Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00

Cylinder Head

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REMOVAL & INSTALLATION



2RZ-FE and 3RZ-FE Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the air cleaner cap, Mass Air Flow (MAF) meter, and the resonator.
  6.  
  7. If equipped with a manual transmission, disconnect the accelerator cable from the throttle body.
  8.  
  9. If equipped with an automatic transmission, disconnect the accelerator and throttle cables from the throttle body.
  10.  
  11. Remove the intake air connector, as follows:

    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. Detach 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. Tag for identification then disconnect the following harnesses:

    A/C compressor wiring, if equipped
     
    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 connectors from the following:

      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, and 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 (also called the fuel rail) 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°).
  16.  



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Fig. Set No. 1 cylinder to TDC compression stroke2RZ-FE and 3RZ-FE engines



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Fig. Check that the marks on the gears are properly aligned2RZ-FE and 3RZ-FE engines



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Fig. Matchmark the position of the chain on the gear2RZ-FE and 3RZ-FE engines



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Fig. Hold the hexagon head portion of the camshaft with a wrench and remove the bolt securing the gear2RZ-FE and 3RZ-FE engines

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

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 the 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 two bolts in the front of the head before the other head bolts are removed. Uniformly loosen and remove the remaining head bolts. Do this in several passes, following the sequence shown.
  2.  
  3. Lift the cylinder head from the block and place the head on wooden blocks on a bench.
  4.  



Click image to see an enlarged view

Fig. Remove the two bolts at the front of the head first2RZ-FE and 3RZ-FE engines



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Fig. Remove the cylinder head bolts using this order, in several passes2RZ-FE and 3RZ-FE engines

To install:

  1. Clean all parts well. Cylinder head rebuilding is best left to professionals. The head should be cleaned and inspected before installation. More information is available in the "Engine Reconditioning" section.
  2.  

The head bolts used in this engine are designed to stretch and deform slightly. They should be carefully inspected. New service replacement head bolts are strongly recommended.

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage.
  2.  
  3. Apply a proper sealant (0882600080, or equivalent) to the two 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. Apply sealant to the head in these areas2RZ-FE and 3RZ-FE engines



Click image to see an enlarged view

Fig. New head bolts are strongly recommended. Tighten the head bolts down uniformly using this sequence in several passes2RZ-FE and 3RZ-FE engines

  1. Tighten all bolts to 29 ft. lbs. (39 Nm).
  2.  
  3. Mark the front of the bolt with paint and retighten bolts 90° in the proper sequence.
  4.  
  5. Retighten an additional 90°. Check that the painted mark is now facing rearward.
  6.  



Click image to see an enlarged view

Fig. Mark the front of the bolt with paint and retighten bolts 90° in the proper sequence2RZ-FE and 3RZ-FE Engines

  1. Install and tighten the two front mounting bolts to 15 ft. lbs. (20 Nm).
  2.  
  3. Install the intake camshaft.
  4.  
  5. Install the exhaust camshaft.
  6.  
  7. 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.
  8.  
  9. 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.  

  10.  
  11. 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, and then install the two 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.  

  12.  
  13. Check and adjust the valve clearance. Intake valve clearance is 0.0060.010 inch (0.150.25mm) and exhaust valve clearance is 0.0100.014 inch (0.250.35mm).
  14.  
  15. Recheck the engine for proper valve timing. Check and adjust the valve clearance.
  16.  
  17. Install the spark plugs and the semi-circular plug.
  18.  
  19. 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).
  20.  
  21. Install the exhaust manifold and gasket to the engine and install the six nuts. Tighten the nuts to 36 ft. lbs. (49 Nm).
  22.  
  23. Install the heat insulator with the two bolts and two nuts. Tighten the bolts and nuts to 48 inch lbs. (6 Nm).
  24.  
  25. Install the front exhaust pipe to the exhaust manifold.
  26.  
  27. Install the intake manifold using a new gasket. Tighten the bolts and nuts to 22 ft. lbs. (29 Nm).
  28.  
  29. Install the injectors and delivery pipe. Tighten the bolts holding the delivery pipe to 15 ft. lbs. (21 Nm).
  30.  
  31. Install the fuel tube with four new gaskets. Tighten the union bolts to 22 ft. lbs. (29 Nm).
  32.  
  33. 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. (20 Nm).
    2.  
    3. Connect the vacuum hose to the gas filter.
    4.  
    5. Connect the brake booster vacuum hose to the intake chamber.
    6.  

