Toyota Tacoma 2002-06

Cylinder Head

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Removal & Installation



1gr-FE Engine
2wd-Bank 1

NOTE
The engine must first be removed from the vehicle.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system pressure.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  8.  
  9. Remove the hood subassembly.
  10.  
  11. Remove the engine from the vehicle and position it in a suitable holding fixture.
  12.  
  13. Remove the timing chain or belt cover subassembly.
  14.  
  15. Remove the chain subassembly.
  16.  
  17. Remove the number one cool inlet. Remove the front exhaust pipe assembly. Remove the three bolts and remove the exhaust manifold stay.
  18.  
  19. Disconnect the air fuel ratio sensor connector. Remove the six nuts; remove the exhaust manifold and gasket.
  20.  
  21. Disconnect the number one fuel pipe subassembly. Disconnect the number two fuel pipe subassembly.
  22.  
  23. Disconnect the fuel injector connectors. Remove the ten intake manifold retaining bolts. Remove the intake manifold from the engine.
  24.  
  25. Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the two bolts and four nuts, and then remove the water bypass joint RR and two gaskets. Remove the O-ring from the water outlet hose.
  26.  
  27. While raising the chain tensioner number two, insert a 0.039 inch diameter pin, into the hole. Hold the hexagonal portion of the camshaft in place, using a wrench.
    NOTE
    Be careful not to damage the cylinder head and valve lifter with the wrench.

  28.  
  29. Remove the two bolts. Remove the camshaft timing gear, camshaft timing gear assembly and timing chain number two.
    NOTE
    Do not disassemble the camshaft timing gear assembly.

  30.  
  31. Remove the bolt and then remove the chain tensioner number two.
  32.  
  33. Remove the camshafts.
  34.  
  35. Remove the two bolts. Separate the two ground cables.
  36.  
  37. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    NOTE
    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.

  38.  
  39. Lift the cylinder head from the dowels on the cylinder block and remove it from the engine.

    Click image to see an enlarged view

    Fig. Bank 1 cylinder head bolt loosening sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head gasket sealant application-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1 cylinder head gasket positioning-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1 cylinder head bolt torque sequence-4.0L engine

  40.  

To install:

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage. Remove any old packing material. Be careful not to drop any oil on the contact surfaces of the cylinder head or engine block.
  2.  
  3. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder head gasket. Bead width should be 0.098-0.118 inch.
    NOTE
    Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing.

  4.  
  5. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
    NOTE
    Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.

  6.  
  7. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
    NOTE
    Replace defective bolts, as required.

  8.  
  9. Continue the installation in the reverse of the removal procedure.
  10.  
  11. Be sure to fill the cooling system with the proper grade and type engine coolant.
  12.  
  13. Be sure to fill the engine oil with the proper grade and type oil.
    NOTE
    Do not fill the engine with oil for at least four hours after the cylinder head has been installed.

  14.  
  15. Start the engine and check for leaks. Correct as required.
  16.  

2wd-Bank 2

NOTE
The engine must first be removed from the vehicle.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system pressure.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  8.  
  9. Remove the hood subassembly.
  10.  
  11. Remove the engine from the vehicle and position it in a suitable holding fixture.
  12.  
  13. Remove the timing chain or belt cover subassembly.
  14.  
  15. Remove the chain subassembly.
  16.  
  17. Remove the number one cool inlet. Remove the number two front exhaust pipe assembly. Remove the three bolts and remove the exhaust manifold stay.
  18.  
  19. Disconnect the air fuel ratio sensor connector. Remove the six nuts; remove the exhaust manifold and gasket.
  20.  
  21. Disconnect the fuel injector connectors. Remove the ten intake manifold retaining bolts. Remove the intake manifold from the engine.
  22.  
  23. Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the two bolts and four nuts, and then remove the water bypass joint RR and two gaskets. Remove the O-ring from the water outlet hose.
  24.  
  25. Remove the two bolts and then remove the chain vibration damper number one.
  26.  
  27. While pushing down on chain tensioner number two, insert a 0.039 inch diameter pin, into the hole. Hold the hexagonal portion of the camshaft in place, using a wrench.
    NOTE
    Be careful not to damage the cylinder head and valve lifter with the wrench.

  28.  
  29. Remove the two bolts. Remove the camshaft timing gear, camshaft timing gear assembly and timing chain number two.
    NOTE
    Do not disassemble the camshaft timing gear assembly.

