Lexus GS, SC 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°. The paint mark should now face 90° to the side. Again following the correct order, tighten the bolts another 90° of rotation.

    Click image to see an enlarged view

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

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

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

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

3.3L (3MZ-FE) Engine


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

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

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

 


Click image to see an enlarged view

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



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



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

 
If diameter is lees than minimum, replace the bolts.
 

To install:



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

 


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



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


Click image to see an enlarged view

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

Mark the front side of each head bolt with paint.
 


Click image to see an enlarged view

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

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

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

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

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

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

    Click image to see an enlarged view

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



    Click image to see an enlarged view

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



    Click image to see an enlarged view

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

     

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

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

  12.  

To install:

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

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

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

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

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

      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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

    18.  

  2.  
  3. Install or connect the following:

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

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

3UZ-FE Engine


Click image to see an enlarged view

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



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

 


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



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


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



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



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


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



Click image to see an enlarged view

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

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

To install:

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


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


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

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

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

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

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


    Click image to see an enlarged view

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




Click image to see an enlarged view

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

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


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



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



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



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

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



    Click image to see an enlarged view

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

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

To install:

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


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

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

    Click image to see an enlarged view

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

  14.  
  15. Install or reconnect the following:

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

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

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

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

 
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