Lexus Car ES, IS, LS 1998-06

Cylinder Head 1

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Removal & Installation



1MZ-FE Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator and the throttle cables
     
    Air cleaner cover, air flow meter and the air duct
     
    Cruise control actuator and bracket, if equipped
     
    2 engine ground straps
     
    Right engine mounting support
     
    Radiator hoses
     
    2 heater hoses
     

  8.  
  9. Plug the fuel feed and return lines from the fuel rail assembly.
  10.  
  11. Plug the pressure hose from the hydraulic motor
  12.  
  13. Remove or disconnect the following:

    V-bank cover
     
    Fuel pressure control Vacuum Switching Valve (VSV)
     
    Fuel pressure regulator
     
    Cylinder head rear plate
     
    Intake air control valve VSV
     
    Exhaust Gas Recirculation (EGR) vacuum modulator
     
    EGR valve
     
    Intake Air Control (IAC) valve
     
    Fuel pressure regulator
     
    EGR VSV
     
    2 nuts and the emission control valve set
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Intake air control valve vacuum hose
     
    Data link connector from the mounting bracket
     
    2 ground straps from the intake chamber
     
    Hydraulic motor pressure hose from the intake chamber
     
    Right Oxygen (O2) sensor connector from the power steering pressure tube
     
    2 nuts and the power steering pressure tube from the intake chamber
     
    2 power steering air hoses
     
    Engine hanger and the intake chamber support
     
    EGR pipe and gaskets
     
    Throttle Pressure (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    EGR gas temperature connector
     
    air conditioning idle up connector
     
    2 vacuum hoses from the Thermal Vacuum Valve (TVV)
     
    Vacuum hose from the cylinder head rear plate
     
    Vacuum hose from the charcoal canister
     
    Air assist hose and the 2 Water by-pass hoses
     
    Air intake chamber
     
    Left engine wiring harness and position it out of the way
     
    Wiring harness from the rear of the engine
     
    Right engine wiring harness and position it out of the way
     
    Ignition coils and the spark plugs
     
    Timing belt
     
    Camshaft pulleys and the timing belt rear cover
     
    Cylinder head rear plate
     
    Water inlet pipe
     
    Air assist hose and vacuum hose
     
    Intake manifold and fuel rail assembly
     
    Water outlet
     
    EGR pipe from the right exhaust manifold
     
    Exhaust manifolds
     
    Dipstick assembly and the power steering pump bracket
     
    Valve covers and the Camshaft Position (CMP) sensor
     
    Camshafts
     

  14.  
  15. Be sure the engine is at or near ambient temperature and remove the 2 (one on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the tightening sequence. Carefully lift the head from the engine; if it is necessary to pry the head loose, take great care not to damage the mating surfaces. Place the head on wood blocks in a clean work area.
  16.  


WARNING
If the cylinder head bolts are loosened out of sequence, warpage or cracking could result.

  1. Remove the cylinder head gasket. With a gasket scraper, carefully remove all the old gasket material from the cylinder head and engine block surfaces.
  2.  

To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L (1MZ-FE) engine

  1. Place the new cylinder head gasket onto the cylinder block. Place the cylinder head onto the gasket.
  2.  
  3. Coat the threads of the 8 cylinder head bolts (12-sided) with clean engine oil and install the bolts into the cylinder head. Uniformly tighten the bolts in sequence in 3 steps to an ultimate tighten of 40 ft. lbs. (54 Nm). If any of the bolts does not meet the torque, replace it.
  4.  
  5. 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.
  6.  
  7. Coat the threads of the 2 remaining 8mm bolts with engine oil and install them. Tighten to 13 ft. lbs. (18 Nm).
  8.  
  9. Install or connect the following:

    Camshafts and adjust the valves
     

  10.  


NOTE
Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads.



Cylinder head covers. Use new gaskets.
 
Dipstick and power steering pump bracket
 
Exhaust manifolds. Tighten the nuts to 36 ft. lbs. (49 Nm).
 
EGR pipe to the right exhaust manifold
 
Water outlet
 
Intake manifold and the fuel rail assembly. Tighten the intake manifold nuts and bolts to 11 ft. lbs. (15 Nm).
 
Air assist hose and the 2 water bypass hoses
 
Water inlet pipe and the cylinder head rear plate
 
Timing belt rear cover and the camshaft pulleys
 
Timing belt
 
Spark plugs and the ignition coils
 
Right engine wiring harness
 
Wiring harness to the rear of the engine
 
Left engine wiring harness
 
Air intake chamber
 
EGR pipe. Use new gaskets
 
2 TVV vacuum hoses
 
Vacuum hose to the rear cylinder head plate
 
Charcoal canister vacuum hose
 
TP sensor connector
 
IAC valve connector
 
EGR gas temperature connector
 
Air conditioning idle up connector
 
Engine hanger and the intake chamber support
 
2 power steering air hoses
 
Power steering pressure tube to the intake chamber
 
O2sensor connector to the pressure tube
 
2 ground straps to the intake chamber
 
Data link connector to the bracket
 
Power brake booster vacuum hose
 
PCV hose
 
IAC valve vacuum hose
 
Emission control valve set and related vacuum hoses and connectors
 
V-bank cover
 
Pressure hose to the hydraulic motor
 
Fuel lines to the fuel rail assembly
 
Heater and radiator hoses
 
Right engine mounting support
 
2 engine ground straps
 
Cruise control actuator and bracket
 
Air cleaner, air flow meter and air duct assembly
 
Accelerator and the throttle cables
 
Negative battery cable
 

  1. Fill the cooling system to the proper level with coolant.
  2.  
  3. Start the engine and check for leaks. Bleed the air from the cooling system.
  4.  
  5. Adjust the ignition timing.
  6.  
  7. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  8.  
  9. Recheck the coolant and engine oil levels.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator and the throttle cables
     
    Air cleaner cover, air flow meter and the air duct
     
    Cruise control actuator and bracket, if equipped
     
    2 engine ground straps
     
    Right engine mounting support
     
    Radiator hoses
     
    2 heater hoses
     
    And plug the fuel feed and return lines from the fuel rail assembly.
     
    And plug the pressure hose from the hydraulic motor
     
    V-bank cover
     
    Fuel pressure control Vacuum Switching Valve (VSV)
     
    Fuel pressure regulator
     
    Cylinder head rear plate
     
    Intake air control valve VSV
     
    Exhaust Gas Recirculation (EGR) vacuum modulator
     
    EGR valve
     
    Intake Air Control (IAC) valve
     
    Fuel pressure regulator
     
    EGR VSV
     
    2 nuts and the emission control valve set
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Intake air control valve vacuum hose
     
    Data link connector from the mounting bracket
     
    2 ground straps from the intake chamber
     
    Hydraulic motor pressure hose from the intake chamber
     
    Right Oxygen (O 2 ) sensor connector from the power steering pressure tube.
     
    2 nuts and the power steering pressure tube from the intake chamber
     
    2 power steering air hoses
     
    Engine hanger and the intake chamber support
     
    EGR pipe and gaskets
     
    Throttle Pressure (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    EGR gas temperature connector
     
    air conditioning idle up connector
     
    2 vacuum hoses from the Thermal Vacuum Valve (TVV)
     
    Vacuum hose from the cylinder head rear plate
     
    Vacuum hose from the charcoal canister
     
    Air assist hose and the 2 water bypass hoses
     
    Air intake chamber
     
    Left engine wiring harness and position it out of the way
     
    Wiring harness from the rear of the engine
     
    Right engine wiring harness and position it out of the way
     
    Ignition coils and the spark plugs
     
    Timing belt
     
    Camshaft pulleys and the timing belt rear cover
     
    Cylinder head rear plate
     
    Water inlet pipe
     
    Air assist hose and vacuum hose
     
    Intake manifold and fuel rail assembly
     
    Water outlet
     
    EGR pipe from the right exhaust manifold
     
    Exhaust manifolds
     
    Dipstick assembly and the power steering pump bracket
     
    Valve covers and the Camshaft Position (CMP) sensor
     
    Camshafts
     

  8.  
  9. Be sure the engine is at or near ambient temperature and remove the 2 (one on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the tightening sequence. Carefully lift the head from the engine; if it is necessary to pry the head loose, take great care not to damage the mating surfaces. Place the head on wood blocks in a clean work area.
    WARNING
    If the cylinder head bolts are loosened out of sequence, warpage or cracking could result.