  30.  
  31. Remove the bolt and then remove the chain tensioner number three.
  32.  
  33. Remove the camshafts.
  34.  
  35. Remove the two bolts. Separate the two ground cables.
  36.  
  37. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    NOTE
    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.

  38.  
  39. Lift the cylinder head from the dowels on the cylinder block and remove it from the engine.
  40.  

To install:

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage. Remove any old packing material. Be careful not to drop any oil on the contact surfaces of the cylinder head or engine block.
  2.  
  3. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder head gasket. Bead width should be 0.098-0.118 inch.
    NOTE
    Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing.

  4.  
  5. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
    NOTE
    Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.

  6.  
  7. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
    NOTE
    Replace defective bolts, as required.

  8.  
  9. Continue the installation in the reverse of the removal procedure.
  10.  
  11. Be sure to fill the cooling system with the proper grade and type engine coolant.
  12.  
  13. Be sure to fill the engine oil with the proper grade and type oil.
    NOTE
    Do not fill the engine with oil for at least four hours after the cylinder head has been installed.

  14.  
  15. Start the engine and check for leaks. Correct as required.

    Click image to see an enlarged view

    Fig. Bank 2 recessed cylinder head bolt loosening sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 cylinder head bolt loosening sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 cylinder head gasket positioning-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 Cylinder head bolt torque sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 recessed cylinder head bolt torque sequence-4.0L engine

  16.  

4wd And Prerunner-Bank 1
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system pressure.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  8.  
  9. Remove the power steering gear assembly.
  10.  
  11. Remove the front differential carrier assembly.
  12.  
  13. Remove the timing chain or belt cover subassembly.
  14.  
  15. Remove the chain subassembly.
  16.  
  17. Remove the number one cool inlet. Remove the front exhaust pipe assembly. Remove the three bolts and remove the exhaust manifold stay.
  18.  
  19. Disconnect the air fuel ratio sensor connector. Remove the six nuts; remove the exhaust manifold and gasket.
  20.  
  21. Disconnect the number one fuel pipe subassembly. Disconnect the number two fuel pipe subassembly.
  22.  
  23. Disconnect the fuel injector connectors. Remove the ten intake manifold retaining bolts. Remove the intake manifold from the engine.
  24.  
  25. Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the two bolts and four nuts, and then remove the water bypass joint RR and two gaskets. Remove the O-ring from the water outlet hose.
  26.  
  27. While raising the chain tensioner number two, insert a 0.039 inch diameter pin, into the hole. Hold the hexagonal portion of the camshaft in place, using a wrench.
    NOTE
    Be careful not to damage the cylinder head and valve lifter with the wrench.

  28.  
  29. Remove the two bolts. Remove the camshaft timing gear, camshaft timing gear assembly and timing chain number two.
    NOTE
    Do not disassemble the camshaft timing gear assembly.

  30.  
  31. Remove the bolt and then remove the chain tensioner number two.
  32.  
  33. Remove the camshafts.
  34.  
  35. Remove the two bolts. Separate the two ground cables.
  36.  
  37. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    NOTE
    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.

  38.  
  39. Lift the cylinder head from the dowels on the cylinder block and remove it from the engine.
  40.  

To install:

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage. Remove any old packing material. Be careful not to drop any oil on the contact surfaces of the cylinder head or engine block.
  2.  
  3. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder head gasket. Bead width should be 0.098-0.118 inch.
    NOTE
    Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing.

  4.  
  5. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
    NOTE
    Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.

  6.  
  7. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
    NOTE
    Replace defective bolts, as required.

  8.  
  9. Continue the installation in the reverse of the removal procedure.
  10.  
  11. Be sure to fill the cooling system with the proper grade and type engine coolant.
  12.  
  13. Be sure to fill the engine oil with the proper grade and type oil.
    NOTE
    Do not fill the engine with oil for at least four hours after the cylinder head has been installed.

  14.  
  15. Start the engine and check for leaks. Correct as required.
  16.  

