AutoZone 1969 Toyota Truck Land Cruiser 2WD 3.9L 2BL 6cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Cylinder Head 2 | AutoZone.com

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    Lexus GS, SC 1998-06

    Cylinder Head 2

    Print

    Removal & Installation



    2jz-GE Engine
    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
    4.  
    5. Relieve the fuel pressure from the fuel lines.
    6.  
    7. Remove or disconnect the following:

      Coolant
       
      Undercovers
       
      Accelerator, throttle control (automatic transmission only) and cruise control cables from the throttle body
       
      Cleaner duct
       
      Air cleaner, airflow meter and the intake air pipe
       
      Drive belt, the fan and fluid coupling and the water pump pulley
       
      No. 2 front exhaust pipe
       
      Exhaust manifold cover
       
      2 Heated Oxygen (HO 2 ) sensor connector(s).
       
      Exhaust manifolds and gaskets by removing the 8 bolts
       
      Water bypass outlet and the No. 1 water bypass pipe
       
      Power steering air hose from the No. 4 timing belt cover
       
      Power steering hose from the air intake chamber
       
      2 bolts and the vane pump from the pump bracket.
       
      2 bolts, the pump rear stay. Put aside the vane pump and suspend it.
       
      Fuel return hose from the fuel return pipe. Plug the hose end.
       
      Fuel return hose from the oil dipstick guide.
       
      Bolt and bracket
       
      Engine wire from the intake manifold stay
       
      Throttle body and intake air connector assembly
       
      Bolt, pull out the oil dipstick guide with the dipstick and remove the O-ring from the dipstick guide.
       
      Transmission dipstick and guide, if equipped with automatic transmission
       
      Connector from the No. 2 vacuum pipe
       
      Exhaust Gas Recirculation (EGR) gas temperature sensor wiring harness
       
      2 nuts and the vacuum pipe from the air intake chamber and intake manifold.
       
      No. 2 vacuum pipe and Vacuum Switching Valve (VSV) assembly.
       
      Nuts and the vacuum tank from the intake manifold.
       
      VSV connector and hoses
       
      Vacuum hose (from the air intake chamber) from port B of the vacuum tank
       
      Vacuum hose (from actuator) from the VSV
       
      Vacuum control valve set
       
      Data Link Connector (DLC1) bracket and VSV assembly
       
      Vacuum hose from the brake booster union and the Evaporative Emission (EVAP) hose from the No. 2 vacuum pipe.
       
      Bolt holding the engine wire protector to the air intake chamber
       
      5 bolts, nut, air intake chamber and gasket
       
      No. 3 (top) timing belt cover by removing the oil filler cap and the 6 bolts using a 5mm hexagon wrench.
       
      4 bolts, using a 5mm hexagon wrench, and the rear cylinder head cover
       
      Distributor with the spark plug wires attached
       
      Spark plugs.
       
      Drive belt tensioner by removing the 3 bolts
       

    8.  
    9. Set the engine to Top Dead Center (TDC)/compression for cylinder No. 1.
    10.  
    11. Remove or disconnect the following:

      Timing belt tensioner and dust boot. Remove the timing belt from the camshaft pulleys. Support the belt so that it remains in contact with the crankshaft pulley.
       
      Wire clamp from the bracket.
       
      HO 2 and the Crankshaft Position (CKP) sensors.
       
      2 ground straps from the intake manifold.
       
      Engine Coolant Temperature (ECT) sender gauge
       
      Knock Sensor (KS)
       
      Oil pressure switch
       
      Oil level sensor
       
      air conditioning compressor
       
      6 injector electrical connectors.
       
      3 nuts and the engine wire protector from the intake manifold.
       
      Water bypass hose from the clamp on the oil filter bracket
       
      Water outlet, 2 nuts, and the bolt with the water bypass hose.
       
      2 bolts and the intake manifold stay.
       
      Fuel pressure pulsation damper.
       
      Clamp bolt from the intake manifold
       
      Union bolt and gaskets
       
      Fuel inlet pipe
       
      6 bolts, 2 nuts, the intake manifold
       
      Delivery pipe assembly and gasket
       
      Cylinder head covers (valve covers)
       
      Camshaft timing pulleys
       
      Rear (No. 4) timing belt cover
       
      Camshafts
       
      Cylinder head bolts in several passes and in the reverse order of the tightening sequence
       
      Head from the engine
       

    12.  
    13. Clean the head and block of all gasket material.
    14.  

    To install:

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.0L (2JZ-GE) engine

    1. Install or connect the following:
      WARNING
      Correct bolt torque must be achieved in 3 steps; do not attempt to shorten the procedure by combining the two 90 degree steps.



      New gasket and cylinder head on the block
       
      Head bolts, lightly coated with engine oil and plate washers. Uniformly tighten the head bolts in several passes, in sequence to 26 ft. lbs. (35 Nm). Following the correct order, tighten each bolt an additional 90 degrees. Again following the correct order, tighten the bolts another 90 degrees of rotation.
       



      Camshafts. Coat the thrust portions of each with engine oil.
       
      No. 3 and No. 7 bearing caps in place. Coat the bolt threads with oil, then uniformly and alternately tighten them temporarily.

      Click image to see an enlarged view

      Fig. Position the knock pins as shown when installing the camshafts-3.0L (2JZ-GE) engine

       



      New oil seals, coated with multi-purpose grease, over the camshafts
       
      Seal packing to the No. 1 bearing cap
       
      Remaining bearing caps in their proper locations. Coat the threads of each bolt with clean oil, then tighten them, in several passes, in the correct sequence, to 14 ft. lbs. (20 Nm).
       
