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EM-89
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
EM1XU-01

INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
(a) Remove any old packing material (FIPG) and be careful
not to drop any oil on the contact surfaces of the cylinder
head and cylinder block.
(b) Install the RH cylinder head gasket.

(1) Apply a continuous bead of seal packing (diameter
10 to 15 mm 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder
head gasket as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
2.5 to 3 mm NOTICE:
Install the cylinder head within 3 minutes after applying
Gasket
seal packing. After installing it, the cylinder head bolts
must be tightened within 15 minutes. Otherwise the seal
1.25 to packing must be removed and reapplied.
1.5 mm

10 to 15 mm
Seal Packing A22891

(2) Place the cylinder head gasket on the cylinder block
Lot No. surface with the Lot No. stamp upper side facing up-
ward.
NOTICE:
S Be careful of the installation direction.
S Place the cylinder head carefully in order not to dam-
age the gasket with the bottom part of the head.

A22892
EM-90
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

(c) Install the LH cylinder head gasket.
10 to 15 mm
(1) Apply a continuous bead of seal packing (diameter
2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder
2.5 to 3 mm head gasket as shown in the illustration.
Gasket Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the cylinder head within 3 minutes after applying
1.25 to seal packing. After installing it, the cylinder head bolts
1.5 mm must be tightened within 15 minutes. Otherwise the seal
packing must be removed and reapplied.

10 to 15 mm

Seal Packing A22914

(2) Place the cylinder head gasket on the cylinder block
surface with the Lot No. stamp upper sied facing up-
ward.
NOTICE:
S Be careful of the installation direction.
S Place the cylinder head carefully in order not to dam-
age the gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD
Lot No. A22915 (a) Place the RH cylinder head on the cylinder head gasket.
(b) Install the 8 cylinder head bolts.
HINT:
S The cylinder head bolts are tightened in 2 successive
steps (steps (3) and (5)).
S If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil to the threads of the
cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.

(3) Using several steps, tighten each bolt with a 10 mm
6 4 2 7
bi-hexagon wrench uniformly in the sequence as
shown in the illustration.
Torque: 36 Nm (367 kgfcm, 27 ftlbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
NOTICE:
8 1 3 5 Do not drop the washers into the cylinder head.
A22888
EM-91
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

(4) Mark the front side of each cylinder head bolt with
180 _ paint.
(5) Retighten the cylinder head bolts by 180 _ as
shown.
Engine (6) Check that the painted marks are now at 180_ op-
Front
posite to the engine front.
(c) Place the LH cylinder head on the cylinder head gasket.
Paint Mark (d) Install the 8 cylinder head bolts.
A22893 HINT:
S The cylinder head bolts are tightened in 2 successive
steps (steps (3) and (5)).
S If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil to the threads of the
cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.

(3) Using several steps, tighten each bolt with a 10 mm
8 1 3 5 bi-hexagon wrench uniformly in the sequence as
shown in the illustration.
Torque: 36 Nm (367 kgfcm, 27 ftlbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
NOTICE:
Do not drop the washers into the cylinder head.
6 4 2 7
A22912

Paint Mark
A22893

(e) Install the 2 cylinder head bolts.
(1) Apply a light coat of engine oil to the threads of the
1 cylinder head bolts.
(2) Install the 2 cylinder head bolts. Using several
steps, tighten the bolts uniformly in the sequence as
2 shown in the illustration.
Torque: 30 Nm (306 kgfcm, 22 ftlbf)

A22911
EM-92
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

3. INSTALL CAMSHAFT BEARING NO.1
Align the bearing claw with the claw groove of the bearing cap,
and push in the camshaft bearing.
NOTICE:
Claw S Install the bearing while aligning it with the oil hole in
the bearing cap.
S Clean the backside of the bearing and the bearing
surface of the bearing cap and prevent oil from adher-
A23006 ing to them.

4. INSTALL CAMSHAFT BEARING NO.2
Install the camshaft bearing No. 2 to the cylinder head.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the cylinder head and prevent oil from adhering to them.
5. INSTALL CAMSHAFT
NOTICE:
As the thrust clearance of the camshaft is small, the cam-
A22894 shaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
which receives 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.

