Toyota Camry 1983-1996 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1C-LTC and 2CL-TC Engines

See Figures 1, 2, 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the cylinder head mounting on diesel engines

  1. Remove the cruise control actuator.
  2.  
  3. Disconnect and tag all wires connected to or running across the head.
  4.  
  5. Disconnect the accelerator control rod from the injection pump.
  6.  
  7. Disconnect the PCV hose from the cylinder head cover. Remove the air cleaner hose with case cover.
  8.  
  9. Disconnect the following hoses:

    Air intake hose
     
    Fuel inlet and outlet hoses
     
    Radiator inlet hose
     
    Heater inlet and outlet hoses
     
    Pressure hose from the turbocharger indicator and warning switch
     
    Vacuum hose to the HAC
     
    Air conditioning or heater idle-up vacuum hose
     

  10.  
  11. Remove the electronic vacuum regulating valve assembly, pipe and hoses.
  12.  
  13. Remove the current sensor.
  14.  
  15. Disconnect the water temperature sender gauge wiring, heater or idle-up water temperature sensor and air conditioning cut water temperature sensor.
  16.  
  17. Raise and support the vehicle safely.
  18.  
  19. Drain the engine oil.
  20.  
  21. Disconnect the exhaust pipe from the turbine elbow.
  22.  
  23. Remove the exhaust manifold stay mounting bolt.
  24.  
  25. Lower the vehicle.
  26.  
  27. Remove the turbocharger. Discard the old gasket.
  28.  
  29. Remove the water outlet with pipe.
  30.  
  31. Remove the EGR valve and pipe.
  32.  
  33. Remove the heater pipe.
  34.  
  35. Disconnect the by-pass hose from the cylinder head union.
  36.  
  37. Disconnect the current sensor plate and glow plug wiring. Using a 12mm deep socket, loosen and remove the four glow plugs.
  38.  
  39. Remove the injection nozzle holders.
  40.  
  41. Remove the level gauge guide support mounting bolt.
  42.  
  43. Remove the No. 2 timing cover.
  44.  
  45. Turn the engine so that the No. 1 cylinder is at TDC of the firing stroke. Make sure that the line mark on the camshaft pulley is aligned with the top end of the head.
  46.  
  47. Place matchmarks on the camshaft timing pulley, injection pump pulley and belt. Remove the camshaft timing pulley.
  48.  

Support the timing belt so the meshing of the injection pump timing pulley and timing pulley does not shift. Be careful not to drop anything inside the belt cover and do not allow oil or grease to come into contact with the timing belt.

  1. Remove the head cover and gasket. Discard the cover gasket and purchase a new one.
  2.  
  3. Remove the front head lifting eye.
  4.  
  5. Loosen the head bolts gradually, in three passes, in the order shown.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Cylinder head bolt loosening sequence


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

  1. Support the timing belt so the meshing of the injection pump timing pulley and timing pulley does not shift, and carefully lift off the head from the cylinder block dowels. Place the head on wooden blocks on a clean work bench. If the head is difficult to break loose, there is a recess at the front end in which you may pry with a suitable tool.
  2.  
  3. Remove the cylinder head gasket and purchase a new one (cylinder head gaskets must never be re-used). With a gasket scraper, remove all the old gasket material from the cylinder head and engine block surfaces.
  4.  

To install:

WARNING
When installing the cylinder head, position the camshaft key upward to prevent interference with the valve and piston.

  1. Position the new head gasket over the dowels on the cylinder block. Position the head over the gasket and lower the head onto the dowels.
  2.  
  3. If any of the cylinder head bolts are damaged or worn, replace them. Coat the cylinder head bolts lightly with clean engine oil and install the bolts into the head.
  4.  
  5. On 1C-LTC engines, tighten the head bolts, in three passes, in the order shown, to 62 ft. lbs. (84 Nm). On 2CL-TC engines, tighten the head bolts, in three stages, to 33 ft. lbs. (46 Nm). Matchmark one point on each bolt and the head, and tighten each bolt, in sequence, an additional 90 degrees from that point. When all bolts are tightened, tighten each an additional 90° turn, in sequence again.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Mark the top of each head bolt prior to angle torquing



