Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Cylinder Head

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REMOVAL & INSTALLATION



22R Engine

See Figures 1 through 11


WARNING
Do not perform this operation on a warm engine. Allow the engine to cool a minimum of 3 hours, more in hot weather. Overnight cold is best.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system (both radiator and block). If the coolant is to be reused, place a large, clean container underneath the drains.
  4.  


CAUTION
When draining 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 coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Remove the three exhaust pipe flange nuts and separate the pipe from the manifold.
  2.  
  3. Remove the air cleaner assembly, complete with hoses, from the carburetor.
  4.  

Cover the carburetor with a clean shop cloth so that nothing can fall into it.

  1. Drain the engine oil.
  2.  


CAUTION
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  1. Disconnect the radiator inlet hose from the water outlet.
  2.  
  3. If equipped with an air pump, disconnect the air hose from the check valve.
  4.  
  5. Disconnect the two heater hoses from the engine.
  6.  
  7. Disconnect the accelerator cable at the carburetor.
  8.  
  9. Label and disconnect these wires:

    EGR temperature sensor (Calif. vehicles only)
     
    Water temperature gauge sender
     
    Cold mixture heater wire
     
    Temperature sensor
     
    Fuel cut solenoid valve
     
    EACV (Calif. only)
     

  10.  
  11. Label and disconnect these hoses and lines:

    Charcoal canister
     
    Brake booster
     
    Main fuel line from fuel inlet
     
    Fuel return line
     
    HAC from the bracket
     
    Electronic Bleed Air Control Valve (EBCV) Calif. vehicles
     
    Vacuum Switching Valve (VSV) with bracket
     

  12.  
  13. Remove the rear ground strap from the engine.
  14.  
  15. Remove the distributor.
  16.  
  17. Remove the spark plugs.
  18.  
  19. Disconnect the power steering bracket from the head.
  20.  
  21. Remove the valve cover and gasket.
  22.  
  23. Turn the engine clockwise (use the crank pulley bolt) until the piston is at TDC on its compression stroke. Matchmark the timing sprocket to the cam chain, and remove the semi-circular plug. Remove the cam sprocket bolt. Slide the distributor drive gear and spacer off the cam. Leave the chain on the sprocket; either wire the cam sprocket in place just off the end of the cam or rest the sprocket on the vibration damper. Tie a string or wire to the chain to keep it from falling in the engine.
  24.  



Click image to see an enlarged view

Fig. Fig. 1: Set the timing marks to TDC on the No.1 cylinder; matchmark the chain and sprocket



Click image to see an enlarged view

Fig. Fig. 2: Using a 19mm wrench, remove the cam sprocket bolt



Click image to see an enlarged view

Fig. Fig. 3: Do not allow the chain to slip off while removing the sprocket



Click image to see an enlarged view

Fig. Fig. 4: Remove the front cover bolt before loosening the cylinder head bolts

  1. Remove the timing chain cover bolt at the front of the head. This must be done before the head bolts are removed.
  2.  
  3. Remove the cylinder head bolts in the correct order. Make two or three passes to loosen the bolts. Do not loosen any one bolt all at once; improper removal could cause head damage.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Loosen the head bolts in this order, in three passes

  1. Using prybars applied evenly at the front and the rear of the valve rocker assembly, gently pry the assembly off its mounting dowels.
  2.  
  3. Lift the head off its dowels. If it is difficult to lift off, pry gently with small tools. Do NOT damage the mating surfaces of the head or block. Do NOT attempt to slide the head off the block; it must be lifted.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Lift the old gasket from the block



Click image to see an enlarged view

Fig. Fig. 7: Scrape and clean the area well, insert paper into the cylinder walls to keep dirt from entering

  1. Support the head on a workbench.
  2.  
  3. Remove the manifolds and EGR valve from the head on the workbench. Keep the head covered and the manifold ports plugged with rags when not working on it.
  4.  
  5. Re-drain the oil pan after the head has been removed; coolant will have spilled into the pan during head removal. The coolant will pollute the oil.
  6.  
  7. Remove the head gasket, never reuse the old one.
  8.  

To install:
  1. Apply liquid sealer to the front corners of the block and install the head gasket.
  2.  
  3. Lower the head over the locating dowels. Do not attempt to slide it into place.
  4.  
  5. Install the rocker arm assembly over its positioning dowels.
  6.  
  7. Install the cylinder head bolts. Tighten the bolts sequentially in three passes and in the correct order, coming to final torque on the last pass. Correct tightness is 58 ft. lbs. (78 Nm)
  8.  



Click image to see an enlarged view

Fig. Fig. 8: Apply liquid sealer to the corners of the block



Click image to see an enlarged view

Fig. Fig. 9: Tighten the head bolts in this order, in three passes



Click image to see an enlarged view

Fig. Fig. 10: Always tighten the bolts with a torque wrench

  1. Install the chain cover bolt. Tighten it to 9 ft. lbs. (13 Nm).
  2.  
  3. Hold the chain and sprocket; double check that the engine is set to No. 1 TDC. If necessary, manually rotate the engine so that the sprocket hole is also at the top.
  4.  
  5. Fit the sprocket over the camshaft dowel. If the chain won't allow the sprocket to reach, rotate the crankshaft back and forth, while lifting up on the chain and sprocket.
  6.  
  7. Install the distributor drive gear and cam thrust plate over the chain sprocket; tighten the camshaft sprocket bolt to 58 ft. lbs. (78 Nm).
  8.  



Click image to see an enlarged view

Fig. Fig. 11: Exploded view of the cylinder head components on the 22R and 22R-E engines

  1. Set the No. 1 piston at TDC of its compression stroke and adjust the valves.
  2.  
  3. Apply sealant only the cylinder head side of the half-circle plug; install the plug.
  4.  
  5. Install the valve cover
  6.  
  7. Attach the power steering bracket and compressor support to the cylinder head. Tighten the bolts to 33 ft. lbs. (44 Nm)
  8.  
  9. Install the power steering belt and adjust the tension.
  10.  
  11. Install the distributor. Install the spark plugs.
  12.  
  13. Connect the rear ground strap.
  14.  
  15. Install the lines and hoses disconnected:

    Charcoal canister
     
    Brake booster
     
    Main fuel line from fuel inlet
     
    Fuel return line
     
    HAC from the bracket
     
    Electronic Bleed Air Control Valve (EBCV) Calif. vehicles
     
    Vacuum Switching Valve (VSV) with bracket
     

  16.  
  17. Connect the wires removed:

    EGR temperature sensor (Calif. vehicles only)
     
    Water temperature gauge sender
     
    Cold mixture heater wire
     
    Temperature sensor
     
    Fuel cut solenoid valve
     
    EACV (Calif. only)
     

  18.  
  19. Attach the accelerator cable.
  20.  
  21. Connect the air pump hose to the check valve if it was removed.
  22.  
  23. Connect the 2 heater hoses and install the radiator hose to the water outlet.
  24.  
  25. Use a new gasket and connect the exhaust pipe to the manifold. New nuts are recommended.
  26.  
  27. Install the air cleaner and connect the hoses.
  28.  
  29. Refill the engine oil and engine coolant.
  30.  
  31. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start the engine, allowing it to idle and warm up gradually.
  36.  
  37. Shut the engine OFF . Readjust the valves.
  38.  
  39. Restart the engine and adjust the timing as necessary.
  40.  
  41. Recheck the fluid levels.
  42.  
  43. Road test the vehicle for general performance and driveability.
  44.  

22R-E Engine

See Figures 1 through 11


CAUTION
Never perform this operation on a hot engine. Allow the engine to cool a minimum of 3 hours, more in hot weather. Overnight cold is best.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant from the radiator and the cylinder block. Drain the engine oil.
  4.  

  1. Remove the air intake connector.
  2.  
  3. Disconnect the oxygen sensor wire.
  4.  
  5. Remove the three nuts attaching the manifold to the exhaust pipe and then separate the two.
  6.  
  7. Remove the oil dipstick.
  8.  
  9. Remove the distributor with the spark plug leads attached. Remove the spark plugs.
  10.  
  11. Disconnect the upper radiator hose and the two heater hoses where they attach to the engine and then position them out of the way.
  12.  
  13. Disconnect the actuator cable, the accelerator cable and the throttle cable for the automatic transmission at their brackets.
  14.  
  15. Tag and disconnect the following:

    Both PCV vacuum hoses
     
    Brake booster hose
     
    Actuator hose (if equipped with cruise control)
     
    Air control valve hoses (with power steering)
     
    Vacuum Switching Valve (VSV) hoses (with air conditioning)
     
    Evaporative emissions (EVAP) hoses
     
    EGR valve hose
     
    fuel pressure hose
     
    Reed valve hose
     
    Pressure regulator hose
     
    Vacuum hoses from throttle body
     
    Water bypass hoses from throttle body
     

  16.  
  17. Tag and disconnect the EGR vacuum modulator hoses and then remove the modulator itself along with the bracket.
  18.  
  19. Disconnect the following wires:

    Cold start injector pipe and wire
     
    Throttle position sensor wire
     
    EGR temperature sensor (Calif. vehicles)
     

  20.  
  21. Disconnect the cold start injector pipe from the intake chamber. Remove the bolt holding the EGR pipe to the air chamber. Disconnect the chamber from the stay. Remove the air chamber-to-intake manifold bolts and then lift off the chamber with the throttle body, resonator and gasket.
  22.  
  23. Disconnect the fuel return hose.
  24.  
  25. Tag and disconnect the following wires:

    Knock sensor
     
    Oil pressure sender gauge or switch
     
    Starter wire
     
    Transmission wires
     
    Compressor wires (with air conditioning)
     
    Injector wires
     
    Water temperature sender gauge wire
     
    Overdrive temperature switch wire (auto. trans.)
     
    Igniter wire
     
    Vacuum Switching Valve (VSV) wires
     
    Cold start injector time switch wire
     
    Water temperature sensor wire
     

  26.  
  27. Disconnect the bypass hose at the intake manifold.
  28.  
  29. If equipped with power steering, remove the pump and position it out of the way without disconnecting the hydraulic lines.
  30.  
  31. Remove the power steering bracket from the cylinder head.
  32.  
  33. Remove the valve cover.
  34.  