  34.  
  35. Install the fuel return pipe by installing the two bolts and hoses.
  36.  
  37. Install the intake chamber stay by installing the two bolts. Tighten the bolts to 14 ft. lbs. (19 Nm).
  38.  
  39. Install the EGR valve and vacuum modulator.
  40.  
  41. Install the cylinder head rear cover with a new gasket. Tighten the three bolts to 10 ft. lbs. (14 Nm).
  42.  
  43. Connect the heater water bypass pipe.
  44.  
  45. Connect the injector wiring.
  46.  
  47. 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.  

  48.  
  49. Attach the following connections to the engine:

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

  50.  
  51. Install the throttle body.
  52.  
  53. 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.
  54.  
  55. Install the distributor.
  56.  
  57. Install the two PCV hoses.
  58.  
  59. Install the power steering pump bracket by installing the four bolts, tighten to 14 ft. lbs. (20 Nm).
  60.  
  61. Install the power steering pump to the bracket.
  62.  
  63. Install the idler pulley with the three bolts; tighten to 14 ft. lbs. (20 Nm).
  64.  
  65. With A/C, install the A/C idle up valve.
  66.  
  67. Install the air intake connector by installing the two bolts, hose clamp, and two air hoses.
  68.  
  69. If equipped with a manual transaxle, connect the accelerator cable to the throttle body.
  70.  
  71. If equipped with a automatic transaxle, connect the throttle and accelerator cables to the throttle body.
  72.  
  73. Install the MAF meter, resonator, and the air cleaner cap.
  74.  
  75. Refill the cooling system. Since coolant can contaminate the oil system when a cylinder head is removed, it is important to drain and refill the engine oil.
  76.  
  77. Connect the negative battery cable. Start the engine and check for leaks.
  78.  
  79. Road test the vehicle for proper operation.
  80.  
  81. Recheck all fluid levels and add as required.
  82.  

5VZ-FE Engine


Click image to see an enlarged view

Fig. Use a breaker bar and deep socket to remove the cylinder head bolts



Click image to see an enlarged view

Fig. Removing the cylinder head from the block

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure using the procedures found in .
  4.  
  5. Remove the engine under cover.
  6.  
  7. Drain the cooling system.
  8.  



Click image to see an enlarged view

Fig. Exploded view of the cylinder heads and related components5VZ-FE Engine

  1. Remove the front exhaust pipe.
  2.  
  3. Disconnect the air cleaner cap, Mass Air Flow (MAF) meter and the resonator.
  4.  
  5. Disconnect the following cables:

    Actuator cable with the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable if equipped with an automatic transmission
     

  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 reusing 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 0996010010, or equivalent, to hold the pulley to keep it from turning, remove the pulley bolt, timing pulley, and 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 (TP) sensor
     
    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. Tag for identification, then disconnect the wiring from the following:

      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, and 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 8-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 flat washers.
  14.  
  15. Lift the cylinder head from the dowels on the cylinder block.
  16.  



Click image to see an enlarged view

Fig. The recessed bolts must be removed first5VZ-FE engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence5VZ-FE engine

To install:

  1. Clean all parts well. Cylinder head rebuilding is best left to professionals. The head should be cleaned and inspected before installation. More information is available in the "Engine Reconditioning" section.
  2.  

The head bolts used in this engine are designed to stretch and deform slightly. They should be carefully inspected. New service replacement head bolts are strongly recommended.

  1. Place two new cylinder head gaskets in position on the cylinder block.
  2.  
  3. Place the two cylinder heads on the dowels of the cylinder block.
  4.  
  5. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  6.  
  7. 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 of sequence.
    6.  
    7. Check that the painted mark is now at a 90°-angle to the front.
    8.  