4wd And Prerunner-Bank 2
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system pressure.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  8.  
  9. Remove the power steering gear assembly.
  10.  
  11. Remove the front differential carrier assembly.
  12.  
  13. Remove the timing chain or belt cover subassembly.
  14.  
  15. Remove the chain subassembly.
  16.  
  17. Remove the number one cool inlet. Remove the number two front exhaust pipe assembly. Remove the three bolts and remove the exhaust manifold stay.
  18.  
  19. Disconnect the air fuel ratio sensor connector. Remove the six nuts; remove the exhaust manifold and gasket.
  20.  
  21. Disconnect the fuel injector connectors. Remove the ten intake manifold retaining bolts. Remove the intake manifold from the engine.
  22.  
  23. Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the two bolts and four nuts, and then remove the water bypass joint RR and two gaskets. Remove the O-ring from the water outlet hose.
  24.  
  25. Remove the two bolts and then remove the chain vibration damper number one.
  26.  
  27. While pushing down on chain tensioner number two, insert a 0.039 inch diameter pin, into the hole. Hold the hexagonal portion of the camshaft in place, using a wrench.
    NOTE
    Be careful not to damage the cylinder head and valve lifter with the wrench.

  28.  
  29. Remove the two bolts. Remove the camshaft timing gear, camshaft timing gear assembly and timing chain number two.
    NOTE
    Do not disassemble the camshaft timing gear assembly.

  30.  
  31. Remove the bolt and then remove the chain tensioner number three.
  32.  
  33. Remove the camshafts.
  34.  
  35. Remove the two bolts. Separate the two ground cables.
  36.  
  37. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    NOTE
    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.

  38.  
  39. Lift the cylinder head from the dowels on the cylinder block and remove it from the engine.
  40.  

To install:

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage. Remove any old packing material. Be careful not to drop any oil on the contact surfaces of the cylinder head or engine block.
  2.  
  3. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder head gasket. Bead width should be 0.098-0.118 inch.
    NOTE
    Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing.

  4.  
  5. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
    NOTE
    Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.

  6.  
  7. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
    NOTE
    Replace defective bolts, as required.

  8.  
  9. Continue the installation in the reverse of the removal procedure.
  10.  
  11. Be sure to fill the cooling system with the proper grade and type engine coolant.
  12.  
  13. Be sure to fill the engine oil with the proper grade and type oil.
    NOTE
    Do not fill the engine with oil for at least four hours after the cylinder head has been installed.

  14.  
  15. Start the engine and check for leaks. Correct as required.
  16.  

2RZ-FE & 3RZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Air cleaner cap
     
    Mass Air Flow (MAF) meter and resonator
     
    Accelerator cable from the throttle body, if equipped with a manual transmission
     
    Accelerator and throttle cables from the throttle body, if equipped with an automatic transmission
     
    Cruise control cable from the actuator, if equipped with cruise control
     
    Intake air connector
     
    Air hose for Idle Air Control (IAC)
     
    Vacuum sensing hose
     
    Wire clamp for the engine wiring harness
     
    Oil dipstick guide
     
    Power steering belt
     
    Power steering pulley pump and bracket
     
    Positive Crankcase Ventilation (PCV) hoses
     
    Distributor
     
    Spark plug wires from the spark plugs
     
    Engine wiring harness
     
    Air conditioning compressor, if equipped with air conditioning
     
    Oil pressure sensor
     
    Engine Coolant Temperature (ECT) sensor connector
     
    ECT sender gauge connector
     
    Exhaust Gas Recirculation (EGR) gas temperature sensor connector
     
    Vacuum Switching Valve (VSV) connector
     
    2 vacuum hose from the VSV
     
    Ground strap from the cowl top panel
     
    Engine wiring harness from the air intake chamber
     
    Throttle Position (TP) sensor connector
     
    IAC valve connector
     
    Crankshaft Position (CKP) sensor connector
     
    Knock Sensor (KS) connector
     
    Data Link Connector 1 (DLC1) from the bracket
     
    Engine wiring harness clamp
     
    EGR pipe
     
    Intake chamber stay
     
    Air intake chamber assembly
     

  10.  
  11. Disconnect the following hoses:

    Evaporative Emissions (EVAP) hose from the throttle body
     
    Brake booster vacuum hose from the union
     
    Water bypass hose from the water bypass pipe
     
    Water bypass hose from the cylinder head rear cover
     

  12.  
  13. Remove or disconnect the following:

    Injector connectors
     
    Fuel inlet pipe
     
    Hoses and the fuel return pipe
     
    Delivery pipe and injectors
     
    Intake manifold
     
    Front exhaust pipe
     
    Exhaust manifold and gasket
     
    Water outlet
     
    Cylinder head rear cover
     
    Spark plugs
     
    Front engine hanger
     
    Engine wiring harness brackets
     
    Cylinder head cover
     

  14.  
  15. Set No. 1 cylinder to Top Dead Center (TDC) of the compression stroke. The groove on the crankshaft pulley should align with the 0 mark on the timing chain cover and the timing marks (1 and 2 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.  
  17. Remove or disconnect the following:

    Chain tensioner and gasket
     
    Camshaft timing gear
     
    Exhaust camshafts
     

  18.  
  19. Remove the intake camshaft, as follows:


    1. Uniformly, loosen and remove the bearing cap bolts in the reverse order of the tightening in several passes, in sequence.
    2.  
    3. Remove the bearing caps and camshaft. Make a note of the bearing cap positions for proper installation.
      NOTE
      If the camshaft is not being lifted out straight and level, reinstall the No. 3 bearing cap with the 2 bolts. Then, alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.

    4.  

  20.  
  21. Remove or disconnect the following:
    NOTE
    Arrange the valve lifters and shims in correct order.



    Valve lifters and shims
     



    Cylinder head, by uniformly loosen and remove the cylinder head bolts in the reverse order of the tightening, in sequence, using several passes
     

  22.  

To install:

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage.
  2.  
  3. Apply sealant (PN 08826-00080) to the 2 locations. Place a new head gasket on the block and install the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-2.4L and 2.7L (3RZ-FE/M) engines

  4.  
  5. Install the cylinder head as follows:


    1. Lightly coat the cylinder head bolts with engine oil.
    2.  
    3. Install the bolts and tighten, in several passes, in the sequence. Tighten all bolts to 29 ft. lbs. (39 Nm).
    4.  
    5. Mark the front of the bolt with paint and retighten bolts 90 degrees in the proper sequence.
    6.  
    7. Retighten an additional 90 degrees. Check that the painted mark is now facing rearward.
    8.  

  6.  
  7. Install or connect the following:

    Tighten the 2 front mounting bolts to 15 ft. lbs. (21 Nm).
     
    Valve lifters and shims in their proper locations. Check that the valve lifter rotates smoothly by hand.
     
    Intake and exhaust camshafts
     

  8.  
  9. 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 (1 and 2 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).
  10.  
  11. Install the timing gear, as follows:
    1. Place the gear over the straight pin of the intake camshaft.
    2.  
    3. Hold the intake camshaft with a wrench. Install and tighten the bolt to 54 ft. lbs. (74 Nm).
    4.  
    5. Hold the exhaust camshaft and install the bolt and distributor gear. Tighten the bolt to 34 ft. lbs. (46 Nm).
    6.  

  12.  
  13. Install or connect the following:

    Chain tensioner, using a new gasket (mark toward the front)
     
    Recheck the valve timing
     
    Check and adjust the valve clearance
     
    Spark plugs
     
    Semi-circular plug
     

  14.  
  15. Recheck the engine for proper valve timing.
  16.  
  17. Install or connect the following:

    Cylinder head cover, using a new gasket
     
    Engine wiring harness brackets
     
    Front engine hanger. Tighten the bolts to 30 ft. lbs. (42 Nm).
     
    Cylinder head rear cover. Tighten the bolts to 10 ft. lbs. (13 Nm).
     
    Water outlet, using a new gasket. Tighten the bolts to 14 ft. lbs. (20 Nm).
     
    Upper radiator hose
     
    Exhaust manifold. Tighten the bolts to 36 ft. lbs. (49 Nm).
     
    Remaining components
     
    Negative battery cable
     

  18.  
  19. Fill the engine and radiator with engine coolant.
  20.  
  21. Start the engine and check for leaks.
  22.  
  23. Check the ignition timing. Road test the vehicle for proper operation.
  24.  
  25. Recheck all fluid levels.
  26.  

