Installation

2AZ-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION

INSTALLATION

1. INSTALL CYLINDER HEAD GASKET

(a) Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.
- Remove any oil from contact surface.
- Be careful of the installation direction.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Place the cylinder head on the head gasket.
NOTE: Place the cylinder head gently in order to avoid damaging the gasket.

(b) Install the cylinder head bolts.
NOTE: The cylinder head bolts are tightened in 2 successive steps.

(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
(2) Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.
Torque: 70 Nm (714 kgf-cm, 52 ft-lbf)

(c) Mark the front of the cylinder head bolts with paint.
(d) Retighten the cylinder head bolts by 90° as shown in the illustration.
(e) Check that the paint mark is now at a 90° angle to the front.
3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
(b) Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
NOTE: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

(c) Check that there is no clearance between the gear fringe and camshaft.
(d) Tighten the flange bolt with the camshaft timing gear fixed in place.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
(e) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
4. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
NOTE: Do not damage the camshaft.

5. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the camshaft.

(b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.

(c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
(d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(e) Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.
Torque: 29.5 Nm (301 kgf-cm, 22 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTE: Install the camshaft with the timing mark of the camshaft timing gear on top.

6. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation

7. INSTALL CHAIN SUB-ASSEMBLY Installation

8. INSTALL CHAIN TENSIONER SLIPPER Installation

9. INSTALL TIMING CHAIN GUIDE Installation

10. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE Installation

11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation

13. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation

14. INSTALL ENGINE MOUNTING BRACKET RH Installation

15. INSTALL CRANKSHAFT PULLEY Installation

16. INSTALL OIL PAN SUB-ASSEMBLY Installation

17. INSTALL CRANKSHAFT POSITION SENSOR Installation

18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation

19. INSTALL SPARK PLUG Adjustments

20. INSTALL IGNITION COIL ASSEMBLY Installation

21. INSTALL IDLER PULLEY Installation

22. INSTALL ENGINE MOUNTING INSULATOR RH Installation

23. INSTALL RADIATOR RESERVOIR Installation

24. INSTALL GENERATOR ASSEMBLY

25. INSTALL FAN AND GENERATOR V BELT Installation

26. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH Installation

27. CONNECT ENGINE WIRE

(a) Connect the ground cable with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(b) Connect the camshaft position sensor connector.
(c) Connect the engine coolant temperature sensor connector.
(d) Connect the engine oil pressure switch connector.
(e) Connect the radio setting condenser connector.
(f) Connect the heater water inlet hose.
28. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the hose to the cylinder head.
29. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation

30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
(a) Install a new gasket onto the cylinder head.
(b) Temporarily tighten the exhaust manifold converter with the 5 nuts.

(d) Connect the air-fuel ratio sensor connector.
31. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
32. INSTALL NO. 2 MANIFOLD STAY

(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
33. INSTALL MANIFOLD STAY

(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
34. INSTALL FRONT EXHAUST PIPE Installation

35. INSTALL OIL DIPSTICK GUIDE
(a) Apply a light coat of engine oil to a new O-ring and install it onto the guide.

(b) Install the guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
36. INSTALL OIL DIPSTICK
37. INSTALL INTAKE MANIFOLD INSULATOR Installation

38. INSTALL INTAKE MANIFOLD Installation

39. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

40. INSTALL THROTTLE BODY Installation

41. INSTALL AIR CLEANER CAP Installation

42. ADD ENGINE OIL Replacement

43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
44. INSPECT FOR FUEL LEAK
45. ADD ENGINE COOLANT Service and Repair

46. INSPECT FOR ENGINE COOLANT LEAK
(a) Check for engine coolant leaks Testing and Inspection.
47. INSPECT FOR ENGINE OIL LEAK
48. INSPECT FOR EXHAUST GAS LEAK
49. INSPECT IGNITION TIMING Engine

50. INSPECT ENGINE IDLING SPEED Engine

51. INSPECT COMPRESSION Engine

52. INSPECT CO/HC Engine

53. INSTALL NO. 1 ENGINE COVER Installation

54. INSTALL FRONT FENDER APRON RH
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL FRONT WHEEL RH
57. INSTALL RADIATOR SUPPORT OPENING COVER