Installation Of Cylinder Head

(See pages EM-61 and 62)

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.

SST 09043-38100

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

What Wavelength Precalculus

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

Retighten Torque

(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.

Outward

Outward

Outward

EM7869

INSTALL CAMSHAFTS

(a) Place the camshaft on the cylinder head with the No.1 cam lobe facing outward as shown.

EM7869

-—r Seal Packing

EM2252

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

Seal packing: Part No. 08826-00080 or equivalent

Camry Camshaft Bearing Cover

(c) Install the bearing caps in their proper locations. HINT: Each bearing cap has a number and front mark.

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

(e) Install and uniformly tighten the ten bearing cap bolts on one side in several passes in the sequence shown.

MP Grease

MP Grease

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

(g) Using SST, tap in the two camshaft oil seals. SST 09223-50010

3. ADJUST VALVE CLEARANCE (See page EM-11)

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

Valve clearance (Cold):

Intake 0.15 - 0.25 mm (0.006 - 0.010 in.) Exhaust 0.20 - 0.30 mm (0.008 - 0.012 in.)

INSTALL NO.3 TIMING BELT COVER

Install the No.3 belt cover with the five bolts. Torque: 90 kg-cm (78 in.-lb, 8.8 N-m)

INSTALL NO.1 IDLER PULLEY (See step 4 on page EM-35)

INSTALL CAMSHAFT TIMING PULLEYS (See steps 9 to 23 on pages EM-36 to 41 )

7. INSTALL CYLINDER HEAD COVER

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

Seal packing: Part No. 08826-00080 or equivalent

(b) Install the two gaskets to the head cover.

(c) Install the head cover with the twelve seal washers and screws. Uniformly tighten the screw in several passes.

8. INSTALL DELIVERY PIPE AND INJECTORS (See steps 2 to 5 on pages FI-117 and 118)

Oil Sending Unit CaterpillarToyota Mr2 Intake Manifold Removal

9. INSTALL T-VIS VALVE AND INTAKE MANIFOLD

(a) Place a new gasket the T-VIS valve and the other new gasket on the cylinder head.

(b) Install the intake manifold with the four bolts and three nuts. Uniformly tighten the bolts and nuts in several passes.

Vaccum Sensing Hose

Vaccum Sensing Hose

10. INSTALL ENGINE WIRE TO INTAKE MANIFOLD

(a) Install the engine wire clamp to the intake manifold with the two bolts.

(b) Connect the vacuum sensing hose to the intake manifold.

Toyota Mr2 Knock Sensor Harness

(c) Connect the alternator connector.

(d) Connect the knock sensor connector.

(e) Connect the ground strap with the bolt.

(f) Connect the injector connectors. (See step 6 on page FI-119)

(g) Install the two wire clamps to the mount bolts of the No.2 timing belt cover.

Vsv For Egr Rav4

11. INSTALL T-VIS VACUUM TANK, T-VIS VSV,

TURBOCHARGING PRESSURE VSV AND BRACKET

(a) Install the T-VIS vacuum tank, T-VIS VSV, tur-bocharging pressure VSV and bracket assembly with the two bolts.

Mr2 Tvis Picture

(b) Connect the following hoses:

(1) Vacuum hose (from T-VIS VSV) from T-VIS actuator

(2) Vacuum hose (from T-VIS vacuum tank) from intake manifold

(c) Connect the following connectors:

• Turbocharging pressure VSV connector

Mr2 3sfe Engine Inlet Manifold

12. INSTALL NO.1 AIR TUBE

(a) Install the air tube and wire bracket with the two bolts.

(b) Install the alternator wire clamp to the wire bracket.

(c) Connect the vacuum hose to turbocharging pressure VSV

13. INSTALL INTAKE MANIFOLD STAYS

(a) Install the manifold stay with the two bolts. Install the two manifold stays

(b) Install the alternator wire clamp to the wire bracket.

Oil Pressure Switch

Oil Pressure Switch

Mr2 Water Hoses Diagram

INSTALL WATER BY PASS PIPE

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

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

(c) Install a new gasket to the water pump.

(d) Install the water by-pass pipe with the two nuts and two bolts.