  8.  
  9. 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).
  10.  
  11. Install the valve lifters and shims. Check that the valve lifter rotates smoothly by hand.
  12.  
  13. Install the right intake camshaft.
  14.  
  15. Install the right exhaust camshaft.
  16.  
  17. Install the left intake camshaft.
  18.  
  19. Install the left exhaust camshaft.
  20.  
  21. Check and adjust the valve clearance.
  22.  
  23. Install the semi-circular plugs.
  24.  
  25. Install the cylinder head covers. Uniformly tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).
  26.  
  27. Attach the exhaust manifolds with new gaskets; tighten the nuts to 30 ft. lbs. (40 Nm).
  28.  
  29. Install the exhaust manifold heat insulators with the nuts; tighten to 71 inch lbs. (8 Nm).
  30.  
  31. Install the exhaust crossover pipe and tighten the nuts to 33 ft. lbs. (45 Nm).
  32.  
  33. Install the alternator bracket and tighten the bolts to 14 ft. lbs. (18 Nm).
  34.  
  35. Install the oil dipstick and guide using a new O-ring.
  36.  
  37. Install the power steering bracket and tighten the mounting bolts to 14 ft. lbs. (18 Nm).
  38.  
  39. Install two new gaskets and the intake manifold assembly. Install the four flat washers, eight bolts, and four nuts. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
  40.  
  41. Install the intake manifold stay with the two bolts. Tighten the bolts to 14 ft. lbs. (18 Nm).
  42.  
  43. Connect the fuel inlet hose.
  44.  
  45. Install the fuel pressure regulator.
  46.  
  47. Install the timing belt cover with the six bolts. Tighten the bolts to 80 inch lbs. (9 Nm).
  48.  
  49. Install the camshaft position sensor; tighten to 71 inch lbs. (8 Nm).
  50.  
  51. 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.  

  52.  
  53. 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, evenly and in several passes, 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, attach the idle up valve connector.
    14.  

  54.  
  55. 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).
  56.  
  57. 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.
     

  58.  
  59. 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
     

  60.  
  61. Install the intake chamber stay. Tighten to 30 ft. lbs. (40 Nm)
  62.  
  63. 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.
  64.  
  65. 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. (19 Nm).
  66.  
  67. Install the alternator but do not tighten the bolts and nuts at this time.
  68.  
  69. Install the timing belt idler with the bolt; tighten to 30 ft. lbs. (40 Nm). Check that the pulley bracket moves smoothly.
  70.  
  71. 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.  

  72.  
  73. Set the No. 1 cylinder to TDC of the compression stroke:
    1. Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing belt cover.
    2.  
    3. Turn the camshaft, and then align the knock pin hole of the camshaft with the timing mark of the timing belt cover.
    4.  
    5. Turn the camshaft timing pulley, and then align the timing marks of the camshaft timing pulley and the timing belt cover.
    6.  

  74.  
  75. 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 0996001000 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.  

  76.  
  77. 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.  

  78.  
  79. Set the timing belt tensioner as follows:
    1. Using a press, slowly press in the pushrod using 2202,205 lbs. (9819,807 N) of force.
    2.  
    3. Align the holes of the pushrod and housing, pass a 1.5mm 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.  

  80.  
  81. Install the timing belt tensioner and alternately tighten the bolts to 20 ft. lbs. (28 Nm). Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
  82.  
  83. 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.
  84.  
  85. Install the fan bracket with the bolt and nut.
  86.  
  87. Install the power steering adjusting strut with the nut.
  88.  
  89. Install the timing belt cover, tighten the bolts to 80 inch lbs. (9 Nm).
  90.  
  91. Connect the three clamps for the spark plug wires to the timing belt cover.
  92.  
  93. Connect the camshaft position sensor connector to the timing belt cover.
  94.  
  95. Install the spark plugs.
  96.  
  97. Install the spark plug wires with the ignition coils.
  98.  
  99. If equipped, install the A/C compressor bracket.
  100.  
  101. If equipped, install the A/C compressor.
  102.  
  103. Install the fan with the fluid coupling and fan pulleys, tighten the nuts to 48 inch lbs. (5 Nm).
  104.  
  105. Install the fan shroud.
  106.  
  107. Install the alternator drive belt.
  108.  
  109. Install the cooling fan, and then tighten the nuts to 4 ft. lbs. (5 Nm).
  110.  
  111. If equipped, install and adjust the A/C drive belt.
  112.  
  113. Install the power steering pump, the pump pulley, and the drive belt.
  114.  
  115. Connect the upper radiator hose.
  116.  
  117. Connect the heater hose.
  118.  
  119. Connect the following cables:

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

  120.  
  121. Install the MAF meter, resonator and air cleaner cap.
  122.  
  123. Install the front exhaust pipe.
  124.  
  125. Fill the radiator with engine coolant.
  126.  
  127. Because coolant can contaminate the oil system when cylinder heads are removed, it is important to drain the oil and refill with fresh oil. A filter change is recommended.
  128.  
  129. Connect the negative battery cable.
  130.  
  131. Start the engine and check for leaks.
  132.  
  133. Check the ignition timing.
  134.  
  135. Install the engine undercover.
  136.  
  137. Road test the vehicle.
  138.  
  139. Recheck all fluid levels and add as required.
  140.  

1FZ-FE Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the battery cables and remove the battery and the battery tray.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove the air cleaner hose and cap.
  8.  
  9. Disconnect the cruise control actuator cable from the throttle body.
  10.  



Click image to see an enlarged view

Fig. Exploded view of the cylinder head components1FZ-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.  
  13. Disconnect the heater hoses.
  14.  
  15. Disconnect the engine wire and heater valve from the cowl panel.
  16.  
  17. Remove the cylinder head covers
  18.  
  19. Remove the distributor.
  20.  
  21. Disconnect the power steering reservoir tank.
  22.  
  23. Disconnect the radiator inlet hose and the water bypass hose.
  24.  
  25. Remove the alternator.
  26.  
  27. Remove the throttle body.
  28.  
  29. Remove the oil dipsticks and guides for the engine and transmission.
  30.  
  31. Remove the intake manifold stay.
  32.  
  33. Disconnect the fuel inlet hose from the fuel filter.
  34.  
  35. 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.  

  36.  
  37. Remove the bolt and disconnect the engine wire harness from the cylinder block.
  38.  
  39. Disconnect the following:
    1. Oil level sensor connector
    2.  
    3. Two connectors from the transmission
    4.  
    5. Starter connector
    6.  
    7. Two heated oxygen sensor connectors
    8.  
    9. Park/Neutral Position (PNP) switch connector
    10.  

  40.  
  41. Remove the two bolts and disconnect the engine wire from the intake manifold and the cylinder block
  42.  
  43. Disconnect the PCV hose from the PCV valve
  44.  
  45. Remove the bolt holding the engine wire to the intake manifold
  46.  
  47. Unplug the connector for the emission control valve set assembly and all three of the injector connectors
  48.  
  49. Disconnect the engine wire harness clamp
  50.  
  51. Disconnect the EGR gas temperature sensor connector
  52.  
  53. Disconnect the clamp of the No. 6 injector wire from the bracket
  54.  
  55. Disconnect the engine wire harness from the cylinder head and the intake manifold
  56.  
  57. Remove the three bolts and disconnect the water bypass pipe from the cylinder head.
  58.  
  59. Disconnect the heated oxygen sensor connector.
  60.  
  61. Remove the nuts and bolts holding the front exhaust pipe to the rear TWC.
  62.  
  63. Disconnect the front exhaust pipe and remove the gasket.
  64.  
  65. Remove the clamp from the support bracket and remove the bracket.
  66.  
  67. Remove the front exhaust pipe and the gaskets.
  68.  
  69. Remove the exhaust manifolds.
  70.  
  71. Remove the heat insulators.
  72.  
  73. Remove the ground cable, heater pipe and gasket.
  74.  



Click image to see an enlarged view

Fig. The ground cable is secured to the front of the heater pipe1FZ-FE engine

  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 semicircular 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. Turn the crankshaft pulley and align its groove with the 0 mark on the timing chain cover1FZ-FE engine

  1. Turn the crankshaft pulley and align its groove with the 0 mark on the timing chain cover.
  2.  
  3. 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 as above.
  4.  



Click image to see an enlarged view

Fig. Check that the marks on the camshaft pulley are aligned1FZ-FE engine

  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. Matchmark the position of the chain on the gear1FZ-FE engine

  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. Remove these two bolts prior to the rest of the head bolts1FZ-FE engine



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Fig. Uniformly loosen and remove the 14 head bolts in several passes1FZ-FE engine

  1. Start by removing the two bolts at the front of the head.
  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, gently 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. Clean all parts well. Cylinder head rebuilding is best left to professionals. The head should be cleaned and inspected before installation. More information is available in the "Engine Reconditioning" section.
  2.  