  10.  
  11. Remove the cylinder head gasket. With a gasket scraper, carefully remove all the old gasket material from the cylinder head and engine block surfaces.
  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L (1MZ-FE) engine

  1. Place the new cylinder head gasket onto the cylinder block. Place the cylinder head onto the gasket.
  2.  
  3. Coat the threads of the 8 cylinder head bolts (12-sided) with clean engine oil and install the bolts into the cylinder head. Uniformly tighten the bolts in sequence in 3 steps to an ultimate tighten of 40 ft. lbs. (54 Nm). If any of the bolts does not meet the torque, replace it.
  4.  
  5. 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.
  6.  
  7. Coat the threads of the 2 remaining 8mm bolts with engine oil and install them. Tighten to 13 ft. lbs. (18 Nm).
  8.  
  9. Install or connect the following:
    NOTE
    Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads.



    Camshafts and adjust the valves
     



    Cylinder head covers. Use new gaskets
     
    Dipstick and power steering pump bracket
     
    Exhaust manifolds. Tighten the nuts to 36 ft. lbs. (49 Nm).
     
    EGR pipe to the right exhaust manifold
     
    Water outlet
     
    Intake manifold and the fuel rail assembly. Tighten the intake manifold nuts and bolts to 11 ft. lbs. (15 Nm).
     
    Air assist hose and the 2 water bypass hoses
     
    Water inlet pipe and the cylinder head rear plate
     
    Timing belt rear cover and the camshaft pulleys
     
    Timing belt
     
    Spark plugs and the ignition coils
     
    Right engine wiring harness
     
    Wiring harness to the rear of the engine
     
    Left engine wiring harness
     
    Air intake chamber
     
    EGR pipe. Use new gaskets
     
    2 TVV vacuum hoses
     
    Vacuum hose to the rear cylinder head plate
     
    Charcoal canister vacuum hose
     
    TP sensor connector
     
    IAC valve connector
     
    EGR gas temperature connector
     
    Air conditioning idle up connector
     
    Engine hanger and the intake chamber support.
     
    2 power steering air hoses
     
    Power steering pressure tube to the intake chamber
     
    O 2 sensor connector to the pressure tube
     
    2 ground straps to the intake chamber
     
    Data link connector to the bracket
     
    Power brake booster vacuum hose
     
    PCV hose
     
    IAC valve vacuum hose
     
    Emission control valve set and related vacuum hoses and connectors
     
    V-bank cover
     
    Pressure hose to the hydraulic motor
     
    Fuel lines to the fuel rail assembly
     
    Heater and radiator hoses
     
    Right engine mounting support
     
    2 engine ground straps
     
    Cruise control actuator and bracket
     
    Air cleaner, air flow meter and air duct assembly
     
    Accelerator and the throttle cables
     
    Negative battery cable.
     

  10.  
  11. Fill the cooling system to the proper level with coolant.
  12.  
  13. Start the engine and check for leaks. Bleed the air from the cooling system.
  14.  
  15. Adjust the ignition timing.
  16.  
  17. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  18.  
  19. Recheck the coolant and engine oil levels.
  20.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator and the throttle cables
     
    Air cleaner cover, air flow meter and the air duct
     
    Cruise control actuator and bracket, if equipped
     
    2 engine ground straps
     
    Right engine mounting support
     
    Radiator hoses
     
    2 heater hoses
     

  8.  
  9. Plug the fuel feed and return lines from the fuel rail assembly.
  10.  
  11. Plug the pressure hose from the hydraulic motor
  12.  
  13. Remove or disconnect the following:

    V-bank cover
     
    Fuel pressure control Vacuum Switching Valve (VSV)
     
    Fuel pressure regulator
     
    Cylinder head rear plate
     
    Intake air control valve VSV
     
    Exhaust Gas Recirculation (EGR) vacuum modulator
     
    EGR valve
     
    Intake Air Control (IAC) valve
     
    Fuel pressure regulator
     
    EGR VSV
     
    2 nuts and the emission control valve set
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Intake air control valve vacuum hose
     
    Data link connector from the mounting bracket
     
    2 ground straps from the intake chamber
     
    Hydraulic motor pressure hose from the intake chamber
     
    Right Oxygen (O 2 ) sensor connector from the power steering pressure tube
     
    2 nuts and the power steering pressure tube from the intake chamber
     
    2 power steering air hoses
     
    Engine hanger and the intake chamber support
     
    EGR pipe and gaskets
     
    Throttle Pressure (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    EGR gas temperature connector
     
    air conditioning idle up connector
     
    2 vacuum hoses from the Thermal Vacuum Valve (TVV)
     
    Vacuum hose from the cylinder head rear plate
     
    Vacuum hose from the charcoal canister
     
    Air assist hose and the 2 water bypass hoses
     
    Air intake chamber
     
    Left engine wiring harness and position it out of the way
     
    Wiring harness from the rear of the engine
     
    Right engine wiring harness and position it out of the way
     
    Ignition coils and the spark plugs
     
    Timing belt
     
    Camshaft pulleys and the timing belt rear cover
     
    Cylinder head rear plate
     
    Water inlet pipe
     
    Air assist hose and vacuum hose
     
    Intake manifold and fuel rail assembly
     
    Water outlet
     
    EGR pipe from the right exhaust manifold
     
    Exhaust manifolds
     
    Dipstick assembly and the power steering pump bracket
     
    Valve covers and the Camshaft Position (CMP) sensor
     
    Camshafts
     

  14.  
  15. Be sure the engine is at or near ambient temperature and remove the 2 (one on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the tightening sequence. Carefully lift the head from the engine; if it is necessary to pry the head loose, take great care not to damage the mating surfaces. Place the head on wood blocks in a clean work area.
    WARNING
    If the cylinder head bolts are loosened out of sequence, warpage or cracking could result.

  16.  
  17. Remove the cylinder head gasket. With a gasket scraper, carefully remove all the old gasket material from the cylinder head and engine block surfaces.
  18.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L (1MZ-FE) engine

  1. Place the new cylinder head gasket onto the cylinder block. Place the cylinder head onto the gasket.
  2.  
  3. Coat the threads of the 8 cylinder head bolts (12-sided) with clean engine oil and install the bolts into the cylinder head. Uniformly tighten the bolts in sequence in 3 steps to an ultimate tighten of 40 ft. lbs. (54 Nm). If any of the bolts does not meet the torque, replace it.
  4.  
  5. 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.
  6.  
  7. Coat the threads of the 2 remaining 8mm bolts with engine oil and install them. Tighten to 14 ft. lbs. (18 Nm).
  8.  
  9. Install or connect the following:
    NOTE
    Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads.



    Camshafts and adjust the valves
     



    Cylinder head covers. Use new gaskets.
     
    Dipstick and power steering pump bracket
     
    Exhaust manifolds. Tighten the nuts to 36 ft. lbs. (49 Nm).
     
    EGR pipe to the right exhaust manifold
     
    Water outlet
     
    Intake manifold and the fuel rail assembly. Tighten the intake manifold nuts and bolts to 11 ft. lbs. (15 Nm).
     