2TR-FE Engine

NOTE
The engine must first be removed from the vehicle.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system pressure.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the hood subassembly.
  10.  
  11. Remove the engine from the vehicle and position it in a suitable holding fixture.
  12.  
  13. Remove the intake air connector. Remove the alternator.
  14.  
  15. Remove the number one exhaust manifold heat insulator. Remove the air switching valve assembly.
  16.  
  17. Remove the exhaust manifold.
  18.  
  19. Remove the belt tensioner assembly. Remove the number one idler pulley subassembly. Remove the idle pulley assembly and bracket.
  20.  
  21. Remove the crankshaft position sensor. Remove the camshaft position sensor.
  22.  
  23. Remove the number one intake manifold.
  24.  
  25. Remove the cylinder head cover. Remove the crankshaft pulley. Remove the oil gauge subassembly.
  26.  
  27. Remove the number two oil pan subassembly. Remove the oil strainer. Remove the oil pap subassembly.
  28.  
  29. Remove the timing chain cover. Remove the timing chain guide. Remove the number one chain tensioner assembly.
  30.  
  31. Remove the chain tensioner slipper. Remove the number one chain vibration damper. Remove the chain subassembly.
  32.  
  33. Remove the camshaft. Remove the valve rocker arms.
  34.  
  35. Remove the valve lash adjuster assembly.
  36.  
  37. Disconnect the water hoses. Disconnect the engine coolant temperature sensor wire. Remove the bolts and separate the wire from the harnesses. Remove the bolt, and then separate the wire harness bracket.
  38.  
  39. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    NOTE
    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-2.7L (2TR-FE) engine



    Click image to see an enlarged view

    Fig. Cylinder head gasket sealant application-2.7L (2TR-FE) engine



    Click image to see an enlarged view

    Fig. Cylinder head gasket positioning-2.7L (2TR-FE) engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-2.7L (2TR-FE) engine

  40.  

To install:

  1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage.
  2.  
  3. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder block upper side and cylinder head gasket upper side. Bead width should be 0.15-0.28 inch.
    NOTE
    Remove any oil from the contact surface. Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing. Do not fill the engine with oil for at least four hours.

  4.  
  5. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
    NOTE
    Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.

  6.  
  7. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
  8.  
  9. Continue the installation in the reverse of the removal procedure.
  10.  
  11. Be sure to fill the cooling system with the proper grade and type engine coolant.
  12.  
  13. Be sure to fill the engine oil with the proper grade and type oil.
    NOTE
    Do not fill the engine with oil for at least four hours after the cylinder head has been installed.

  14.  
  15. Start the engine and check for leaks. Correct as required.
  16.  

5vz-FE Engine


Click image to see an enlarged view

Fig. Cylinder head and related components-3.4L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the engine undercover.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Front exhaust pipe
     
    Air cleaner cap
     
    Mass Air Flow (MAF) meter and resonator
     

  12.  
  13. Disconnect the following cables:

    Actuator cable from the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with an automatic transmission
     
    Heater hose
     
    Upper radiator hose
     
    Power steering drive belt
     
    Air conditioning drive belt, by loosening the idle pulley nut and adjusting bolt
     
    Loosen the lockbolt, pivot bolt and adjusting bolt and the alternator drive belt
     
    No. 2 fan shroud by removing the 2 clips
     
    Fan with the fluid coupling and fan pulleys
     
    Power steering pump and move it aside without disconnecting the pump lines
     
    Compressor and move it aside without disconnecting the compressor lines, if equipped with air conditioning
     
    Air conditioning bracket, if equipped with air conditioning
     
    Spark plug wires with the ignition coils
     
    Spark plugs
     
    No. 2 timing belt cover
     

  14.  
  15. Remove the fan bracket, as follows:
    1. Remove the power steering adjusting strut by removing the nut.
    2.  
    3. Remove the fan bracket by removing the bolt and nut.
    4.  

  16.  
  17. Set the No. 1 cylinder at Top Dead Center (TDC) of the compression stroke.
    1. Turn the crankshaft pulley and align its groove with the timing mark 0 on 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 1 revolution (360 degrees).
    4.  

  18.  
  19. Remove the timing belt tensioner by alternately loosening the 2 bolts.
  20.  
  21. Remove the camshaft timing pulleys, as follows:
    1. Using Variable Pin Wrench Set tool 09960-10010, remove the pulley bolt, the timing pulley and the knock pin.
    2.  
    3. Remove the 2 timing pulleys with the timing belt.
    4.  