Click image to see an enlarged view

Fig. Fig. 4: Cylinder head bolt tightening sequence

  1. Install the head cover with a new gasket. Tighten the cover nuts to 5 ft. lbs. (7 Nm).
  2.  
  3. Install the No. 3 timing belt cover.
  4.  
  5. Install the camshaft timing pulley using the alignment marks made during removal. Tighten the camshaft pulley bolt to 72 ft. lbs. (98 Nm) on the 1C-LTC engine and 65 ft. lbs. (88 Nm) on the 2CL-TC engine.
  6.  
  7. Install the gauge level guide support mounting bolt.
  8.  
  9. Install the injection nozzle holders.
  10.  
  11. Install the glow plugs.
  12.  
  13. Connect the water by-pass hose to the cylinder head.
  14.  
  15. Install the heater pipe.
  16.  
  17. Attach and secure the EGR pipe.
  18.  
  19. Install the water outlet with pipe.
  20.  
  21. Install the turbocharger with a new gasket.
  22.  
  23. Raise and support the vehicle safely.
  24.  
  25. Connect the water temperature sender gauge wiring.
  26.  
  27. Install the current sensor.
  28.  
  29. Install the water by-pass support.
  30.  
  31. Install the electronic vacuum regulating valve assembly, pipe and hoses.
  32.  
  33. Connect all hoses removed in Step 7.
  34.  
  35. Install the air cleaner case with the cover. Connect the PCV hose to the head cover.
  36.  
  37. Connect the accelerator or cruise control rod to the injection pump.
  38.  
  39. If equipped, install the cruise control actuator.
  40.  
  41. Refill the cooling system.
  42.  
  43. Change the engine oil and filter.
  44.  
  45. Connect the negative battery cable.
  46.  
  47. Start the engine and check for leaks.
  48.  
  49. Check the engine idle and maximum idle speeds.
  50.  
  51. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  52.  
  53. Recheck the coolant and engine oil levels.
  54.  

2S-ELC Engine

See Figures 5, 6, 7, 8 and 9

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the cylinder head assembly

  1. On vehicles equipped with AT, disconnect the cable and bracket from the throttle body.
  2.  
  3. Disconnect the accelerator cable from the throttle body.
  4.  
  5. Remove the air pipe and hoses.
  6.  
  7. Disconnect and label the following wires and electrical wiring.

    Ground strap connector
     
    IIA connector
     
    Igniter connector (USA only)
     
    Water temperature sensor gauge connector
     
    Idle-up VSV connector (USA) only
     
    Water temperature switch connector (automatic transmission only)
     
    Alternator terminal wiring and connector
     

  8.  
  9. Disconnect and label the following vacuum hoses:

    Air conditioning idle-up vacuum hoses
     
    Cruise control actuator vacuum hose
     
    Brake booster vacuum hose from the air intake manifold
     
    Vacuum hose to the charcoal canister
     
    Emission control hoses
     

  10.  
  11. Remove the vacuum pipe from the head cover
  12.  
  13. Disconnect and label the following wires

    Oxygen sensor connector (USA only)
     
    Cold start injector time switch connector
     
    Injector connectors
     
    Throttle position sensor connector
     
    Air flow meter connector
     
    Check connector
     
    Solenoid resistor connector
     
    LH fender apron connectors
     
    Air valve connector
     
    Water temperature sensor connector
     
    Start injector time switch connector (normal)
     
    Engine ground strap
     

  14.  
  15. Pull the EFI harness to the right fender apron side.
  16.  
  17. Remove the alternator.
  18.  
  19. Remove the distributor assembly.
  20.  
  21. Remove the upper radiator hose and bypass hose.
  22.  
  23. Unbolt and remove the water outlet housing.
  24.  
  25. Disconnect the heater water outlet hose.
  26.  
  27. Disconnect the two air hoses from the fuel injection air valve.
  28.  
  29. Unbolt and remove the rear end housing with the air valve attached.
  30.  
  31. Remove the heater pipe by disconnecting the water by-pass and heater water inlet hoses and removing the two nuts with the gasket.
  32.  
  33. Disconnect the fuel line at the filter and the fuel return line at the return pipe. Collect all the excess fuel in a small plastic container.
  34.  
  35. Raise and support the vehicle on jackstands.
  36.  
  37. Drain the oil.
  38.  
  39. Disconnect the exhaust pipe at the manifold.
  40.  
  41. Disconnect the two power steering pump vacuum hoses.
  42.  
  43. Remove the intake manifold stay.
  44.  
  45. Lower the vehicle.
  46.  
  47. Remove the timing belt from the camshaft pulley.
  48.  
  49. Remove the No. 1 idler pulley and tension spring.
  50.  
  51. Remove the throttle body.
  52.  
  53. Disconnect the PCV hoses and remove the valve cover.
  54.  
  55. Unbolt and remove the camshaft housing using a small prybar positioned between the cylinder head and camshaft housing projections. Loosen the bolts gradually in the sequence shown.
  56.  



Click image to see an enlarged view

Fig. Fig. 6: Camshaft housing bolt loosening sequence on 2S-ELC engines


WARNING
If the bolts are loosened out of sequence, warpage could occur.

  1. Remove the rocker arms and lash adjusters. Label each assembly as it is removed and keep all the assemblies together.
  2.  
  3. Loosen and remove the head bolts evenly, in three passes, in the order shown. Carefully lift the head from the engine and place it on wood blocks in a clean work area.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: Cylinder head bolt loosening sequence

  1. Remove the cylinder head gasket and purchase a new one (cylinder head gaskets must never be re-used). With a gasket scraper, remove all the old gasket material from the cylinder head and engine block surfaces.
  2.  