The head bolts used in this engine are designed to stretch and deform slightly. They should be carefully inspected. New service replacement head bolts are strongly recommended.

  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. Tighten them, 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°, following the tightening sequence.
    8.  
    9. Finally, again retighten the cylinder head bolts an additional 90°, so that the painted mark is now facing to the rear.
    10.  

  26.  


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

  1. Install and tighten the two bolts at the front of the head to 15 ft. lbs. (21 Nm).
  2.  

  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. Install the assembly 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 to the cylinder head and the intake manifold
    2.  
    3. Connect the clamp of the No. 6 injector wire to 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 all 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 to 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 to 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; 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 power steering reservoir tank; 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 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. Because coolant can contaminate the oil system when a cylinder head is removed, drain and refill the engine oil. A filter change is recommended.
  88.  
  89. Start the engine and check for leaks.
  90.  
  91. Make necessary engine adjustments.
  92.  
  93. Road test the vehicle and recheck the engine coolant level.
  94.  

2UZ-FE Engine

This is a lengthy and complicated procedure requiring careful and precise work.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove the throttle body cover.
  6.  
  7. Disconnect the timing belt from the camshaft pulleys. For additional information, please refer to the following topic(s): "Timing Belt," "Removal and Installation." Use care when working around the timing belt. Do NOT allow anything to drop inside the timing belt cover. Do NOT allow the timing belt to come into contact with oil, water or dust.
  8.  
  9. Remove the camshaft timing pulleys. Please see the "Timing Belt" procedure in this section.
  10.  
  11. Remove the camshaft position sensor by removing the bolt and stud bolt and then removing the sensor.
  12.  
  13. Disconnect the power steering pump from the engine by disconnecting the lines from the steering gear assembly.
  14.  
  15. Disconnect the front exhaust pipe.
  16.  
  17. Remove the automatic transmission dipstick and tube.
  18.  
  19. Remove the ignition coils.
  20.  
  21. Remove the three bolts and the stud bolt and remove the left side and right side timing belt rear plates.
  22.  
  23. Disconnect the fuel lines.
  24.  
  25. Tag and detach the following electrical connectors:

    Throttle Position (TP) sensor
     
    Accelerator pedal position sensor connector
     
    Throttle control motor connector
     
    VSV connector for the EVAP system
     
    Eight fuel injector connectors
     
    Engine Coolant Temperature (ECT) sensor
     
    Water sender gauge connector
     
    Eight ignition coil connectors
     
    Two heated oxygen sensor connectors
     

  26.  
  27. Tag for identification and disconnect the following hoses:

    Vacuum hose from the fuel pressure regulator
     
    PCV hose from the PCV valve on the left side cylinder head
     
    EVAP hose from the charcoal canister from the VSV for the EVAP system
     
    EVAP hose from the charcoal canister from the EVAP pipe on the intake manifold
     
    Power steering vacuum switch lines from the intake manifold
     
    Brake booster vacuum line
     

  28.  
  29. Remove the upper and lower intake manifolds.
  30.  
  31. If necessary, remove the water inlet and inlet housing assembly.
  32.  
  33. Remove the 18 bolts and seal washers from the cylinder head covers and remove the covers and gaskets. If necessary, remove semi-circular plugs and camshaft housing plugs.
  34.  


WARNING
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

  1. Remove the camshafts using the following procedure.
    1. Check the crankshaft pulley position. Check that the timing mark of the crankshaft pulley is aligned with the centers of the crankshaft pulley bolt and the idler pulley.
    2.  

  2.  


WARNING
Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft, causing damage. Always set the crankshaft pulley at the correct angle.

  1. Remove the right side camshafts. Bring the service bolt hole of the sub-gear upward by turning the hexagon wrench portion of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a bolt 6mm in diameter x 1.0mm thread pitch x 1620mm long.
  2.  