  22.  
  23. Remove or disconnect the following:

    Bolt and the No. 2 idler pulley
     
    Alternator
     

  24.  
  25. Remove the Exhaust Gas Recirculation (EGR) pipe and 2 gaskets, if equipped with an EGR valve
  26.  
  27. Remove the intake chamber stay as follows:
    1. Remove the oil filler tube and No. 1 throttle cable clamp by removing the bolt and 2 nuts.
    2.  
    3. Remove the intake chamber stay by removing the 2 bolts.
    4.  

  28.  
  29. Remove the following connectors:

    VSV connector for the fuel pressure control.
     
    Throttle position sensor
     
    IAC valve connector
     
    EGR valve gas temperature sensor, if equipped
     
    Vacuum Switching Valve (VSV) connector for the EGR valve, if equipped
     

  30.  
  31. Disconnect the following hoses:

    Positive Crankcase Ventilation (PCV) hoses
     
    Water bypass hoses.
     
    Air assist hose from the intake air connector
     
    2 vacuum sensing hoses from the VSV
     
    Evaporative Emissions (EVAP) hose
     
    Air hose, from the power steering
     
    Air hose from the air conditioning idle up valve, if equipped with air conditioning
     

  32.  
  33. Remove or disconnect the following:

    4 bolts, 2 nuts and the air intake chamber assembly
     
    Intake air connector
     

  34.  
  35. Disconnect the engine wiring harness from the intake manifold, as follows:

    Oil pressure sensor connector
     
    Crankshaft position sensor connector
     
    6 injector connectors
     
    Engine Coolant Temperature (ECT) sender gauge connector
     
    ECT sensor connector
     
    Knock (KS) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    3 engine wiring harness clamps
     
    3 bolts and the engine wiring harness from the cylinder head
     

  36.  
  37. Remove or disconnect the following:

    CMP sensor
     
    No. 3 (rear) timing belt cover, by removing the 6 bolts

    Click image to see an enlarged view

    Fig. Rear timing belt cover bolt locations-3.4L engine



    Click image to see an enlarged view

    Fig. Intake manifold bolt locations-3.4L engine

     



    Fuel pressure regulator
     
    Intake manifold assembly
     
    Power steering pump bracket
     
    Oil dipstick and guide
     
    Exhaust crossover pipe and gaskets, by removing the 6 nuts
     
    Left-hand exhaust manifold, by removing the heat insulator and 6 nuts
     
    Right-hand exhaust manifold, by removing the heat insulator and 6 nuts
     
    8 bolts, seal washers, cylinder head cover and gasket
     
    Both cylinder head covers
     
    Semi-circular plugs
     
    Right exhaust camshafts
     
    Right-hand intake camshaft
     
    Left exhaust camshafts

    Click image to see an enlarged view

    Fig. Drive gear service bolt (right side)-3.4L engine



    Click image to see an enlarged view

    Fig. Aligning the timing mark (1 dot mark) of the left camshafts-3.4L engine



    Click image to see an enlarged view

    Fig. Drive gear service bolt (left side)-3.4L engine

     



    Left-hand intake camshaft
     
    Valve lifters and shims from the cylinder head; arrange the valve lifters and shims in correct order
     

  38.  
  39. Remove the cylinder heads, as follows:

    Bolt and disconnect the ground strap
     
    Cylinder head (recessed head) bolt on each cylinder head, using an 8mm hexagon wrench; then repeat for the other side
     
    8 cylinder head (12-pointed head) bolts on each cylinder head, by loosening the bolts in several passes and in the reverse order of the tightening sequence
     
    16 cylinder head bolts and plate washers.
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head recessed bolts-3.4L engine

     

  40.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.4L engine

  1. Clean all surfaces.
  2.  
  3. Install or connect the following:

    New cylinder head gaskets
     
    Cylinder heads
     

  4.  
  5. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  6.  
  7. Tighten the cylinder head bolts, in sequence, using several passes, as follows:

    Step 1: 25 ft. lbs. (34 Nm)
     
    Step 2: Mark the front of the cylinder head bolt with paint
     
    Step 3: An additional 90 degrees
     
    Step 4: Check that the painted mark is now at a 90 degrees angle to the front
     

  8.  
  9. Install the recessed head cylinder head bolts, as follows:

    Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts
     
    Cylinder head bolt on each cylinder head, using a 8mm hexagon wrench; then, repeat for the other side, as shown. Tighten the bolts to 13 ft. lbs. (18 Nm).
     
