Installation
2UZ-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 2):
INSTALLATION
1. INSPECT CYLINDER HEAD SET BOLT (Engine Unit)
2. INSPECT CYLINDER HEAD (Testing and Inspection)
3. INSTALL CYLINDER HEAD GASKET RH
(a) Clean the cylinder block and cylinder head with solvent.
(b) Place a new cylinder head gasket in position on the cylinder block.
HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH sides, a "2R" mark for the RH side and a "2L" mark for the LH side.
NOTE: Be careful of the installation direction.
4. INSTALL CYLINDER HEAD RH
(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 with the exhaust manifold to the cylinder block.
NOTE: Ensure that no oil is on the mounting surface of the cylinder head.
(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(d) Step 1:
(1) Set the plate washer to the cylinder head bolt.
(2) Install and uniformly tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration.
Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
HINT: The cylinder head bolts are tightened in 3 progressive steps.
NOTE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
(e) Step 2:
(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
(f) Step 3:
(1) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
(2) Check that the painted marks are now facing rearward.
5. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil to the valve lifters and shims.
(b) Install the valve lifters and shims to the cylinder head.
(c) Check that the valve lifter rotates smoothly by hand.
6. INSTALL CAMSHAFT SETTING OIL SEAL (Reassembly)
7. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY (Reassembly)
8. INSTALL CAMSHAFT SUB-ASSEMBLY RH
NOTICE:
- As 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 which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out.
- Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration.
(a) Apply a light coat of engine oil to the cam lobe and gear of the camshaft and also the journal of the cylinder head.
(b) Using a wrench, align the timing marks (1 dot marks each) of the camshaft drive and driven main gears, and set the No. 1 and No. 2 camshafts in place.
(c) Install the bearing cap.
(1) Apply seal packing to the camshaft housing plug groove.
HINT: Remove any old packing (FIPG) material before applying new seal packing.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
(2) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.
- Be careful of the installation direction.
- Remove any oil from the contact surface.
(3) Apply seal packing to the No. 1 bearing cap as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
1.5 to 2.0 mm (0.0591 to 0.0787 in.)
- Do not apply seal packing to the front bearing cap grooves.
- Install the No. 1 bearing cap and housing plug within 3 minutes.
(4) Install 4 new seal washers to the bearing cap bolts (A and B).
(5) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (C to E).
NOTE: Do not apply engine oil to the bearing cap bolts (A and B).
(6) Temporarily install the oil feed pipe and bearing caps with the 22 bolts, as shown in the illustration.
Bolt length:
(7) Push in the camshaft setting oil seal.
(8) Uniformly tighten the 22 bearing cap bolts in several steps, in the sequence shown in the illustration.
for bolt 21, 22 - Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
for other bolt - Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
(d) Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.
(e) Remove the service bolt.
9. INSTALL REAR NO. 1 TIMING BELT PLATE RH
(a) Install the No. 1 timing belt plate and No. 2 timing belt plate with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
10. INSTALL CAMSHAFT TIMING PULLEY RH
(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
(b) Temporarily install the 4 bolts of the camshaft timing pulley.
(c) Hold the hexagonal portion of the camshaft with a wrench.
(d) Using a 5 mm hexagon wrench, tighten the 4 bolts.
Torque: 8.1 Nm (83 kgf-cm, 72 in-lbf)
11. INSTALL TIMING BELT (Installation)
12. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION (Installation)
13. INSPECT VALVE CLEARANCE
(a) Inspect the valve clearance (Adjustments).
If the result is not as specified, adjust the valve clearance (Adjustments).
14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
(a) Apply seal packing to the semicircular plug grooves.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
(b) Install the 2 semicircular plugs to the cylinder heads.
(c) Install the gasket to the cylinder head cover.
(d) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes after applying seal packing.
(e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
15. INSTALL SPARK PLUG
16. INSTALL IGNITION COIL ASSEMBLY (Installation)
17. INSTALL REAR WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts and connect the air hose.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
HINT: With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine rear side.
18. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Apply soapy water to a new O-ring and install it to the water by-pass pipe.
(b) Push in the water by-pass pipe end into the pipe hole of the water pump.
(c) Install the water by-pass pipe with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
19. INSTALL FRONT WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
HINT: With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine front side.
20. INSTALL WATER INLET HOUSING (Installation)
21. INSTALL INTAKE MANIFOLD (Installation)
22. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 2) (Installation)
23. INSTALL NO. 2 AIR TUBE (Installation)
24. INSTALL NO. 2 AIR INJECTION SYSTEM HOSE (Installation)
25. INSTALL NO. 1 WATER BY-PASS PIPE (Installation)
26. INSTALL FRONT FENDER APRON SEAL RH (Installation)
27. CONNECT FUEL MAIN TUBE (Installation)
28. CONNECT FUEL RETURN TUBE (Installation)
29. INSTALL NO. 2 WATER BY-PASS PIPE (Installation)
30. CONNECT VACUUM HOSE ASSEMBLY (Installation)
31. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (Installation)
32. INSTALL NO. 1 TIMING BELT COVER (Installation)
33. INSTALL CRANKSHAFT PULLEY (Installation)
34. INSTALL FAN BRACKET SUB-ASSEMBLY (Installation)
35. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (Installation)
36. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY (Installation)
37. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH (Installation)
38. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH (Installation)
39. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (Installation)
40. INSTALL OIL COOLER PIPE (Installation)
41. CONNECT COOLER COMPRESSOR ASSEMBLY (Installation)
42. INSTALL GENERATOR ASSEMBLY (Installation)
43. CONNECT VANE PUMP ASSEMBLY (Installation)
44. INSTALL FLUID COUPLING ASSEMBLY (Installation)
45. INSTALL FAN AND GENERATOR V BELT (Installation)
46. INSTALL RADIATOR HOSE OUTLET
47. INSTALL RADIATOR HOSE INLET
48. INSTALL AIR CLEANER ASSEMBLY (Installation)
49. INSTALL AIR CLEANER HOSE ASSEMBLY (Installation)
50. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (Installation)
51. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY (Installation)
52. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Install the windshield wiper motor (Installation).
53. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) for Regular cab standard deck, refer to the following procedures (Installation).
(b) except Regular cab standard deck, refer to the following procedures (Installation).
54. ADD ENGINE OIL (Replacement)
55. ADD ENGINE COOLANT (Service and Repair)
56. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected (Repair Instruction - Initialization).
57. INSPECT FOR OIL LEAK (Replacement)
58. INSPECT FOR COOLANT LEAK (Testing and Inspection)
59. INSPECT FOR FUEL LEAK (Fuel System)
60. INSPECT FOR EXHAUST GAS LEAK (Installation)
61. CHECK ENGINE OIL LEVEL (Testing and Inspection)
62. INSPECT IGNITION TIMING (Engine)
63. INSPECT ENGINE IDLE SPEED (Engine)
64. INSTALL NO. 1 ENGINE UNDER COVER (Replacement)