      The 2 oil seals in as far as it will go
       

    2.  
    3. Rotate each camshaft until the forward straight (knock) pin is straight up. Loosen the exhaust Nos. 1, 2 and 6 bearing cap bolts until they can be turned by hand; retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). Loosen the intake Nos. 1, 2 and 5 bearing cap bolts and retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm).
    4.  
    5. Turn each camshaft 1 / 3 of a revolution (120 degrees). Loosen the exhaust Nos. 4 and 7 bearing cap bolts; retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). Loosen the intake Nos. 4 and 6 bearing cap bolts; retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm).
    6.  
    7. Turn each camshaft an additional 1 / 3 of a revolution, loosen the exhaust bearing cap bolts Nos. 3 and 5, then retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). Loosen the intake bearing cap bolts Nos. 3 and 7, then retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm).
    8.  
    9. Check and adjust the valve clearance.
    10.  
    11. Install or connect the following:

      Rear (No. 4) timing belt cover. Tighten the bolts to 78 inch lbs. (9 Nm).
       
      Camshaft timing pulleys. Align the shaft pin with the pulley groove and slide the pulley on. Install the bolt temporarily. Hold the hex portion of the camshaft with a wrench and tighten the pulley bolt to 59 ft. lbs. (79 Nm).
       
      Cylinder head covers

      Click image to see an enlarged view

      Fig. Apply sealant to the areas indicated on the cylinder head before installing the cover-3.0L (2JZ-GE) engine

       



      Intake manifold and delivery pipe with a new gasket. Tighten the 6 bolts and 2 nuts to 20 ft. lbs. (27 Nm).
       
      Fuel inlet pipe to the fuel rail. Tighten the union bolt to 30 ft. lbs. (42 Nm).
       
      Clamp bolt to the intake manifold
       
      Fuel pressure pulsation damper
       
      Intake manifold stay and tighten the bolts to 29 ft. lbs. (39 Nm)
       
      Water outlet and the bypass hose. Tighten the bolts to 15 ft. lbs. (21 Nm).
       
      Engine wiring harness. Secure the wiring in all clamps and retainers.
       
      Wiring leads to the proper sender, sensor or switch
       
      Injector leads.
       

    12.  
    13. Compress the timing belt tensioner in a vise and retain the pin with a 1.5mm hex wrench. Install the dust boot onto the tensioner.

      Click image to see an enlarged view

      Fig. Compressing the timing belt tensioner-3.0L (2JZ-GE) engine

    14.  
    15. Install the tensioner. Alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the hex wrench with a pair of pliers, allowing the tensioner to be applied to the timing belt.
    16.  
    17. Turn the crankshaft 2 full revolutions clockwise. Check that all timing marks align as before. If the marks (cam and crankshaft) do not align, remove the timing belt and reinstall it.
    18.  
    19. Install the accessory drive belt tensioner. Take great care not to drop the bolts inside the lower timing cover. Tighten the bolts to 15 ft. lbs. (21 Nm).
    20.  
    21. Double check that the engine is still set to TDC/compression for cylinder No. 1. Check the alignment of both the crank and camshaft timing marks. Install the timing belt.
    22.  
    23. Install or connect the following:

      Spark plugs
       
      Wiring to the spark plugs
       
      No. 3 timing belt cover
       
      Cylinder head rear cover
       
      Air intake chamber with a new gasket. Tighten the bolts to 20 ft. lbs. (27 Nm). Install the bolt to hold the engine wire protector to the air intake chamber.
       
      Vacuum hose to the brake booster union and the EVAP hose to the No. 2 vacuum pipe.
       
      DLC connector and bracket and VSV connector
       
      Vacuum control set
       
      No. 2 vacuum pipe assembly and connect the hoses. Tighten the nuts to 20 ft. lbs. (27 Nm).
       
      EGR gas temperature sensor. Tighten it to 14 ft. lbs. (20 Nm).
       
      Vacuum hoses
       
      Dipstick tubes. Always use a new O-ring on each tube.
       
      Intake chamber supports and tighten the bolts to 13 ft. lbs. (18 Nm). The supports are marked F and R for the front and rear positions.
       
      Throttle body and intake air connector assembly
       
      Engine wire bracket
       
      Fuel return hose
       
      Vane pump to the pump bracket
       
      Power steering air hose to the No. 4 timing belt cover and intake chamber.
       
      Water bypass outlet and the bypass pipe. Always use new O-rings.
       
      Exhaust manifolds with new gaskets. Tighten the bolts to 29 ft. lbs. (39 Nm).
       
      O 2 sensor leads.
       
      Front exhaust pipe. Tighten the bolts to 46 ft. lbs. (62 Nm).
       
      Manifold cover
       
      Water pump pulley
       
      Fan and coupling and the drive belt. Tighten the 4 nuts to 12 ft. lbs. (16 Nm).
       
      Air cleaner, airflow meter and the intake air connector pipe
       
      Air cleaner duct
       
      Control and accelerator cables to the throttle body
       
      Coolant
       
      Negative battery cable. Start the engine and check for leaks.
       
      Engine undercovers
       

    24.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
    4.  
    5. Relieve the fuel pressure from the fuel lines.
    6.  
    7. Remove or disconnect the following:

      Coolant
       
      Undercovers
       
      Accelerator, throttle control (automatic transmission only) and cruise control cables from the throttle body
       
      Cleaner duct
       
      Air cleaner, airflow meter and the intake air pipe
       
      Drive belt, the fan and fluid coupling and the water pump pulley
       
      No. 2 front exhaust pipe
       
      Exhaust manifold cover
       
      2 Heated Oxygen (HO 2 ) sensor connector(s)
       
      Exhaust manifolds and gaskets by removing the 8 bolts
       
      Water bypass outlet and the No. 1 water bypass pipe
       
      Power steering air hose from the No. 4 timing belt cover
       
      Power steering hose from the air intake chamber
       
      2 bolts and the vane pump from the pump bracket
       
      2 bolts, the pump rear stay. Put aside the vane pump and suspend it.
       
      Fuel return hose from the fuel return pipe. Plug the hose end.
       