To install:
  1. Place the new cylinder head gasket onto the cylinder block. Place the cylinder head onto the gasket.
  2.  
  3. Coat the threads of the eighteen cylinder head bolts with clean engine oil and install the bolts into the cylinder head. Uniformly tighten the bolts in three passes to 15 ft. lbs. (20 Nm), 30 ft. lbs. (47 Nm), 47 ft. lbs. (64 Nm) using the sequence shown.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Cylinder head bolt tightening sequence

  1. Install the rocker arms and lash adjusters in their original locations.
  2.  
  3. Install the camshaft housing by performing the following:
    1. Using a gasket scraper, thoroughly clean all the old packing material from the gasket surfaces and sealing grooves. Clean the surfaces again with a suitable cleaning solvent.
    2.  
    3. Apply a bead of seal packing (No. 08826-00080 or equivalent) to the camshaft housing contact surface. Do not use to much sealant. The sealant hardens within 3 minutes after application. If the sealant hardens, it must be removed and reapplied.
    4.  
    5. Place the camshaft housing onto the cylinder head.
    6.  
    7. Install the camshaft housing bolts. Tighten the bolts in three passes to 11 ft. lbs. (16 Nm).
    8.  
    9. Install the vacuum idle-up pipe.
    10.  

  4.  



Click image to see an enlarged view

Fig. Fig. 9: Camshaft housing tightening sequence

  1. Install the valve cover with a new gasket. Connect the PCV hoses to the cover.
  2.  
  3. Install the throttle body.
  4.  
  5. Temporarily install the No. idler pulley and tension spring.
  6.  
  7. Install the timing belt to the pulley.
  8.  
  9. Raise the vehicle and support it safely.
  10.  
  11. Connect the exhaust pipe to the exhaust manifold. Tighten the exhaust pipe nuts to 46 ft. lbs. (64 Nm).
  12.  
  13. Install the intake manifold stay.
  14.  
  15. Connect the two vacuum hoses to the power steering pump.
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect the fuel inlet and return hoses. Tighten the filter inlet bolt to 22 ft. lbs. (29 Nm).
  20.  
  21. Install the heater pipe, new gasket, clamp and by-pass and inlet hoses.
  22.  
  23. Install the rear end housing with air valve. Connect the two hoses to the air valve.
  24.  
  25. Connect the water heater outlet and by-pass hoses.
  26.  
  27. Install the water outlet housing with a new gasket.
  28.  
  29. Connect the upper radiator and by-pass hoses. Place the engine wiring harness to the inside of the by-pass hose.
  30.  
  31. Install the IIA distributor assembly.
  32.  
  33. Install the alternator.
  34.  
  35. Pull the EFI wiring harness from the right fender apron through between the engine and the intake manifold.
  36.  
  37. Connect all the wires, electrical connectors and vacuum hose removed in Steps 7, 8 and 10.
  38.  
  39. Install the vacuum pipe on the head cover. Install the air cleaner pipe and hoses.
  40.  
  41. Connect the accelerator cable to the throttle body and adjust it.
  42.  
  43. On vehicles equipped with automatic transmission, connect the throttle cable with bracket to the throttle body and adjust it.
  44.  
  45. Fill the cooling system to the proper level.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. Start and warm up the engine. Inspect for leaks.
  50.  
  51. Adjust the ignition timing and the idle speed.
  52.  
  53. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  54.  
  55. Recheck the coolant and engine oil levels.
  56.  

3S-FE and 5S-FE Engines

See Figures 10, 11, 12, 13 and 14

  1. Drain the cooling system.
  2.  
  3. On vehicles equipped with automatic transmission, disconnect the throttle cable and bracket from the throttle body.
  4.  



Click image to see an enlarged view

Fig. Fig. 10: Exploded view of the cylinder head mounting on 3S-FE and 5S-FE engines

