Installation
1GR-FE ENGINE MECHANICAL: CYLINDER HEAD (for Bank 2 4WD and Pre-Runner): 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 in.)) 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 it.
(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, uniformly tighten each bolt with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)
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 as shown in the illustration.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
(d) Install the ground cables with the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
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 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 leads of the bearing cap bolts.
(f) Using several steps, uniformly install and tighten the 16 bearing cap bolts in the sequence as shown in the illustration.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf) for 10 mm (0.39 in.) head
Torque : 24 Nm (245 kgf-cm, 18 ft-lbf) for 12 mm (0.47 in.) head
4. INSTALL NO.2 CHAIN TENSIONER ASSEMBLY
(a) While pushing in the tensioner, insert a pin of dia 1.0 mm (0.039 in.) into the hole to fix it.
(b) Install the chain tensioner No. 2 with the bolt.
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
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-lbf)
(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-lbf)
7. INSTALL WATER BY-PASS JOINT REAR Installation
8. INSTALL INTAKE MANIFOLD Installation
9. CONNECT NO.2 FUEL PIPE SUB-ASSEMBLY
10. CONNECT NO.1 FUEL PIPE SUB-ASSEMBLY Installation
11. 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-lbf)
(c) Connect the air fuel ratio sensor connector.
12. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
13. INSTALL NO.2 EXHAUST PIPE ASSEMBLY
Installation
14. 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-lbf)
15. INSTALL CHAIN TENSIONER SLIPPER
16. INSTALL NO.1 CHAIN TENSIONER ASSEMBLY Installation
17. INSTALL CHAIN SUB-ASSEMBLY
Installation
18. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
Installation
19. INSTALL DIFFERENTIAL CARRIER ASSEMBLY FRONT (for 4WD)
Installation
20. INSTALL POWER STEERING LINK ASSEMBLY
Installation
21. INSTALL BATTERY
22. ADD ENGINE OIL Installation
23. ADD ENGINE COOLANT Service and Repair
24. ADD DIFFERENTIAL OIL (for 4WD)
25. INSPECT DIFFERENTIAL OIL (for 4WD) Adjustments
26. ADD POWER STEERING FLUID
27. BLEED POWER STEERING FLUID Power Steering System
28. CHECK FOR ENGINE OIL LEAKAGE
29. CHECK FOR ENGINE COOLANT LEAKAGE Service and Repair
30. CHECK FOR FUEL LEAKAGE
31. CHECK FOR EXHAUST GAS LEAKAGE
32. CHECK FOR POWER STEERING FLUID LEAKAGE
33. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Service and Repair
34. INSPECT IGNITION TIMING Engine
35. INSPECT ENGINE IDLING SPEED Engine
36. INSPECT CO/HC Engine
37. INSPECT COMPRESSION Engine