    Air assist hose and the 2 water bypass hoses
     
    Water inlet pipe and the cylinder head rear plate
     
    Timing belt rear cover and the camshaft pulleys
     
    Timing belt
     
    Spark plugs and the ignition coils
     
    Right engine wiring harness
     
    Wiring harness to the rear of the engine
     
    Left engine wiring harness
     
    Air intake chamber
     
    EGR pipe. Use new gaskets
     
    2 TVV vacuum hoses
     
    Vacuum hose to the rear cylinder head plate
     
    Charcoal canister vacuum hose
     
    TP sensor connector
     
    IAC valve connector
     
    EGR gas temperature connector
     
    Air conditioning idle up connector
     
    Engine hanger and the intake chamber support
     
    2 power steering air hoses
     
    Power steering pressure tube to the intake chamber
     
    O 2 sensor connector to the pressure tube
     
    2 ground straps to the intake chamber
     
    Data link connector to the bracket
     
    Power brake booster vacuum hose
     
    PCV hose
     
    IAC valve vacuum hose
     
    Emission control valve set and related vacuum hoses and connectors
     
    V-bank cover
     
    Pressure hose to the hydraulic motor
     
    Fuel lines to the fuel rail assembly
     
    Heater and radiator hoses
     
    Right engine mounting support
     
    2 engine ground straps
     
    Cruise control actuator and bracket
     
    Air cleaner, air flow meter and air duct assembly
     
    Accelerator and the throttle cables
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system to the proper level with coolant.
  12.  
  13. Start the engine and check for leaks. Bleed the air from the cooling system.
  14.  
  15. Adjust the ignition timing.
  16.  
  17. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  18.  
  19. Recheck the coolant and engine oil levels.
  20.  

1UZ-FE & 4.3L 3UZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Oil pan protector
     
    Engine undercover
     
    Coolant
     
    Battery clamp cover
     
    Air cleaner inlet
     
    V bank cover by removing the bolt and 2 cap nuts
     
    Air cleaner and intake air connector assembly
     
    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.
     
    Radiator
     
    Right-hand No. 3 timing belt cover
     
    Left-hand No. 3 timing belt cover
     
    Drive belt idler pulley by removing the pulley bolt and cover plate
     
    Right-hand No. 2 timing belt cover
     
    Left-hand No. 2 timing belt cover
     
    No. 1 ignition coil
     
    Air conditioning compressor from the engine
     
    Fan bracket by removing the 2 bolts and 2 nuts
     

  6.  
  7. Set the engine to Top Dead Center (TDC) on cylinder No. 1.
  8.  


WARNING
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  1. Turn the crankshaft pulley approximately 50 degrees clockwise and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.
  2.  


WARNING
If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley. Always set the crankshaft pulley at the correct angle before removing the timing belt.

  1. If the timing belt is to be reused, turn the crank pulley slowly; check that the 3 installation marks are present on the belt. If the marks are not present, make new installation marks before removing the belt. The marks should align with the timing marks on each camshaft pulley and the crank pulley.
  2.  
  3. Remove the timing belt tensioner. Alternately loosen the 2 bolts; remove the bolts, the tensioner and the dust protector.
  4.  
  5. Loosen the tension between the left side and the right side timing pulleys by slightly turning the left side camshaft clockwise.
  6.  
  7. Remove or disconnect the following:

    Timing belt from the camshaft timing pulleys. Using the proper tool, remove the bolt and the camshaft timing pulleys.
     
    Power steering pump from the engine. Do NOT disconnect the hoses or lines from the power steering pump. Support the power steering pump with a piece of wire. Do NOT allow the pump to hang.
     
    Front catalytic converter
     
    High tension spark plug wires, wire clamps and the wire cover assembly
     
    No. 2 ignition coil by removing the connector and the 2 bolts
     
    2 bolts and the rear timing belt plate. Remove both plates
     
    Intake chamber assembly
     
    Throttle Position Sensor (TPS) connector
     
    With TRAC system, sub TP sensor connector
     
    With TRAC system, sub TP connector
     
    Idle Air Control (IAC) valve connector
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Vacuum Switching Valve (VSV) connector for fuel pressure control
     
    VSV connector for Evaporative Emissions (EVAP) system
     
    EGR gas temperature sensor connector
     
    Brake booster vacuum hose from the union on the air intake chamber
     
    Positive Crankcase Ventilation (PCV) hose from the PCV valve on the left-hand cylinder head
     
    Water bypass hose (from the EGR valve) from the rear water bypass joint
     
    Water bypass hose (from the throttle body) from the rear water bypass joint
     
    Vacuum hose (from the VSV for fuel pressure control) from the fuel pressure regulator
     
    EVAP hose (from charcoal canister) from the VSV for EVAP
     
    Heater hose from the water bypass pipe
     
    Fuel inlet hose from the delivery pipe
     
    Fuel return hose from the fuel return pipe
     
    Engine wire from the delivery pipes and rear water bypass joint
     
    Fuel hose from the fuel pressure regulator
     
    2 bolts and fuel return pipe from the intake manifold
     
    8 injector connectors
     
    6 bolts, 4 nuts, the intake manifold assembly and the 2 gaskets
     
    Water inlet and inlet housing
     
    Front water bypass joint
     
    Rear water bypass joint and No. 1 EGR pipe assembly
     
    Oil dipstick and guide for the automatic transmission
     
    Oil dipstick and guide for the engine
     
    Engine hangers
     
    Right and left cylinder head covers by removing the 8 bolts, seal washers and gaskets
     
    Semi-circular plug, if necessary
     
    Exhaust camshaft from the right side cylinder head. See the camshaft procedure for tightening sequence.
     



    Click image to see an enlarged view

    Fig. Securing the exhaust camshaft on the right cylinder head-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines



    Click image to see an enlarged view

    Fig. Turning the exhaust camshaft 10 degrees on the right cylinder head-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines



    Intake camshaft from the right side cylinder head. See the camshaft procedure for tightening sequence.
     
    Exhaust camshaft of the left side cylinder head. See the camshaft procedure for tightening sequence.
     

  8.  


NOTE
When removing the camshaft, be sure the torsional spring force of the subgear has been eliminated.



Intake camshaft from the left side cylinder head. See the camshaft procedure for tightening sequence.
 
Main Heated Oxygen (HO2) sensor
 
Bolt and HO2the ground cable from the right cylinder head
 
Bolt and the ground strap from the left cylinder head
 
Bolt and the engine wire protector from the left-hand cylinder head
 
2 bolts, seal washers, bearing cap and the camshaft housing plug from the right-hand cylinder head
 
10 cylinder head bolts and plate washers to each cylinder head. Loosen the bolts in the reverse order of the tightening sequence. Lift the heads from the dowels on the block with the exhaust manifolds attached. Place the heads on blocks of wood on the workbench.
 


NOTE
Do NOT drop anything in the opening in the front of the right side cylinder head. The opening leads through the block and into the oil pan. If anything falls into the opening the oil pan will have to be removed in order to retrieve it.


WARNING
If necessary to pry the head loose, take great care not to damage the contact surfaces of the head or block.



2 bolts, seal washers, bearing cap and camshaft housing plug from the right-hand cylinder head
 
Right exhaust manifold from the cylinder head by removing the heat insulator, 8 nuts and the gasket
 
Left exhaust manifold from the cylinder head by removing the heat insulator, 8 nuts and the gasket
 

To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-4.0L (1UZ-FE) engine



Click image to see an enlarged view

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

  1. Install or connect the following:

    Right exhaust manifold. The new gasket must be installed with the white marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Install the right O2sensor.
     
    Left exhaust manifold. The new gasket must be installed with the white marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Install the left O2sensor.
     