  1. Disconnect the accelerator cable and bracket from the throttle body and intake chamber.
  2.  
  3. On vehicles equipped with cruise control, remove the actuator and bracket (3S-FE).
  4.  
  5. Remove the air cleaner hose.
  6.  
  7. Remove the alternator.
  8.  
  9. Remove the oil pressure gauge, engine hangers and alternator upper bracket.
  10.  
  11. Loosen the lug nuts on the right wheel and raise and support the vehicle safely.
  12.  
  13. Remove the right tire and wheel assembly.
  14.  
  15. Remove the right under cover.
  16.  
  17. Remove the suspension lower crossmember (3S-FE).
  18.  
  19. Disconnect the exhaust pipe from the catalytic converter.
  20.  
  21. Separate the exhaust pipe from the catalytic converter.
  22.  
  23. Remove the distributor.
  24.  
  25. Disconnect the water temperature sender gauge connector, water temperature sensor connector, cold start injector time switch connector, upper radiator hose, water hoses, and the emission control vacuum hoses. Unbolt and remove the water outlet and gaskets.
  26.  
  27. Remove the water bypass pipe with O-rings and gasket.
  28.  
  29. Remove the EGR valve and vacuum modulator.
  30.  
  31. Remove the throttle body.
  32.  
  33. Remove the cold start injector pipe (3S-FE).
  34.  
  35. Disconnect the air chamber hose, throttle body air hose and power steering hoses (if equipped). Remove the air tube.
  36.  
  37. Remove the intake manifold stay and disconnect the vacuum sensing hose. Remove the intake manifold and gasket. Purchase a new gasket.
  38.  
  39. Remove the fuel delivery pipe and the injectors.
  40.  
  41. Remove the spark plugs.
  42.  
  43. Remove the camshaft timing pulley. Remove the No. 1 idler pulley and tension spring. Remove the No. 3 timing belt cover. Properly support the timing belt so that meshing of the crankshaft timing pulley does not occur and the timing belt does not shift.
  44.  
  45. Remove the cylinder head cover. Label and arrange the grommets in order so that they can be reinstalled in the correct order. Remove the engine hangers, and the alternator bracket on the 5S-FE.
  46.  
  47. Remove the intake and exhaust camshafts as described in this section.
  48.  
  49. Loosen and remove the ten head bolts evenly, in three passes, in the order shown. Carefully lift the head from the engine and place it on wood blocks in a clean work area.
  50.  



Click image to see an enlarged view

Fig. Fig. 11: Place a paint mark on each cylinder head bolt prior to removal



Click image to see an enlarged view

Fig. Fig. 12: Cylinder head bolt loosening sequence


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

  1. Remove the cylinder head gasket and purchase a new one (cylinder head gaskets must never be re-used). With a gasket scraper, remove all the old gasket material from the cylinder head and engine block surfaces.
  2.  

To install:
  1. Place the new cylinder head gasket onto the cylinder block. Place the cylinder head onto the gasket.
  2.  
  3. Coat the threads of the ten cylinder head bolts with clean engine oil and install the bolts into the cylinder head. Uniformly tighten the bolts in three passes to 47 ft. lbs. (64 Nm) on 1986-88 models, or 36 ft. lbs. (49 Nm) on 1989-96 models, using the sequence shown. If any of the bolts does not meet the torque, replace it. On 1989-96 models, mark the forward edge of each bolt with paint and then retighten each bolt an additional 90°. Check that each painted mark is now at a 90° angle to the front.
  4.  



