Installation
2TR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
(a) Apply continuous beads of seal packing to the cylinder block upper side and cylinder head gasket upper side as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width:
4 to 7 mm (0.15 to 0.28 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head gasket within 3 minutes of applying the seal packing.
* Install the cylinder head bolt within 15 minutes of applying the seal packing.
* Do not pour in engine oil for at least 4 hours after installation.
(b) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp facing upward.
NOTICE:
* Make sure that the cylinder head gasket is installed in the correct direction.
* Place the cylinder head gently in order to avoid damaging the gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
HINT
The cylinder head bolts are tightened in 2 successive steps.
(a) Place the cylinder head on the cylinder block.
(b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(c) Using several steps, uniformly install and tighten the 10 cylinder head bolts with plate washers with a 10 mm bi- hexagon wrench in the sequence shown in the illustration.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts by 90° in the same order as in step (c).
(f) Retighten the cylinder head bolts by an additional 90°.
(g) Check that the painted mark is at a 180° from the original position.
(h) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
(i) Install the wire harness bracket with the bolt.
(j) Install the wire harness with the bolts.
(k) Connect the engine coolant temperature sensor connector.
(l) Install the water hose.
3. INSPECT VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
* Keep the lash adjuster free from dirt and foreign objects.
* Only use clean engine oil.
(a) Place the lash adjuster into a container full of engine oil.
(b) Insert the tip of SST into the lash adjuster's plunger and press down the checkball inside the plunger.
SST : 09276-75010
(c) Firmly hold SST and lash adjuster together and move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed air.
OK:
Plunger moves up and down.
NOTICE:
When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, the air will not bleed.
(e) After bleeding the air, remove SST. Then quickly and firmly press the plunger with a finger.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
4. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Install the valve lash adjuster.
5. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Install the 16 valve rocker arms.
6. INSTALL CAMSHAFT Installation
7. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
8. INSTALL CHAIN SUB-ASSEMBLY Installation
9. INSTALL CHAIN TENSIONER SLIPPER Installation
10. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation
11. INSTALL TIMING CHAIN GUIDE Installation
12. INSTALL TIMING CHAIN COVER Installation
13. INSTALL OIL PAN SUB-ASSEMBLY Installation
14. INSTALL OIL STRAINER SUB-ASSEMBLY Installation
15. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Installation
16. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
17. INSTALL CRANKSHAFT PULLEY Installation
18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
19. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET Installation
20. INSTALL CAMSHAFT POSITION SENSOR Installation
21. INSTALL CRANKSHAFT POSITION SENSOR Installation
22. INSTALL IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System) Installation
23. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY Installation
24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
25. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with 8 new nuts.
Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)
26. INSTALL AIR SWITCHING VALVE ASSEMBLY Installation
27. INSTALL INTAKE PIPE INSULATOR Installation
28. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
29. INSTALL GENERATOR ASSEMBLY Installation
30. INSTALL INTAKE AIR CONNECTOR Installation
31. INSTALL REAR END PLATE
(a) Install the rear end plate with the 2 bolts.
Torque : 18 Nm (178 kgf-cm, 13 ft-lbf)
32. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) Installation
33. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) Installation
34. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)
35. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)
36. INSTALL ENGINE ASSEMBLY Installation
37. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
38. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)
39. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation
40. INSTALL EXHAUST PIPE ASSEMBLY TAIL Installation
41. CONNECT ENGINE WIRE
42. CONNECT NO. 1 AIR INJECTION HOSE Installation
43. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
44. CONNECT NO. 2 FUEL HOSE Installation
45. CONNECT FUEL HOSE Installation
46. INSTALL WATER HOSE SUB-ASSEMBLY Installation
47. INSTALL RADIATOR HOSE INLET
48. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (With Air Conditioning) Installation
49. INSTALL NO. 2 RADIATOR HOSE
50. INSTALL VANE PUMP ASSEMBLY Installation
51. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
52. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
53. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
54. INSTALL FAN SHROUD Installation
55. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH Installation
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. ADD ENGINE OIL Installation
59. ADD ENGINE COOLANT Service and Repair
60. CHECK ENGINE OIL LEVEL
61. CHECK FOR FUEL LEAKAGE
62. CHECK FOR ENGINE COOLANT LEAKAGE Testing and Inspection
63. CHECK FOR OIL LEAKAGE
64. CHECK FOR EXHAUST GAS LEAKAGE
65. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type)
(a) Install the No. 1 engine under cover with the 4 bolts.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
66. INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type, Regular Cab)
(a) Install the No. 2 engine under cover with the 4 bolts.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
67. INSTALL HOOD SUB-ASSEMBLY
Reassembly