    The 2 new cylinder head gaskets in position on the engine block. Each gasket has a painted mark denoting the rear of the gasket. The gasket for the right bank has a white mark and the gasket for the left bank has a yellow mark. Double check the gasket position and placement.
     

  2.  
  3. For 4.0L engines, install the cylinder heads and tighten the bolts in sequence as follows:
    1. Step 1: 29 ft. lbs. (39 Nm)
    2.  
    3. Step 2: Plus 90 degrees
    4.  

  4.  
  5. For 4.3L engines, install the cylinder heads and tighten the bolts in sequence as follows:
    1. Step 1: 44 ft. lbs. (60 Nm)
    2.  
    3. Step 2: Plus 90 degrees
    4.  


      Click image to see an enlarged view

      Fig. Apply a dot of paint at the front of each bolt-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines



      Click image to see an enlarged view

      Fig. The paint mark must be 90 degrees from the starting point-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

    5. HO2.
    6.  
    7. Engine wire to the right-hand cylinder head with the 2 bolt
    8.  
    9. Ground cable to the right-hand cylinder head with the bolt
    10.  
    11. The engine wire protector to the left-hand cylinder head with the bolt
    12.  
    13. Ground cable to the left-hand cylinder head with the bolt
    14.  
    15. Old packing and apply new seal packing to the bearing caps
    16.  
    17. Bearing cap on the right side cylinder head, markedI1I6
    18.  
    19. Bearing cap bolts with new washers. Apply a light coat of oil on the threads of the cap bolts. Alternately tighten each bolt to 12 ft. lbs. (16 Nm).
    20.  

  6.  


NOTE
Use silver colored bolts 1.50 in. (38mm) in length.



Camshaft housing plugs on the cylinder heads. Be sure to face the cupped side forward.
 



Turn the crankshaft pulley clockwise or counterclockwise and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.
 


WARNING
Since 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 receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  1. Install or connect the following:
    1. Right side cylinder head intake camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
    2.  
    3. Right side cylinder head exhaust camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
    4.  
    5. Left side cylinder head intake camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
    6.  
    7. Left side cylinder head exhaust camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
    8.  

  2.  
  3. Check and adjust the valve clearance.
  4.  
  5. Install or connect the following:

    Camshaft oil seals with the proper tool (SST 09223-46011). Be sure to apply MP grease to the new oil seal lip.
     
    Semi-circular plugs, if removed
     

  6.  
  7. Clean the cylinder head covers. Apply new sealant in the correct locations and install the gaskets.
  8.  
  9. Install or connect the following:

    Right cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
     
    Left cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
     
    Engine hanger with the 2 bolts. Install both engine hangers. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Oil dipstick guide for the engine
     
    Oil dipstick for the transmission
     
    Rear water bypass joint and No. 1 EGR pipe
     
    Front water bypass joints. Install 2 gaskets and alternately tighten the nuts to 13 ft. lbs. (18 Nm).
     
    Water inlet and inlet housing, alternately tighten the bolts to 13 ft. lbs. (18 Nm)
     
    Delivery pipe and intake manifold
     
    Return pipe with 2 new gaskets. Tighten the union bolt to 26 ft. lbs. (35 Nm).
     
    Engine wire to the delivery pipes and rear water bypass joint
     
    Fuel return hose to the fuel return pipe
     
    Fuel inlet hose to the left-hand delivery pipe
     
    Fuel hose to the fuel pressure regulator
     
    Air intake chamber assembly
     
    Brake booster vacuum hose to the union on the air intake chamber
     
    PCV hose to the PCV valve on the left-hand cylinder head
     
    Water bypass hose (from EGR valve) to the rear water bypass joint
     
    Water bypass hose (from throttle body) to the rear water bypass joint
     
    Vacuum hose (from VSV for fuel pressure control) to the fuel pressure regulator
     
    EVAP hose (from charcoal canister) from the VSV for EVAP
     
    TPS connector
     
    With TRAC system, sub TPS connector
     
    With TRAC system, sub throttle actuator connector
     
    IAC valve connector
     
    EGR valve connector
     
    EGR gas temperature sensor connector
     
    VSV connector for fuel pressure control
     
    VSV connector for EVAP
     
    Accelerator bracket with the 2 bolts
     
    Accelerator, automatic transmission throttle control and the cruise control actuator cable
     
    Spark plug wires and clamps to the right and left cylinder head cover
     
    Belt rear plates by installing the bolts. Tighten the bolts to 66 inch lbs. (8 Nm).
     
    No. 2 ignition coil
     
    A new gasket to the exhaust manifold and install the catalytic converters. Tighten the 3 nuts to each converter to 46 ft. lbs. (62 Nm).
     
    Front exhaust pipe, tighten the bolts and nuts to 32 ft. lbs. (44 Nm). Tighten the 4 bolts holding the pipe support bracket to the transmission. Tighten the bolts to 32 ft. lbs. (44 Nm).
     
    Power steering pump with the nut and 3 bolts. Tighten the nut to 32 ft. lbs. (43 Nm) and the bolts to 29 ft. lbs. (39 Nm).
     

  10.  
  11. Align the knock pin on the right side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the right side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).
  12.  
  13. Align the knock pin on the left side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the left side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).
  14.  
  15. Install the timing belt to the left side camshaft timing pulley as follows:

    Using the proper tool, slightly turn the left side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left side camshaft pulley.
     
    Align the timing marks of the left side camshaft pulley and the timing belt rear plate.
     
    Check that the timing belt has tension between crankshaft timing pulley and the left side camshaft pulley.
     

  16.  
  17. Install the timing belt to the right side camshaft timing pulley as follows:
    1. Using the proper tool, slightly turn the right side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the right side camshaft pulley.
    2.  
    3. Align the timing marks of the right side camshaft pulley and the timing belt rear plate.
    4.  
    5. Check that the timing belt has tension between crankshaft timing pulley and the right side camshaft pulley.
    6.  

  18.  
  19. The timing belt tensioner must be set prior to installation. The tensioner can be set by:
    1. Place a plate washer between the tensioner and a block. Using a press, press in the pushrod using 220-225 lbs. of pressure.
    2.  
    3. Align the holes of the pushrod and housing, pass a 0.05 inch (1.27mm) rod through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot to the tensioner.
    6.  

  20.  
  21. Loosely install the tensioner. Evenly and alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the tool from the tensioner.
  22.  
  23. Turn the crankshaft pulley 2 complete revolutions from TDC to TDC. Always turn the crankshaft clockwise. Check that all belt and pulley marks align with their reference marks. If any mark is out of perfect alignment, the timing belt must be removed and reinstalled.
  24.  
  25. Install or connect the following:
    1. Drive belt tensioner and tighten the bolt and nuts to 12 ft. lbs. (16 Nm).
    2.  

  26.  
  27. Install the fan bracket by installing the 2 bolts and 2 nuts. Tighten as follows:

    12mm: 12 ft. lbs. (16 Nm)
     
    14mm: 24 ft. lbs. (32 Nm)
     

  28.  
  29. Remove or disconnect the following:
    1. Air conditioning compressor. Tighten the bolts to 36 ft. lbs. (49 Nm) and the nut to 22 ft. lbs. (29 Nm).
    2.  
    3. No. 1 ignition coil
    4.  
    5. Right side No. 2 timing belt cover
    6.  
    7. Left side No. 2 timing belt cover
    8.  
    9. Drive belt idler pulley and cover plate. Tighten the bolt to 27 ft. lbs. (37 Nm).
    10.  
    11. Secure the ignition wires. Make certain that all clips and retainers are securely engaged and that the wires are properly routed.
    12.  
    13. Right side No. 3 timing belt
    14.  
    15. Left-hand No. 3 timing belt cover
    16.  
    17. Radiator assembly
    18.  
    19. Fan pulley, fan, fluid coupling and the drive belt
    20.  
    21. The air cleaner and intake air connector assembly
    22.  
    23. V bank cover
    24.  
    25. Coolant
    26.  
    27. Negative battery cable to the battery
    28.  
    29. Air cleaner inlet
    30.  
    31. Battery clamp cover
    32.  
    33. Engine undercover
    34.  
    35. Oil pan protector
    36.  