Click image to see an enlarged view

Fig. Fig. 13: Check that the painted mark is 90 degrees to the front



Click image to see an enlarged view

Fig. Fig. 14: Cylinder head bolt tightening sequence

  1. Using a 30mm socket, install the spark plug tubes and tighten them to 29 ft. lbs. (39 Nm).
  2.  
  3. Install the intake and exhaust camshafts.
  4.  
  5. Install the cylinder head cover. Tighten the cover nuts to 13 ft. lbs. (18 Nm) on 1986-88 models, or 17 ft. lbs. (23 Nm) on 1989-96 models.
  6.  
  7. Install the No. 3 timing belt cover with the four cover bolts; tighten them to 69 inch lbs. (8 Nm). Install the hangers and alternator bracket on the 5S-FE. Tighten the hangers to 18 ft. lbs. (25 Nm) and the bracket to 31 ft. lbs. (42 Nm).
  8.  
  9. Install the No. 1 idler pulley and tension spring.
  10.  
  11. Install the camshaft timing pulley.
  12.  
  13. Install the spark plugs.
  14.  
  15. Install the injector and delivery pipe. Tighten the mounting bolts to 9 ft. lbs. (13 Nm).
  16.  
  17. Attach the intake manifold with new gasket. Tighten the nuts and bolts to 14 ft. lbs. (19 Nm).
  18.  
  19. Install the air tube and connect the air intake chamber hose, throttle body air hose and power steering pump hoses (if equipped).
  20.  
  21. Install the cold start injector pipe.
  22.  
  23. Install the throttle body. Refer to Fuel System .
  24.  
  25. Install the EGR valve and modulator with new gaskets. Tighten the union nut to 43 ft. lbs. (59 Nm) and the bolt to 9 ft. lbs. (13 Nm).
  26.  
  27. Install the water by-pass pipe with new O-ring and gasket. Coat the O-ring with clean engine oil after installing it into the groove in the pipe. Tighten the bolts to 82 inch lbs. (9 Nm) on the 3S-FE, 78 inch lbs. (88 Nm) on the 5S-FE. Connect the water hoses.
  28.  
  29. Install the water outlet with a new gasket. Tighten the bolts to 11 ft. lbs. (15 Nm). Attach the upper radiator hose, water hose, emission control vacuum hoses, water temperature sender gauge connector, water temperature sensor connector and cold start injector time switch connector.
  30.  
  31. Install the distributor assembly.
  32.  
  33. Assemble the exhaust manifold and the catalytic converter with new gaskets. Tighten the bolts to 22 ft. lbs.
  34.  
  35. Install the exhaust manifold and catalytic converter with new gasket to the engine. The exhaust manifold gasket should be installed so that the R mark (most models) is toward the back.
  36.  
  37. Connect the exhaust pipe to the catalytic converter.
  38.  
  39. Install the suspension lower crossmember.
  40.  
  41. Install the engine right under cover.
  42.  
  43. Install the right front wheel and make the lug nuts snug.
  44.  
  45. Lower the vehicle.
  46.  
  47. Install the oil pressure gauge, engine hangers and alternator bracket on the 3S-FE. Tighten the bolts to 31 ft. lbs. (41 Nm).
  48.  
  49. Install the alternator and adjust the drive belt tension.
  50.  
  51. Install the air cleaner hose.
  52.  
  53. If equipped, install the cruise control actuator and bracket.
  54.  
  55. Install the radiator reservoir tank.
  56.  
  57. Install and adjust the accelerator cable.
  58.  
  59. If equipped with automatic transaxle, connect and adjust the throttle cable.
  60.  
  61. Fill the cooling system to the proper level with a good brand of ethylene glycol coolant.
  62.  
  63. Connect the negative battery cable.
  64.  
  65. Start the engine and check for leaks.
  66.  
  67. Adjust the valves and the ignition timing.
  68.  
  69. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  70.  
  71. Recheck the coolant and engine oil levels.
  72.  

2VZ-FE and 3VZ-FE Engines

See Figures 15, 16, 17, 18 and 19

  1. Drain the cooling system.
  2.  



Click image to see an enlarged view

Fig. Fig. 15: Exploded view of the cylinder head assembly found on 2VZ-FE and 3VZ-FE engines

  1. On vehicles equipped with automatic transmission, disconnect the throttle cable and bracket from the throttle body.
  2.  
  3. Disconnect the accelerator cable and bracket from the throttle body and intake chamber.
  4.  
  5. On vehicles equipped with cruise control, remove the actuator, vacuum pump and bracket (2VZ-FE).
  6.  
  7. Remove the air cleaner hose.
  8.  
  9. Remove the alternator.
  10.  
  11. Remove the oil pressure gauge, engine hangers and alternator upper bracket.
  12.  
  13. Loosen the lug nuts on the right wheel and raise and support the vehicle safely.
  14.  
  15. Remove the right tire and wheel assembly.
  16.  
  17. Remove the right under cover.
  18.  
  19. Remove the suspension lower crossmember (2VZ-FE).
  20.  
  21. Disconnect the exhaust pipe from the catalytic converter.
  22.  
  23. Separate the exhaust pipe from the catalytic converter.
  24.  
  25. Remove the distributor. Remove the V-bank cover on the 3VZ-FE.
  26.  
  27. Disconnect the water temperature sender gauge connector, water temperature sensor connector, cold start injector time switch connector, upper radiator hose, water hoses, and the emission control vacuum hoses. Unbolt and remove the water outlet and gaskets.
  28.  
  29. Remove the water bypass pipe with O-rings and gasket.
  30.  
  31. Remove the EGR valve and vacuum modulator. Remove the exhaust crossover pipe.
  32.  
  33. Remove the throttle body.
  34.  
  35. Remove the cold start injector pipe (2VZ-FE).
  36.  
  37. Disconnect the air chamber hose, throttle body air hose and power steering hoses (if equipped). Remove the air tube.
  38.  
  39. Remove the intake manifold stay and disconnect the vacuum sensing hose. Remove the intake manifold and gasket. Purchase a new gasket.
  40.  
  41. Remove the fuel delivery pipe and the injectors.
  42.  
  43. Remove the rear cylinder head plate. On the 3VZ-FE, remove the emission control valve set and the left side engine harness.
  44.  
  45. Remove the exhaust manifolds. Remove the spark plugs. On the 3VZ-FE, remove the oil dipstick.
  46.  
  47. Remove the timing belt, all camshaft timing pulleys and the No. 2 idler pulley.
  48.  
  49. Remove the No. 3 timing belt cover. Support the belt carefully so that the belt and pulley mesh does not shift.
  50.  
  51. Remove the cylinder head covers. Remove the spark plug tube gaskets on the 2VZ-FE.
  52.  
  53. Remove the intake and exhaust camshafts from each head as described in this section.
  54.  
  55. On the 3VZ-FE, remove the power steering pump bracket and the left side engine hanger.
  56.  
  57. Remove the two (one on each head) 8mm hex bolts. Loosen and remove the eight head bolts evenly, in three passes, in the order shown. Carefully lift the head from the engine and place it on wood blocks in a clean work area.
  58.  