Be sure to cover the oil return hole in the cylinder head with a clean rag to prevent anything from falling in.

  1. Turn the engine clockwise (use the crank pulley bolt) until the No. 1 piston is at TDC on its compression stroke. Matchmark the timing sprocket to the cam chain, and remove the semi-circular plug. Remove the cam sprocket bolt. Slide the distributor drive gear and spacer off the cam. Leave the chain on the sprocket; either wire the cam sprocket in place just off the end of the cam or rest the sprocket on the vibration damper.
  2.  
  3. Remove the timing chain cover bolt at the front of the head. This must be done before the head bolts are removed.
  4.  
  5. Remove the cylinder head bolts in the correct order. Make two or three passes to loosen the bolts. Do not loosen any one bolt all at once; improper removal could cause head damage.
  6.  

Refer to the bolt removal diagram for the 22R engine. All illustrations for the 22R are valid for the 22R-E.

  1. Using prybars applied evenly at the front and the rear of the valve rocker assembly, gently pry the assembly off its mounting dowels.
  2.  
  3. Lift the head off its dowels. If it is difficult to lift off, pry gently with small tools. Do NOT damage the mating surfaces of the head or block. Do NOT attempt to slide the head off the block; it must be lifted.
  4.  
  5. Support the head on a workbench.
  6.  
  7. Remove the manifolds and EGR valve from the head on the workbench. Keep the head covered and the manifold ports plugged with rags when not working on it.
  8.  
  9. Re-drain the oil pan after the head has been removed; coolant will have spilled into the pan during head removal. The coolant will pollute the oil.
  10.  

To install:
  1. Apply liquid sealer to the front corners of the block and install the head gasket. 29'>
  2.  
  3. Lower the head over the locating dowels. Do not attempt to slide it into place.
  4.  
  5. Install the rocker arm assembly over its positioning dowels.
  6.  
  7. Install the cylinder head bolts. Tighten the bolts sequentially in three passes and in the correct order, coming to final torque on the last pass. Correct tightness is 58 ft. lbs. (78 Nm)
  8.  

Refer to the bolt tightening diagram for the 22R engine. All illustrations for the 22R are valid for the 22R-E.

  1. Install the chain cover bolt. Tighten it to 9 ft. lbs. (13 Nm).
  2.  
  3. Hold the chain and sprocket; double check that the engine is set to No. 1 TDC. If necessary, manually rotate the engine so that the sprocket hole is also at the top.
  4.  
  5. Fit the sprocket over the camshaft dowel. If the chain won't allow the sprocket to reach, rotate the crankshaft back and forth, while lifting up on the chain and sprocket.
  6.  
  7. Install the distributor drive gear and cam thrust plate over the chain sprocket; tighten the camshaft sprocket bolt to 58 ft. lbs. (78 Nm).
  8.  
  9. Set the No. 1 piston at TDC of its compression stroke and adjust the valves.
  10.  
  11. Apply sealant only the cylinder head side of the half-circle plug; install the plug.
  12.  
  13. Install the valve cover.
  14.  
  15. Attach the power steering bracket to the head; tighten the 4 bolts to 33 ft. lbs. (44 Nm).
  16.  
  17. Install the power steering pump and belt. Adjust the belt.
  18.  
  19. Connect the bypass hose to the intake manifold.
  20.  
  21. Connect the fuel hose to the delivery pipe. Tighten the bolt to 33 ft. lbs. (44 Nm).
  22.  
  23. Connect the wires removed:

    Knock sensor
     
    Oil pressure sender gauge or switch
     
    Starter wire
     
    Transmission wires
     
    Compressor wires (with air conditioning)
     
    Injector wires
     
    Water temperature sender gauge wire
     
    Overdrive temperature switch wire (auto. trans.)
     
    Igniter wire
     
    Vacuum Switching Valve (VSV) wires
     
    Cold start injector time switch wire
     
    Water temperature sensor wire
     
    Cold start injector pipe and wire
     
    Throttle position sensor wire
     
    EGR temperature sensor (Calif. vehicles)
     

  24.  
  25. Connect the fuel return hose.
  26.  
  27. Position new gaskets on the intake manifold and EGR pipe. Install the air intake chamber, throttle body and resonator. Install the bolts holding the EGR valve to the chamber. Use a new gasket and install the cold start injector pipe.
  28.  
  29. Connect the throttle position wire, the cold start injector wire and the EGR temperature sensor wire (Calif. only)
  30.  
  31. Install the EGR vacuum modulator.
  32.  
  33. Connect the hoses removed:

    Both PCV vacuum hoses
     
    Brake booster hose
     
    Actuator hose (if equipped with cruise control)
     
    Air control valve hoses (with power steering)
     
    Vacuum Switching Valve (VSV) hoses (with air conditioning)
     
    Evaporative emissions (EVAP) hoses
     
    EGR valve hose
     
    Fuel pressure hose
     
    Reed valve hose
     
    Pressure regulator hose
     
    Vacuum hoses from throttle body
     
    Water bypass hoses from throttle body
     

  34.  
  35. Connect the rear ground strap.
  36.  
  37. Connect the throttle and accelerator cables.
  38.  
  39. Install the heater hoses and the radiator inlet hose.
  40.  
  41. Install the spark plugs and the distributor. Install the engine oil dipstick.
  42.  
  43. Use new gaskets and connect the exhaust pipe to the manifold. Don't forget the clamp.
  44.  
  45. Install the air intake connector
  46.  
  47. Refill the engine oil and engine coolant.
  48.  
  49. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  50.  
  51. Connect the negative battery cable.
  52.  
  53. Start the engine, allowing it to idle and warm up gradually.
  54.  
  55. Turn the engine OFF . Readjust the valves.
  56.  
  57. Restart the engine and adjust the timing as necessary.
  58.  
  59. Recheck the fluid levels.
  60.  
  61. Road test the vehicle for general performance and driveability.
  62.  

3F-E Engine

See Figures 12 through 17

  1. Drain the engine coolant.
  2.  


WARNING
When draining 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 coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Disconnect the negative battery cable.
  2.  
  3. Scribe matchmarks around the hood hinges and then remove the hood.
  4.  
  5. Disconnect the accelerator and throttle cables.
  6.  
  7. Remove the hoses and parts as follows:

    Air intake
     
    Air flow meter
     
    Air cleaner cap
     
    ISC hose
     
    Air pump hose
     
    Distributor hose
     
    PCV hose
     
    Remove the 3 hoses from the rear of the intake chamber
     
    The 2 hoses from the charcoal canister vacuum valve
     

  8.  
  9. Unbolt the power steering pump and position it out of the way without disconnecting the hydraulic lines.
  10.  
  11. Unbolt the air conditioning compressor and position it out of the way without disconnecting the refrigerant lines. Use stiff wire or string to support the compressor; do not allow it to hang by the hoses.
  12.  



Click image to see an enlarged view

Fig. Fig. 12: Loosen the rocker assembly bolts in several passes in this order



Click image to see an enlarged view

Fig. Fig. 13: Remove the pushrods and keep them in order

  1. Remove the power steering pump and air conditioning compressor brackets.
  2.  
  3. Disconnect the high tension cords from the spark plugs and the coil.
  4.  
  5. Disconnect and remove the hoses from the water outlet, water pump, oil cooler and heater water pipe. Unbolt the oil cooler water pipe from the cylinder head.
  6.  
  7. Disconnect the upper radiator hose.
  8.  
  9. Disconnect and plug the fuel lines.
  10.  
  11. Raise the vehicle, making certain it is well supported. Disconnect the exhaust pipe at the manifold.
  12.  
  13. Remove the air pump.
  14.  
  15. Remove the fuel delivery pipe along with the fuel injectors.
  16.  
  17. Remove the air injection manifold.
  18.  
  19. Remove the intake and exhaust manifolds.
  20.  
  21. Disconnect the water bypass hose at the water outlet and then remove the outlet assembly.
  22.  
  23. Remove the spark plugs.
  24.  
  25. Disconnect the water bypass hose from the water outlet. Remove the water outlet assembly.
  26.  
  27. Loosen the eight bolts and four nuts that attach the rocker shaft assembly in several stages and in the correct order. Remove the rocker shaft.
  28.  
  29. Remove the twelve pushrods, be sure they are kept in the order in which they were removed; they MUST be installed in the original locations. An upside-down box with holes punched in the bottom will make a good holder; number the holes to correspond with the pushrod position.
  30.  



Click image to see an enlarged view

Fig. Fig. 14: Tighten the head bolts using this sequence in several passes to prevent head damage



Click image to see an enlarged view

Fig. Fig. 15: Tighten the rocker assembly bolts using this order in several passes

  1. Loosen the cylinder head bolts in several stages and in the opposite order of the tightening sequence. Remove the air pump bracket and engine hanger.
  2.  


CAUTION
Removing the head bolts in the improper order could cause damage to the aluminum cylinder head.

  1. Lift the cylinder head off of its mounting dowels, Do NOT attempt to slide the head off; it must be lifted. Support the head on a workbench.
  2.  



Click image to see an enlarged view

Fig. Fig. 16: A, B and C bolt locations

To install:
  1. Lift the old gasket from the block, then scrape and clean the area well. Insert paper into the cylinder walls to keep dirt from entering.
  2.  
  3. Install the cylinder head on the cylinder block using a new gasket.
  4.  
  5. Lightly coat the threads of the cylinder head bolts with engine oil and then install them into the head. Tighten them in several stages, in the order shown.
  6.  
  7. Install the pushrods in the order that they were removed.
  8.  
  9. Position the rocker shaft assembly on the cylinder head and align the rocker arm adjusting screws with the heads of the pushrods. Tighten the mounting bolts with a 12mm head to 17 ft. lbs. (24 Nm); tighten the bolts with a 14mm head to 25 ft. lbs. (33 Nm).
  10.  
  11. Adjust the valve clearance and install the spark plugs.
  12.  
  13. Install the valve cover and tighten the cap nuts to 78 inch lbs. (9 Nm).
  14.  
  15. Install the water outlet and connect the bypass hose. Tighten the bolts to 18 ft. lbs. (25 Nm).
  16.  
  17. Install the intake and exhaust manifolds using a new gasket. Make sure the front mark on the gasket is towards the front of the engine. Tighten the following:

    17mm bolts (A)-51 ft. lbs. (69 Nm)
     
    14mm bolts (B)-37 ft. lbs. (50 Nm)
     
    Nuts (C)-41 ft. lbs. (56 Nm)
     

  18.  
  19. Install the heat insulators and the manifold stay. Tighten the manifold heat shield bolts to 9 ft. lbs. (12 Nm) and the manifold support bolts to 22 ft. lbs. (29 Nm).
  20.  
  21. Install the air injection manifold and tighten the union nuts and clamp bolts to 15 ft. lbs. (21 Nm).
  22.  



