Lexus Car ES, IS, LS 1998-06

Cylinder Head 2

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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 degrees. The paint mark should now face 90 degrees to the side. Again following the correct order, tighten the bolts another 90 degrees 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.  

  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
     
    Lower radiator air deflector
     
    RF wheel
     
    V bank cover by removing the bolt and 2 cap nuts
     
    Air cleaner and intake air connector assembly
     
    Emission control valve
     
    Air intake surge tank
     
    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.
     
    PS pump drive belt
     
    Radiator
     

  6.  
  7. Remove intake manifold
  8.  
  9. Remove timing belt
  10.  
  11. Remove PS pump assembly
  12.  
  13. Front and rear exhaust pipe and brackets
  14.  
  15. Remove camshafts
  16.  
  17. Remove LH or RH cylinder head assemblies
  18.  
  19. Remove or disconnect the following:
    WARNING
    Head warpage or cracking could result from removing the bolts in an incorrect order.



    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

     

  20.  
  21. Inspect the cylinder head set bolts. Ensure they match the following:

    Outside diameter is .3524 to .3563 in. (8.95 to 9.05mm)
     
    Minimum diameter is .3445 in. (8.75mm)
     

  22.  
  23. If diameter is lees than minimum, replace the bolts.
  24.  

To install:

  1. Install new head gasket with R mark upward
  2.  
  3. Install cylinder head assembly
    NOTE
    Cylinder head bolts are tightened in two successive steps. Install and tighten 8 cylinder head bolts in required sequence.



    Apply light oil to the cylinder head bolts
     
    Install plate washers on the cylinder head bolts
     

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

      Click image to see an enlarged view

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

    2.  
    3. 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

    4.  
    5. Retighten cylinder head bolts 90 degrees in the same sequence
    6.  
    7. Check that each painted mark is now at a 90 degree angle to the front
    8.  

  4.  
  5. Install or connect the following:

    Wiring harness clamp
     
    Camshaft timing oil valve connector
     
    Camshaft assemblies
     
    Valve cover assemblies
     
    Exhaust manifold assemblies and support brackets. Torque to 36 ft. lbs. (49 Nm)
     
    Exhaust manifold heat insulators
     
    PS pump assembly
     
    Timing belt inner cover
     
    Camshaft timing pulleys
     
    Timing belt and idler assemblies
     
    RH engine mounting bracket
     
    Timing belt covers
     
    Alternator bracket
     
    Engine mounting stay No 2
     
    Engine stabilizer rod
     
    PS drive belt
     
    A/C compressor drive belt
     
    Water outlet
     
    Intake manifold assembly
     
    Intake air surge tank
     
    Emission control valve set
     
    Air cleaner assembly
     
    Vacuum hoses
     
    V-bank cover sub-assembly
     
    Front suspension upper brace
     
    RF wheel
     
    Install engine oil
     
    Installed engine coolant
     

  6.  
  7. Inspect for fuel leaks
  8.  
  9. Inspect for oil leaks
  10.  
  11. Inspect for exhaust leaks
  12.  
  13. Check engine timing and idle speed
  14.  
  15. Run system initialization
  16.  

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.  

4.0L Engine

NOTE
This procedure can be done with the engine in or out of the vehicle. Disconnect the battery negative cable.


WARNING
Do not remove the cylinder block drain plugs or loosen the radiator drain cock with the system hot and pressurized because serious burns from the coolant can occur.

  1. Drain the coolant and disconnect the hoses at the engine thermostat housing and the water pump inlet. DO NOT waste reusable coolant. If the solution is clean and is being drained only to service the engine or cooling system, drain the coolant into a clean container for reuse.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the cylinder head cover.
  6.  
  7. Remove the cap screws, bridge and pivot assemblies and rocker arms.
  8.  
  9. Remove the push rods. Retain the push rods, bridges, pivots and rocker arms in the same order as removed.
  10.  
  11. Remove the accessory drive belt.
  12.  
  13. Remove the A/C compressor mounting bolts and secure the compressor to the side.
  14.  
  15. Remove the power steering pump and bracket from the intake manifold and water pump. Set the pump and bracket aside. DO NOT disconnect the hoses.
  16.  
  17. Perform the Fuel System Pressure Release procedure.
  18.  
  19. Disconnect the fuel supply line at the fuel rail.
  20.  
  21. Remove the intake and exhaust manifolds from the engine cylinder head.
  22.  
  23. Remove the coil rail.
  24.  
  25. Remove spark plugs.
  26.  
  27. Disconnect the temperature sending unit wire connector.
  28.  
  29. Remove the engine cylinder head bolts. Bolt No.14 cannot be removed until the head is moved forward. Pull bolt No.14 out as far as it will go and then suspend the bolt in this position (tape around the bolt).
  30.  
  31. Remove the engine cylinder head and gasket.
  32.  
  33. If this was the first time the bolts were removed, put a paint dab on the top of the bolt. If the bolts have a paint dab on the top of the bolt or it isn't known if they were used before, discard the bolts.
  34.  
  35. Stuff a clean lint free shop towels into the cylinder bores.
  36.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence for the 4.0L engine


NOTE
This procedure can be done with the engine in or out of the vehicle. The engine cylinder head gasket is a composition gasket. The gasket is to be installed DRY. DO NOT use a gasket sealing compound on the gasket.


NOTE
If the engine cylinder head is to be replaced and the original valves used, measure the valve stem diameter. Only standard size valves can be used with a service replacement engine cylinder head unless the replacement head valve stem guide bores are reamed to accommodate oversize valve stems. Remove all carbon buildup and reface the valves.

