Installation Of Cylinder Head

(See page EM-97) 1. INSTALL CYLINDER HEAD

A. Place cylinder head on cylinder block

(a) Place a new cylinder head gasket in position on the cylinder block.

NOTICE: Be careful of the installation direction.

(b) Place the cylinder head in position on the cylinder head gasket.

B. Install cylinder head bolts HINT:

• The cylinder head bolts are tightened in two progressive steps (steps(b)and (d)).

• If any cylinder head bolt is broken or deformed, replace it.

(a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

(b) Using SST, install and uniformly tighten the ten cylinder head bolts in several passes in the sequence shown.

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If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

(c) Mark the front of the cylinder head bolt head with paint.

1kz Torque Settings For Head

(d) Retighten the cylinder head bolts 90° in the numerical order shown.

(e) Check that the painted mark is now at a 90° angle to front.

2. INSTALL SPARK PLUG TUBES

(a) Clean the cylinder head tube holes of any residual adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline.

(b) Screw the threads of the spark plug tube coated with adhesive into the cylinder head.

(c) Using the spark plug tube nut and a 30 mm socket wrench, tighten the spark plug tubes.

3. ASSEMBLE EXHAUST CAMSHAFT

(a) Mount the hexagonal wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.

(b) Install the following parts:

(1) Camshaft gear spring

(2) Camshaft sub-gear

(3) Wave washer

HINT: Align the pins on the gears with the spring ends.

(c) Using snap ring pliers, install the snap ring.

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(d) Insert a service bolt (A) into the service hole of the camshaft sub-gear.

(e) Using a screwdriver, align the holes of the camshaft main gear and sub-gear by turning the camshaft sub-gear clockwise, and install a service bolt (B).

NOTICE: Be careful not to damage the camshaft.

4. INSTALL CAMSHAFTS

NOTICE: 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 cylinder 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.

1999 Toyota Camry Timing Marks

A. Install intake camshaft

(a) Apply MP grease to the thrust portion of the camshaft.

(b) Place the intake camshaft at 80 - 115° BTDC of camshaft angle on the cylinder head.

HINT: The above angle allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.

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Seal Packing

(c) Apply seal packing to the No.1 bearing cap as shown.

Seal packing: Part No. 08826-00080 or equivalent

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(d) Install the bearing caps in their proper locations.

(e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

(f) Install and uniformly tighten the ten bearing cap bolts in several passes in the sequence shown.

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(g) Apply MP grease to a new oil seal lip.

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(h) Using SST, tap in the oil seal. SST 09223-46011

B. Install exhaust camshaft

(a) Set the knock pin of the intake camshaft at 10 - 45° BTDC of camshaft angle.

HINT: The above angle allows the No.2and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.

2000 Toyota Rav4 Timing MarksCruiser Front Body Diagram

(b) Apply MP grease to the thrust portion of the camshaft.

(c) Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks on each gear.

(d) Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.

NOTICE: There are also assembly reference marks on each gear as shown in the illustration. Do not use these marks.

(e) Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals.

NOTICE: It is very important to replace the camshaft in the bearing journals evenly while tightening bearing caps in the subsequent steps.

(f) Install the bearing caps in their proper location.

(g) Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts.

(h) Install and uniformly tighten the ten bearing cap bolts in several passes, in the sequence shown.

Valves Adjust Toyota Carina

5. CHECK AND ADJUST VALVE CLEARANCE (See page EM-16)

Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance.

Valve clearance (Cold):

Intake 0.19 - 0.29 mm (0.007 - 0.011 in.) Exhaust 0.28-0.38 mm (0.011 -0.015 in.)

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6. INSTALL SEMI-CIRCULAR PLUGS

(a) Remove any old packing (FIPG) material.

(b) Apply seal packing to the semi-circular plug grooves.

Seal packing: Part No. 08826-00080 or equivalent

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(c) Install the two semi-circular plugs to the cylinder head.

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7. INSTALL CYLINDER HEAD COVER

(a) Remove any old packing (FIPG) material.

(b) Apply seal packing to the cylinder head as shown in the figure.

Seal packing: Part No. 08826-00080 or equivalent em9086

1997 Toyota Camry Seal Part Name Figures

(c) Install the gasket to the head cover.

(d) Install the head cover with the four grommets and nuts.

HINT: Install the grommets so that its markings are as shown in the illustration. Then install the grommet to its original position.

Corolla Oil Pressure Switch

8. INSTALL OIL PRESSURE SWITCH

Apply adhesive to two or three threads.

Adhesive: Part No. 08833-00080, THREE BOND 1324 or equivalent

9. INSTALL RH FRONT ENGINE HANGER

Install the engine hanger with the two bolts. Torque: 250 kg-cm (18 ft-lb, 25 N-m)

10. INSTALL LH FRONT ENGINE HANGER

Install the engine hanger with the bolt. Torque: 250 kg-cm (18 ft-lb, 25 N-m)

11. INSTALL NO.3 TIMING BELT COVER

Install the timing belt cover with the four bolts. Torque: 80 kg-cm (69 in.-lb, 7.8 N-m)

12. INSTALL NO.1 IDLER PULLEY AND TENSION SPRING (See step 4 on page EM-55)

13. INSTALL CAMSHAFT TIMING PULLEY (See steps 9 to 17 on pages EM-56 to 59)

14. INSTALL INJECTOR AND DELIVERY PIPE (See steps 1 and 3 to 6 on pages FI-125 to 127)

Mr2 Alternator Wiring

Alternator Wire

15. INSTALL INTAKE MANIFOLD

(a) Install a new gasket and the intake manifold with the six bolts and two nuts.