      Fuel return hose from the oil dipstick guide
       
      Bolt and bracket
       
      Engine wire from the intake manifold stay
       
      Throttle body and intake air connector assembly
       
      Bolt, pull out the oil dipstick guide with the dipstick and remove the O-ring from the dipstick guide
       
      Transmission dipstick and guide, if equipped with automatic transmission
       
      Connector from the No. 2 vacuum pipe
       
      Exhaust Gas Recirculation (EGR) gas temperature sensor wiring harness
       
      2 nuts and the vacuum pipe from the air intake chamber and intake manifold
       
      No. 2 vacuum pipe and Vacuum Switching Valve (VSV) assembly
       
      Nuts and the vacuum tank from the intake manifold
       
      VSV connector and hoses
       
      Vacuum hose (from the air intake chamber) from port B of the vacuum tank
       
      Vacuum hose (from actuator) from the VSV
       
      Vacuum control valve set
       
      Data Link Connector (DLC1) bracket and VSV assembly
       
      Vacuum hose from the brake booster union and the Evaporative Emission (EVAP) hose from the No. 2 vacuum pipe
       
      Bolt holding the engine wire protector to the air intake chamber
       
      5 bolts, nut, air intake chamber and gasket
       
      No. 3 (top) timing belt cover by removing the oil filler cap and the 6 bolts using a 5mm hexagon wrench.
       
      4 bolts, using a 5mm hexagon wrench, and the rear cylinder head cover
       
      Spark plugs
       
      Drive belt tensioner by removing the 3 bolts
       

    8.  
    9. Set the engine to Top Dead Center (TDC)/compression for cylinder No. 1 piston
    10.  
    11. Remove or disconnect the following:

      Timing belt tensioner and dust boot. Remove the timing belt from the camshaft pulleys. Support the belt so that it remains in contact with the crankshaft pulley.
       
      Wire clamp from the bracket.
       
      HO 2 and the Crankshaft Position (CKP) sensors.
       
      2 ground straps from the intake manifold.
       
      Engine Coolant Temperature (ECT) sender gauge
       
      Knock Sensor (KS)
       
      Oil pressure switch
       
      Oil level sensor
       
      air conditioning compressor
       
      6 injector electrical connectors
       
      3 nuts and the engine wire protector from the intake manifold
       
      Water bypass hose from the clamp on the oil filter bracket
       
      Water outlet, 2 nuts, and the bolt with the water bypass hose
       
      2 bolts and the intake manifold stay
       
      Fuel pressure pulsation damper
       
      Clamp bolt from the intake manifold
       
      Union bolt and gaskets
       
      Fuel inlet pipe
       
      6 bolts, 2 nuts, the intake manifold
       
      Delivery pipe assembly and gasket
       
      Cylinder head covers (valve covers)
       
      Camshaft timing pulleys
       
      Rear (No. 4) timing belt cover
       
      Camshafts
       
      Cylinder head bolts in several passes and in the reverse order of the tightening sequence
       
      Head from the engine
       

    12.  
    13. Clean the head and block of all gasket material.

      Click image to see an enlarged view

      Fig. Showing the cylinder head bolt removal sequence-3.0L (2JZ-GE) engine

    14.  

    To install:

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.0L (2JZ-GE) engine

    1. Install or connect the following:
      WARNING
      Correct bolt torque must be achieved in 3 steps; do not attempt to shorten the procedure by combining the two 90 degree steps.



      New gasket and cylinder head on the block
       
      Head bolts, lightly coated with engine oil and plate washers. Uniformly tighten the head bolts in several passes, in sequence to 26 ft. lbs. (35 Nm). Following the correct order, tighten each bolt an additional 90 degrees. Again following the correct order, tighten the bolts another 90 degrees of rotation.
       



      Camshafts. Coat the thrust portions of each with engine oil.
       
      No. 3 and No. 7 bearing caps in place. Coat the bolt threads with oil, then uniformly and alternately tighten them temporarily.

      Click image to see an enlarged view

      Fig. Position the knock pins as shown when installing the camshafts-3.0L (2JZ-GE) engine

       



      New oil seals, coated with multi-purpose grease, over the camshafts
       
      Seal packing to the No. 1 bearing cap
       
      Remaining bearing caps in their proper locations. Coat the threads of each bolt with clean oil, then tighten them, in several passes, in the correct sequence, to 14 ft. lbs. (20 Nm).
       
      The 2 oil seals in as far as it will go
       

    2.  
    3. Rotate each camshaft until the forward straight (knock) pin is straight up. Loosen the exhaust Nos. 1, 2 and 6 bearing cap bolts until they can be turned by hand; retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). Loosen the intake Nos. 1, 2 and 5 bearing cap bolts and retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm).
    4.  
    5. Turn each camshaft 1 / 3 of a revolution (120 degrees). Loosen the exhaust Nos. 4 and 7 bearing cap bolts; retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). Loosen the intake Nos. 4 and 6 bearing cap bolts; retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm).
    6.  
    7. Turn each camshaft an additional 1 / 3 of a revolution, loosen the exhaust bearing cap bolts Nos. 3 and 5, then retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). Loosen the intake bearing cap bolts Nos. 3 and 7, then retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm).
    8.  
    9. Check and adjust the valve clearance.
    10.  
    11. Install or connect the following:

      Rear (No. 4) timing belt cover. Tighten the bolts to 78 inch lbs. (9 Nm).
       
      Camshaft timing pulleys. Align the shaft pin with the pulley groove and slide the pulley on. Install the bolt temporarily. Hold the hex portion of the camshaft with a wrench and tighten the pulley bolt to 59 ft. lbs. (79 Nm).
       
      Cylinder head covers

      Click image to see an enlarged view

      Fig. Apply sealant to the areas indicated on the cylinder head before installing the cover-3.0L (2JZ-GE) engine

       



      Intake manifold and delivery pipe with a new gasket. Tighten the 6 bolts and 2 nuts to 20 ft. lbs. (27 Nm).
       