Click image to see an enlarged view

Fig. Fig. 17: Exploded view of the cylinder head components on the 3F-E engine

  1. Install the fuel injector/delivery pipe assembly.
  2.  
  3. Install the air pump and connect the air hose.
  4.  
  5. Connect the exhaust pipe to the manifold. Use a new gasket and tighten the bolts to 46 ft. lbs. (62 Nm).
  6.  
  7. Connect the fuel lines and the upper radiator hose.
  8.  
  9. Install the oil cooler pipe; connect the hoses to the water outlet, water pump, oil cooler and heater water pipe.
  10.  
  11. Connect the spark plugs and coil wires.
  12.  
  13. Install the air conditioning compressor and the power steering pump. Adjust the belt tension; tighten the power steering pulley nut to 35 ft. lbs. (47 Nm).
  14.  
  15. Install the air intake hose, the air flow meter and the air cleaner cap. Connect the hoses removed during Step 5 of the removal procedure.
  16.  
  17. Connect and adjust the accelerator and throttle cables. Adjust them properly.
  18.  
  19. Refill the engine coolant.
  20.  
  21. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Start the engine, allowing it to idle and warm up gradually.
  26.  
  27. Shut the engine OFF . Readjust the valves.
  28.  
  29. Restart the engine and adjust the timing as necessary.
  30.  
  31. Recheck the fluid level.
  32.  
  33. Install the hood.
  34.  
  35. Road test the vehicle for general performance and driveability.
  36.  

3VZ-E Engine

See Figures 18 through 35

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner hose and case.
  4.  



Click image to see an enlarged view

Fig. Fig. 18: Exploded view of the cylinder head-3VZ-FE engine

  1. Drain the engine coolant.
  2.  

  1. Remove the radiator.
  2.  
  3. Unbolt the power steering pump and position it out of the way with the hoses still attached.
  4.  
  5. Remove the alternator drive belt; remove the fluid coupling and fan pulley.
  6.  
  7. Disconnect the following wires and connectors:

    Ground strap from left fender apron
     
    Alternator connector and wire
     
    Igniter connector
     
    Oil pressure switch connector
     
    Ground strap at rear of engine
     
    Electronic Control Unit (ECU) connectors
     
    Vacuum Switching Valve (VSV) connectors
     
    Starter relay connector (manual trans. only)
     
    Solenoid resistor connector
     
    The check connector
     
    Compressor connector
     

  8.  
  9. Disconnect the following hoses:

    Power steering air hoses
     
    Brake booster hose
     
    Cruise control vacuum hose
     
    Charcoal canister hose at the canister
     
    Vacuum Switching Valve (VSV) vacuum hose
     

  10.  
  11. Disconnect the accelerator, throttle and cruise control cables.
  12.  
  13. Disconnect the clutch release (slave) cylinder hose (manual transmission only).
  14.  
  15. Disconnect the two heater hoses and the two fuel lines.
  16.  
  17. Remove the left side scuff plate (inside the left door). Disconnect the oxygen sensor. Disconnect the exhaust pipe at the manifold and at the catalytic converter. Remove the front exhaust pipe.
  18.  
  19. Remove the timing belt. Follow the procedure given later in this section. This is a complicated operation requiring accurate work.
  20.  
  21. Remove the distributor with the spark plug leads attached; position it out of the way.
  22.  
  23. Remove the air intake chamber as follows:
    1. Disconnect the throttle position sensor connector
    2.  
    3. Disconnect the canister vacuum hose from the throttle body.
    4.  
    5. Disconnect the vacuum and fuel hoses from the pressure regulator.
    6.  
    7. Remove the PCV hose from the hose union.
    8.  
    9. Disconnect the water bypass hose from the intake manifold hose union.
    10.  
    11. Remove the water bypass hose from the water bypass pipe.
    12.  
    13. Disconnect the cold start injector connector.
    14.  
    15. Disconnect the vacuum hose from the fuel filter.
    16.  
    17. Remove the union bolt and remove the cold start injector tube.
    18.  
    19. On California vehicles, disconnect the EGR temperature sensor.
    20.  
    21. Disconnect the EGR vacuum hoses from the air pipe and EGR vacuum modulator.
    22.  
    23. Remove the intake chamber support. Remove the two water hoses from the EGR valve if so equipped.
    24.  
    25. Remove the EGR valve with its pipes.
    26.  
    27. Remove the six bolts and two nuts; remove the intake air chamber.
    28.  

  24.  
  25. Disconnect the following, then when all are released, remove the two bolts and the engine wire harness:

    Knock sensor
     
    Water temperature sensor
     
    Cold start injector time switch connector
     
    Water temperature sensor
     
    Water temperature sender gauge connector
     
    Right ground strap
     
    Injector connectors
     

  26.  
  27. Remove the fuel pipes.
  28.  
  29. Remove the timing belt cover.
  30.  
  31. Remove the idler pulley and the timing belt cover.
  32.  
  33. Remove the right side fuel delivery pipe (fuel rail) with the injectors.
  34.  
  35. Remove the left fuel delivery pipe and the injectors.
  36.  
  37. Disconnect the hose and remove the water bypass outlet.
  38.  
  39. Remove the intake manifold.
  40.  
  41. Remove the knock sensor wire.
  42.  
  43. Remove the exhaust crossover pipe.
  44.  

Right side:
  1. Remove the reed valve with the air injection manifold.
  2.  
  3. Remove the water bypass pipe mounting bolt.
  4.  
  5. Remove the alternator.
  6.  
  7. Remove the right valve cover.
  8.  
  9. Remove the two bolts and camshaft housing rear cover. Loosen each cam bearing cap bolt a little at a time and in the correct order. When all are loose, remove the bolts and remove the camshaft along with the oil seal and housing plug.
  10.  



Click image to see an enlarged view

Fig. Fig. 19: Release the camshaft retaining bolts in this order-RH shown

  1. Remove the 6-point head bolt from the head first.
  2.  



Click image to see an enlarged view

Fig. Fig. 20: Remove the 6 point head bolt first

  1. Loosen the cylinder head bolts in several stages, in the correct order.
  2.  


WARNING
Removing the head bolts in the improper order could cause damage to the cylinder head.



Click image to see an enlarged view

Fig. Fig. 21: Remove the head bolts using this sequence in several passes

  1. Lift the cylinder head off of its mounting dowels; do NOT attempt to slide it off. If the head is difficult to remove, gently pry with a small tool between the head and block projection. Take great care not to damage the mating faces of the block and/or head. Support the head on wooden blocks on the workbench.
  2.  
  3. Remove the exhaust manifold from the cylinder head.
  4.  

Left side:
  1. Remove the alternator.
  2.  
  3. Remove the oil dipstick. Remove the bolt and remove the dipstick guide tube.
  4.  
  5. Remove the left valve cover.
  6.  
  7. Remove the two bolts and camshaft housing rear cover. Loosen each cam bearing cap bolt a little at a time and in the correct order. When all are loose, remove the bolts and remove the camshaft along with the oil seal and housing plug.
  8.  



Click image to see an enlarged view

Fig. Fig. 22: Release the camshaft retaining bolts in this order-LH shown

  1. Remove the 6 point cylinder head bolt.
  2.  



Click image to see an enlarged view

Fig. Fig. 23: Left side 6 point head bolt location

  1. Loosen the cylinder head bolts in several stages, in the correct order.
  2.  



Click image to see an enlarged view

Fig. Fig. 24: Remove the head bolts following this pattern in several passes



Click image to see an enlarged view

Fig. Fig. 25: Arrange the bearing caps in the correct order



Click image to see an enlarged view

Fig. Fig. 26: If the head is difficult to remove, gently pry with a small tool between the head and block projection


WARNING
Removing the head bolts in the improper order could cause damage to the cylinder head.

  1. Lift the cylinder head off of its mounting dowels; do NOT attempt to slide it off. If the head is difficult to remove, gently pry with a small tool between the head and block projection. Take great care not to damage the mating faces of the block and/or head. Support the head on wooden blocks on the workbench.
  2.  
  3. Remove the exhaust manifold from the cylinder head.
  4.  

To install:
  1. Lift the old gasket from the block, then scrape and clean the area well. Insert paper into the cylinder walls to keep dirt from entering.
  2.  



Click image to see an enlarged view

Fig. Fig. 27: Carefully clean the top surfaces of the pistons ...



Click image to see an enlarged view

Fig. Fig. 28: ... and the cylinder block

  1. Install the cylinder head on the cylinder block using a new gasket.
  2.  



Click image to see an enlarged view

Fig. Fig. 29: Position the new gaskets on the cylinder heads as shown

  1. Lightly coat the threads of the cylinder head bolts with engine oil and then install them into the head. Do not install bolt 6-pointed bolt at this time. Tighten the bolts in several stages, in the order shown to 33 ft. lbs. (44 Nm). After the initial tightening, mark the front side of the top of the bolt with paint. Tighten the bolts an additional 90° ( 1 / 4 turn) and check that the mark is now facing the side of the head. Tighten the bolts an additional 90° and check that the mark is now facing the rear of the head.
  2.  