(b) Install the manifold stay with the two bolts. Torque:

12 mm head bolt 195 kg-cm (14 ft-lb, 19 N-m) 14 mm head bolt 425 kg-cm (31 ft-lb, 42 N-m)

(c) Connect the two wire clamps to the wire bracket.

(d) Connect the wire clamp to the accelerator bracket.

Alterntor Connector

Alternator Wire

(e) Connect the alternator connector and wire.

16. INSTALL EGR VSV

(a) Install the VSV with the bolt.

(b) Connect the VSV connector.

16. INSTALL EGR VSV

(a) Install the VSV with the bolt.

(b) Connect the VSV connector.

17. INSTALL FUEL PRESSURE VSV

(a) Install the VSV with the two bolts. Connect the ground strap.

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(b) Connect the following hoses:

(1) Vacuum hose from fuel pressure regulator

(2) Vacuum hose from intake manifold

(c) Connect the VSV connector.

Toyota Carina Egr Valve Cleaning

18. INSTALL EGR VALVE AND VACUUM MODULATOR

(a) Install a new gasket and the EGR valve with the union nut and two bolts.

Torque:

Union nut 600 kg-cm (43 ft-lb, 59 N-m) Bolt 130 kg-cm (9 ft-lb, 13 N-m)

(b) Install the EGR modulator to the clamp.

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(c) Connect the following hoses:

(1) Vacuum hose (from Q port of EGR vacuum modulator) to G port of EGR VSV

(2) Vacuum hose (from EGR valve) to E port of EGR VSV

(3) Vacuum hose to charcoal canister

Connect the EGR gas temperature sensor connector.

19. INSTALL COLD START INJECTOR (See steps 1 and 3 on page FI-104)

20. INSTALL COLD START INJECTOR PIPE (See step 2 on page FI-104)

21. INSTALL THROTTLE BODY

(See steps 2 to 5 on pages FI-146 and 147)

22. INSTALL WATER BY-PASS PIPE

(a) Install a new O-ring to the by-pass pipe.

(b) Apply soapy water on the O-ring.

(c) Install a new gasket and the by-pass pipe with the two nuts and two bolts.

(d) Connect the following hoses:

(1) ISC water by-pass hose

(2) Heater water hose

(3) Two oil cooler water by-pass hoses

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(e) Install the oil cooler heat protector with the bolt and two nuts.

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23. INSTALL WATER OUTLET AND HOUSING

(a) Install a new gasket, the water outlet and housing assembly with the two bolts.

(b) Connect the following hoses:

(1) Water by-pass pipe hose

(2) EVAP BVSV vacuum hose (from P port of throttle body)

(3) EVAP BVSV vacuum hose (from charcoal canister)

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(4) Water filler hose

(5) Radiator hose

(6) Heater water hose

(7) ISC water by-pass hose

(c) Install the fuel inlet hose (with the return tube) from the water outlet and cylinder head.

(d) Connect the following connectors:

• Water temperature sender gauge connector

• Water temperature sensor connector

• Cold start injector time switch connector

2000 Avalon Catalytic Converter

24. ASSEMBLE EXHAUST MANIFOLD AND CATALYTIC CONVERTER

Assemble the following parts:

(1)

Catalytic converter

(2)

Cushion

(3)

Retainer

(4)

Gasket

(5)

Exhaust manifold

(6)

Three bolts and two nuts

Torque:

300 kg-cm (22 ft-lb, 29 N m)

(7)

Two converter heat insulators

(8)

Eight bolts

(9)

Manifold lower heat insulator

(10) Five bolts

(10) Five bolts

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25. INSTALL EXHAUST MANIFOLD AND CATALYTIC CONVERTER ASSEMBLY

(a) Install a new gasket the exhaust manifold and catalytic converter assembly with the new six nuts.

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(b) Install the catalytic converter stay with the two bolts and two new nuts.

(c) Install the manifold upper heat insulator with the six bolts.

(d) Connect the oxygen sensor (main) connector.

Connect the sub-oxygen sensor connector.

26. INSTALL FRONT EXHAUST PIPE (See step 15 on page EM-197)

27. INSTALL DISTRIBUTOR

28. CONNECT VACUUM HOSES

(a) A/C VSV vacuum hose from intake manifold

(b) A/C VSV air hose from ISC valve

1991 Toyota Mr2 Throttle Cable Assembly

(c) Vacuum sensor hose from intake manifold

1991 Toyota Mr2 Throttle Cable Assembly

(d) Brake booster vacuum hose from intake manifold 29. CONNECT GROUND STRAP CONNECTOR

30. INSTALL AIR CLEANER CAP (See page 35 on page EM-226)

31. INSTALL CRUISE CONTROL ACTUATOR (w/ CRUISE CONTROL SYSTEM) AND ACCELERATOR LINKAGE (See step 33 on page EM-225)

32. INSTALL ACCELERATOR CABLE, AND ADJUST IT

CONNECT THROTTLE CABLE, AND ADJUST IT

34. INSTALL SUSPENSION UPPER BRACE (See step 36 on page EM-226)

35. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY

36. FILL WITH ENGINE COOLANT (See page CO-7)

Capacity (w/ Heater):

37. START ENGINE AND CHECK FOR LEAKS

38. ADJUST IGNITION TIMING

(See steps 9 to 13 on pages IG-21 and 22)

Ignition timing:

10"BTDC @ idle

(w/ Terminals TE1 and E1 connected)

39. INSTALL ENGINE HOOD SIDE PANELS

40. INSTALL ENGINE UNDER COVER

41. PERFORM ROAD TEST

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  • Porro
    How connect the hose of egr valve camry 1997?
    8 years ago

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