT
20. ADD ENGINE OIL
21. CHECK FOR ENGINE COOLANT LEAKAGE
22. CHECK FOR ENGINE OIL LEAKAGE
23. CHECK FOR FUEL LEAKAGE
24. CHECK FOR EXHAUST GAS LEAKAGE
25. INSPECT IGNITION TIMING
26. INSPECT ENGINE IDLING SPEED
27. INSPECT CO/HC
28. INSPECT COMPRESSION