Click image to see an enlarged view

Fig. Fig. 30: Tighten the head bolts down in several passes in this order



Click image to see an enlarged view

Fig. Fig. 31: Mark the head of the bolt with some paint



Click image to see an enlarged view

Fig. Fig. 32: Turn the bolts exactly 90°

  1. Install the 6-pointed head bolts. Tighten to 30 ft. lbs. (41 Nm).
  2.  
  3. Install the camshaft. Install a new oil seal and install the camshaft housing plug.
  4.  



Click image to see an enlarged view

Fig. Fig. 33: Apply sealant to the No. 1 and No. 5 bearing caps as shown

  1. Apply sealant to the Nos. 1 and 5 cam bearing caps. Place the caps on each journal with the arrows correctly aligned. On the right head, they should point to the front; on the left head, to the rear.
  2.  



Click image to see an enlarged view

Fig. Fig. 34: Position the caps in the correct places



Click image to see an enlarged view

Fig. Fig. 35: Bolt tightening sequence for the camshaft bearing caps

  1. Temporarily tighten the bearing cap bolts just snug, a little at a time and in the correct order.
  2.  
  3. Use a seal driver of the correct diameter to install the oil seal. Use the same tool to install the camshaft housing plug.
  4.  
  5. Tighten the bearing caps to the correct torque. Make several passes and proceed in the proper order. Correct torque is 12 ft. lbs. (16 Nm).
  6.  
  7. Check the valve clearance. Intake 0.007-0.011 in. (0.18-0.28mm) and exhaust is 0.009-0.013 in. (0.22-0.32mm).
  8.  
  9. Install the valve covers.
  10.  
  11. Install the alternator and the water bypass pipe mounting bolt.
  12.  
  13. Install the reed valve with the injection manifold. Tighten the bolts to the cylinder head to 27 ft. lbs. (37 Nm); tighten the bolts to the exhaust manifold to 22 ft. lbs. (29 Nm).
  14.  
  15. Repeat installation for the opposite head if it was removed.
  16.  
  17. Install the oil dipstick tube.
  18.  
  19. Install the crossover pipe and tighten it to 29 ft. lbs. (39 Nm).
  20.  
  21. Connect the oxygen sensor wire.
  22.  
  23. Install the intake manifold with new gaskets and tighten the mounting bolts to 13 ft. lbs. (18 Nm).
  24.  
  25. Install the water bypass outlet and tighten the two bolts to 13 ft. lbs. (18 Nm).
  26.  
  27. Install the fuel delivery pipes and injectors. Tighten the bolts to 9 ft. lbs. (13 Nm)
  28.  
  29. Install the idler pulley. Install the timing belt covers and tighten the bolts to 74 inch lbs. (8 Nm).
  30.  
  31. Install the remaining timing belt cover.
  32.  
  33. Install the fuel pipes and tighten the union bolts to 22 ft. lbs. (29 Nm).
  34.  
  35. Install the timing belt.
  36.  
  37. Check and adjust the valve clearance.
  38.  
  39. Install the cylinder head covers. Apply sealant to the head in the locations shown.
  40.  
  41. Install the engine wire harness and secure the two bolts.
  42.  
  43. Attach the wires and connectors removed:

    Knock sensor
     
    Water temperature sensor
     
    Cold start injector time switch connector
     
    Water temperature sender gauge connector
     
    Right ground strap
     
    Injector connectors
     

  44.  
  45. Install the air intake chamber and tighten the nuts and bolts to 13 ft. lbs. (18 Nm).
  46.  
  47. Install the EGR valve and connect all hoses and lines. Install and tighten the bolts and nuts correctly.

    A-9 ft. lbs. (12 Nm)
     
    B-13 ft. lbs. (18 Nm)
     
    C-22 ft. lbs. (29 Nm)
     

  48.  
  49. Install the distributor and spark plug wires.
  50.  
  51. Install the front exhaust pipe, using new gaskets. Connect the oxygen sensor and replace the left sill plate.
  52.  
  53. Connect the fuel lines and heater hoses.
  54.  
  55. Connect the clutch release (slave) cylinder hose (manual trans. only.)
  56.  
  57. Install the power steering pump.
  58.  
  59. Connect the throttle control cable (auto. trans.), cruise control cable and the accelerator cable.
  60.  
  61. Connect the hoses detached:

    Power steering air hoses
     
    Brake booster hose
     
    Cruise control vacuum hose
     
    Charcoal canister hose at the canister
     
    Vacuum Switching Valve (VSV) vacuum hose
     

  62.  
  63. Attach the wires and connectors detached:

    Ground strap from left fender apron
     
    Alternator connector and wire
     
    Igniter connector
     
    Oil pressure switch connector
     
    Ground strap at rear of engine
     
    Electronic Control Unit (ECU) connectors
     
    Vacuum Switching Valve (VSV) connectors
     
    Starter relay connector (manual trans. only)
     
    Solenoid resistor connector
     
    The check connector
     
    Compressor connector
     

  64.  
  65. Install the fan pulley, fluid coupling and drive belts.
  66.  
  67. Install and adjust the air conditioning belt.
  68.  
  69. Install the power steering belt and adjust it.
  70.  
  71. Install the radiator.
  72.  
  73. Install the air cleaner case and hose.
  74.  
  75. Refill the engine with coolant.
  76.  
  77. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  78.  
  79. Connect the battery cable. Start the engine, allowing it to warm up at idle. Check carefully for leaks.
  80.  
  81. Check and adjust engine specifications as necessary.
  82.  
  83. Road test the vehicle for general performance and driveability.
  84.  
  85. Check and adjust fluid levels.
  86.  

2RZ-FE and 3RZ-FE Engines

See Figures 36 through 44

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the air cleaner cap, MAF meter, and the resonator.
  6.  
  7. If equipped with a manual transaxle, disconnect the accelerator cable from the throttle body.
  8.  
  9. If equipped with a automatic transaxle, disconnect the accelerator and throttle cables from the throttle body.
  10.  
  11. Remove the intake air connector:

    Air hose for the IAC
     
    Vacuum sensing hose
     
    Wire clamp for the engine
     

  12.  
  13. Remove the oil dipstick guide.
  14.  
  15. If equipped with A/C, remove the air conditioning idle-up valve.
  16.  
  17. Remove the power steering drive belt.
  18.  
  19. Remove the idler pulley by removing the three bolts.
  20.  
  21. Remove the power steering drive belt, pump and bracket.
  22.  
  23. Remove the PCV hoses.
  24.  
  25. Remove the distributor connector, hold-down bolts, and the distributor.
  26.  
  27. Remove the water housing as follows:
    1. Disconnect the radiator inlet hose.
    2.  
    3. Disconnect the ECT sender gauge connector.
    4.  
    5. Remove the two bolts, water housing, and the gasket.
    6.  

  28.  
  29. Remove the throttle body.
  30.  
  31. Disconnect the following harnesses:

    If equipped with A/C, the A/C compressor wiring
     
    Oil pressure sensor
     
    ECT sensor
     
    EGR gas temperature sensor
     
    EGR Vacuum Switching Valve (VSV)
     

  32.  
  33. Disconnect the engine wire as follows:
    1. Remove the two bolts and disconnect the engine wire from the intake chamber.
    2.  
    3. Disconnect the five engine wire clamps and engine wire.
    4.  
    5. Detach the following connectors:

      Knock sensor
       
      Crankshaft position sensor
       
      Fuel pressure control VSV
       

    6.  
    7. Disconnect the DLC1 from the bracket.
    8.  
    9. Disconnect the two engine wire clamps.
    10.  
    11. Remove the bolt, then disconnect the engine wire from the engine.
    12.  

  34.  
  35. Disconnect the fuel injectors.
  36.  
  37. Remove the cylinder head rear cover by disconnecting the heater bypass hose, then remove the three bolts.
  38.  
  39. Remove the EGR valve and vacuum modulator.
  40.  
  41. Remove the intake chamber stay by removing the two bolts.
  42.  


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Unbolt the fuel return pipe and separate from the hoses.
  2.  
  3. Remove the intake chamber as follows:
    1. Disconnect the vacuum hose from the gas filter.
    2.  
    3. Disconnect the brake booster vacuum hose from the intake chamber.
    4.  
    5. Remove the three bolts, two nuts, air intake chamber, and the gasket.
    6.  

  4.  
  5. Remove the fuel inlet tube by removing the union bolts.
  6.  
  7. Remove the delivery pipe and injectors.
  8.  

Be careful not to drop the injectors when removing the delivery pipe.

  1. Remove the intake manifold by removing the three bolts and two nuts.
  2.  
  3. Disconnect the front exhaust pipe from the exhaust manifold.
  4.  
  5. Remove the heat insulator by loosening the two bolts and two nuts.
  6.  
  7. Remove the exhaust manifold and gasket.
  8.  
  9. Remove the engine hangers.
  10.  
  11. Remove the valve cover and gasket.
  12.  
  13. Remove the spark plug wires and plugs from the engine.
  14.  
  15. Set No. 1 cylinder to TDC compression stroke. The groove on the crankshaft pulley should align with the 0 mark on the timing chain cover and the timing marks (one and two dots) of the camshaft gears should form a straight line in respect to the cylinder head surface. If not, turn the crankshaft 1 revolution (360 degrees).
  16.  



Click image to see an enlarged view

Fig. Fig. 36: Set No. 1 cylinder to TDC compression stroke



Click image to see an enlarged view

Fig. Fig. 37: Check that the marks on the gears are properly aligned

  1. Remove the chain tensioner and gasket by removing the two nuts.
  2.  
  3. Remove the camshaft timing gear.
  4.  



Click image to see an enlarged view

Fig. Fig. 38: Matchmark the position of the chain on the gear



Click image to see an enlarged view

Fig. Fig. 39: Hold the hexagon head portion of the camshaft with a wrench and remove the bolt securing the gear

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

  1. Remove exhaust camshaft.
  2.  


WARNING
When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

  1. Remove the intake camshaft.
  2.  

Do not pry on or attempt to force the camshaft with a tool or other object.

  1. Remove the 2 bolts in the front of the head before the other head bolts are removed. Uniformly loosen and remove the remaining head bolts, in several passes, in the sequence shown.
  2.  