  30.  
  31. Start the engine and check for leaks
  32.  
  33. Bleed the cooling system and recheck the engine coolant level.
  34.  
  35. Make all the necessary engine adjustments.
  36.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Oil pan protector
     
    Engine undercover
     
    Coolant
     
    Battery clamp cover
     
    Air cleaner inlet
     
    V bank cover by removing the bolt and 2 cap nuts
     
    Air cleaner and intake air connector assembly
     
    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.
     
    Radiator
     
    Right-hand No. 3 timing belt cover
     
    Left-hand No. 3 timing belt cover
     
    Drive belt idler pulley by removing the pulley bolt and cover plate
     
    Right-hand No. 2 timing belt cover
     
    Left-hand No. 2 timing belt cover
     
    Distributor housings
     
    No. 1 ignition coil
     
    Air conditioning compressor from the engine
     
    Fan bracket by removing the 2 bolts and 2 nuts
     

  6.  
  7. Set the engine to Top Dead Center (TDC) on cylinder No. 1.
    WARNING
    Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  8.  
  9. Turn the crankshaft pulley approximately 50 degrees clockwise and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.
    WARNING
    If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley. Always set the crankshaft pulley at the correct angle before removing the timing belt.

  10.  
  11. If the timing belt is to be reused, turn the crank pulley slowly; check that the 3 installation marks are present on the belt. If the marks are not present, make new installation marks before removing the belt. The marks should align with the timing marks on each camshaft pulley and the crank pulley.
  12.  
  13. Remove the timing belt tensioner. Alternately loosen the 2 bolts; remove the bolts, the tensioner and the dust protector.
  14.  
  15. Loosen the tension between the left side and the right side timing pulleys by slightly turning the left side camshaft clockwise.
  16.  
  17. Remove or disconnect the following:
    NOTE
    When removing the camshaft, be sure the torsional spring force of the subgear has been eliminated.


    NOTE
    Do not drop anything in the opening in the front of the right side cylinder head. The opening leads through the block and into the oil pan. If anything falls into the opening the oil pan will have to be removed in order to retrieve it.


    WARNING
    If necessary to pry the head loose, take great care not to damage the contact surfaces of the head or block.



    Timing belt from the camshaft timing pulleys. Using the proper tool, remove the bolt and the camshaft timing pulleys.
     
    Power steering pump from the engine. Do not disconnect the hoses or lines from the power steering pump. Support the power steering pump with a piece of wire. Do not allow the pump to hang.
     
    Front catalytic converter
     
    High tension spark plug wires, wire clamps and the wire cover assembly
     
    No. 2 ignition coil by removing the connector and the 2 bolts
     
    2 bolts and the rear timing belt plate. Remove both plates
     
    Intake chamber assembly
     
    Throttle Position Sensor (TPS) connector
     
    With TRAC system, sub TP sensor connector
     
    With TRAC system, sub TP connector
     
    Idle Air Control (IAC) valve connector
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Vacuum Switching Valve (VSV) connector for fuel pressure control
     
    VSV connector for Evaporative Emissions (EVAP) system
     
    EGR gas temperature sensor connector
     
    Brake booster vacuum hose from the union on the air intake chamber
     
    Positive Crankcase Ventilation (PCV) hose from the PCV valve on the left-hand cylinder head
     
    Water bypass hose (from the EGR valve) from the rear water bypass joint
     
    Water bypass hose (from the throttle body) from the rear water bypass joint
     
    Vacuum hose (from the VSV for fuel pressure control) from the fuel pressure regulator
     
    EVAP hose (from charcoal canister) from the VSV for EVAP
     
    Heater hose from the water bypass pipe
     
    Fuel inlet hose from the delivery pipe
     
    Fuel return hose from the fuel return pipe.
     
    Engine wire from the delivery pipes and rear water bypass joint
     
    Fuel hose from the fuel pressure regulator
     
    2 bolts and fuel return pipe from the intake manifold
     
    8 injector connectors
     
    6 bolts, 4 nuts, the intake manifold assembly and the 2 gaskets
     
    Water inlet and inlet housing
     
    Front water bypass joint
     
    Rear water bypass joint and No. 1 EGR pipe assembly
     
    Oil dipstick and guide for the automatic transmission
     
    Oil dipstick and guide for the engine
     
    Engine hangers
     
    Right and left cylinder head covers by removing the 8 bolts, seal washers and gaskets
     
    If necessary, the semi-circular plug.
     
    Exhaust camshaft from the right side cylinder head. See the camshaft procedure for tightening sequence.

    Click image to see an enlarged view

    Fig. Securing the exhaust camshaft on the right cylinder head-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines



    Click image to see an enlarged view

    Fig. Turning the exhaust camshaft 10 degrees on the right cylinder head-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

     



    Intake camshaft from the right side cylinder head. See the camshaft procedure for tightening sequence.
     
    Exhaust camshaft of the left side cylinder head. See the camshaft procedure for tightening sequence.
     



    Intake camshaft from the left side cylinder head. See the camshaft procedure for tightening sequence.
     
    Main Heated Oxygen (HO 2 ) sensor
     
    Bolt and HO 2 the ground cable from the right cylinder head
     
    Bolt and the ground strap from the left cylinder head
     
    Bolt and the engine wire protector from the left-hand cylinder head.
     
    2 bolts, seal washers, bearing cap and the camshaft housing plug from the right-hand cylinder head.
     
    10 cylinder head bolts and plate washers to each cylinder head. Loosen the bolts in the reverse order of the tightening sequence. Lift the heads from the dowels on the block with the exhaust manifolds attached. Place the heads on blocks of wood on the workbench.
     



    2 bolts, seal washers, bearing cap and camshaft housing plug from the right-hand cylinder head.
     
    Right exhaust manifold from the cylinder head by removing the heat insulator, 8 nuts and the gasket.
     
    Left exhaust manifold from the cylinder head by removing the heat insulator, 8 nuts and the gasket.
     

  18.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-4.0L (1UZ-FE) engine



Click image to see an enlarged view

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

  1. Install or connect the following:

    Right exhaust manifold. The new gasket must be installed with the white marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Install the right O 2 sensor.
     
    Left exhaust manifold. The new gasket must be installed with the white marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Install the left O 2 sensor.
     
    The 2 new cylinder head gaskets in position on the engine block. Each gasket has a painted mark denoting the rear of the gasket. The gasket for the right bank has a white mark and the gasket for the left bank has a yellow mark. Double check the gasket position and placement.
     

  2.  
  3. For 4.0L engines, install the cylinder heads and tighten the bolts in sequence as follows:

    Step 1: 29 ft. lbs. (39 Nm)
     
    Step 2: Plus 90 degrees
     

  4.  
  5. For 4.3L engines, install the cylinder heads and tighten the bolts in sequence as follows:
    NOTE
    Use silver colored bolts 1.50 in. (38mm) in length.



    Step 1: 44 ft. lbs. (60 Nm)
     
    Step 2: Plus 90 degrees

    Click image to see an enlarged view

    Fig. Apply a dot of paint at the front of each bolt-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines



    Click image to see an enlarged view

    Fig. The paint mark must be 90 degrees from the starting point-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

     
    HO 2 .
     