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

  1. Set the timing mark (one dot mark) of the camshaft main gear at an angle approximately 10° above horizontal by turning the hexagon wrench portion of the exhaust camshaft with a wrench.
  2.  
  3. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence illustrated.
  4.  
  5. Remove the oil feed pipe, the bearing caps and the camshafts.
  6.  
  7. Remove the left side camshafts. Bring the service bolt hole of the sub-gear upward by turning the hexagon wrench portion of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a bolt 6mm in diameter x 1.0mm thread pitch x 1620mm long.
  8.  


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

  1. Align timing marks (two dot marks) of the camshaft drive gear by turning the hexagon wrench portion of the exhaust camshaft with a wrench.
  2.  
  3. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence illustrated.
  4.  

Note that there are five different length bearing cap bolts that, at assembly, MUST be returned to their proper locations. Mark these bolts or place in holes punched through cardboard to make sure they will be in the proper location and sequence. Take the time to accurately measure each bolt and mark its length on the cardboard. The reason for this is that at assembly, certain lengths of bolts are handled differently, and they are identified by length.

  1. Remove the oil feed pipe, the bearing caps and the camshafts.
  2.  

Use care to keep the bearing caps in order, in the exact same sequence and direction as originally installed on the engine.

  1. Uniformly loosen the ten cylinder head bolts on one side of each cylinder head, in several passes, following the sequence illustrated. Repeat for the other side. Remove the twenty head bolts and the flat washers.
  2.  


WARNING
Use care. Cylinder head warping or cracking could result from removing the bolts in an incorrect order.


WARNING
Use care not to drop the flat washer for a head bolt into the open portion (oil drain-back) of the cylinder head. Anything dropped through this opening will pass through the head and cylinder block and into the oil pan.

  1. Lift the cylinder heads (with the exhaust manifolds attached) from the locating dowels in the cylinder block, and place the heads on protective soft wood block on a workbench. If the cylinder head is reluctant to come off, it may be carefully pried off but use great care not the damage the sealing surfaces of the head or the block. Do NOT tilt the cylinder head at removal or the valve lifters may fall out.
  2.  
  3. Remove the exhaust manifolds, as required.
  4.  



Click image to see an enlarged view

Fig. Cylinder heads, camshafts and related components2UZ-FE engine



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Fig. Set up the engine and align the timing marks before RIGHT side camshaft removal. Note the 6mm bolt used to lock together the two-piece cam gear2UZ-FE engine



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Fig. Set up the engine and align the timing marks before LEFT side camshaft removal. Note the 6mm bolt used to lock together the two-piece cam gear2UZ-FE engine



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Fig. Use this sequence to loosen the camshaft bearing cap bolts. TopLeft Side Bank; BottomRight Side Bank2UZ-FE engine



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Fig. Use this sequence to loosen the cylinder head bolts. If necessary, carefully pry where indicated2UZ-FE engine



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Fig. Use a precision straightedge and feeler gauges to check for cylinder head distortion in the directions indicated. Maximum warpage allowed is only 0.0039 inch (0.10mm)2UZ-FE engine



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Fig. Inspect and measure the outside diameter of the head bolts. New head bolts are recommended2UZ-FE engine



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Fig. Inspect the head gaskets and find the marks indicating left side or right side2UZ-FE engine



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Fig. Use this sequence to tighten the cylinder head bolts2UZ-FE engine



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Fig. When installing the right side camshafts, align the timing marks as shown and apply sealer to the front bearing cap where indicated2UZ-FE engine



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Fig. When installing the left side camshafts, align the timing marks as shown and apply sealer to the front bearing cap where indicated2UZ-FE engine



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Fig. After the camshaft front bearing caps are set in place, but before the bolts are final-tightened, push in new oil seals2UZ-FE engine



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Fig. Make sure the camshaft bearing caps are properly identified and correctly installed. Verify the proper length bolt is installed in the correct location, then tighten in the sequence shownRight side bank shown



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Fig. Make sure the camshaft bearing caps are properly identified and correctly installed. Verify the proper length bolt is installed in the correct location, then tighten in the sequence shownLeft side bank shown

To install:

  1. Clean all parts well. Cylinder head rebuilding is best left to professionals. The head should be cleaned and inspected before installation. More information is available in the "Engine Reconditioning" section.
  2.  

The head bolts used in this engine are designed to stretch and deform slightly. They should be carefully inspected. New service replacement head bolts are strongly recommended.