Click image to see an enlarged view

Fig. Fig. 40: Remove the 2 bolts at the front of the head first

  1. Lift the cylinder head from the block and place the head on wooden blocks on a bench.
  2.  



Click image to see an enlarged view

Fig. Fig. 41: Remove the cylinder head bolts using this order, in several passes

To install:
  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage.
  2.  
  3. Apply sealant (08826-00080 or equivalent) to the 2 locations, as shown. Place a new head gasket on the block and install the cylinder head.
  4.  
  5. Lightly coat the cylinder head bolts with engine oil. Install the bolts and tighten in several passes in the sequence shown:
  6.  



Click image to see an enlarged view

Fig. Fig. 42: Apply sealant to the head in these areas



Click image to see an enlarged view

Fig. Fig. 43: Tighten the head bolts down uniformly using this sequence in several passes



Click image to see an enlarged view

Fig. Fig. 44: Mark the front of the bolt with paint and retighten bolts 90 degrees in the proper sequence

  1. Install and tighten the 2 front mounting bolts to 15 ft. lbs.(21 Nm).
  2.  

If any of the bolts break, deform or do not meet the torque specification, replace them.

  1. Install the intake camshaft.
  2.  
  3. Install the exhaust camshaft.
  4.  
  5. Set No. 1 cylinder to TDC compression stroke: the crankshaft pulley groove will align with the 0 mark on timing cover and camshafts timing marks with one dot and two dots will be in a straight line on the cylinder head surface.
  6.  
  7. Install the timing gear. Place the gear over the straight pin of the intake camshaft.
    1. Hold the intake camshaft with a wrench. Install and tighten the bolt to 54 ft. lbs. (74 Nm).
    2.  
    3. Hold the exhaust camshaft and install the bolt and distributor gear. Tighten the bolt to 34 ft. lbs. (46 Nm).
    4.  

  8.  
  9. Install the chain tensioner, using a new gasket (mark toward the front) as follows:
    1. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
    2.  
    3. Turn the crankshaft pulley clockwise to provide some slack for the chain on the tensioner side.
    4.  
    5. Push the tensioner by hand until it touches the head installation surface, then install the 2 nuts. Tighten the nuts to 13 ft. lbs. (18 Nm). Check that the hook of the tensioner is not released.
    6.  
    7. Turn the crankshaft to the left so that the hook of the chain tensioner is released from the pin of the plunger, allowing the plunger to spring out and the slipper to be pushed into the chain.
    8.  

  10.  
  11. Check and adjust the valve clearance. Intake valve clearance is 0.006-0.010 inch (0.15-0.25 mm) and exhaust valve clearance is 0.010-0.014 inch (0.25-0.35 mm).
  12.  
  13. Recheck the engine for proper valve timing. Check and adjust the valve clearance.
  14.  
  15. Install the spark plugs and the semi-circular plug.
  16.  
  17. Recheck the engine for proper valve timing. Install the valve cover and engine hangers. Tighten the engine hanger bolts to 30 ft. lbs. (42 Nm).
  18.  
  19. Install the exhaust manifold and gasket to the engine and install the six nuts. Tighten the nuts to 36 ft. lbs. (49 Nm).
  20.  
  21. Install the heat insulator with the two bolts and two nuts. Tighten the bolts and nuts to 48 inch lbs. (6 Nm).
  22.  
  23. Install the front exhaust pipe to the exhaust manifold.
  24.  
  25. Install the intake manifold using a new gasket. Tighten the bolts and nuts to 22 ft. lbs. (29 Nm).
  26.  
  27. Install the injectors and delivery pipe. Tighten the bolts holding the delivery pipe to 15 ft. lbs. (21 Nm).
  28.  
  29. Install the fuel tube with four new gaskets. Tighten the union bolts to 22 ft. lbs. (29 Nm).
  30.  
  31. Install the air intake chamber as follows:
    1. Install a new gasket and the air intake chamber with the three bolts and two nuts. Tighten the bolts and nuts to 15 ft. lbs. (21 Nm).
    2.  
    3. Connect the vacuum hose to the gas filter.
    4.  
    5. Connect the brake booster vacuum hose to the intake chamber.
    6.  

  32.  
  33. Install the fuel return pipe by installing the two bolts and hoses.
  34.  
  35. Install the intake chamber stay by installing the two bolts. Tighten the bolts to 14 ft. lbs. (20 Nm).
  36.  
  37. Install the EGR valve and vacuum modulator.
  38.  
  39. Install the cylinder head rear cover with a new gasket. Tighten the three bolts to 10 ft. lbs. (14 Nm).
  40.  
  41. Connect the heater water bypass pipe.
  42.  
  43. Connect the injector wiring.
  44.  
  45. Connect the engine wire to the engine as follows:
    1. Secure the engine wire to the intake manifold.
    2.  
    3. Connect the two engine wire clamps.
    4.  
    5. Attach the DLC1 to the bracket.
    6.  
    7. Attach the following connectors:

      Fuel pressure control VSV connector
       
      Knock sensor connector
       
      Crankshaft position sensor connector
       

    8.  
    9. Connect the five engine wire clamps.
    10.  
    11. Connect the engine wire to the intake chamber with the two bolts.
    12.  

  46.  
  47. Attach the following connections to the engine:

    EGR-Vacuum Switching Valve (VSV)
     
    EGR gas temperature sensor
     
    ECT sensor
     
    Oil pressure sensor
     
    With A/C, connect the compressor
     

  48.  
  49. Install the throttle body.
  50.  
  51. Install the water outlet with a new gasket. Install the two bolts and tighten the bolts to 14 ft. lbs. (20 Nm). Connect the ECT sender gauge connector and radiator inlet hose.
  52.  
  53. Install the distributor.
  54.  
  55. Install the 2 PCV hoses.
  56.  
  57. Install the power steering pump bracket by installing the four bolts, tighten to 14 ft. lbs. (20 Nm).
  58.  
  59. Install the power steering pump to the bracket.
  60.  
  61. Install the idler pulley with the three bolts, tighten to 14 ft. lbs. (20 Nm).
  62.  
  63. With A/C, install the A/C idle up valve.
  64.  
  65. Install the air intake connector by installing the two bolts, hose clamp, and two air hoses.
  66.  
  67. If equipped with a manual transaxle, connect the accelerator cable to the throttle body.
  68.  
  69. If equipped with a automatic transaxle, connect the throttle and accelerator cables to the throttle body.
  70.  
  71. Install the MAF meter, resonator, and the air cleaner cap.
  72.  
  73. Refill the cooling system. Drain and refill the engine oil.
  74.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Connect the negative battery cable. Start the engine and check for leaks.
  2.  
  3. Check the ignition timing. Road test the vehicle for proper operation.
  4.  
  5. Recheck and top off all fluid levels.
  6.  

5VZ-FE Engine

See Figures 45, 46 and 47

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  

  1. Remove the engine under cover.
  2.  
  3. Drain the cooling system.
  4.  



Click image to see an enlarged view

Fig. Fig. 45: Exploded view of the cylinder head

  1. Remove the front exhaust pipe as follows.
  2.  
  3. Disconnect the air cleaner cap, MAF meter and the resonator.
  4.  
  5. Disconnect the following cables:

    If equipped with cruise control, disconnect the actuator cable with the bracket
     
    Accelerator cable
     
    With A/T, Throttle cable
     

  6.  
  7. Disconnect the heater hose.
  8.  
  9. Disconnect the upper radiator hose from the engine.
  10.  
  11. Remove the power steering drive belt.
  12.  
  13. Remove the A/C drive belt by loosening the idle pulley nut and adjusting bolt.
  14.  
  15. Loosen the lock bolt, pivot bolt and adjusting bolt and the alternator drive belt.
  16.  
  17. Remove the fan shroud by removing the two clips.
  18.  
  19. Remove the fan with the fluid coupling and fan pulleys.
  20.  
  21. Disconnect the power steering pump from the engine and set aside. Do not disconnect the lines from the pump.
  22.  
  23. If equipped with A/C, remove the compressor from the engine and set aside. Do not disconnect the lines from the compressor.
  24.  
  25. If equipped with A/C, remove the A/C bracket.
  26.  
  27. Remove the spark plug wires with the ignition coils.
  28.  
  29. Remove the spark plugs.
  30.  
  31. Remove the timing belt cover.
  32.  
  33. Remove the fan bracket.
  34.  
  35. Set the No. 1 cylinder at TDC of the compression stroke.
    1. Turn the crankshaft pulley and align its groove with the timing mark O of the No. 1 timing belt cover.
    2.  
    3. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley one revolution (360°).
    4.  

  36.  

If re-using the timing belt, make sure that you can still read the installation marks. If not, place new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys.

  1. Remove the timing belt tensioner by alternately loosening the two bolts.
  2.  
  3. Remove the camshaft timing pulleys. Using SST 09960-10010 or equivalent, remove the pulley bolt, the timing pulley and the straight pin. Remove the two timing pulleys with the timing belt.
  4.  
  5. Remove the bolt and the idler pulley.
  6.  
  7. Remove the alternator from the engine.
  8.  
  9. Remove the nuts and remove the EGR pipe and two gaskets.
  10.  
  11. Remove the oil filler tube and throttle cable clamp by removing the bolt and two nuts.
  12.  
  13. Remove the intake chamber stay by removing the two bolts.
  14.  
  15. Remove the following connectors:

    Vacuum Switching Valve (VSV) for the fuel pressure control
     
    Throttle Position Sensor (TPS)
     
    IAC valve
     
    Disconnect the EGR gas temperature wire
     
    Disconnect the VSV wire for the EGR valve
     

  16.  
  17. Disconnect the following hoses:

    PCV hoses
     
    Water bypass
     
    Air assist hose from the intake air wire
     
    Two vacuum sensing hoses from the VSV
     
    EVAP
     
    Air hose from the power steering
     
    If equipped with A/C, disconnect the air hose from the A/C idle up valve.
     