    Bolt and the ground strap
     

  10.  
  11. Install or connect the following:
    NOTE
    Check that the valve lifter rotates smoothly by hand.



    Valve lifters and shims
     



    Camshafts

    Click image to see an enlarged view

    Fig. Aligning the right camshafts for installation-3.4L engine

     
    Check and adjust the valve clearance
     
    Semi-circular plugs
     
    Cylinder head covers. Tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).
     
    Exhaust manifolds, with new gaskets. Tighten the nuts to 30 ft. lbs. (40 Nm).
     
    Exhaust manifold heat insulators. Tighten the nuts to 71 inch lbs. (8 Nm).
     
    Exhaust crossover pipe. Tighten the nuts to 33 ft. lbs. (45 Nm).
     
    Alternator bracket. Tighten to 14 ft. lbs. (18 Nm).
     
    Oil dipstick and guide, using a new O-ring
     
    Power steering bracket. Tighten the fasteners to 14 ft. lbs. (18 Nm).
     
    New gaskets and the intake manifold assembly. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
     
    Intake manifold stay with the 2 bolts. Tighten the bolts to 14 ft. lbs. (18 Nm).
     
    Fuel inlet hose
     
    Fuel pressure regulator
     
    No. 3 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).
     
    CMP sensor. Tighten to 71 inch lbs. (8 Nm).
     
    Engine wiring harness
     

  12.  
  13. Install or connect the intake air connector, as follows:

    Intake manifold. Tighten the bolts and nuts to 14 ft. lbs. (19 Nm).
     
    DLC1 to the bracket on the intake manifold
     
    Ground strap to the intake manifold
     
    Brake booster vacuum hose to the intake air connector
     
    2 fuel return hoses
     
    Engine wiring harness to the intake manifold
     
    Idle up valve connector, if equipped with air conditioning
     

  14.  
  15. Install or connect the following:

    Air intake chamber assembly. Tighten the bolts and nuts to 14 ft. lbs. (18.5 Nm).
     
    Hoses
     

  16.  
  17. Attach the following connectors:
    NOTE
    Check that the pulley bracket moves smoothly.



    VSV connector for the fuel pressure control
     
    TP sensor connector
     
    IAC valve connector
     
    EGR gas temperature connector, if equipped with an EGR valve
     
    VSV connector, if equipped with an EGR valve
     
    Intake chamber stay
     
    New gaskets and the EGR pipe. Tighten the clamp nuts to 71 inch lbs. (8 Nm) and the EGR pipe nuts to 14 ft. lbs. (18 Nm).
     
    Alternator but do not tighten the bolts and nuts at this time.
     
    No. 2 timing belt idler. Tighten the bolt to 30 ft. lbs. (40 Nm).
     



    Left camshaft timing pulley
     

  18.  
  19. Set the No. 1 cylinder to TDC of the compression stroke, as follows:
    1. Turn the crankshaft pulley and align its groove with the timing mark 0 on the No. 1 timing belt cover.
    2.  
    3. Turn the camshaft, align the knock pin hole of the camshaft with the timing mark of the No. 3 timing belt cover.
    4.  
    5. Turn the camshaft timing pulley, align the timing marks of the camshaft timing pulley and the No. 3 timing belt cover.
    6.  

  20.  
  21. Connect the timing belt to the left camshaft timing pulley, as follows:
    1. Check that the installation mark on the timing belt is aligned with the end of the No. 1 timing belt cover.
    2.  
    3. Using Variable Pin Wrench Set 09960-01000, 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.
    4.  
    5. Align the timing marks of the left camshaft pulley and the No. 3 timing belt cover.
    6.  
    7. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft timing pulley.
    8.  

  22.  
  23. 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 No. 3 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.  

  24.  
  25. 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 1.5mm 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.  

  26.  
  27. Install the timing belt tensioner. Tighten the bolts alternately to 20 ft. lbs. (28 Nm).
  28.  
  29. Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
  30.  
  31. Check the valve timing.
  32.  
  33. Install or connect the following:

    Remaining components
     
    Negative battery cable
     

  34.  
  35. Fill the radiator with engine coolant.
  36.  
  37. Start the engine and check for leaks.
  38.  
  39. Check the ignition timing.
  40.  
  41. Install the engine undercover.
  42.  
  43. Road test the vehicle.
  44.  
  45. Recheck all fluid levels.
  46.  

 
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