  1. Remove the shop towels from the cylinder bores. Coat the bores with clean engine oil. Position the engine cylinder head gasket (with the numbers facing up) using the alignment dowels in the cylinder block, to position the gasket.
    CAUTION
    Engine cylinder head bolts should be reused only once. Replace the head bolts if they were used before or if they have a paint dab on the top of the bolt.

  2.  
  3. With bolt No.14 held in place (tape around bolt), install the engine cylinder head over the same dowels used to locate the gasket. Remove the tape from bolt No.14.
  4.  
  5. Coat the threads of stud bolt No.11 with Loctite 592 sealant, or equivalent.
  6.  
  7. Tighten the engine cylinder head bolts in sequence according to the following procedure
    CAUTION
    During the final tightening sequence, bolt No.11 will be tightened to a lower torque than the rest of the bolts. DO NOT over tighten bolt No.11.

  8.  
  9. Tighten all bolts in sequence (1 through 14) to 22 ft. lbs. (30 Nm).
  10.  
  11. Tighten all bolts in sequence (1 through 14) to 45 ft. lbs. (61 Nm).
  12.  
  13. Check all bolts to verify they are set to 45 ft. lbs. (61 Nm).
  14.  
  15. Tighten bolts in sequence:
  16.  
  17. Bolts 1 through 10 to 110 ft. lbs. (149 Nm).
  18.  
  19. Bolt 11 to 100 ft. lbs. (135 Nm).
  20.  
  21. Bolts 12 through 14 to 110 ft. lbs. (149 Nm).
  22.  
  23. Check all bolts in sequence to verify the correct torque.
  24.  
  25. If not already done, clean and mark each bolt with a dab of paint after tightening. Should you encounter bolts which were painted in an earlier service operation, replace them.
  26.  
  27. Install the spark plugs.
  28.  
  29. Connect the temperature sending unit wire connector.
  30.  
  31. Install the ignition coil rail.
  32.  
  33. Install the intake and exhaust manifolds.
  34.  
  35. Install the fuel line.
  36.  
  37. Attach the power steering pump and bracket.
  38.  
  39. Install the push rods, rocker arms, pivots and bridges in the order they were removed.
  40.  
  41. Install the engine cylinder head cover.
  42.  
  43. Attach the air conditioner compressor mounting bracket to the engine cylinder head and block. Tighten the bolts to 30 ft. lbs. (40 Nm).
  44.  
  45. Attach the air conditioning compressor to the bracket. Tighten the bolts to 20 ft. lbs. (27 Nm).
    CAUTION
    The serpentine drive belt must be routed correctly. Incorrect routing can cause the water pump to turn in the opposite direction causing the engine to overheat.

  46.  
  47. Install the serpentine drive belt.
  48.  
  49. Install the air cleaner and ducting.
  50.  
  51. Connect the hoses to the engine thermostat housing and fill the cooling system to the specified level.
  52.  
  53. The automatic transmission throttle linkage and cable must be adjusted after completing the engine cylinder head installation.
  54.  
  55. Install the temperature sending unit and connect the wire connector.
  56.  
  57. If equipped with air conditioning, install A/C compressor and charge A/C system.
  58.  
  59. Connect negative cable to battery.
    WARNING
    Use extreme caution when the engine is operating. Do not stand in direct line with the fan. Do not put hands near the pulleys, belts or fan. Do not wear loose clothing.

  60.  
  61. Operate the engine with the radiator cap off. Inspect for leaks and continue operating the engine until the engine thermostat opens. Add coolant, if required.
  62.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep valve train components in order for reassembly.



    Negative battery cable
     
    Crankcase Ventilation (CCV) hoses
     
    Air cleaner assembly
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Control cable bracket
     
    Valve cover
     



    Rocker arms
     
    Pushrods
     
    Accessory drive belt
     
    A/C compressor and bracket, if equipped
     
    Power steering pump and bracket, if equipped
     
    Fuel line
     
    Combination manifold
     
    Thermostat housing coolant hoses
     
    Spark plugs
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-4.0L engine


WARNING
Cylinder head bolts may only be reused one time. If reusing a cylinder head bolt, place a paint mark on the bolt after installation. If a cylinder head bolt has a paint mark, discard it and use a new bolt.

  1. Install the cylinder head with a new gasket. Coat the threads of bolt No. 11 with Loctite®F 592 sealant.
    CAUTION
    During the final tightening sequence, bolt No. 11 will be tightened to a lower torque value than the rest of the bolts. Do not over tighten bolt No. 11.

  2.  
  3. Tighten the cylinder head bolts, in sequence, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm)
    2.  
    3. Step 2: 45 ft. lbs. (61 Nm)
    4.  
    5. Step 3: 45 ft. lbs. (61 Nm)
    6.  
    7. Step 4: Bolts 1-10 to 110 ft. lbs. (149 Nm)
    8.  
    9. Step 5: Bolt 11 to 100 ft. lbs. (136 Nm)
    10.  
    11. Step 6: Bolts 12-14 to 110 ft. lbs. (149 Nm)
    12.  
    13. Step 7: Repeat steps 4, 5 and 6
    14.  

  4.  
  5. Install or connect the following:

    ECT sensor connector
     
    Spark plugs
     
    Thermostat housing coolant hoses
     
    Combination manifold
     
    Fuel line
     
    Power steering pump and bracket, if equipped
     
    A/C compressor and bracket, if equipped. Torque the bolts to 30 ft. lbs. (40 Nm).
     
    Accessory drive belt
     
    Pushrods and rocker arms in their original positions
     
    Valve cover
     
    Control cable bracket
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Air cleaner assembly
     
    CCV hoses
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

 
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