Click image to see an enlarged view

Fig. Fig. 16: Remove the two (one on each head) 8mm hex bolts first


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



Click image to see an enlarged view

Fig. Fig. 17: Cylinder head bolt loosening sequence

  1. Remove the cylinder head gasket and purchase a new one (cylinder head gaskets must never be re-used). With a gasket scraper, remove all the old gasket material from the cylinder head and engine block surfaces.
  2.  

To install:
  1. Place the new cylinder head gasket onto the cylinder block. Place the cylinder head onto the gasket.
  2.  



Click image to see an enlarged view

Fig. Fig. 18: Cylinder head gaskets must be positioned correctly

  1. Coat the threads of the eight cylinder head bolts (12-sided) with clean engine oil and install the bolts into the cylinder head. Uniformly tighten the bolts in three passes to 25 ft. lbs. (34 Nm), using the sequence shown. If any of the bolts does not meet the torque, replace it.
  2.  
  3. Mark the forward edge of each bolt with paint and then retighten each bolt an additional 90°, in the order shown. Now repeat the process once more, for an additional 90°. Check that each painted mark is now at a 180° angle to the front, facing the rear.
  4.  



Click image to see an enlarged view

Fig. Fig. 19: Cylinder head bolt tightening sequence

  1. Coat the threads of the two remaining 8mm bolts with engine oil and install them. Tighten to 13 ft. lbs. (18 Nm).
  2.  
  3. Install the left engine hanger and tighten it to 27 ft. lbs. (37 Nm). Install the power steering pump bracket on the 3VZ-FE.
  4.  
  5. Install the camshafts. On the 2VZ-FE, install the spark plug tube gaskets.
  6.  
  7. Install the cylinder head covers and tighten the bolts to 52 inch lbs. (6 Nm).
  8.  
  9. Install the No. 3 timing belt cover and tighten the six bolts to 65 inch lbs. (7.4 Nm). Install the No. 2 idler pulley, the camshaft timing pulleys and the timing belt.
  10.  
  11. Install the spark plugs.
  12.  
  13. Install the right and left side exhaust manifolds and tighten them to 29 ft. lbs. (39 Nm).
  14.  
  15. Install the intake manifold and the No. 2 idler pulley bracket. Tighten all bolts to 13 ft. lbs. (18 Nm).
  16.  
  17. Install the cylinder head rear plate and the oil dipstick tube.
  18.  
  19. Install the water by-pass outlet and tighten the bolts to 14 ft. lbs. (20 Nm) on the 2VZ-FE, or 74 inch lbs. (8 Nm) on the 3VZ-FE. On the 2VZ-FE, install the water outlet.
  20.  
  21. Install the injectors and delivery pipe. Tighten the bolts to 9 ft. lbs. (13 Nm).
  22.  
  23. On the 3VZ-FE, install the air pipe, the engine harness and the No. 1 EGR cooler. Tighten the pipe to 73 inch lbs. (8 Nm) and the cooler to 13 ft. lbs. (18 Nm).
  24.  
  25. Install the air intake chamber. Tighten the mounting bolts to 32 ft. lbs. (43 Nm), the stays to 27 ft. lbs. (37 Nm) on the 2VZ-FE or 29 ft. lbs. (39 Nm) on the 3VZ-FE.
  26.  
  27. Install the cold start injector. Install the distributor and the EGR assembly. Tighten the EGR bolts to 13 ft. lbs. (18 Nm).
  28.  
  29. On the 2VZ-FE, install the crossover pipe and tighten the bolts to 25 ft. lbs. (34 Nm) and the nuts to 29 ft. lbs. (39 Nm). On the 3VZ-FE, install the emission control valve set and tighten it to 73 inch lbs. (8 Nm).
  30.  
  31. Install the EGR pipe and tighten the bolt to 13 ft. lbs. (18 Nm) and the union nut to 58 ft. lbs. (78 Nm).
  32.  
  33. Install the throttle body and the ISC valve. Tighten both sets of bolts to 9 ft. lbs. (13 Nm).
  34.  
  35. On the 3VZ-FE, install the V-bank cover.
  36.  
  37. Install the front exhaust pipe and tighten the manifold nuts to 46 ft. lbs. (62 Nm), tighten the converter nuts to 32 ft. lbs. (43 Nm). Install the engine under cover on the 2VZ-FE.
  38.  
  39. Install the alternator and adjust the drive belt tension.
  40.  
  41. Install the air cleaner hose.
  42.  
  43. If equipped, install the cruise control actuator and bracket.
  44.  
  45. Install and adjust the accelerator cable.
  46.  
  47. If equipped with automatic transaxle, connect and adjust the throttle cable.
  48.  
  49. Fill the cooling system to the proper level with a good brand of ethylene glycol coolant.
  50.  
  51. Connect the negative battery cable. Start the engine and check for leaks.
  52.  
  53. Adjust the valves and the ignition timing. Check the toe-in.
  54.  
  55. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  56.  
  57. Recheck the coolant and engine oil levels.
  58.  