  18.  
  19. Remove the four bolts, two nuts and remove the air intake chamber assembly from the engine.
  20.  
  21. Remove the intake air connector as follows:
    1. Disconnect the engine wire from the intake air connector by removing the bolt.
    2.  
    3. Disconnect the two fuel return hoses.
    4.  
    5. Disconnect the brake booster vacuum hose from the intake air connector.
    6.  
    7. Remove the bolt and disconnect the ground strap from the intake air harness.
    8.  
    9. Disconnect the DLC1 from the bracket of the intake air harness.
    10.  
    11. If equipped with A/C, disconnect idle up valve.
    12.  
    13. Remove the intake air connector from the engine by removing the three bolts and two nuts.
    14.  

  22.  
  23. Disconnect the engine wire from the intake manifold as follows:
    1. Disconnect the following wiring:

      Oil pressure sensor
       
      Crankshaft position sensor
       
      Six injectors
       
      ECT sender gauge
       
      ECT sensor
       
      Knock sensor
       
      Camshaft position sensor
       

    2.  
    3. Disconnect the three engine wire clamps.
    4.  
    5. Remove the three bolts, then disconnect the engine wire from the cylinder head.
    6.  

  24.  
  25. Remove the camshaft position sensor.
  26.  
  27. Remove the (rear) timing belt cover by removing the six bolts.
  28.  
  29. Remove the fuel pressure regulator.
  30.  
  31. Remove the intake manifold assembly.
  32.  
  33. Remove the power steering pump bracket.
  34.  
  35. Remove the oil dipstick and guide.
  36.  
  37. Remove the exhaust crossover pipe and gaskets by removing the six nuts.
  38.  
  39. Remove the left hand exhaust manifold by unbolting the heat insulator and nuts for the exhaust manifold.
  40.  
  41. Remove the right hand exhaust manifold by unbolting the heat insulator and six nuts for the exhaust manifold.
  42.  
  43. Remove the eight bolts, seal washers, valve cover and gasket. Remove both valve covers.
  44.  
  45. Remove the semi-circular plugs.
  46.  
  47. Remove the right side exhaust camshaft.
  48.  


WARNING
Do not pry on or attempt to force the camshaft with a tool or other object.

  1. Remove the right side intake camshaft.
  2.  
  3. Remove the left side exhaust camshaft.
  4.  
  5. Remove the left side intake camshaft.
  6.  
  7. Remove the valve lifters and shims from the cylinder head. Arrange the valve lifters and shims in correct order.
  8.  
  9. Using a 8mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then repeat for the other side.
  10.  
  11. Uniformly loosen and remove the eight cylinder head (12 pointed head) bolts on each cylinder head. Loosen the bolts in several passes using the reverse of the tightening sequence.
  12.  
  13. Remove the 16 cylinder head bolts and plate washers.
  14.  
  15. Lift the cylinder head from the dowels on the cylinder block.
  16.  



Click image to see an enlarged view

Fig. Fig. 46: The recessed bolts must be removed first



Click image to see an enlarged view

Fig. Fig. 47: Cylinder head bolt tightening sequence

To install:
  1. Clean all surfaces.
  2.  
  3. Place two new cylinder head gaskets in position on the cylinder block.
  4.  
  5. Place the two cylinder heads on the dowels of the cylinder block.
  6.  
  7. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  8.  
  9. Install and uniformly tighten the cylinder head bolts on each cylinder as follows:
    1. In several passes and in the sequence shown, tighten the cylinder bolts to 25 ft. lbs. (34 Nm).
    2.  
    3. Mark the front of the cylinder head bolt with paint.
    4.  
    5. Retighten the cylinder head bolts by 90° in order.
    6.  
    7. Check that the painted mark is now at a 90° angle to the front.
    8.  

  10.  
  11. Apply a light coat of engine oil on the threads and under the heads of the recessed cylinder head bolts. Using a 8mm hexagon wrench, install the cylinder head bolt on each cylinder head, then repeat for the other side. Tighten the bolts to 13 ft. lbs. (18 Nm).
  12.  
  13. Install the valve lifters and shims. Check that the valve lifter rotates smoothly by hand.
  14.  
  15. Install the right intake camshaft.
  16.  
  17. Install the right exhaust camshaft.
  18.  
  19. Install the left intake camshaft.
  20.  
  21. Install the left exhaust camshaft.
  22.  
  23. Check and adjust the valve clearance.
  24.  
  25. Install the semi circular plugs.
  26.  
  27. Install the cylinder head covers. Uniformly tighten the bolts in several passes to 53 inch lbs. (6 Nm).
  28.  
  29. Attach the exhaust manifolds with new gaskets, tighten the nuts to 30 ft. lbs. (40 Nm).
  30.  
  31. Install the exhaust manifold heat insulators with the nuts, tighten to 71 inch lbs. (8 Nm).
  32.  
  33. Install the exhaust crossover pipe and tighten the nuts to 33 ft. lbs. (45 Nm).
  34.  
  35. Install the alternator bracket and tighten to 14 ft. lbs. (18 Nm).
  36.  
  37. Install the oil dipstick and guide using a new O-ring.
  38.  
  39. Install the power steering bracket and tighten to 14 ft. lbs. (18 Nm).
  40.  
  41. Install two new gaskets and the intake manifold assembly. Install the four plate washers, eight bolts and four nuts. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
  42.  
  43. Install the intake manifold stay with the two bolts. Tighten the bolts to 14 ft. lbs. (18 Nm).
  44.  
  45. Connect the fuel inlet hose.
  46.  
  47. Install the fuel pressure regulator.
  48.  
  49. Install the timing belt cover with the six bolts. Tighten the bolts to 80 inch lbs. (9 Nm).
  50.  
  51. Install the camshaft position sensor, tighten to 71 inch lbs. (8 Nm).
  52.  
  53. Connect the engine wire to the intake manifold as follows:
    1. Install the engine wire to the cylinder head by installing the three bolts.
    2.  
    3. Connect the three engine wire clamps.
    4.  
    5. Attach the following connectors:

      Oil pressure sensor
       
      Crankshaft position sensor
       
      Six injectors
       
      ECT sender gauge
       
      ECT sensor
       
      Knock sensor
       
      Camshaft position sensor
       

    6.  

  54.  
  55. Install the intake air connector as follows:
    1. Install the intake manifold to the engine by installing the three bolts and two nuts. Tighten the bolts and nuts to 14 ft. lbs. (19 Nm).
    2.  
    3. Attach the DLC1 to the bracket on the intake manifold.
    4.  
    5. Attach the ground strap to the intake manifold by installing the bolt.
    6.  
    7. Connect the brake booster vacuum hose to the intake air connector.
    8.  
    9. Connect the two fuel return hoses.
    10.  
    11. Connect the engine wire to the intake manifold by installing the bolt.
    12.  
    13. If equipped with A/C, connect the idle up valve connector.
    14.  

  56.  
  57. Install the air intake chamber assembly to the engine by installing the four bolts and two nuts. Tighten the bolts and nuts to 14 ft. lbs. (19 Nm).
  58.  
  59. Connect the following hoses:

    PCV
     
    Water bypass
     
    Air assist hose to the intake manifold
     
    Two vacuum sensing hoses to the VSV
     
    EVAP hose
     
    Air hose to the power steering
     
    If equipped with A/C, connect the air hose to the A/C idle up valve.
     

  60.  
  61. Attach the following connectors:

    VSV for the fuel pressure control
     
    Throttle position sensor
     
    Idle Air Control (IAC) Valve
     
    Connect the EGR gas temperature sensor
     
    Connect the VSV wire for the EGR valve
     

  62.  
  63. Install the intake chamber stay. Tighten to 30 ft. lbs. (40 Nm)
  64.  
  65. Install a new O-ring to the oil filler tube. Push in the oil filler tube end into the tube hole in the oil pan. Install the oil filler tube and throttle cable clamp and install the bolt and two nuts.
  66.  
  67. Install two new gaskets and the EGR pipe with the nuts. Tighten the clamp nuts to 71 inch lbs. (8 Nm) and the EGR pipe nuts to 14 ft. lbs. (18 Nm).
  68.  
  69. Install the alternator but do not tighten the bolts and nuts at this time.
  70.  
  71. Install the timing belt idler with the bolt, tighten to 30 ft. lbs. (40 Nm). Check that the pulley bracket moves smoothly.
  72.  
  73. Install the left camshaft timing pulley as follows:
    1. Install the knock pin to the camshaft.
    2.  
    3. Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley.
    4.  
    5. Slide the timing pulley on the camshaft with the flange side facing outward. Tighten the pulley bolt to 81 ft. lbs. (110 Nm).
    6.  

  74.  
  75. Set the No. 1 cylinder to TDC of the compression stroke.
    1. Turn the crankshaft pulley, and align its groove with the timing mark O of the timing belt cover.
    2.  
    3. Turn the camshaft, align the knock pin hole of the camshaft with the timing mark of the timing belt cover.
    4.  
    5. Turn the camshaft timing pulley, align the timing marks of the camshaft timing pulley and the timing belt cover.
    6.  

  76.  
  77. Connect the timing belt to the left camshaft timing pulley. Check that the installation mark on the timing belt is aligned with the end of the timing belt cover.
    1. Using SST 09960-01000 or equivalent, slightly turn the left camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the left camshaft timing pulley.
    2.  
    3. Align the timing marks of the left camshaft pulley and the timing belt cover.
    4.  
    5. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft timing pulley.
    6.  

  78.  
  79. Install the right camshaft timing pulley and the timing belt as follows:
    1. Align the installation mark on the timing belt with the timing mark of the right camshaft timing pulley, and hang the timing belt on the right camshaft timing pulley with the flange side facing inward.
    2.  
    3. Slide the right camshaft timing pulley on the camshaft. Align the timing marks on the right camshaft timing pulley and the timing belt cover.
    4.  
    5. Align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the knock pin. Install the bolt and tighten to 81 ft. lbs. (110 Nm).
    6.  

  80.  
  81. Set the timing belt tensioner as follows:
    1. Using a press, slowly press in the pushrod using 220-2,205 lbs. (981-9,807 N) of force.
    2.  
    3. Align the holes of the pushrod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the pushrod.
    4.  
    5. Release the press and install the dust boot to the tensioner.
    6.  