(e) Connect the following hoses:

(1) Water by-pass hose from cylinder block

(2) Water by-pass hoses from No.1 air tube

(3) Vacuum hose from turbocharging pressure

Heater water hose

INSTALL OIL COOLER

(See steps 2 to 4 on pages LU-21 and 22)

16. INSTALL OIL PRESSURE SWITCH

Apply adhesive to two or three threads.

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

17. INSTALL WATER OUTLET AND HOUSING

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

(b) Connect the following hoses:

(1) Water by-pass hose from water by-pass pipe

(2) Two EVAP VSV vacuum hoses

(3) Water filler hose

(4) Radiator hose

(5) Water by-pass pipe hose from ISC valve

(6) Heater water hose

Camry Water Bypass Pipe

(c) Install the fuel inlet hose with the bolt.

(d) Install the fuel return hose with the bolt.

(e) Connect the following connectors:

• Water temperature sender gauge connector

• Water temperature sensor

• Cold start injector time switch connector

18. INSTALL EGR VALVE AND PIPE

(a) Install two new gaskets, the EGR valve and pipe assembly with the four bolts.

Torque:

Intake manifold side

195 kg-cm (14 ft-lb, 19 Nm) Cylinder head side

(b) Connect the vacuum hose to the EGR valve.

19. INSTALL VACUUM PIPE

(a) Install the vacuum pipe with the bolt.

(b) Connect the vacuum hose to the vacuum pipe.

20. INSTALL EGR VACUUM MODULATOR AND VSV

(a) Install the EGR vacuum modulator and VSV assembly with the bolt.

Egr Vsv Instal Rav4

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EM9050

Avalon Egr Setup

(b) Connect the following hoses:

(1) Vacuum hose from EGR valve

(2) Vacuum hose from EGR vacuum modulator

(c) Connect the EGR VSV connector.

21. INSTALL LH ENGINE HANGER

Install the LH engine hanger with the two bolts. Torque:

12 mm head bolt 130 kg-cm (9 ft-lb, 13 Nm) 14 mm head bolt 195 kg-cm (14 ft-lb, 19 Nm)

22. INSTALL NO.2 AIR TUBE

(a) Install the No.2 air tube with the bolt.

(b) Connect the following hoses:

(1) Air hose from No.1 air tube

(2) Air hose from intake manifold

23. INSTALL DISTRIBUTOR

(See steps 1 to 7 on pages IG-16 and 17)

24. INSTALL EXHAUST MANIFOLD

(a) Install the heat insulator with the bolt and nut.

2002 Camry Exhaust Manifold Torque Specs

(b) Install a new gasket and the exhaust manifold with the seven nuts. Uniformly tighten the nuts in several passes.

25. INSTALL COLD START INJECTOR (See steps 1 to 3 on page FI-101)

26. INSTALL THROTTLE BODY

(See steps 2, 3 and 4 to 8 on pages FI-138 and 139)

27. INSTALL TURBOCHARGER

(See steps 5 to 11,17,18 and 21 on pages TC-16 to 19)

-New Gasket

-Retainer

-Cushion

28. INSTALL CATALYTIC CONVERTER

(a) Install the front heat insulator with the five bolts.

(b) Install the rear heat insulator with the four bolts.

-New Gasket

-Retainer

-Cushion

(c) Place the cushion, retainer and a new gasket on the catalytic converter.

(d) Install the catalytic converter with the three bolts and two nuts.

(e) Install the RH converter stay with the four bolts. Torque: 600 kg-cm (43 ft-lb, 59 N m)

(f) Install the LH converter stay with the three bolts. Torque: 600 kg-cm (43 ft-lb, 59 N m)

29. INSTALL FRONT EXHAUST PIPE

(See steps 18 and 19 on pages EM-174 and 175)

30. INSTALL INTERCOOLER

(See steps 2 to 5, 7, 8,10 and 11 on pages TC-23 to 25)

31. INSTALL RH FRONT ENGINE HANGER

Install the engine hanger with the three bolts. Torque: 400 kg-cm (29 ft-lb, 39 N m)

32. CONNECT HOSES

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

1996 Toyota Rav4 Vacuum Piping

(c) Turbocharging pressure sensor hose from intake manifold

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Responses

  • Isabella
    Where is the oil pressure switch on a mk2 toyota mr2?
    8 years ago
  • elsa
    How to install a oil pressure sensor on a toyota sequoia 2002?
    7 years ago

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