  1. Toyota suggests installing the exhaust manifold(s) to the cylinder head before the head is installed. Use new gaskets. Factory replacement gaskets should have white painted marks facing the manifold side. Use eight new manifold nuts per manifold and tighten uniformly, in several passes, to 32 ft. lbs. (44 Nm).
  2.  
  3. Place new cylinder head gaskets on the block. On the rear side of the cylinder head gasket are marks to distinguish the left side and right side banks. There is a 2UR mark on the right side bank and a 2UL mark on the left side bank. Use care to install the gaskets on the correct sides.
  4.  
  5. Install the cylinder heads and prepare the head bolts. New service replacement head bolts are strongly recommended. Care must be taken when tightening the head bolts. Use the following guide:
    1. The cylinder head bolts are tightened in two progressive steps.
    2.  
    3. Apply a light coat of engine oil on the threads and under the heads of the bolts.
    4.  
    5. Install the flat washers to the head bolts
    6.  
    7. Install and uniformly tighten the ten cylinder head bolts (per bank) in several passes in the sequence illustrated. Perform this operation on both banks. On this first pass, tighten the bolts to 24 ft. lbs. (32 Nm).
    8.  
    9. Mark the front of the cylinder head bolts with a small amount of paint.
    10.  
    11. On a second pass, tighten the cylinder head bolts, in sequence, another 90° ( 1 / 4 turn).
    12.  
    13. On a third pass, again tighten the cylinder head bolts, in sequence, another 90° ( 1 / 4 turn).
    14.  
    15. Check that the painted mark is now 180° ( 1 / 2 -turn) from its original position.
    16.  

  6.  
  7. Install the spark plugs.
  8.  
  9. If disassembled, assemble the exhaust camshafts and sprockets using the following procedure:
    1. Install the camshaft gear spring, camshaft sub-gear and wave washer. Attach the pins on the gears to the gear spring ends.
    2.  
    3. Install the snapring.
    4.  
    5. Mount the hexagon wrench head portion of the camshaft in a vise. Use care not to damage the camshaft.
    6.  
    7. Using Toyota's Special Service tool or a suitable pin-type spanner, align the holes of the camshaft main gear and sub-gear by turning the camshaft sub-gear counterclockwise, and temporarily install a bolt 6mm in diameter x 1.0mm thread pitch x 1620mm long. Make sure the teeth of the gears are aligned, and then tighten the bolt to secure the assembly.
    8.  

  10.  
  11. Remove any old sealer from the semi-circular camshaft housing plugs. Apply fresh sealer to the plug grooves and install the camshaft housing plugs to the cylinder heads.
  12.  


WARNING
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

  1. Install the right side camshafts using the following procedure.
    1. Apply engine assembly lube or multipurpose grease to the thrust portion of the intake and exhaust camshafts.
    2.  
    3. Lay the intake and exhaust camshafts carefully in position.
    4.  
    5. Set the timing mark (one dot mark) of the camshaft main gear at an angle approximately 10° above horizontal by turning the hexagon wrench portion of the exhaust camshaft with a wrench.
    6.  
    7. Remove any old sealer from the front bearing cap. Apply a bead of fresh sealer approximately 1 / 16 inch in diameter, to the areas indicated in the illustration. Use care to keep sealer out of the front bearing cap grooves. Assemble the front bearing cap before the sealer has a chance to skin-over (start to cure). Note that installing the front bearing cap will determine the thrust clearance of the camshaft.
    8.  
    9. Install the other bearing caps in the sequence illustrated with the arrow mark facing forward. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.
    10.  
    11. Install a new camshaft oil seal.
    12.  
    13. Apply a light coat of engine oil on the threads of only two sizes (the two longest) of camshaft bearing cap bolts. These bolts are:

      The 2.83 inch (72mm) bolts (called bolt "D").
       
      The 3.70 inch (94mm) bolts (called bolt "E").
       

    14.  
    15. Do NOT apply engine oil under the heads of the remaining camshaft bearing cap bolts. These bolts are:

      The 0.98 inch (25mm) bolts (called bolt "A").
       
      The 1.50 inch (38mm) bolts (called bolt "B").
       
      The 2.05 inch (52mm) bolts (called bolt "C").
       

    16.  