1MZ-FE Engine

See Figures 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 and 31


CAUTION
Fuel injection systems remain under pressure even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Relieve the fuel pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the accelerator cable and the throttle cable on vehicles equipped with an automatic transaxle.
  6.  
  7. Remove the air cleaner cover, air flow meter, and the air duct.
  8.  
  9. Remove the cruise control actuator and bracket, if equipped.
  10.  
  11. Disconnect the two engine ground straps.
  12.  
  13. Remove the right engine mounting support.
  14.  
  15. Disconnect the radiator hoses.
  16.  
  17. Disconnect the two heater hoses.
  18.  
  19. Disconnect and plug the fuel feed and return lines from the fuel rail assembly.
  20.  
  21. Disconnect and plug the pressure hose from the hydraulic motor.
  22.  
  23. Remove the V-bank cover.
  24.  
  25. Disconnect the following vacuum hoses:

    Fuel pressure control VSV
     
    Fuel pressure regulator
     
    Cylinder head rear plate
     
    Intake air control valve VSV
     
    EGR vacuum modulator
     
    EGR valve
     

  26.  
  27. Disconnect the following wiring and hoses:

    Intake air control valve
     
    Fuel pressure regulator
     
    EGR VSV
     

  28.  
  29. Remove the two nuts and the emission control valve set.
  30.  



Click image to see an enlarged view

Fig. Fig. 20: Remove the emission control valve set. Make sure to label each connection

  1. Disconnect the following hoses;

    Brake booster vacuum hose
     
    PCV hose
     
    Intake air control valve vacuum hose
     

  2.  
  3. Remove the data link connector from the mounting bracket.
  4.  
  5. Remove the two ground straps from the intake chamber.
  6.  
  7. Remove the hydraulic motor pressure hose from the intake chamber.
  8.  
  9. Remove the right oxygen sensor connector from the pressure tube.
  10.  
  11. Remove the two nuts and the pressure tube from the intake chamber.
  12.  
  13. Disconnect the two air hoses.
  14.  
  15. Remove the engine hanger and the intake chamber support.
  16.  
  17. Remove the EGR pipe and gaskets.
  18.  
  19. Disconnect the following wiring;

    Throttle position sensor connector
     
    IAC valve connector
     
    EGR gas temperature connector
     
    A/C idle up connector
     

  20.  
  21. Disconnect the following vacuum hoses:

    Two vacuum hoses from the TVV
     
    Vacuum hose from the cylinder head rear plate
     
    Vacuum hose from the charcoal canister
     

  22.  
  23. Disconnect the air assist hose and the two water bypass hoses.
  24.  
  25. Remove the air intake chamber.
  26.  
  27. Disconnect the left engine wire harness and position it out of the way.
  28.  
  29. Remove the wire harness from the rear of the engine.
  30.  
  31. Disconnect the right engine wire harness and position it out of the way.
  32.  
  33. Remove the ignition coils and lay them aside in the exact positions where they are placed in the heads.
  34.  
  35. Remove the timing belt.
  36.  
  37. Remove the camshaft pulleys and the timing belt rear cover.
  38.  
  39. Remove the cylinder head rear plate.
  40.  



Click image to see an enlarged view

Fig. Fig. 21: Disconnect the vacuum hoses and remove the cylinder head rear plate

  1. Remove the water inlet pipe.
  2.  
  3. Remove the air assist hose and vacuum hose.
  4.  
  5. Remove the intake manifold and fuel rail assembly.
  6.  
  7. Remove the water outlet.
  8.  
  9. Remove the EGR pipe from the right exhaust manifold.
  10.  
  11. Remove the front exhaust pipe and exhaust manifolds.
  12.  
  13. Remove the dipstick assembly and the pump bracket.
  14.  



Click image to see an enlarged view

Fig. Fig. 22: Unbolt and remove the oil dispstick from the front of the engine

  1. Remove the valve covers and the camshaft position sensor.
  2.  
  3. Remove the camshafts following the proper sequences and procedures.
  4.  
  5. Make sure the engine is at or near ambient temperature and remove the two (one on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the installation sequence. Carefully lift the head from the engine; if it is necessary to pry the head loose, take great care not to damage the mating surfaces. Place the head on wood blocks in a clean work area.
  6.  