      Fuel inlet pipe to the fuel rail. Tighten the union bolt to 30 ft. lbs. (42 Nm).
       
      Clamp bolt to the intake manifold
       
      Fuel pressure pulsation damper
       
      Intake manifold stay and tighten the bolts to 29 ft. lbs. (39 Nm)
       
      Water outlet and the bypass hose. Tighten the bolts to 15 ft. lbs. (21 Nm).
       
      Engine wiring harness. Secure the wiring in all clamps and retainers.
       
      Wiring leads to the proper sender, sensor or switch
       
      Injector leads
       

    12.  
    13. Compress the timing belt tensioner in a vise and retain the pin with a 1.5mm hex wrench. Install the dust boot onto the tensioner.

      Click image to see an enlarged view

      Fig. Compressing the timing belt tensioner-3.0L (2JZ-GE) engine

    14.  
    15. Install the tensioner. Alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the hex wrench with a pair of pliers, allowing the tensioner to be applied to the timing belt.
    16.  
    17. Turn the crankshaft 2 full revolutions clockwise. Check that all timing marks align as before. If the marks (cam and crankshaft) do not align, remove the timing belt and reinstall it.
    18.  
    19. Install the accessory drive belt tensioner. Take great care not to drop the bolts inside the lower timing cover. Tighten the bolts to 15 ft. lbs. (21 Nm).
    20.  
    21. Double check that the engine is still set to TDC/compression for cylinder No. 1. Check the alignment of both the crank and camshaft timing marks. Install the timing belt.
    22.  
    23. Install or connect the following:

      Spark plugs
       
      Wiring to the spark plugs
       
      No. 3 timing belt cover
       
      Cylinder head rear cover
       
      Air intake chamber with a new gasket. Tighten the bolts to 20 ft. lbs. (27 Nm). Install the bolt to hold the engine wire protector to the air intake chamber.
       
      Vacuum hose to the brake booster union and the EVAP hose to the No. 2 vacuum pipe.
       
      DLC connector and bracket and VSV connector
       
      Vacuum control set
       
      No. 2 vacuum pipe assembly and connect the hoses. Tighten the nuts to 20 ft. lbs. (27 Nm).
       
      EGR gas temperature sensor. Tighten it to 14 ft. lbs. (20 Nm).
       
      Vacuum hoses
       
      Dipstick tubes. Always use a new O-ring on each tube.
       
      Intake chamber supports and tighten the bolts to 13 ft. lbs. (18 Nm). The supports are marked F and R for the front and rear positions.
       
      Throttle body and intake air connector assembly
       
      Engine wire bracket
       
      Fuel return hose
       
      Vane pump to the pump bracket
       
      Power steering air hose to the No. 4 timing belt cover and intake chamber.
       
      Water bypass outlet and the bypass pipe. Always use new O-rings.
       
      Exhaust manifolds with new gaskets. Tighten the bolts to 29 ft. lbs. (39 Nm).
       
      O 2 sensor leads
       
      Front exhaust pipe. Tighten the bolts to 46 ft. lbs. (62 Nm).
       
      Manifold cover
       
      Water pump pulley
       
      Fan and coupling and the drive belt. Tighten the 4 nuts to 12 ft. lbs. (16 Nm).
       
      Air cleaner, airflow meter and the intake air connector pipe
       
      Air cleaner duct
       
      Control and accelerator cables to the throttle body
       
      Coolant
       
      Negative battery cable. Start the engine and check for leaks.
       
      Engine undercovers
       

    24.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
    4.  
    5. Relieve the fuel pressure from the fuel lines.
    6.  
    7. Remove or disconnect the following:

      Undercover(s)
       
      Coolant
       
      Upper radiator hose from water outlet
       
      Engine cover
       
      Air cleaner inlet, air cleaner assembly, MAF meter, and intake air resonator assembly
       
      Serpentine drive belt
       
      Power steering pump from mounting (Do NOT disconnect hoses)
       
      Oxygen sensor wiring and grommet for bank 2, No. 2 sensor
       
      Front exhaust pipe from exhaust manifold
       
      Exhaust manifold
       
      Vacuum control valve set and No. 2 vacuum pipe from lower side of engine
       
      No. 3 timing belt cover
       
      Ignition coils and high-tension wires
       
      Spark plugs
       

    8.  
    9. Properly mark all engine wiring before disconnecting as needed for access to cylinder head, then disconnect the following:

      Ground strap from cylinder head
       
      2 water bypass hoses from cylinder head and oil filter bracket
       
      Bank 2, No. 1 and bank 1, No. 1 oxygen sensor connectors and wire clamp
       
      Alternator wiring
       
      Wiring from water pump clamp
       
      2 ground terminals from intake manifold
       
      2 engine wire clamps from No. 1 oil pipe and clamp on intake manifold
       
      ECT, knock, oil pressure switch, and oil level sensor connectors
       
      Starter connector
       
      Injector connectors
       
      Camshaft timing oil control valve connector
       
      Camshaft position sensor connector
       
      Wiring protector from No. 2 cylinder head cover
       
      Engine wiring protector from intake manifold
       

    10.  
    11. Remove the fuel pressure pulsation damper.
    12.  
    13. Remove the intake manifold assembly, including stays.
    14.  
    15. Remove both cylinder head covers and gaskets.
    16.  
    17. While holding the timing belt so its position to timing marks does not change, remove the timing belt from the camshaft pulleys.
    18.  
    19. Remove both camshaft pulleys (exhaust pulley first, while holding the hex portion of the camshaft in order to loosen the pulley bolt).
      NOTE
      See CAMSHAFT & VALVE LIFTERS for detailed removal procedure, if needed.