(a) Set the crankshaft position.
90 _ Using the crankshaft pulley set bolt, turn the crankshaft,
and set the crankshaft set key into the left horizontal posi-
tion.
NOTICE:
Having the crankshaft at the wrong angle can cause the
Set Key
piston head and valve head to come into contact with each
Turn other when you install the camshaft, causing damage. So
A22895 always set the crankshaft at the correct angle.
(b) Apply new engine oil to the thrust portion and journal of
the camshafts.
EM-93
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

RH Bank
(c) Install the camshaft of the RH bank.
(1) Place the 2 camshafts onto the RH cylinder head
with the cam lobes of No. 1 cylinder facing each
direction as shown in the illustration.

A22896

RH Bank (2) Install the 8 bearing caps in their proper locations.
(3) Apply a light coat of engine oil to the threads of the
bearing cap bolts.

A22897

RH Bank (4) Install the 16 bearing cap bolts. Using several
steps, tighten the bolts uniformly in the sequence as
6
14 10 2 shown in the illustration.
Torque:
13 9 1 5 9.0 Nm (92 kgfcm, 80 in.lbf) for 10 mm (0.39 in.) head
15 11 3 7 24 Nm (245 kgfcm, 18 ftlbf) for 12 mm (0.47 in.) head

16 12 4 8

A22898

RH Bank (5) Turn the camshafts clockwise with a wrench until
the camshaft knock pin comes 90_ position to the
Turn
cylinder head.
Turn

90 _

A22899

LH Bank
(d) Install the camshafts of the LH bank.
(1) Place the 2 camshafts onto the LH cylinder head
with the cam lobes of No. 2 cylinder facing as shown
in the illustration.

A22917
EM-94
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

LH Bank (2) Install the 8 bearing caps in their proper locations.
(3) Apply a light coat of engine oil to the threads and un-
der the heads of the bearing cap bolts.

A22918

LH Bank
(4) Install the 16 bearing cap bolts. Using several
steps, tighten the bolts uniformly in the sequence as
6
2 10 14 shown in the illustration.
Torque:
5 9.0 Nm (92 kgfcm, 80 in.lbf) for 10 mm (0.39 in.) head
1 3 9 11 13 15
7 24 Nm (245 kgfcm, 18 ftlbf) for 12 mm (0.47 in.) head
6. INSTALL TIMING CHAIN (See page EM-44)
4 12 16 7. INSTALL TIMING CHAIN COVER (See page EM-44)
8
A22910 8. INSTALL OIL PAN (See page EM-44)

9. INSTALL EXHAUST MANIFOLD
(a) Install the RH exhaust manifold.
(1) Set a new gasket to the RH cylinder head with the
oval shape facing forward.
Oval Shape
NOTICE:
Be careful of the installation direction.

Forward
A22906

(2) Install the exhaust manifold with the 6 nuts. Tighten
the nuts uniformly in several steps.
Torque: 21 Nm (214 kgfcm, 15 ftlbf)
(3) Connect the A/F sensor connector.
(4) Install the manifold stay with the 3 bolts.
Torque: 40 Nm (408 kgfcm, 30 ftlbf)

A23251

(b) Install the LH exhaust manifold.
(1) Set a new gasket to the LH cylinder head with the
oval shape facing backward.
Oval shape NOTICE:
Be careful of the installation direction.

Forward
A22922
EM-95
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

12. INSTALL OIL CONTROL VALVE FILTER
Mesh Part (a) Check that no foreign objects on the mesh part of the 2
filters.
Apply
Adhesive (b) Install 2 new gaskets to each new plug.
(c) Insert the filters to the plugs.
(d) Apply adhesive to 2 or 3 threads of the plugs.
Adhesive: Part No. 08833-00080, THREE BOND 1344
LOCTITE 242 or equivalent
A23017 (e) Install the plugs to each cylinder head.
Torque: 62 Nm (632 kgfcm, 46 ftlbf)
13. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE

14. INSTALL WATER BY-PASS JOINT
(a) Install a new O-ring to the water outlet pipe.
(b) Apply soapy water to the O-ring.

A22904

(c) Install 2 new gaskets and water by-pass joint with the 2
bolts and 4 nuts.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
(d) Connect the heater hose.
(e) Connect the engine coolant temperature sensor connec-
tor.

A22883
EM-96
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

15. INSTALL INTAKE MANIFOLD
(a) Set a new gasket on each cylinder head.
NOTICE:
S Align the port holes of the gasket and cylinder head.
S Be careful of the installation direction.
(b) Set the intake manifold on the cylinder heads.

