Installation

1ZZ-FE ENGINE MECHANICAL: CYLINDER HEAD:

COMPONENTS

























INSTALLATION

1. INSTALL CYLINDER HEAD GASKET





(a) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

- Make sure that the cylinder head gasket is mounted in the correct direction.
- Place the cylinder head gently in order to avoid damaging the gasket.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT: The cylinder head bolts should be tightened in 2 successive steps.

(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.





(b) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration (Procedure "A").
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)





(c) Mark the front of the cylinder head bolts with paint.
(d) Retighten the cylinder head bolts 90° in the same sequence as procedure "A".
(e) Check that the paint mark of each bolt is at a 90° angle to the front.
(f) Install the water by-pass pipe No. 1 with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(g) Connect the heater inlet water hose.
(h) Connect the radiator hose inlet.
(i) Connect the engine wire.
(1) Connect the heated oxygen sensor connector.
(2) Install the clamp onto the clamp bracket.
(3) Connect the 2 engine earths.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(4) Connect the radio setting condenser connector.
(5) Connect the engine coolant temperature sensor connector.
(6) Connect the camshaft position sensor connector.
(7) Connect the knock sensor connector.
(8) Connect the crankshaft position sensor connector.
(9) Connect the oil pressure switch connector.
(10) Connect the 4 fuel injector connectors.
3. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel tube sub-assembly (Installation).
4. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the camshaft journals.





(b) Place the 2 camshafts on the cylinder head as shown in the illustration.





(c) Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then tighten the bolts.
Bearing cap No. 1 - Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
Bearing cap No. 3 - Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)

- Bearing cap No. 1 is used for bearings numbered from 9 to 11 in the illustration.
- Bearing cap No. 3 is used for bearings numbered from 1 to 8 in the illustration.

5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.





(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
6. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.





(b) Install the intake manifold and throttle body with the 2 brackets, 4 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
(c) Connect the union to check valve hose to the intake manifold.
(d) Connect the water by-pass hose No. 2 to the throttle body.
(e) Connect the water by-pass hose to the throttle body.
(f) Connect the throttle control motor connector.
(g) Install the 2 clamps of the engine wire onto the clamp bracket.
7. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
8. INSTALL AIR CLEANER HOSE NO.1
(a) Install the air cleaner hose No. 1 with the 2 hose clamp bolts.
(b) Connect the fuel vapor feed hose No. 3 to the VSV.
(c) Connect the fuel vapor feed hose No. 1 to the VSV.
(d) Install the clamp of the engine wire.
(e) Connect the VSV connector.
9. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper No. 1 (Installation).
10. INSTALL CHAIN SUB-ASSEMBLY
(a) Install the chain sub-assembly (Installation).
SST: 09223-22010
11. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper (Installation).
12. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the crankshaft position sensor plate No. 1 (Installation).
13. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
(a) Install the timing chain or belt cover oil seal (Installation).
SST: 09223-22010
14. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Install the timing chain or belt cover sub-assembly (Installation).
15. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
(a) Install the chain tensioner assembly No. 1 (Installation).
16. INSTALL CRANKSHAFT PULLEY
(a) Install the crankshaft pulley (Installation).
SST: 09960-10010
09962-01000
09963-01000
17. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor (Installation).
18. INSTALL WATER PUMP ASSEMBLY
(a) Install the water pump assembly (Installation).
19. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH (Installation).
20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner assembly (Installation).
21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Install the cylinder head cover sub-assembly (Installation).
22. INSTALL IGNITION COIL ASSEMBLY
(a) Install the ignition coil assembly (Installation).
23. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH (Installation).
24. INSTALL GENERATOR ASSEMBLY
(a) Install the generator assembly (Installation).
25. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump assembly (Installation).
26. INSTALL FAN AND GENERATOR V BELT
27. INSTALL MANIFOLD STAY
(a) Install the manifold stay (Installation).
28. INSTALL EXHAUST PIPE ASSEMBLY FRONT
(a) Install the exhaust pipe assembly front (Installation).
29. ADD ENGINE COOLANT
(a) Add the engine coolant (Testing and Inspection).
30. INSTALL BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
31. INSPECT FOR ENGINE COOLANT LEAK
(a) Check for the engine coolant leakage (Testing and Inspection).
32. INSPECT FOR ENGINE OIL LEAK
33. INSPECT FOR FUEL LEAK
34. INSPECT FOR EXHAUST GAS LEAK
35. INSPECT IGNITION TIMING
(a) Inspect the ignition timing (On-Vehicle Inspection).
SST: 09843-18040
36. INSPECT ENGINE IDLING SPEED
(a) Inspect the engine idling speed (On-Vehicle Inspection).
37. INSPECT COMPRESSION
(a) Inspect the compression (On-Vehicle Inspection).
SST: 09992-00500
38. INSPECT CO/HC
(a) Inspect the CO/HC (On-Vehicle Inspection).
39. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover No. 2 (Installation).
40. INSTALL ENGINE UNDER COVER RH
41. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)