    20.  
    21. Remove the No. 4 timing belt cover.
    22.  
    23. Uniformly remove the No. 3 camshaft bearing cap bolts from both camshafts. Use a screwdriver to pry out the No. 1 and No. 3 camshaft bearing caps and oil seals. Then, evenly loosen all remaining 12 camshaft bearing cap bolts, in the order shown. Remove the No. 2 camshaft bearing caps and remove the camshafts.
    24.  
    25. Loosen and remove all 14 cylinder head bolts in the sequence shown, using several passes during loosening sequence.
    26.  
    27. Lift the cylinder head from the block dowels. Disconnect the heater hose from the union. Remove the cylinder head from the vehicle and place on wooden blocks on the workbench.

      Click image to see an enlarged view

      Fig. Showing the cylinder head bolt removal sequence-3.0L (2JZ-GE) engine

    28.  

    To install:

    1. With a new gasket, position the cylinder head onto the block.
    2.  
    3. Apply a light coat of engine oil to the cylinder head bolt threads and install the washers.
    4.  
    5. Install the cylinder head bolts, following the bolt tightening sequence shown. Torque bolts to 26 ft. lbs. (35 Nm).
    6.  
    7. Mark the front of each cylinder head bolt with paint, then retighten each bolt, in the same sequence, an additional 90°. The paint mark should now face 90° to the side. Again following the correct order, tighten the bolts another 90° of rotation.

      Click image to see an enlarged view

      Fig. Cylinder head torque sequence-3.0L (2JZ-GE) engine

    8.  
    9. Install the camshafts. See CAMSHAFTS & VALVE LIFTERS section.
    10.  
    11. Check and adjust the valve lash.
    12.  
    13. Install the No. 4 timing belt cover.
    14.  
    15. Install both camshaft pulleys. Torque the exhaust camshaft pulley bolt to 60 ft. lbs. (81 Nm).
    16.  
    17. Install the timing belt back onto the camshaft pulleys, making sure the timing marks align properly.
    18.  
    19. Install both cylinder head covers, with new gaskets.
    20.  
    21. Install the intake manifold assembly.
    22.  
    23. Install the fuel pressure pulsation damper to the lower side of the engine.
    24.  
    25. Reconnect all engine wiring and hoses in reverse order of removal. Ensure components are reinstalled in original positions, as marked.
    26.  
    27. Install or reconnect the following:

      Spark plugs
       
      Ignition coils and wires
       
      No. 3 timing belt cover
       
      Vacuum control valve set and No. 2 vacuum pipe; torque nuts to 15 ft. lbs. (21 Nm)
       
      Air intake chamber
       
      Oil dipstick and guide
       
      Throttle body and intake air connector
       
      Water bypass outlet and No. 1 water bypass pipe
       
      Exhaust manifold, with new gaskets; torque nuts to 30 ft. lbs. (40 Nm)
       
      Front exhaust pipe to manifold; torque bolts and nuts to 32 ft. lbs. (44 Nm)
       
      Reconnect wire grommet and wiring for bank 2, No. 2 oxygen sensor
       
      Power steering pump to mounting; torque bolts to 43 ft. lbs. (58 Nm)
       
      Serpentine drive belt
       
      Air cleaner, MAF meter and intake air resonator
       
      Upper radiator hose
       
      Engine cover
       

    28.  
    29. Refill the coolant and engine oil. Start the engine and check for leaks or abnormal conditions. Perform and road test. Then, recheck for leaks and recheck fluid levels.
    30.  

    3.3L (3MZ-FE) Engine


    Before servicing the vehicle, refer to the Precautions section.
     
    Relieve the fuel system pressure.
     
    Remove or disconnect the following:
    1. Negative battery cable. Wait at least 90 seconds before performing any other work
    2.  
    3. Oil pan protector
    4.  
    5. Engine undercover
    6.  
    7. Coolant
    8.  
    9. Battery clamp cover
    10.  
    11. Air cleaner inlet
    12.  
    13. Lower radiator air deflector
    14.  
    15. RF wheel
    16.  
    17. V bank cover by removing the bolt and 2 cap nuts
    18.  
    19. Air cleaner and intake air connector assembly
    20.  
    21. Emission control valve
    22.  
    23. Air intake surge tank
    24.  
    25. Drive belt, fluid coupling and the fan pulley. The drive belt tension may be slackened by turning the tensioner counterclockwise. The pulley bolt for the drive belt tensioner has a left-handed thread.
    26.  
    27. PS pump drive belt
    28.  
    29. Radiator
    30.  

     
    Remove intake manifold
     
    Remove timing belt
     
    Remove PS pump assembly
     
    Front and rear exhaust pipe and brackets
     
    Remove camshafts
     
    Remove LH or RH cylinder head assemblies
     
    Remove or disconnect the following:

    The VVT Sensor connector
     
    Camshaft timing oil valve connector
     
    Engine wire harness clamp
     
    8 cylinder head bolts uniformly in the sequence
     

     


    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-3.3L (3MZ-FE) Engine



    WARNING
    Head warpage or cracking could result from removing the bolts in an incorrect order.



    Inspect the cylinder head set bolts. Ensure they match the following:
    1. Outside diameter is .3524 to .3563 in. (8.95 to 9.05mm)
    2.  
    3. Minimum diameter is .3445 in. (8.75mm)
    4.  

     
    If diameter is lees than minimum, replace the bolts.
     

    To install:



    Install new head gasket with R mark upward
     
    Install cylinder head assembly
    1. Apply light oil to the cylinder head bolts
    2.  
    3. Install plate washers on the cylinder head bolts
    4.  

     


    NOTE
    Cylinder head bolts are tightened in two successive steps. Install and tighten 8 cylinder head bolts in required sequence.



    Tighten to 40 ft. lbs. Torque 40 ft. lbs (54 Nm)
     


    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-3.3L (3MZ-FE) Engine

    Mark the front side of each head bolt with paint.
     