  2.  
  3. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence illustrated.
    1. Torque the shortest bolts (bolt A) to 69 inch lbs. (7.5 Nm).
    2.  
    3. Torque all other bolts to 144 inch lbs. (16 Nm).
    4.  
    5. Bring the service bolt hole of the sub-gear upward by turning the hexagon wrench portion of the exhaust camshaft with a wrench. Remove the bolt. This allows the torsion spring and sub-gear to remove gear backlash.
    6.  

  4.  
  5. Install the left side camshafts using the same procedure.
  6.  
  7. Turn the camshaft(s) and position so the lobes are upward, and check and adjust the valve clearance, noting the following:
    1. Turn the crankshaft pulley and align its groove with the timing mark 0 on the No. 1 timing belt cover.
    2.  
    3. Install the timing belt rear plates.
    4.  
    5. Check that the timing marks of the camshaft timing pulleys and the timing belt rear plates are aligned. If not, turn the crankshaft exactly one revolution (360°) and align the marks.
    6.  
    7. Using a feeler gauge, measure the distance between the valve lifter and camshaft. Clearance should be 0.0060.010 inch (0.150.25mm) on the intake camshaft and 0.0100.014 inch (0.250.35mm) on the exhaust camshaft.
    8.  

  8.  
  9. Clean all old sealer from the four semi-circular camshaft plugs. Apply a fresh bead of sealer to the center groove of the plugs and install the plugs to the cylinder head.
  10.  
  11. Clean all old sealer from the cylinder head covers. Apply fresh sealer at the joint where the camshaft front bearing cap meets the cylinder head cover sealing surface. Use new cylinder head cover gaskets. Make sure the seal washers under the bolt heads are in good condition. Install the cylinder head covers. Uniformly tighten the bolts in several passes with final torque to 53 inch lbs. (6 Nm).
  12.  
  13. Install the engine lift hangers, if removed and the oil dipstick and guide tube.
  14.  
  15. Install the rear and front water bypass assemblies using new gaskets. Tighten the nuts evenly and alternately to 156 inch lbs. (18 Nm). Attach the ECT sensor and water sender gauge connectors.
  16.  
  17. Install the water inlet housing assembly.
  18.  
  19. Install the upper and lower intake manifolds using the procedures found in this section. Use care to make sure the lower intake manifold gaskets are properly installed. Factory replacement gaskets should have white paint marks which should be facing upward. Align the port holes of the gasket and the cylinder head.
  20.  
  21. Using the identification tags made at disassembly, connect the following hoses to the intake manifold:

    The vacuum hose from the fuel pressure regulator.
     
    The PCV hose from the PCV valve on the left side cylinder head.
     
    The EVAP hose from the charcoal canister from the VSV for the EVAP system.
     
    The EVAP hose from the charcoal canister from the EVAP pipe on the intake manifold.
     
    The power steering vacuum switch lines from the intake manifold.
     
    The brake booster vacuum line.
     

  22.  
  23. Using the identification tags made at disassembly, attach the following electrical connectors:

    Throttle Position (TP) sensor
     
    Accelerator pedal position sensor connector
     
    Throttle control motor connector
     
    VSV connector for the EVAP system
     
    Eight fuel injector connectors
     
    Engine Coolant Temperature (ECT) sensor
     
    Water sender gauge connector
     
    Eight ignition coil connectors
     
    Two heated oxygen sensor connectors
     

  24.  
  25. Connect the fuel lines.
  26.  
  27. If not done so earlier, install the timing belt rear plates and tighten the bolts to 66 inch lbs. (7.5 Nm).
  28.  
  29. Install the throttle body.
  30.  
  31. Install the ignition coils to their proper spark plug.
  32.  
  33. Install the automatic transmission fluid dipstick and fill tube.
  34.  
  35. Connect the front exhaust pipe.
  36.  
  37. install the power steering pump.
  38.  
  39. Install the camshaft position sensor.
  40.  
  41. Install the camshaft timing pulleys and the timing belt, using the procedure found in this section.
  42.  
  43. Because the engine oil can become contaminated with coolant when a cylinder head is removed, change the oil and install a new filter.
  44.  
  45. Refill the engine with coolant.
  46.  
  47. Start the engine and check for leaks and abnormal noises.
  48.  

 
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