    Engine wire to the right-hand cylinder head with the 2 bolt
     
    Ground cable to the right-hand cylinder head with the bolt
     
    The engine wire protector to the left-hand cylinder head with the bolt
     
    Ground cable to the left-hand cylinder head with the bolt
     
    Old packing and apply new seal packing to the bearing caps
     
    Bearing cap on the right side cylinder head, marked I1 , in position with the arrow mark facing the rear. Install the bearing cap on the left side cylinder head, marked I6 , in position with the arrow mark facing the front.
     
    Bearing cap bolts with new washers. Apply a light coat of oil on the threads of the cap bolts. Alternately tighten each bolt to 12 ft. lbs. (16 Nm).
     



    Camshaft housing plugs on the cylinder heads. Be sure to face the cupped side forward.
     

  6.  
  7. Turn the crankshaft pulley clockwise or counterclockwise and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.
    WARNING
    Since 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 receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  8.  
  9. Install or connect the following:

    Right side cylinder head intake camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
     
    Right side cylinder head exhaust camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
     
    Left side cylinder head intake camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
     
    Left side cylinder head exhaust camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
     

  10.  
  11. Check and adjust the valve clearance.
  12.  
  13. Install or connect the following:

    Camshaft oil seals with the proper tool (SST 09223-46011). Be sure to apply MP grease to the new oil seal lip.
     
    Semi-circular plugs, if removed
     

  14.  
  15. Clean the cylinder head covers. Apply new sealant in the correct locations and install the gaskets.
  16.  
  17. Install or connect the following:

    Right cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
     
    Left cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
     
    Engine hanger with the 2 bolts. Install both engine hangers. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Oil dipstick guide for the engine
     
    Oil dipstick for the transmission
     
    Rear water bypass joint and No. 1 EGR pipe
     
    Front water bypass joints. Install 2 gaskets and alternately tighten the nuts to 13 ft. lbs. (18 Nm).
     
    Water inlet and inlet housing, alternately tighten the bolts to 13 ft. lbs. (18 Nm).
     
    Delivery pipe and intake manifold
     
    Return pipe with 2 new gaskets. Tighten the union bolt to 26 ft. lbs. (35 Nm).
     
    Engine wire to the delivery pipes and rear water bypass joint
     
    Fuel return hose to the fuel return pipe
     
    Fuel inlet hose to the left-hand delivery pipe
     
    Fuel hose to the fuel pressure regulator
     
    Air intake chamber assembly
     
    Brake booster vacuum hose to the union on the air intake chamber
     
    PCV hose to the PCV valve on the left-hand cylinder head
     
    Water bypass hose (from EGR valve) to the rear water bypass joint
     
    Water bypass hose (from throttle body) to the rear water bypass joint
     
    Vacuum hose (from VSV for fuel pressure control) to the fuel pressure regulator
     
    EVAP hose (from charcoal canister) from the VSV for EVAP
     
    TPS connector
     
    With TRAC system, sub TPS connector
     
    With TRAC system, sub throttle actuator connector
     
    IAC valve connector
     
    EGR valve connector
     
    EGR gas temperature sensor connector
     
    VSV connector for fuel pressure control
     
    VSV connector for EVAP
     
    Accelerator bracket with the 2 bolts.
     
    Accelerator, automatic transmission throttle control and the cruise control actuator cable.
     
    Spark plug wires and clamps to the right and left cylinder head cover
     
    Belt rear plates by installing the bolts. Tighten the bolts to 66 inch lbs. (8 Nm).
     
    No. 2 ignition coil
     
    A new gasket to the exhaust manifold and install the catalytic converters. Tighten the 3 nuts to each converter to 46 ft. lbs. (62 Nm).
     
    Front exhaust pipe, tighten the bolts and nuts to 32 ft. lbs. (44 Nm). Tighten the 4 bolts holding the pipe support bracket to the transmission. Tighten the bolts to 32 ft. lbs. (44 Nm).
     
    Power steering pump with the nut and 3 bolts. Tighten the nut to 32 ft. lbs. (43 Nm) and the bolts to 29 ft. lbs. (39 Nm).
     

  18.  
  19. Align the knock pin on the right side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the right side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).
  20.  
  21. Align the knock pin on the left side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the left side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).
  22.  
  23. Install the timing belt to the left side camshaft timing pulley as follows:
    1. Using the proper tool, slightly turn the left side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left side camshaft pulley.
    2.  
    3. Align the timing marks of the left side camshaft pulley and the timing belt rear plate.
    4.  
    5. Check that the timing belt has tension between crankshaft timing pulley and the left side camshaft pulley.
    6.  

  24.  
  25. Install the timing belt to the right side camshaft timing pulley as follows:
    1. Using the proper tool, slightly turn the right side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the right side camshaft pulley.
    2.  
    3. Align the timing marks of the right side camshaft pulley and the timing belt rear plate.
    4.  
    5. Check that the timing belt has tension between crankshaft timing pulley and the right side camshaft pulley.
    6.  

  26.  
  27. The timing belt tensioner must be set prior to installation. The tensioner can be set by:
    1. Place a plate washer between the tensioner and a block. Using a press, press in the pushrod using 220-225 lbs. of pressure.
    2.  
    3. Align the holes of the pushrod and housing, pass a 0.05 inch (1.27mm) rod through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot to the tensioner.
    6.  

  28.  
  29. Loosely install the tensioner. Evenly and alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the tool from the tensioner.
  30.  
  31. Turn the crankshaft pulley 2 complete revolutions from TDC to TDC. Always turn the crankshaft clockwise. Check that all belt and pulley marks align with their reference marks. If any mark is out of perfect alignment, the timing belt must be removed and reinstalled.
  32.  
  33. Install or connect the following:

    Drive belt tensioner and tighten the bolt and nuts to 12 ft. lbs. (16 Nm).
     
    Both distributor housings and tighten the mounting bolts to 13 ft. lbs. (18 Nm). The distributors are marked L or R for correct installation.
     
    Distributor rotors and caps
     
    Fan bracket by installing the 2 bolts and 2 nuts. Tighten as follows:
     
    12mm: 12 ft. lbs. (16 Nm)
     
    14mm: 24 ft. lbs. (32 Nm)
     
    Air conditioning compressor. Tighten the bolts to 36 ft. lbs. (49 Nm) and the nut to 22 ft. lbs. (29 Nm).
     
    No. 1 ignition coil
     
    Right side No. 2 timing belt cover
     
    Left side No. 2 timing belt cover
     
    Drive belt idler pulley and cover plate. Tighten the bolt to 27 ft. lbs. (37 Nm).
     
    And secure the ignition wires. Make certain that all clips and retainers are securely engaged and that the wires are properly routed.
     
    Right side No. 3 timing belt
     
    Left-hand No. 3 timing belt cover
     
    Radiator assembly
     
    Fan pulley, fan, fluid coupling and the drive belt
     
    The air cleaner and intake air connector assembly
     
    V bank cover
     
    Coolant
     
    Negative battery cable to the battery
     
    Air cleaner inlet
     
    Battery clamp cover
     
    Engine undercover
     
    Oil pan protector
     

  34.  
  35. Start the engine and check for leaks
  36.  
  37. Bleed the cooling system and recheck the engine coolant level.
  38.  
  39. Make all the necessary engine adjustments.
  40.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Oil pan protector
     
    Engine undercover
     
    Coolant
     
    Battery clamp cover
     
    Air cleaner inlet
     
    V bank cover by removing the bolt and 2 cap nuts
     
    Air cleaner and intake air connector assembly
     
    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.
     
    Radiator
     
    Right-hand No. 3 timing belt cover
     
    Left-hand No. 3 timing belt cover
     
    Drive belt idler pulley by removing the pulley bolt and cover plate
     
    Right-hand No. 2 timing belt cover
     
    Left-hand No. 2 timing belt cover
     
    No. 1 ignition coil
     
    Air conditioning compressor from the engine
     
    Fan bracket by removing the 2 bolts and 2 nuts
     

  6.  
  7. Set the engine to Top Dead Center (TDC) on cylinder No. 1.
    WARNING
    Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  8.  
  9. Turn the crankshaft pulley approximately 50° clockwise and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.
    WARNING
    If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley. Always set the crankshaft pulley at the correct angle before removing the timing belt.