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



Click image to see an enlarged view

Fig. Fig. 23: There are bolts recessed in the cylinder heads, remove these first



Click image to see an enlarged view

Fig. Fig. 24: Left side cylinder head bolt loosening sequence



Click image to see an enlarged view

Fig. Fig. 25: Right side cylinder head bolt loosening sequence

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



Click image to see an enlarged view

Fig. Fig. 26: Use a prybar to help separate the head from the block



Click image to see an enlarged view

Fig. Fig. 27: Lift the cylinder head off the block



Click image to see an enlarged view

Fig. Fig. 28: Remove the old head gasket and discard



Click image to see an enlarged view

Fig. Fig. 29: Scrape the old gasket material off the mating surfaces

To install:
  1. Place the new cylinder head gasket onto the cylinder block. Place the cylinder head onto the gasket.
  2.  
  3. Coat the threads of the 8 cylinder head bolts (12-sided) with clean engine oil and install the bolts into the cylinder head. Uniformly tighten the bolts in sequence in three steps to 40 ft. lbs. (54 Nm), using the proper sequence. If any bolt does not meet the torque, replace it.
  4.  



Click image to see an enlarged view

Fig. Fig. 30: Only use a torque wrench to tighten the cylinder head bolts



Click image to see an enlarged view

Fig. Fig. 31: Cylinder head bolt tightening sequence

  1. Mark the forward edge of each bolt with paint and then tighten each bolt, in proper sequence, an additional 90 °. Check that each painted mark is now at a 90 ° 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.
  2.  
  3. Coat the threads of the two remaining 8mm bolts with engine oil and install them. Tighten to 13 ft. lbs. (18 Nm).
  4.  
  5. Install the camshafts following the proper sequences and procedures.
  6.  
  7. Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads.
  8.  
  9. Use new gaskets and install the cylinder head covers.
  10.  
  11. Install the dipstick and power steering pump bracket.
  12.  
  13. Install the exhaust manifolds. Tighten the nuts to 36 ft. lbs. (49 Nm).
  14.  
  15. Install the EGR pipe to the right exhaust manifold.
  16.  
  17. Install the water outlet.
  18.  
  19. Install the intake manifold and the fuel rail assembly. Tighten the intake manifold nuts and bolts to 11 ft. lbs. (15 Nm).
  20.  
  21. Install the air assist hose and the two water bypass hoses.
  22.  
  23. Install the water inlet pipe and the cylinder head rear plate.
  24.  
  25. Install the timing belt rear cover and the camshaft pulleys.
  26.  
  27. Install the timing belt.
  28.  
  29. Install the spark plugs and the ignition coils.
  30.  
  31. Install the right engine wire harness.
  32.  
  33. Install the wire harness to the rear of the engine.
  34.  
  35. Install the left engine wire harness.
  36.  
  37. Attach and secure the air intake chamber.
  38.  
  39. Use new gaskets and install the EGR pipe.
  40.  
  41. Connect the following vacuum hoses:

    The two TVV vacuum hoses
     
    The vacuum hose to the rear cylinder head plate
     
    Charcoal canister vacuum hose
     

  42.  
  43. Connect the following electrical wiring:

    Throttle position sensor connector
     
    IAC valve connector
     
    EGR gas temperature connector
     
    A/C idle up connector
     

  44.  
  45. Install the engine hanger and the intake chamber support
  46.  
  47. Connect the two air hoses.
  48.  
  49. Install the pressure tube to the intake chamber.
  50.  
  51. Install the oxygen sensor connector to the pressure tube.
  52.  
  53. Install the two ground straps to the intake chamber.
  54.  
  55. Install the data link connector to the bracket.
  56.  
  57. Connect the following hoses:

    Power brake booster vacuum hose
     
    PCV hose
     
    IAC valve vacuum hose
     

  58.  
  59. Install the emission control valve set and related vacuum hoses and connectors.
  60.  
  61. Install the V-bank cover.
  62.  
  63. Connect the pressure hose to the hydraulic motor.
  64.  
  65. Connect the fuel lines to the fuel rail assembly.
  66.  
  67. Connect the heater and radiator hoses.
  68.  
  69. Install the right engine mounting support.
  70.  
  71. Connect the two engine ground straps.
  72.  
  73. Install the cruise control actuator and bracket.
  74.  
  75. Install the air cleaner, air flow meter, and air duct assembly.
  76.  
  77. Connect the accelerator cable and the throttle cable on vehicles equipped with an automatic transaxle.
  78.  
  79. Fill the cooling system to the proper level with coolant.
  80.  
  81. Connect the negative battery cable.
  82.  
  83. Start the engine and check for leaks. Bleed the air from the cooling system.
  84.  
  85. Adjust the ignition timing.
  86.  
  87. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  88.  
  89. Recheck the coolant and engine oil levels.
  90.  

 
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