Installation

2UZ-FE ENGINE MECHANICAL: CYLINDER HEAD:

INSTALLATION

1. INSTALL NO. 2 CYLINDER HEAD GASKET

(a) Place a new cylinder head gasket in position on the cylinder block.
HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank.
NOTE: Be careful of the installation direction.

(b) Place the cylinder head in position on the cylinder head gasket.
2. INSTALL CYLINDER HEAD GASKET

(a) Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.
(b) Install the cylinder head with the exhaust manifold to the cylinder block.
HINT:
- The cylinder head bolts are tightened in 2 progressive steps.
- If any cylinder head bolt is broken or deformed, replace it.

(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(d) Install the plate washer to the cylinder head bolt.

(e) Install and uniformly tighten the 10 cylinder head bolts, and plate washers, in the order shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
NOTE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(f) Mark the front of the cylinder head bolt head with paint.
(g) Retighten the cylinder head bolts by 90° in the order shown.
(h) Retighten the cylinder head bolts by an additional 90°.
(i) Check that the painted mark is now at a 180° angle to front.
5. INSTALL FRONT EXHAUST PIPE
(a) Place a new gasket to the front exhaust pipe.
(b) Install the 2 nuts and front exhaust pipe.
Torque: 62 Nm (632 kgf-cm, 46 ft-lbf)
6. INSTALL REAR TIMING BELT PLATE LH
(a) Install the bolt and rear timing belt plate LH.
Torque: 7.5 Nm (80 kgf-cm, 66 ft-lbf)
7. INSTALL NO. 2 REAR TIMING BELT PLATE LH
(a) Install the 2 bolts and No. 2 rear timing belt plate LH.
Torque: 7.5 Nm (80 kgf-cm, 66 ft-lbf)
8. INSTALL REAR TIMING BELT PLATE RH
(a) Install the timing belt plate with the bolt and stud bolt.
Torque: 7.5 Nm (80 kgf-cm, 66 ft-lbf)
9. INSTALL NO. 2 REAR TIMING BELT PLATE RH
(a) Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 ft-lbf)
10. INSTALL WATER BY-PASS JOINT RR Installation

11. INSTALL NO. 2 AIR SWITCHING VALVE Installation

12. INSTALL WATER BY-PASS JOINT FR Installation

13. INSTALL WATER INLET HOUSING Installation

14. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Install a new O-ring to the water by-pass pipe.
(b) Apply soapy water to the O-ring.
(c) Push in the water by-pass pipe end into the pipe hole of the water pump.
(d) Install the water by-pass pipe with the bolt.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)
15. INSTALL INTAKE MANIFOLD ASSEMBLY Installation

16. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O-ring to the oil level gauge guide.
(b) Install the oil level gauge guide with the bolt.
Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
17. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
(a) Install the transmission oil filler tube sub-assembly with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
18. INSTALL CAMSHAFT (for LH Side)
(a) Install the camshaft (for LH side) Installation.
19. INSTALL CAMSHAFT (for RH Side)
(a) Install the camshaft (for RH side) Installation.
20. INSTALL TIMING BELT
HINT: Installation