Part 2

CYLINDER HEAD Continued

COMPONENTS (Part 1) (for Hatchback):

COMPONENTS (Part 2) (for Sedan):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8) (for Sedan):

COMPONENTS (Part 9) (for Sedan):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

COMPONENTS (Part 13):

COMPONENTS (Part 14):

COMPONENTS (Part 15):

COMPONENTS (Part 16):

COMPONENTS (Part 17):

COMPONENTS (Part 18):

COMPONENTS (Part 19):

COMPONENTS (Part 20):

14. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT: The cylinder head bolts are tightened in 3 successive steps.

(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.

(b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench, in the sequence shown in the illustration.
Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
(c) Mark the front of the cylinder head bolt with paint.

(d) Retighten the cylinder head bolts 90° and then an additional by 90° as shown in the illustration.
(e) Check that the paint mark is now at a 180° angle from the front.

(f) Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as shown in the illustration.
Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTICE:
^ Remove any oil from the contact surfaces.
^ Install the oil pump assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.

15. INSTALL CAMSHAFT
(a) Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then provisionally tighten the 19 bolts.

(b) Uniformly tighten the bolts in several steps in the sequence shown in the illustration and install camshaft bearing cap No. 1 and camshaft bearing cap No. 2.
Torque: Camshaft bearing cap No. 1
23 N*m (235 kgf*cm, 17 ft.*lbf)
Camshaft bearing cap No. 2
13 N*m (129 kgf*cm, 9.4 ft.*lbf)

NOTICE: Tighten each bolt uniformly while keeping the camshaft level.

16. INSTALL CHAIN SUB-ASSEMBLY
17. INSTALL CHAIN TENSIONER SLIPPER
18. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
19. INSTALL OIL PUMP SEAL
20. INSTALL OIL PUMP ASSEMBLY
21. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
22. INSTALL WATER PUMP ASSEMBLY
23. INSTALL WATER PUMP PULLEY
24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
25. INSTALL CRANKSHAFT POSITION SENSOR
26. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
27. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
28. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
29. INSTALL VENTILATION HOSE NO. 2
30. INSTALL VENTILATION HOSE
31. INSTALL IGNITION COIL NO. 1
32. INSTALL GENERATOR ASSEMBLY
33. INSTALL FAN AND GENERATOR V BELT
34. ADJUST FAN AND GENERATOR V BELT
35. INSPECT FAN AND GENERATOR V BELT

36. INSTALL MANIFOLD SUPPORT BRACKET
(a) Install the manifold support bracket with the 3 bolts.
Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)

37. INSTALL EXHAUST PIPE ASSEMBLY FRONT
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum length: 40.5 mm (1.594 in.)

If the length is not as specified, replace the compression spring.

(b) Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

NOTICE:
^ Install the exhaust pipe gasket in the correct direction.
^ Do not damage the outer surface of the exhaust pipe gasket.
^ Do not reuse the exhaust pipe gasket.
^ Do not push in the gasket with the exhaust pipe when installing.

(c) Install the exhaust front pipe assembly with the 2 compression springs and 2 bolts.
Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf)

38. CONNECT WIRE HARNESS
(a) Connect the wire harness with the 2 bolts.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)

39. INSTALL WATER BY-PASS HOSE NO. 1
(a) Install water by-pass pipe No. 1 with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

40. CONNECT HEATER WATER INLET HOSE A
(a) Connect heater water inlet hose A.

41. CONNECT HEATED OXYGEN SENSOR CONNECTOR
(a) Connect the heated oxygen sensor connector.
(b) Install the sensor bracket with the bolt.

42. CONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR
(a) Connect the engine coolant temperature sensor connector.

43. CONNECT CAMSHAFT POSITION SENSOR CONNECTOR
(a) Connect the camshaft position sensor connector.

44. CONNECT BOOSTER VACUUM TUBE
(a) Connect the booster vacuum tube.

45. CONNECT FUEL TUBE SUB-ASSEMBLY

46. INSTALL OIL LEVEL GAUGE GUIDE
(a) Apply engine oil to a new O-ring.
(b) Install the oil level gauge guide with the bolt through a new O-ring.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(c) Install the wire harness.

47. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.

(b) Install the intake manifold with the 3 bolts and 2 nuts.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

49. CONNECT UNION TO CONNECTOR TUBE HOSE
(a) Connect the union to connector tube hose.

50. CONNECT VENTILATION HOSE
(a) Connect the ventilation hose.

51. CONNECT THROTTLE WITH MOTOR BODY CONNECTOR
(a) Install the throttle with motor body connector bracket with the nut.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(b) Connect the throttle with motor body connector.
(c) Connect the wire harness clamp.

52. CONNECT WATER BY-PASS HOSE
(a) Connect the water by-pass hose.

53. CONNECT WATER BY-PASS HOSE NO. 2
(a) Connect water by-pass hose No. 2.

54. INSTALL WATER FILLER SUB-ASSEMBLY
(a) Install the water filler sub-assembly with the 2 nuts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(b) Connect radiator hose No. 1 to the cylinder head.

55. CONNECT RESERVE TANK HOSE
(a) Connect the reserve tank hose.

56. CONNECT RADIATOR HOSE NO. 3
(a) Connect radiator hose No. 3.

57. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1
58. INSTALL BATTERY TRAY
59. INSTALL BATTERY
60. ADD ENGINE OIL
61. ADD ENGINE COOLANT
62. CHECK ENGINE OIL LEVEL
63. CHECK FOR ENGINE OIL LEAKAGE
64. CHECK FOR ENGINE COOLANT LEAKAGE
65. CHECK FOR EXHAUST GAS LEAKAGE
66. CHECK FOR FUEL LEAKAGE
67. INSTALL CYLINDER HEAD COVER NO. 2
68. INSTALL ENGINE UNDER COVER RH
69. INSTALL FRONT WHEEL RH
70. INSTALL COWL TOP PANEL OUTER (for Hatchback)
71. INSTALL COWL TOP PANEL OUTER (for Sedan)
72. INSTALL COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 (for Hatchback)
73. INSTALL FRONT AIR SHUTTER SEAL RH (for Sedan)
74. INSTALL FRONT WIPER MOTOR AND LINK (for Hatchback)
75. INSTALL FRONT WIPER MOTOR AND LINK (for Sedan)
76. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback)
77. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback)
78. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan)
79. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan)
80. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan)
81. INSTALL HOOD TO COWL TOP SEAL (for Hatchback)
82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback)
83. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan)
84. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback)
85. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan)
86. INSTALL FRONT WIPER ARM HEAD CAP (for Hatchback)
87. INSTALL FRONT WIPER ARM HEAD CAP (for Sedan)