    Click image to see an enlarged view

    Fig. Head bolt marking procedure-3.3L (3MZ-FE) Engine

    Retighten cylinder head bolts 90 degrees in the same sequence
     
    Check that each painted mark is now at a 90 degree angle to the front
     

    1. Install or connect the following:
      1. Wiring harness clamp
      2.  
      3. Camshaft timing oil valve connector
      4.  
      5. Camshaft assemblies
      6.  
      7. Valve cover assemblies
      8.  
      9. Exhaust manifold assemblies and support brackets Torque to 36 ft. lbs. (49 Nm)
      10.  
      11. Exhaust manifold heat insulators
      12.  
      13. PS pump assembly
      14.  
      15. Timing belt inner cover
      16.  
      17. Camshaft timing pulleys
      18.  
      19. Timing belt and idler assemblies
      20.  
      21. RH engine mounting bracket
      22.  
      23. Timing belt covers
      24.  
      25. Alternator bracket
      26.  
      27. Engine mounting stay No 2
      28.  
      29. Engine stabilizer rod
      30.  
      31. PS drive belt
      32.  
      33. A/C compressor drive belt
      34.  
      35. Water outlet
      36.  
      37. Intake manifold assembly
      38.  
      39. Intake air surge tank
      40.  
      41. Emission control valve set
      42.  
      43. Air cleaner assembly
      44.  
      45. Vacuum hoses
      46.  
      47. V-bank cover sub-assembly
      48.  
      49. Front suspension upper brace
      50.  
      51. RF wheel
      52.  
      53. Install engine oil
      54.  
      55. Installed engine coolant
      56.  

    2.  
    3. Inspect for fuel leaks
    4.  
    5. Inspect for oil leaks
    6.  
    7. Inspect for exhaust leaks
    8.  
    9. Adjust engine timing and idle speed
    10.  
    11. Run system initialization
    12.  

    3gr-Fse Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Drain the engine oil.
    6.  
    7. Relieve the fuel system pressure.
    8.  
    9. Remove or disconnect the following:

      Negative battery cable. Wait at least 90 seconds before performing any other work
       
      Oil filler cap and gasket
       
      Radiator cap
       
      No. 1 and 2 engine hangers
       
      Spark plugs
       
      Ventilation valve
       
      4 camshaft position sensors
       
      4 camshaft timing oil control valves
       
      Crankshaft position sensor
       
      Left and right side oil check valve bolt, oil pipe union and oil pipe
       
      Left and right side oil control valve filter and gaskets
       
      Cylinder block water drain cocks
       
      Oil filter element
       
      Water inlet and thermostat assembly
       
      Rear water by-pass joint
       
      Cylinder head cover and gaskets
       
      Timing chain cover, timing chain and timing chain sprockets
       
      Camshaft and camshaft housing assembly
       
      Valve rocker arms. Arrange the removed rocker arms in the correct order.
       
      Valve lash adjusters. Arrange the removed valve lash adjusters in the correct order.

      Click image to see an enlarged view

      Fig. Cylinder head bolt loosening sequence (right side)-3.0L (3GR-FSE) engine



      Click image to see an enlarged view

      Fig. Cylinder head 14mm bolt loosening sequence (left side)-3.0L (3GR-FSE) engine



      Click image to see an enlarged view

      Fig. Cylinder head bolt loosening sequence (left side)-3.0L (3GR-FSE) engine

       

    10.  
    11. Remove the cylinder head (left or right) as follows:
      1. Using a 10mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
        WARNING
        Be careful not to drop washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in an incorrect order. Be sure to keep separate the removed parts for each installation position.

      2.  
      3. Remove the cylinder head and gasket.
      4.  

    12.  

    To install:

    1. Install the cylinder head to the engine as follows:
      1. Apply a continuous line approximately 2.5 to 3.0mm (0.098 to 0.118 in.) of the seal packing to a new cylinder head gasket.
        NOTE
        Remove any oil from the contact surface. Install the cylinder head gasket within 3 minutes after applying the seal packing. Install the cylinder head bolt within 15 minutes after applying the seal packing. Do not apply engine oil within 2 hours of installation.

      2.  
      3. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
        WARNING
        Be careful of the installation direction. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

      4.  
      5. Place the cylinder head on the cylinder block.
        WARNING
        Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      6.  
      7. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
      8.  
      9. Using a 10mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers to 27 ft. lbs. (36 Nm) in the sequence shown in the illustration. If any of the bolts does not meet the torque, replace it.
      10.  
      11. Mark the forward edge of each bolt with paint, then retighten each bolt, in proper sequence, an additional 90 degrees. Check that each painted mark is now at a 90 degrees angle to the front. The paint mark should have been applied to the bolt in the 9 o'clock position and should now be in the 12 o'clock position.
      12.  
      13. Tighten each bolt again, in proper sequence, an additional 90 degrees. Check that each painted mark is now facing rearward.
      14.  
      15. Tighten the 2 bolts on the left cylinder head in the order shown in the illustration. Torque to 22 ft. lbs. (30 Nm).
        NOTE
        Do not use the tightening procedure for a plastic region bolt (if equipped) when tightening bolts 1 and 2 shown in the illustration.

      16.  
      17. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.

        Click image to see an enlarged view

        Fig. Cylinder head bolt tightening sequence (right side)-3.0L (2GR-FSE) engine



        Click image to see an enlarged view

        Fig. Cylinder head 14mm bolt tightening sequence (left side)-3.0L (3GR-FSE) engine



        Click image to see an enlarged view

        Fig. Cylinder head bolt tightening sequence (left side)-3.0L (2GR-FSE) engine

      18.  

    2.  
    3. Install or connect the following:

      Valve lash adjusters
       
      Valve rocker arms
       
      Camshaft and camshaft housing assembly
       
      Timing chain cover, timing chain and timing chain sprockets
       
      Cylinder head cover
       
      New gaskets, O-ring and rear water by-pass joint. Torque to 7 ft. lbs. (10 Nm).
       