  82.  
  83. Install the timing belt tensioner and alternately tighten the bolts to 20 ft. lbs. (28 Nm). Using pliers, remove the 1.5 mm hexagon wrench from the belt tensioner.
  84.  
  85. Slowly turn the crankshaft pulley two revolutions from the TDC to TDC. Always turn the crankshaft pulley clockwise. Check that each pulley aligns with the timing marks. If the timing marks do not align, remove the timing belt and reinstall it.
  86.  
  87. Install the fan bracket with the bolt and nut.
  88.  
  89. Install the power steering adjusting strut with the nut.
  90.  
  91. Install the timing belt cover, tighten the bolts to 80 inch lbs. (9 Nm).
  92.  
  93. Connect the three clamps for the spark plug wires to the timing belt cover.
  94.  
  95. Connect the camshaft position sensor connector to the timing belt cover.
  96.  
  97. Install the spark plugs.
  98.  
  99. Install the spark plug wires with the ignition coils.
  100.  
  101. If equipped, install the A/C compressor bracket.
  102.  
  103. If equipped, install the A/C compressor.
  104.  
  105. Install the fan with the fluid coupling and fan pulleys, tighten the nuts to 48 inch lbs. (5 Nm).
  106.  
  107. Install the fan shroud.
  108.  
  109. Install the alternator drive belt.
  110.  
  111. Install the cooling fan, then tighten the nuts to 4 ft. lbs. (5 Nm).
  112.  
  113. If equipped, install and adjust the A/C drive belt.
  114.  
  115. Install the PS pump, pump pulley and the drive belt.
  116.  
  117. Connect the upper radiator hose.
  118.  
  119. Connect the heater hose.
  120.  
  121. Connect the following cables:

    On cruise control, attach the actuator cable with bracket
     
    Accelerator cable
     
    With A/T, the throttle cable
     

  122.  
  123. Install the MAF meter, resonator and air cleaner cap.
  124.  
  125. Install the front exhaust pipe.
  126.  
  127. Fill the radiator with engine coolant.
  128.  
  129. Add oil to the engine if needed.
  130.  
  131. Connect the negative battery cable.
  132.  
  133. Start the engine and check for leaks.
  134.  
  135. Check the ignition timing.
  136.  
  137. Install the engine under cover.
  138.  
  139. Road test the vehicle.
  140.  
  141. Recheck and top off all fluid levels.
  142.  

1FZ-FE Engine

See Figures 48 through 54

  1. Release the fuel system pressure.
  2.  
  3. Disconnect the battery cables and remove the battery and the battery tray.
  4.  


CAUTION
On vehicles with air bags, work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.

  1. Drain the engine coolant.
  2.  
  3. Remove the air cleaner hose and cap.
  4.  
  5. Disconnect the cruise control actuator cable from the throttle body.
  6.  



Click image to see an enlarged view

Fig. Fig. 48: Exploded view of the cylinder head components-1FZ-FE engine

  1. Disconnect the accelerator cable from the throttle body.
  2.  
  3. Disconnect the throttle cable from the throttle body.
  4.  
  5. Disconnect the engine ground strap from the engine hanger and the ground strap from the air intake chamber.
  6.  
  7. Unplug the connector on the intake manifold from the left fender apron.
  8.  
  9. Disconnect the brake booster vacuum hose.
  10.  
  11. Disconnect the EVAP hose and disconnect the fuel return hose.
  12.  


CAUTION
Fuel injection systems remain under pressure after the engine has been turnedOFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Disconnect the heater hoses.
  2.  
  3. Disconnect the engine wire and heater valve from the cowl panel.
  4.  
  5. Remove the cylinder head covers
  6.  
  7. Remove the distributor.
  8.  
  9. Disconnect the P/S reservoir tank.
  10.  
  11. Disconnect the radiator inlet hose and the water bypass hose.
  12.  
  13. Remove the alternator.
  14.  
  15. Remove the throttle body.
  16.  
  17. Remove the oil dipsticks and guides for the engine and transmission.
  18.  
  19. Remove the intake manifold stay.
  20.  
  21. Disconnect the fuel inlet hose from the fuel filter.
  22.  
  23. Unplug the following connectors:
    1. ECT sender gauge connector, the ECT cut switch connector, and the ECT sensor connector
    2.  
    3. Knock sensor connector
    4.  
    5. Crankshaft position sensor connector
    6.  

  24.  
  25. Remove the bolt and disconnect the engine wire harness from the cylinder block.
  26.  
  27. Disconnect the following:
    1. Oil level sensor connector
    2.  
    3. Two connectors from the transmission
    4.  
    5. Starter connector
    6.  
    7. Disconnect the two heated oxygen sensor connectors
    8.  
    9. Disconnect the Park/Neutral Position (PNP) switch connector
    10.  
    11. Remove the two bolts and disconnect the engine wire from the intake manifold and the cylinder block
    12.  
    13. Disconnect the PCV hose from the PCV valve
    14.  
    15. Remove the bolt holding the engine wire to the intake manifold
    16.  
    17. Unplug the connector for the emission control valve set assembly and the three injector connectors
    18.  
    19. Disconnect the engine wire harness clamp
    20.  
    21. Disconnect the EGR gas temperature sensor connector
    22.  
    23. Disconnect the clamp of the No. 6 injector wire from the bracket
    24.  
    25. Disconnect the engine wire harness from the cylinder head and the intake manifold
    26.  

  28.  
  29. Remove the three bolts and disconnect the water bypass pipe from the cylinder head.
  30.  
  31. Disconnect the heated oxygen sensor connector.
  32.  
  33. Remove the nuts and bolts holding the front exhaust pipe to the rear TWC.
  34.  
  35. Disconnect the front exhaust pipe and remove the gasket.
  36.  
  37. Remove the clamp from the support bracket and remove the bracket.
  38.  
  39. Remove the front exhaust pipe and the gaskets.
  40.  
  41. Remove the exhaust manifolds.
    1. Remove the heat insulators.
    2.  

  42.  
  43. Remove the ground cable, heater pipe and gasket.
  44.  



Click image to see an enlarged view

Fig. Fig. 49: The ground cable is secured to the front of the heater pipe

  1. Remove the water bypass outlet and the pipe. Remove the three O-rings from the water bypass outlet and the pipe.
  2.  
  3. Remove the valve cover.
  4.  
  5. Remove the semi-circular plug from the cylinder head.
  6.  
  7. Remove the spark plugs.
  8.  
  9. Set the No. 1 cylinder to TDC of the compression stroke as follows:
  10.  



Click image to see an enlarged view

Fig. Fig. 50: Turn the crankshaft pulley and align its groove with the 0 mark on the timing chain cover



Click image to see an enlarged view

Fig. Fig. 51: Check that the marks on the camshaft pulley are aligned

  1. Remove the chain tensioner.
  2.  
  3. Place matchmarks on the camshaft timing gear and the timing chain.
  4.  



Click image to see an enlarged view

Fig. Fig. 52: Matchmark the position of the chain on the gear

  1. Hold the intake camshaft with a wrench and remove the bolt and the distributor gear.
  2.  
  3. Remove the camshaft timing gear and chain from the intake camshaft and leave on the slipper and the damper.
  4.  
  5. Remove the camshafts.
  6.  


WARNING
Do not pry on or attempt to force the camshaft with a tool or any other object.



Click image to see an enlarged view

Fig. Fig. 53: Remove these two bolts prior to the rest of the head bolts



Click image to see an enlarged view

Fig. Fig. 54: Uniformly loosen and remove the 14 head bolts in several passes

  1. Remove the two bolts in the front of the head first.
  2.  
  3. Loosen and remove the 14 cylinder head bolts in sequence using several passes.
  4.  


WARNING
Cylinder head warpage or cracking could result from removing bolts in incorrect order.

  1. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on the bench. If the cylinder head is difficult to lift off, pry between the cylinder head and the cylinder block with a flat prying tool.
  2.  
  3. Remove the alternator bracket.
  4.  
  5. Remove the two nuts, the water outlet, and the gasket.
  6.  
  7. Loosen the union nut and remove the EGR pipe and gasket.
  8.  
  9. Remove the heater inlet pipe and hose.
  10.  
  11. Remove the air intake chamber and the intake manifold assembly.
  12.  
  13. Remove the water bypass hose.
  14.  
  15. Remove the engine hanger brackets.
  16.  
  17. Remove the two engine wire clamp brackets.
  18.  
  19. Remove the accelerator cable bracket and the throttle cable bracket.
  20.  
  21. Remove the valve lifters and shims. Arrange the valve lifters and shims in correct order for reinstallation.
  22.  

To install:
  1. Install the valve lifters and shims. Check to make sure that the valve lifter rotates smoothly by hand.
  2.  
  3. Install the accelerator cable bracket and the throttle cable bracket.
  4.  
  5. Install the engine wire clamp brackets.
  6.  
  7. Install the engine hangers. Tighten to 30 ft. lbs. (41 Nm).
  8.  
  9. Install the air intake chamber and intake manifold assembly.
  10.  
  11. Install the heater hose to the cylinder head, and connect the pipe to the intake manifold. Tighten the bolts to 15 ft. lbs. (21 Nm).
  12.  
  13. Temporarily install the union nut to the EGR valve. Install the EGR pipe to the cylinder head. Tighten the bolts to 15 ft. lbs. (21 Nm). Tighten the union nut to 58 ft. lbs. (78 Nm).
  14.  
  15. Install a new gasket and the water outlet. Tighten the nuts to 15 ft. lbs. (21 Nm).
  16.  
  17. Install the alternator bracket and tighten the bolts to 32 ft. lbs. (43 Nm).
  18.  
  19. Apply sealant on the end of the engine block by the timing belt.
  20.  
  21. Install a new cylinder head gasket on the cylinder block.
  22.  
  23. Install the cylinder head.
  24.  
  25. Install the cylinder head bolts as follows:
    1. The cylinder head bolts are tightened in three progressive steps. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
    2.  
    3. Install the 14 cylinder head bolts and tighten progressively in sequence to 29 ft. lbs. (39 Nm). Use the reverse of the loosening sequence.
    4.  
    5. Mark the front of the cylinder head bolt head with paint.
    6.  
    7. Retighten the cylinder head bolts by 90° in numerical order.
    8.  
    9. Retighten the cylinder head bolts an additional 90° so that the painted mark is now facing to the rear.
    10.  
    11. Install and tighten the two bolts at the front of the head to 15 ft. lbs. (21 Nm).
    12.  