  10.  
  11. If the timing belt is to be reused, turn the crank pulley slowly; check that the 3 installation marks are present on the belt. If the marks are not present, make new installation marks before removing the belt. The marks should align with the timing marks on each camshaft pulley and the crank pulley.
  12.  
  13. Remove the timing belt tensioner. Alternately loosen the 2 bolts; remove the bolts, the tensioner and the dust protector.
  14.  
  15. Loosen the tension between the left side and the right side timing pulleys by slightly turning the left side camshaft clockwise.
  16.  
  17. Remove or disconnect the following:
    NOTE
    When removing the camshaft, be sure the torsional spring force of the subgear has been eliminated.


    NOTE
    Do NOT drop anything in the opening in the front of the right side cylinder head. The opening leads through the block and into the oil pan. If anything falls into the opening the oil pan will have to be removed in order to retrieve it.


    WARNING
    If necessary to pry the head loose, take great care not to damage the contact surfaces of the head or block.



    Timing belt from the camshaft timing pulleys. Using the proper tool, remove the bolt and the camshaft timing pulleys.
     
    Power steering pump from the engine. Do NOT disconnect the hoses or lines from the power steering pump. Support the power steering pump with a piece of wire. Do NOT allow the pump to hang.
     
    Front catalytic converter
     
    High tension spark plug wires, wire clamps and the wire cover assembly
     
    No. 2 ignition coil by removing the connector and the 2 bolts
     
    2 bolts and the rear timing belt plate. Remove both plates
     
    Intake chamber assembly
     
    Throttle Position Sensor (TPS) connector
     
    With TRAC system, sub TP sensor connector
     
    With TRAC system, sub TP connector
     
    Idle Air Control (IAC) valve connector
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Vacuum Switching Valve (VSV) connector for fuel pressure control
     
    VSV connector for Evaporative Emissions (EVAP) system
     
    EGR gas temperature sensor connector
     
    Brake booster vacuum hose from the union on the air intake chamber
     
    Positive Crankcase Ventilation (PCV) hose from the PCV valve on the left-hand cylinder head
     
    Water bypass hose (from the EGR valve) from the rear water bypass joint
     
    Water bypass hose (from the throttle body) from the rear water bypass joint
     
    Vacuum hose (from the VSV for fuel pressure control) from the fuel pressure regulator
     
    EVAP hose (from charcoal canister) from the VSV for EVAP
     
    Heater hose from the water bypass pipe
     
    Fuel inlet hose from the delivery pipe
     
    Fuel return hose from the fuel return pipe
     
    Engine wire from the delivery pipes and rear water bypass joint
     
    Fuel hose from the fuel pressure regulator
     
    2 bolts and fuel return pipe from the intake manifold
     
    8 injector connectors
     
    6 bolts, 4 nuts, the intake manifold assembly and the 2 gaskets
     
    Water inlet and inlet housing
     
    Front water bypass joint
     
    Rear water bypass joint and No. 1 EGR pipe assembly
     
    Oil dipstick and guide for the automatic transmission
     
    Oil dipstick and guide for the engine
     
    Engine hangers
     
    Right and left cylinder head covers by removing the 8 bolts, seal washers and gaskets
     
    Semi-circular plug, if necessary
     
    Exhaust camshaft from the right side cylinder head. See the camshaft procedure for tightening sequence.

    Click image to see an enlarged view

    Fig. Securing the exhaust camshaft on the right cylinder head-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines



    Click image to see an enlarged view

    Fig. Turning the exhaust camshaft 10 degrees on the right cylinder head-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

     



    Intake camshaft from the right side cylinder head. See the camshaft procedure for tightening sequence.
     
    Exhaust camshaft of the left side cylinder head. See the camshaft procedure for tightening sequence.
     



    Intake camshaft from the left side cylinder head. See the camshaft procedure for tightening sequence.
     
    Main Heated Oxygen (HO 2 ) sensor
     
    Bolt and HO 2 the ground cable from the right cylinder head
     
    Bolt and the ground strap from the left cylinder head
     
    Bolt and the engine wire protector from the left-hand cylinder head
     
    2 bolts, seal washers, bearing cap and the camshaft housing plug from the right-hand cylinder head
     
    10 cylinder head bolts and plate washers to each cylinder head. Loosen the bolts in the reverse order of the tightening sequence. Lift the heads from the dowels on the block with the exhaust manifolds attached. Place the heads on blocks of wood on the workbench.
     



    2 bolts, seal washers, bearing cap and camshaft housing plug from the right-hand cylinder head
     
    Right exhaust manifold from the cylinder head by removing the heat insulator, 8 nuts and the gasket
     
    Left exhaust manifold from the cylinder head by removing the heat insulator, 8 nuts and the gasket
     

  18.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-4.0L (1UZ-FE) engine



Click image to see an enlarged view

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

  1. Install or connect the following:

    Right exhaust manifold. The new gasket must be installed with the white marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Install the right O 2 sensor.
     
    Left exhaust manifold. The new gasket must be installed with the white marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Install the left O 2 sensor.
     
    The 2 new cylinder head gaskets in position on the engine block. Each gasket has a painted mark denoting the rear of the gasket. The gasket for the right bank has a white mark and the gasket for the left bank has a yellow mark. Double check the gasket position and placement.
     

  2.  
  3. For 4.0L engines, install the cylinder heads and tighten the bolts in sequence as follows:
    1. Step 1: 29 ft. lbs. (39 Nm)
    2.  
    3. Step 2: Plus 90 degrees
    4.  

  4.  
  5. For 4.3L engines, install the cylinder heads and tighten the bolts in sequence as follows:
    1. Step 1: 44 ft. lbs. (60 Nm)
    2.  
    3. Step 2: Plus 90 degrees
      NOTE
      Use silver colored bolts 1.50 in. (38mm) in length.



      Click image to see an enlarged view

      Fig. Apply a dot of paint at the front of each bolt-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines



      Click image to see an enlarged view

      Fig. The paint mark must be 90 degrees from the starting point-4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines



      HO 2
       
      Engine wire to the right-hand cylinder head with the 2 bolt
       
      Ground cable to the right-hand cylinder head with the bolt
       
      The engine wire protector to the left-hand cylinder head with the bolt
       
      Ground cable to the left-hand cylinder head with the bolt
       
      Old packing and apply new seal packing to the bearing caps
       
      Bearing cap on the right side cylinder head, marked I1 , in position with the arrow mark facing the rear. Install the bearing cap on the left side cylinder head, marked I6 , in position with the arrow mark facing the front.
       
      Bearing cap bolts with new washers. Apply a light coat of oil on the threads of the cap bolts. Alternately tighten each bolt to 12 ft. lbs. (16 Nm).
       



      Camshaft housing plugs on the cylinder heads. Be sure to face the cupped side forward.
       

    4.  

  6.  
  7. Turn the crankshaft pulley clockwise or counterclockwise and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.
    WARNING
    Since 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 receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

  8.  
  9. Install or connect the following:

    Right side cylinder head intake camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
     
    Right side cylinder head exhaust camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
     
    Left side cylinder head intake camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
     
    Left side cylinder head exhaust camshaft. Tighten the bracket bolt in the reverse order of the loosening sequence.
     

  10.  
  11. Check and adjust the valve clearance.
  12.  
  13. Install or connect the following:

    Camshaft oil seals with the proper tool (SST 09223-46011). Be sure to apply MP grease to the new oil seal lip.
     