      New gasket, water inlet and thermostat assembly. Torque to 7 ft. lbs. (10 Nm).
       
      Oil filter element
       
      Adhesive sealer, left and right side cylinder block water drain cocks. Torque to 22 ft. lbs. (30 Nm).
       
      Left and right side oil control valve filter and gaskets
       
      Left and right side oil check valve bolt, oil pipe union and oil pipe. Torque to 44 ft. lbs. (60 Nm).
       
      Crankshaft position sensor. Torque to 7 ft. lbs. (10 Nm).
       
      4 camshaft timing oil control valves
       
      4 camshaft position sensors
       
      Adhesive and ventilation valve
       
      Spark plugs. Torque to 13 ft. lbs. (18 Nm).
       
      Engine hangers. Torque to 24 ft. lbs. (33 Nm).
       
      Radiator cap
       
      Oil filler cap and gasket
       
      Negative battery cable
       

    4.  
    5. Refill the coolant and engine oil. Start the engine and check for leaks or abnormal conditions. Perform and road test. Then, recheck for leaks and recheck fluid levels.
    6.  

    3UZ-FE Engine


    Click image to see an enlarged view

    Fig. Exploded view of the cylinder heads and related components-4.3L (3UZ-FE) Engine (2004 Model)



     
    Before servicing the vehicle, refer to the Precautions section.
     
    Relieve the fuel system pressure.
     
    Remove or disconnect the following, as applicable to each engine:
    1. Engine under cover
    2.  
    3. Drain engine coolant
    4.  
    5. V-bank cover
    6.  
    7. Air cleaner assembly
    8.  
    9. Intake air pipe
    10.  
    11. Radiator (if necessary)
    12.  
    13. Throttle body
    14.  
    15. Upper and lower intake manifold assembly
    16.  
    17. Camshaft position sensor and LH timing belt rear plates
    18.  
    19. RH timing belt rear plates
    20.  

     


    WARNING
    Do NOT drop anything inside timing belt cover during this procedure. Keep oil, water and dust from timing belt.



    Power steering pump from engine mount (Do NOT disconnect hoses)
     
    Catalytic converters
     
    Water inlet housing assembly
     
    Water bypass pipe, front bypass joint, and rear bypass joint
     
    Ignition coils
     
    Variable valve timing (VVT) sensors
     
    Engine hangers
     
    Oil dipsticks and guides for engine oil and transmission fluid
     
    Cylinder head covers
     
    Spark plugs
     
    Camshafts
     


    WARNING
    Since the thrust clearance of the camshaft is small, the camshaft must be kept level during removal. If not, the portion of the cylinder head receiving the camshaft thrust may crack or be otherwise damaged, causing the camshaft to later seize or break. Follow the camshaft removal procedure carefully as given in this section.



    Both oxygen sensor connectors
     
    Ground wire from LH cylinder head
     
    Engine wire bracket for oxygen sensor on LH cylinder head
     



    Uniformly loosen the 10 cylinder head bolts on each cylinder head, in several passes, following loosening sequence as shown.
     


    WARNING
    Use care so that no bolts or washers are dropped into the recesses or enclosed portions of the cylinder head or block.



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-4.3L (3UZ-FE) Engine (2004 Model)

    1. Carefully lift the cylinder head from the locating dowels on the engine block. Place cylinder heads on wooden blocks on the workbench.
    2.  
    3. If necessary, exhaust manifolds may be removed from the cylinder heads at this time.
    4.  

    To install:

    1. If removed, install exhaust manifolds to cylinder heads, with new gaskets. Ensure the white mark on the gasket is facing the manifold side.
    2.  
    3. Install and tighten the exhaust manifold bolts, in an alternating pattern, to a final torque of 32 ft. lbs. (44 Nm).
    4.  
    5. Install the heat shields.
    6.  
    7. With a new cylinder head gasket in place, carefully position the cylinder head onto the engine block locating dowels.
    8.  


    NOTE
    The cylinder head gaskets have a -3R- marks for the RIGHT cylinder head, and a -3L- mark for the LEFT cylinder head.


    NOTE
    If any cylinder head bolt appears stretched or damaged, replace it. If a bolt will not reach final torque setting, replace it.

    1. Apply a light coat of oil to the cylinder head bolt threads. Install the washers and insert the cylinder head bolts into position.
    2.  
    3. In several passes, following the tightening sequence shown, tighten the cylinder head bolts to a final torque of 44 ft. lbs. (59 Nm).
    4.  
    5. Once the bolts reach this setting, then place a white paint mark on the front of each bolt head. Using the torque wrench, turn each bolt, in the sequence shown, an additional 90°, using the paint mark as a reference.
    6.  
    7. Install or reconnect the following:
      1. Engine wiring and ground straps
      2.  
      3. Oxygen sensor wire bracket on LH cylinder head
      4.  
      5. Spark plugs
      6.  
      7. Camshafts
      8.  

    8.  
    9. Inspect and adjust the valve lash.
    10.  
    11. Install or reconnect the following:

      Cylinder head covers, with new gaskets
       
      Engine hangers
       
      VVT sensors
       
      Engine and transmission dipsticks and tubes
       
      Ignition coils
       
      Water bypass joints and pipe; torque nuts and bolt to 13 ft. lbs. (18 Nm)
       
      Water inlet housing assembly
       
      Catalytic converters, with new gaskets and new nuts; torque nuts to 46 ft. lbs. (62 Nm)
       
      Power steering pump to mounting; torque bolts to 29 ft. lbs. (39 Nm) and nut to 32 ft. lbs. (43 Nm)
       
      LH timing belt rear plates and camshaft position sensor; torque bolts to 66 inch lbs. (7.5 Nm)
       
      RH right belt rear plates; torque bolts to 66 inch lbs. (7.5 Nm)
       
      Camshaft pulleys
       
      Timing belt to camshaft pulleys
       
      Upper and lower intake manifold assembly, with new gaskets; torque bolts, in alternating pattern, to 13 ft. lbs. (18 Nm)
       
      Throttle body
       
      Radiator
       
      Intake air connector and air cleaner assembly
       

    12.  
    13. Refill the engine cooling system. Start the engine and check for leaks and proper operation.
    14.  
    15. Recheck the engine oil level.
    16.  
    17. Install the V-bank cover and the engine under cover.
    18.  


