Installation

1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION

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 surfaces of the cylinder head and cylinder block.

(b) Apply seal packing (diameter: 2.5 to 3 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

NOTE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. 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 upper side facing 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 (Procedures "A" and "B").
- If any cylinder head bolt is 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 to the cylinder head bolt.

(3) Using several steps, tighten each bolt uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration (Procedure "A").
Torque: 36 Nm (367 kgf-cm, 27 ft-lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

NOTE: Do not drop the washers into the cylinder head.

(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, install and tighten the 2 cylinder head bolts uniformly in the sequence as shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
(d) Install the ground cable with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
3. INSTALL CYLINDER HEAD GASKET
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

(c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing 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.

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(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 (Procedures "A" and "B").
- If any cylinder head bolt is 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 to the cylinder head bolt.

(4) Mark the front side of each cylinder head bolt with paint.
(5) Retighten the cylinder head bolts 180° as shown (Procedure "B").
(6) Check that the painted marks are now at 180° opposite to the engine front.
(c) Install the ground cables with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
5. INSTALL CAMSHAFTS (for Bank 2)

NOTE: As 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 which receives 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) Set the crankshaft position.
(1) Install the crankshaft pulley set bolt, and turn the crankshaft, and set the crankshaft set key at the left horizontal position.

NOTE: Setting the crankshaft at a wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.

(b) Apply new engine oil to the thrust portions and journals of the camshafts.

(c) Place the 2 camshafts onto the cylinder head with the cam lobes of No. 2 cylinder facing each correct direction as shown in the illustration.

(d) Install the 8 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(f) Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.
For 10 mm (0.39 in.) head - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
For 12 mm (0.47 in.) head - Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
6. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) While pushing in the tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it.

(b) Install the No. 3 chain tensioner with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
7. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) Align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the 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 to the LH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.

NOTE: Do not push the camshaft timing gear assembly to 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 No. 3 tensioner.
8. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
9. INSTALL NO. 2 CAMSHAFT BEARING

(a) Install the No. 2 camshaft bearing to the cylinder head.

NOTE: Clean the backside of the bearing and the contact surface of the cylinder head and prevent oil from adhering to them.

10. INSTALL CAMSHAFTS (for Bank 1)

NOTE: As 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 which receives 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) Set the crankshaft position.
(1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position.

NOTE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.

(b) Apply new engine oil to the thrust portions and journals of the camshafts.

(c) Place the 2 camshafts onto the cylinder head with the cam lobes of No. 1 cylinder facing each direction as shown in the illustration.

(d) Install the 8 bearing caps in their proper locations.
(e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(g) Turn the camshafts clockwise until the knock pin comes to 90° position to the cylinder head.
11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) While pushing in the tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it.

(b) Install the No. 2 chain tensioner with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) Align the mark links (yellow) with the timing marks (1-dot mark) of the 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 to the RH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.

NOTE: Do not push the camshaft timing gear assembly to 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 No. 2 tensioner.
13. INSTALL WATER BY-PASS JOINT RR

(a) Install a new O-ring to the water outlet pipe.
(b) Apply soapy water to the O-ring.
(c) Install 2 new gaskets and water by-pass joint RR with the 2 bolts and 4 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(d) Connect the heater hose.
(e) Connect the engine coolant temperature sensor connector.
14. INSTALL INTAKE MANIFOLD

(a) Set a new gasket on each cylinder head.

NOTICE:
- Align the port holes of the gasket and cylinder head.
- Be careful of the installation direction.

(b) Set the intake manifold on the cylinder heads.
(c) Install and tighten the 10 bolts uniformly in several steps.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
(d) Connect the 6 fuel injector connectors.
15. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Installation
16. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Installation
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Set a new gasket to the LH cylinder head with the oval shape facing backward.

NOTE: Be careful of the installation direction.

(b) Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
(c) Connect the A/F sensor connector.
18. INSTALL NO. 2 MANIFOLD STAY
(a) Install the No. 2 manifold stay with the 3 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
19. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY Installation
20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Set a new gasket to the RH cylinder head with the oval shape facing forward.

NOTE: Be careful of the installation direction.

(b) Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
(c) Connect the A/F sensor connector.
21. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
22. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation
23. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the oil filler tube.
(b) Push in the oil filler tube end into the oil pan lower tube.
(c) Install the oil filler tube with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
(d) Install the ATF level gauge.
24. INSTALL NO. 1 COOL AIR INLET
(a) Install the cool air inlet with air cleaner hose with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
25. INSTALL CHAIN SUB-ASSEMBLY

HINT: Installation

26. ADD ENGINE OIL Installation
27. ADD ENGINE COOLANT Service and Repair
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. INSPECT ENGINE IDLE SPEED Engine
33. INSPECT COMPRESSION Engine
34. INSPECT CO/HC Engine