2NZ-FE ENGINE MECHANICAL  CYLINDER HEAD GASKET  INSTALLATION  


PROCEDURE

Hide 11101A 1.INSPECT CYLINDER HEAD SET BOLT

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Hide 11115 2.INSTALL CYLINDER HEAD GASKET

a.
A302801C02
0.479,1.927 0.708,1.927 false 0.531,0.708 0.719,0.542 false 0.51,1.677 0.75,1.792 false 2.865,1.104 3.01,1.281 false 3.01,1.313 3.323,1.469 0.313,0.156 10 false *1 0.375,1.573 0.688,1.729 0.313,0.156 10 false *2 0.375,0.698 0.688,0.854 0.313,0.156 10 false *a 0.292,1.865 0.604,2.021 0.313,0.156 10 false *b 0.385,0.094 0.542,0.292 0.156,0.198 10 false A 1.063,0.094 1.219,0.292 0.156,0.198 10 false A 2.042,0.594 2.333,0.76 0.292,0.167 10 false A-A 2.083,1.406 2.354,1.688 0.271,0.281 10 false *c
*1 Cylinder Head Gasket
*2 No. 1 Chain Vibration Damper
*a Apply enough seal packing so that it will spread to the inner side
*b Apply enough seal packing so that it will spread onto the No. 1 Chain Vibration Damper
*c 4.5 to 5.5 mm (0.177 to 0.217 in.)
V100145

Seal Packing Black


Apply seal packing to a new cylinder head gasket in the locations shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent


NOTICE:

Remove any oil from the cylinder block sub-assembly.



b.
A166936C01
0.76,0.344 1.073,0.542 0.313,0.198 10 false *a
*a Lot No.


Place the cylinder head gasket on the cylinder block sub-assembly with the Lot No. stamp facing upward.

NOTICE:
·

Remove any oil from the contact surfaces.

·

Check the mounting orientation of the cylinder head gasket.

·

Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the cylinder head gasket.




Hide 11101 3.INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT:

The cylinder head set bolts are tightened in 3 progressive steps.


a.

Place the cylinder head sub-assembly on the cylinder block sub-assembly.

NOTICE:
·

Make sure that no oil is on the contact surface of the cylinder head sub-assembly.

·

Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the cylinder head gasket with the bottom part of the cylinder head sub-assembly.




b.

Install the 10 plate washers to the 10 cylinder head set bolts.


c.

Apply a light coat of engine oil to the threads and under the heads of the 10 cylinder head set bolts.


d.
A328114N01
0.604,1.885 0.885,2.104 0.281,0.219 10 false 10 1.146,1.792 1.302,1.99 0.156,0.198 10 false 6 1.667,1.781 1.823,1.979 0.156,0.198 10 false 1 2.219,1.802 2.375,2 0.156,0.198 10 false 3 2.583,1.813 2.74,2.01 0.156,0.198 10 false 7 2.75,0.115 2.906,0.313 0.156,0.198 10 false 9 2.219,0.198 2.375,0.396 0.156,0.198 10 false 5 1.688,0.198 1.865,0.354 0.177,0.156 10 false 2 1.146,0.25 1.323,0.406 0.177,0.156 10 false 4 0.635,0.135 0.813,0.292 0.177,0.156 10 false 8

Step 1:

i.

Using an 8 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps, in the order shown in the illustration.