      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.3L (3UZ-FE) Engine (2004 Model)




    Click image to see an enlarged view

    Fig. Exploded view of the cylinder heads and related components-4.3L (3UZ-FE) Engine

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Relieve the fuel system pressure.
    4.  
    5. Remove or disconnect the following, as applicable to each engine:
      WARNING
      Do NOT drop anything inside timing belt cover during this procedure. Keep oil, water and dust from timing belt.


      WARNING
      Since the thrust clearance of the camshaft is small, the camshaft must be kept level during removal. If not, the portion of the cylinder head receiving the camshaft thrust may crack or be otherwise damaged, causing the camshaft to later seize or break. Follow the camshaft removal procedure carefully as given in this section.



      Engine under cover
       
      Drain engine coolant
       
      V-bank cover
       
      Air cleaner assembly
       
      Intake air pipe
       
      Radiator (if necessary)
       
      Throttle body
       
      Upper and lower intake manifold assembly
       
      Camshaft position sensor and LH timing belt rear plates
       
      RH timing belt rear plates
       



      Power steering pump from engine mount (Do NOT disconnect hoses)
       
      Catalytic converters
       
      Water inlet housing assembly
       
      Water bypass pipe, front bypass joint, and rear bypass joint
       
      Ignition coils
       
      Variable valve timing (VVT) sensors
       
      Engine hangers
       
      Oil dipsticks and guides for engine oil and transmission fluid
       
      Cylinder head covers
       
      Spark plugs
       
      Camshafts
       



      Both oxygen sensor connectors
       
      Ground wire from LH cylinder head
       
      Engine wire bracket for oxygen sensor on LH cylinder head
       

    6.  
    7. Uniformly loosen the 10 cylinder head bolts on each cylinder head, in several passes, following loosening sequence as shown.
      WARNING
      Use care so that no bolts or washers are dropped into the recesses or enclosed portions of the cylinder head or block.



      Click image to see an enlarged view

      Fig. Cylinder head bolt loosening sequence-4.3L (3UZ-FE) Engine

    8.  
    9. Carefully lift the cylinder head from the locating dowels on the engine block. Place cylinder heads on wooden blocks on the workbench.
    10.  
    11. If necessary, exhaust manifolds may be removed from the cylinder heads at this time.
    12.  

    To install:

    1. If removed, install exhaust manifolds to cylinder heads, with new gaskets. Ensure the white mark on the gasket is facing the manifold side.
    2.  
    3. Install and tighten the exhaust manifold bolts, in an alternating pattern, to a final torque of 32 ft. lbs. (44 Nm).
    4.  
    5. Install the heat shields.
    6.  
    7. With a new cylinder head gasket in place, carefully position the cylinder head onto the engine block locating dowels.
      NOTE
      The cylinder head gaskets have a -3R- marks for the RIGHT cylinder head, and a -3L- mark for the LEFT cylinder head.


      NOTE
      If any cylinder head bolt appears stretched or damaged, replace it. If a bolt will not reach final torque setting, replace it.

    8.  
    9. Apply a light coat of oil to the cylinder head bolt threads. Install the washers and insert the cylinder head bolts into position.
    10.  
    11. In several passes, following the tightening sequence shown, tighten the cylinder head bolts to a final torque of 44 ft. lbs. (59 Nm).
    12.  
    13. Once the bolts reach this setting, then place a white paint mark on the front of each bolt head. Using the torque wrench, turn each bolt, in the sequence shown, an additional 90 degrees, using the paint mark as a reference.

      Click image to see an enlarged view

      Fig. Cylinder head torque sequence-4.3L (3UZ-FE) engine

    14.  
    15. Install or reconnect the following:

      Engine wiring and ground straps
       
      Oxygen sensor wire bracket on LH cylinder head
       
      Spark plugs
       
      Camshafts
       

    16.  
    17. Inspect and adjust the valve lash.
    18.  
    19. Install or reconnect the following:

      Cylinder head covers, with new gaskets
       
      Engine hangers
       
      VVT sensors
       
      Engine and transmission dipsticks and tubes
       
      Ignition coils
       
      Water bypass joints and pipe; torque nuts and bolt to 13 ft. lbs. (18 Nm)
       
      Water inlet housing assembly
       
      Catalytic converters, with new gaskets and new nuts; torque nuts to 46 ft. lbs. (62 Nm)
       
      Power steering pump to mounting; torque bolts to 29 ft. lbs. (39 Nm) and nut to 32 ft. lbs. (43 Nm)
       
      LH timing belt rear plates and camshaft position sensor; torque bolts to 66 inch lbs. (7.5 Nm)
       
      RH right belt rear plates; torque bolts to 66 inch lbs. (7.5 Nm)
       
      Camshaft pulleys
       
      Timing belt to camshaft pulleys
       
      Upper and lower intake manifold assembly, with new gaskets; torque bolts, in alternating pattern, to 13 ft. lbs. (18 Nm)
       
      Throttle body
       
      Radiator
       
      Intake air connector and air cleaner assembly
       

    20.  
    21. Refill the engine cooling system. Start the engine and check for leaks and proper operation.
    22.  
    23. Recheck the engine oil level.
    24.  
    25. Install the V-bank cover and the engine under cover.
    26.  

     
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