    Semi-circular plugs, if removed
     

  14.  
  15. Clean the cylinder head covers. Apply new sealant in the correct locations and install the gaskets.
  16.  
  17. Install or connect the following:

    Right cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
     
    Left cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
     
    Engine hanger with the 2 bolts. Install both engine hangers. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Oil dipstick guide for the engine
     
    Oil dipstick for the transmission
     
    Rear water bypass joint and No. 1 EGR pipe
     
    Front water bypass joints. Install 2 gaskets and alternately tighten the nuts to 13 ft. lbs. (18 Nm).
     
    Water inlet and inlet housing, alternately tighten the bolts to 13 ft. lbs. (18 Nm)
     
    Delivery pipe and intake manifold
     
    Return pipe with 2 new gaskets. Tighten the union bolt to 26 ft. lbs. (35 Nm).
     
    Engine wire to the delivery pipes and rear water bypass joint
     
    Fuel return hose to the fuel return pipe
     
    Fuel inlet hose to the left-hand delivery pipe
     
    Fuel hose to the fuel pressure regulator
     
    Air intake chamber assembly
     
    Brake booster vacuum hose to the union on the air intake chamber
     
    PCV hose to the PCV valve on the left-hand cylinder head
     
    Water bypass hose (from EGR valve) to the rear water bypass joint
     
    Water bypass hose (from throttle body) to the rear water bypass joint
     
    Vacuum hose (from VSV for fuel pressure control) to the fuel pressure regulator
     
    EVAP hose (from charcoal canister) from the VSV for EVAP
     
    TPS connector
     
    With TRAC system, sub TPS connector
     
    With TRAC system, sub throttle actuator connector
     
    IAC valve connector
     
    EGR valve connector
     
    EGR gas temperature sensor connector
     
    VSV connector for fuel pressure control
     
    VSV connector for EVAP
     
    Accelerator bracket with the 2 bolts
     
    Accelerator, automatic transmission throttle control and the cruise control actuator cable
     
    Spark plug wires and clamps to the right and left cylinder head cover
     
    Belt rear plates by installing the bolts. Tighten the bolts to 66 inch lbs. (8 Nm).
     
    No. 2 ignition coil
     
    A new gasket to the exhaust manifold and install the catalytic converters. Tighten the 3 nuts to each converter to 46 ft. lbs. (62 Nm).
     
    Front exhaust pipe, tighten the bolts and nuts to 32 ft. lbs. (44 Nm). Tighten the 4 bolts holding the pipe support bracket to the transmission. Tighten the bolts to 32 ft. lbs. (44 Nm).
     
    Power steering pump with the nut and 3 bolts. Tighten the nut to 32 ft. lbs. (43 Nm) and the bolts to 29 ft. lbs. (39 Nm).
     

  18.  
  19. Align the knock pin on the right side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the right side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).
  20.  
  21. Align the knock pin on the left side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the left side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).
  22.  
  23. Install the timing belt to the left side camshaft timing pulley as follows:
    1. Using the proper tool, slightly turn the left side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left side camshaft pulley.
    2.  
    3. Align the timing marks of the left side camshaft pulley and the timing belt rear plate.
    4.  
    5. Check that the timing belt has tension between crankshaft timing pulley and the left side camshaft pulley.
    6.  

  24.  
  25. Install the timing belt to the right side camshaft timing pulley as follows:
    1. Using the proper tool, slightly turn the right side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the right side camshaft pulley.
    2.  
    3. Align the timing marks of the right side camshaft pulley and the timing belt rear plate.
    4.  
    5. Check that the timing belt has tension between crankshaft timing pulley and the right side camshaft pulley.
    6.  

  26.  
  27. The timing belt tensioner must be set prior to installation. The tensioner can be set by:
    1. Place a plate washer between the tensioner and a block. Using a press, press in the pushrod using 220-225 lbs. of pressure.
    2.  
    3. Align the holes of the pushrod and housing, pass a 0.05 inch (1.27mm) rod through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot to the tensioner.
    6.  

  28.  
  29. Loosely install the tensioner. Evenly and alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the tool from the tensioner.
  30.  
  31. Turn the crankshaft pulley 2 complete revolutions from TDC to TDC. Always turn the crankshaft clockwise. Check that all belt and pulley marks align with their reference marks. If any mark is out of perfect alignment, the timing belt must be removed and reinstalled.
  32.  
  33. Install or connect the following:

    Drive belt tensioner and tighten the bolt and nuts to 12 ft. lbs. (16 Nm).
     

  34.  
  35. Install the fan bracket by installing the 2 bolts and 2 nuts. Tighten as follows:
    1. 12mm: 12 ft. lbs. (16 Nm)
    2.  
    3. 14mm: 24 ft. lbs. (32 Nm)
    4.  

  36.  
  37. Remove or disconnect the following:

    Air conditioning compressor. Tighten the bolts to 36 ft. lbs. (49 Nm) and the nut to 22 ft. lbs. (29 Nm).
     
    No. 1 ignition coil
     
    Right side No. 2 timing belt cover
     
    Left side No. 2 timing belt cover
     
    Drive belt idler pulley and cover plate. Tighten the bolt to 27 ft. lbs. (37 Nm).
     
    Secure the ignition wires. Make certain that all clips and retainers are securely engaged and that the wires are properly routed.
     
    Right side No. 3 timing belt
     
    Left-hand No. 3 timing belt cover
     
    Radiator assembly
     
    Fan pulley, fan, fluid coupling and the drive belt
     
    The air cleaner and intake air connector assembly
     
    V bank cover
     
    Coolant
     
    Negative battery cable to the battery
     
    Air cleaner inlet
     
    Battery clamp cover
     
    Engine undercover
     
    Oil pan protector
     

  38.  
  39. Start the engine and check for leaks
  40.  
  41. Bleed the cooling system and recheck the engine coolant level.
  42.  
  43. Make all the necessary engine adjustments.
  44.  

2.5L (4gr-Fse) And 3.5L (2gr-Fse) Engines
  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
     
    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)-2.5L (4GR-FSE) and 3.5L (2GR-FSE) Engines



    Click image to see an enlarged view

    Fig. Cylinder head 14mm bolt loosening sequence (left side)-2.5L (4GR-FSE) and 3.5L (2GR-FSE) Engines



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence (left side)-2.5L (4GR-FSE) and 3.5L (2GR-FSE) Engines

     

  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)-2.5L (4GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Cylinder head 14mm bolt tightening sequence (left side)-2.5L (4GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence (left side)-2.5L (4GR-FSE) and 3.5L (2GR-FSE) Engines

    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

    Click image to see an enlarged view

    Fig. Cylinder head cover bolt tightening sequence (right side)-2.5L (4GR-FSE) and 3.5L (2GR-FSE) Engines



    Click image to see an enlarged view

    Fig. Cylinder head cover bolt tightening sequence (left side)-2.5L (4GR-FSE) and 3.5L (2GR-FSE) Engines

     

  4.  
  5. Install the cylinder head cover and gaskets as follows:
    1. Apply seal packing where the cylinder head meets the timing cover.
      NOTE
      Remove any oil from the contact surface. Install the head cover within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

    2.  
    3. Install all new gaskets.
    4.  
    5. Install the head cover along with the retaining bolts. Torque the A bolts to 15 ft. lbs. (21 Nm); and remaining bolts to 7 ft. lbs. (10 Nm).

      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 18 ft. lbs. (24 Nm) for 2.5L and 3.5L engines; 13 ft. lbs. (18 Nm) for 3.0L engine.
       
      Engine hangers (if equipped). Torque to 24 ft. lbs. (33 Nm).
       
      Radiator cap
       
      Oil filler cap and gasket
       
      Negative battery cable
       

    6.  

  6.  
  7. 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.
  8.  

 
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