Torque:
29.4 N*m (300 kgf*cm, 22 ft.*lbf)

NOTICE:

Do not drop the plate washers into the cylinder head sub-assembly.




e.
A116959C02
1.406,1.323 1.01,1.563 false 2.75,2.979 2.969,2.76 false 2.208,2.979 2.208,2.667 false 1.698,2.979 1.896,2.656 false 1.156,2.99 1.156,2.688 false 0.615,2.99 0.302,2.76 false 0.604,3.625 0.406,3.854 false 1.156,3.635 1.156,3.917 false 1.667,3.635 1.583,3.906 false 2.208,3.635 2.208,3.906 false 2.75,3.615 3.01,3.833 false 0.938,0.677 1.25,0.854 0.313,0.177 10 false 90° 2.323,0.677 2.635,0.854 0.313,0.177 10 false 90° 0.865,1.531 1.052,1.708 0.188,0.177 10 false *a 0.208,2.615 0.365,2.792 0.156,0.177 10 false 8 1.135,2.5 1.292,2.677 0.156,0.177 10 false 4 1.906,2.469 2.063,2.646 0.156,0.177 10 false 2 2.177,2.458 2.333,2.635 0.156,0.177 10 false 5 3.01,2.615 3.167,2.792 0.156,0.177 10 false 9 0.25,3.833 0.427,4.01 0.177,0.177 10 false 10 1.125,3.948 1.281,4.125 0.156,0.177 10 false 6 1.51,3.938 1.667,4.115 0.156,0.177 10 false 1 2.177,3.927 2.333,4.104 0.156,0.177 10 false 3 3.042,3.813 3.198,3.99 0.156,0.177 10 false 7
*a Paint Mark


Step 2:

i.

Mark each cylinder head set bolt head with paint as shown in the illustration.


ii.

Tighten the cylinder head set bolts 90° in the order shown in step 1.



f.

Step 3:

i.

Tighten the cylinder head set bolts another 90° in the order shown in step 1.



g.

Check that the paint marks are now at a 180° angle to the front.


h.

Wipe off any excess seal packing that seeped out.


Hide 13506 6.INSTALL CHAIN SUB-ASSEMBLY

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Hide 13561 7.INSTALL NO. 1 CHAIN VIBRATION DAMPER

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Hide 13559 8.INSTALL CHAIN TENSIONER SLIPPER

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Hide 13540 9.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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Hide 44763A 10.INSTALL NO. 1 HOSE TO HOSE TUBE

a.

Install the No. 1 hose to hose tube with the 2 bolts.

Torque:
9.0 N*m (92 kgf*cm, 80 in.*lbf)


Hide 16268 11.INSTALL NO. 1 WATER BY-PASS PIPE

a.

Install a new gasket and the No. 1 water by-pass pipe with the 2 bolts and 2 nuts.

Torque:
9.0 N*m (92 kgf*cm, 80 in.*lbf)


Hide 87246 12.CONNECT OUTLET HEATER WATER HOSE

a.

Connect the outlet heater water hose to the No. 1 water by-pass pipe and slide the clip to secure it.


Hide 87245 13.CONNECT INLET HEATER WATER HOSE

a.

Connect the inlet heater water hose to the cylinder head sub-assembly and slide the clip to secure it.


Hide 44774E 14.CONNECT VACUUM BRAKE HOSE

a.

Connect the vacuum brake hose to the No. 1 hose to hose tube and slide the clip to secure it.


Hide 44774 16.CONNECT UNION TO CONNECTOR TUBE HOSE

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Hide 23250 17.INSTALL FUEL INJECTOR ASSEMBLY

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Hide 23291 18.INSTALL INJECTOR VIBRATION INSULATOR

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Hide 23807V 19.INSTALL NO. 1 DELIVERY PIPE SPACER

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Hide 23807 20.INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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Hide 23901 21.CONNECT FUEL TUBE SUB-ASSEMBLY

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Hide 22.CONNECT WIRE HARNESS

a.

Connect the wire harness with the 2 bolts.

Torque:
8.4 N*m (86 kgf*cm, 6 ft.*lbf)


b.

Connect the engine coolant temperature sensor connector.


c.

Connect the camshaft position sensor connector.


d.

Engage the 2 clamps to connect the engine wire to the 2 wire harness clamp brackets.


e.

Connect the 4 fuel injector assembly connectors.


Hide 15100 23.INSTALL OIL PUMP ASSEMBLY

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Hide 27020 26.INSTALL GENERATOR ASSEMBLY

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