  26.  


WARNING
Do not combine steps D and E in one pass; the above steps must be followed exactly and in order to prevent cylinder head damage or pre-mature gasket failure.

  1. Install the camshafts.
  2.  
  3. Set the No. 1 cylinder to TDC of the compression stroke. Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing chain cover. Turn the camshaft so that the timing marks with one and two dots will be in straight line on the cylinder head surface.
  4.  
  5. Install the camshaft timing gear as follows:
    1. Check that the matchmarks on the camshaft timing gear and the timing chain are aligned. Place the gear over the straight pin of the intake camshaft.
    2.  
    3. Align the straight pin of the distributor gear with the straight pin groove of the intake camshaft gear.
    4.  
    5. Hold the intake camshaft with a wrench, install and tighten the bolt to 54 ft. lbs. (74 Nm).
    6.  

  6.  
  7. Install the chain tensioner. Push the tensioner by hand until it touches the head installation surface, then install and tighten the two nuts to 15 ft. lbs. (21 Nm).
  8.  
  9. Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing chain cover. Always turn the crankshaft clockwise. Check that the timing marks (one and two dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface. If not, turn the crankshaft one revolution (360°) and align the marks.
  10.  
  11. Check valve clearance and adjust if necessary.
  12.  
  13. Install the spark plugs.
  14.  
  15. Install the semi-circular plug to the cylinder head.
  16.  
  17. Make sure that the No. 1 cylinder is in TDC of the compression stroke.
  18.  
  19. Install the valve cover.
  20.  
  21. Install the water bypass outlet and the pipe as flows:
    1. Install a new O-ring to the water bypass outlet. Install new O-rings to the water bypass pipe.
    2.  
    3. Assemble the water bypass outlet and the pipe and install with the two bolts tightened to 15 ft. lbs. (21 Nm).
    4.  

  22.  
  23. Install the heater pipe and the ground cable. Tighten the heater pipe bolt to 14 ft. lbs. (20 Nm) and the nut to 15 ft. lbs. (21 Nm).
  24.  
  25. Install the exhaust manifolds. Tighten the nuts to 29 ft. lbs. (39 Nm).
  26.  
  27. Install the insulator and heat insulator and tighten the bolts to 14 ft. lbs. (20 Nm).
  28.  
  29. Install the front exhaust pipe. Tighten the nuts to 46 ft. lbs. (63 Nm).
  30.  
  31. Install the support bracket and tighten to 17 ft. lbs. (24 Nm).
  32.  
  33. Connect the clamp and tighten the clamp bolt to 14 ft. lbs. (20 Nm).
  34.  
  35. Connect the front exhaust pipe to the rear catalytic converter and tighten the bolts to 34 ft. lbs. (46 Nm).
  36.  
  37. Connect the water bypass pipe to the cylinder head and tighten the bolts to 14 ft. lbs. (20 Nm).
  38.  
  39. Connect the following:
    1. Connect the engine wire harness from the cylinder head and the intake manifold
    2.  
    3. Connect the clamp of the No. 6 injector wire from the bracket
    4.  
    5. Connect the EGR gas temperature sensor connector
    6.  
    7. Connect the engine wire harness clamp
    8.  
    9. Attach the connector for the emission control valve set assembly and the three injector connectors
    10.  
    11. Install the bolt holding the engine wire to the intake manifold
    12.  
    13. Connect the PCV hose from the PCV valve
    14.  
    15. Install the two bolts and connect the engine wire from the intake manifold and the cylinder block
    16.  
    17. Connect the Park/Neutral Position (PNP) switch connector
    18.  
    19. Connect the two heated oxygen sensor connectors
    20.  
    21. Starter connector
    22.  
    23. Two connectors from the transmission
    24.  
    25. Oil level sensor connector
    26.  

  40.  
  41. Install the bolt and connect the engine wire harness from the cylinder block.
  42.  
  43. Engage the following connectors:
    1. ECT sender gauge connector, the ECT cut switch connector, and the ECT sensor connector
    2.  
    3. Knock sensor connector
    4.  
    5. Crankshaft position sensor connector
    6.  

  44.  
  45. Connect the fuel inlet hose to the fuel filter with the union bolt. Tighten to 22 ft. lbs. (29 Nm).
  46.  
  47. Install the intake manifold stay and tighten the bolts to 26 ft. lbs. (36 Nm).
  48.  
  49. Install the oil dipsticks and the guides for the engine and the transmission. Tighten the oil dipstick guide bolts to 14 ft. lbs. (20 Nm).
  50.  
  51. Install the throttle body.
  52.  
  53. Install the alternator and the drive belts.
  54.  
  55. Connect the water bypass hose.
  56.  
  57. Connect the radiator inlet hose.
  58.  
  59. Connect the P/S reservoir tank and tighten the bolts to 14 ft. lbs. (20 Nm).
  60.  
  61. Install the distributor.
  62.  
  63. Install the cylinder head covers.
  64.  
  65. Connect the heater valve and the engine wire harness to the cowl panel.
  66.  
  67. Connect the heater hoses.
  68.  
  69. Connect the fuel return hose, the EVAP hose, and the brake booster vacuum hose.
  70.  
  71. Attach the connector on the intake manifold to the left fender apron.
  72.  
  73. Connect the ground strap to the engine hanger and the air intake chamber.
  74.  
  75. Attach the throttle cable to the throttle body. Adjust the throttle cable.
  76.  
  77. Connect the accelerator cable to the throttle body.
  78.  
  79. Connect the cruise control actuator cable to the the throttle body.
  80.  
  81. Install the air cleaner hose and cap.
  82.  
  83. Install the battery tray, the battery, and connect the cables.
  84.  
  85. Refill the engine coolant.
  86.  
  87. Start the engine and check for leaks.
  88.  
  89. Make necessary engine adjustments.
  90.  
  91. Road test the vehicle and recheck the engine coolant level.
  92.  

CLEANING AND INSPECTION



See Figures 55, 56, 57 and 58

When the rocker assembly and valve train have been removed from the cylinder head, set the head on two wooden blocks on the bench, combustion chamber side up. Using a scraper or putty knife, carefully scrape away any gasket material that may have stuck to the head-to-block mating surface when the head was removed. Make sure you DO NOT gouge the mating surface with the tool. Wood, plastic or even brass scrapers are best.



Click image to see an enlarged view

Fig. Fig. 55: Use a gasket scraper to remove the bulk of the old head gasket from the mating surface

Using a wire brush attached to your electric drill, remove the carbon in each combustion chamber. Make sure the brush is actually removing the carbon and not merely burnishing it.



Click image to see an enlarged view

Fig. Fig. 56: An electric drill equipped with a wire wheel will expedite complete gasket removal

Clean all the valve guides using a valve guide brush (available at most auto parts or auto tool shops) and solvent. A fine-bristled rifle bore cleaning brush also works here.



Click image to see an enlarged view

Fig. Fig. 57: Using a valve guide brush, clean the bore with solvent

Inspect the threads of each spark plug hole by screwing a plug into each, making sure it screws down completely. Heli-coil® any plug hole that is damaged.


WARNING
You may wish to send the bare head to a machine shop for cleaning. There are many ways to clean the head including solvent baths and glass bead blasting. DO NOT hot tank the cylinder head. The head material on most engines is aluminum, which is ruined if subjected to the hot tank solution.

To inspect for cracks, use a dye penetrant, check the combustion chambers, intake ports, exhaust ports and cylinder block surface. If cracked, replace the head.

Click image to see an enlarged view

Fig. Fig. 58: Spray a dye penetrant to check for cracks

Finally, go over the entire head with a clean shop rag soaked in solvent to remove any grit, old gasket particles, etc. Blow out the bolt holes, coolant galleys, intake and exhaust ports, valve guides and plug holes with compressed air.

RESURFACING



See Figures 59 and 60

While the head is removed, check the head-to-block mating surface for straightness. If the engine has overheated and blown a head gasket, this must be done as a matter of course. A warped mating surface must be resurfaced (milled). This is done by a machine shop on a milling machine and is quite similar to planing a piece of wood.



Click image to see an enlarged view

Fig. Fig. 59: Check the cylinder head for warpage along the center using a straightedge and a feeler gauge



Click image to see an enlarged view

Fig. Fig. 60: Be sure to check for warpage across the cylinder head at both diagonals

Using a precision steel straight-edge and a blade-type feeler gauge, check the surface of the head across its length, width and diagonal length. Also check the intake and exhaust manifold mating surfaces and cam cover mating surfaces. If warpage exceeds 0.0039 in (0.010mm), the head must be replaced. Warpage under this amount allows resurfacing, if done carefully.

If the head is sent out for resurfacing, have it crack checked at the same time. The few dollars extra is worth the peace of mind.

CYLINDER BLOCK CLEANING



While the cylinder head is removed, the top of the cylinder block and pistons should also be cleaned. Before you begin, rotate the crankshaft until one or more pistons are flush with the top of the block (on the four cylinder engines, you will either have Nos. 1 and 4 up, or Nos. 2 and 3 up). Carefully stuff clean rags into the cylinders in which the pistons are down. This will help keep grit and carbon chips out during cleaning. Using care not to gouge or scratch the block-to-head mating surface and the piston top(s), clean away any old gasket material with a wire brush and/or scraper. On the piston tops, make sure you are actually removing the carbon and not merely burnishing it.

Remove the rags from the down cylinders after you have wiped the top of the block with a solvent soaked rag. Rotate the crankshaft until the other pistons come up flush with the top of the block, and clean those pistons.

Because you have rotated the crankshaft, you will have to re-time the engine following the procedure listed under the Timing Chain/Timing Belt removal. Make sure you wipe out each cylinder thoroughly with a solvent-soaked rag, to remove all traces of grit, before the head is reassembled to the block. Any particles trapped by the piston will score the cylinder wall.

 
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