A22905

(c) Install and tighten the 10 bolts uniformly in several steps.
Torque: 26 Nm (265 kgfcm, 19 ftlbf)
(d) Connect the 6 fuel injector connectors.
16. INSTALL CYLINDER HEAD COVER
(a) Install the RH cylinder head cover.
(1) Remove any old packing material (FIPG) and be
careful not to drop any oil on the contact surfaces
of the cylinder head, timing chain cover and cylinder
A22882 head cover.

(2) Apply a continuous bead of seal packing (diameter
Seal Packing
2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the cylinder head cover within 3 minutes after apply-
ing seal packing. After installing it, cylinder head cover
bolts and nuts must be tightened within 15 minutes. Other-
Seal Width: 2 to 3 mm A23016 wise the seal packing must be removed and reapplied.
(3) Install the seal washers to the bolts.
B (4) Install the cylinder head cover with the 10 bolts and
B B B 2 nuts. Tighten the bolts and nuts uniformly in sever-
al steps.
Torque:
Bolt A, Nut: 9.0 Nm (92 kgfcm, 80 in.lbf)
Bolt B: 10 Nm (102 kgfcm, 7 ftlbf)
(b) Install a new gasket and oil filler cap housing with the 2
B A A A
nuts.
B Nut B Nut
A23092 Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)

(c) Install the LH cylinder head cover.
Seal Packing
(1) Apply a continuous bead of seal packing (diameter
2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and
timing chain cover as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Install the cylinder head cover within 3 minutes after apply-
ing seal packing. After installing it, cylinder head cover
Seal Width: 2 to 3 mm A23015 bolts and nuts must be tightened within 15 minutes. Other-
wise the seal packing must be removed and reapplied.
EM-97
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

(2) Install the seal washers to the bolts.

B (3) Install the cylinder head cover with the 10 bolts and
B B
B 2 nuts. Tighten the bolts and nuts uniformly in sever-
al steps.
Torque:
Bolt A, Nut: 9.0 Nm (92 kgfcm, 80 in.lbf)
B Bolt B: 10 Nm (102 kgfcm, 7 ftlbf)
A 17. INSTALL IGNITER
A A B
Nut B Nut A22970

18. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket to the intake air surge tank.
(b) Using the socket hexagon wrench 8, install the intake air
surge tank with the 4 bolts.
Torque: 28 Nm (286 kgfcm, 21 ftlbf)
(c) Install the 2 intake air surge tank nuts.
Torque: 28 Nm (286 kgfcm, 21 ftlbf)

A23091

(d) Install the 2 surge tank stays with the 4 bolts.
Torque: 21 Nm (214 kgfcm, 15 ftlbf)
(e) Install the oil baffle plate with the bolt.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)

A23090

(f) Install the throttle body bracket with the 2 bolts.
Torque: 21 Nm (214 kgfcm, 15 ftlbf)

A23089
EM-98
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

(g) Install the 3 wire harness clamps and hose clamp.
(h) Connect the throttle body w/ motor connector.
(i) Connect the 2 VSV connectors.

A23088

(j) Connect the ventilation hose.

A23087

(k) Connect the fuel vapor feed hose.

A23086

(l) Connect the 2 water by-pass hoses.
19. CONNECT HEATER WATER OUTLET AND INLET
HOSE
20. INSTALL COOLER COMPRESSOR
(See page AC-58)
21. INSTALL GENERATOR (See page CH-15)
22. INSTALL VANE PUMP (See page SR-57)
23. INSTALL FAN W/FLUID COUPLING
A23085
EM-99
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

24. INSTALL DRIVE BELT
(a) While turning the belt tensioner counterclockwise, align
with the holes. Insert a bar of 6 mm (0.24 in.) into the
holes to fix the belt tensioner.
(b) Install the V-ribbed belt.
(c) While turning the belt tensioner counterclockwise, re-
move the bar.

Turn

Holes
A22798

Water Pump Generator
(d) If it is hard to install the V-ribbed belt, perform the follow-
P/S Pump Idler No. 2 ing procedure.
(1) Put the V-ribbed belt on every parts except the P/S
pump as shown in the illustration.
Tensioner (2) While releasing the belt tension by turning the belt
tensioner counterclockwise, put the V-ribbed belt
Idler No. 2 on the P/S pump.
Crankshaft
Idler No. 1 A/C Compressor
A22799

25. TIGHTEN FAN W/FLUID COUPLING
Tighten the 4 fluid coupling bolts.
Torque: 21 N

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