Toyota Tacoma Cylinder head Removal?

In this chapter Cylinder head removal procedure details mentioned for 2RZ-FE & 3RZ-FE Engines Cylinder head details.4wd And Prerunner-Bank 1 & Bank 2 cylinder head replacing diagrams.2TR-FE Engine Cylinder head replacement.
5vz-FE Engine Cylinder head removal Procedure.
The complete cylinder head removal with Diagrams.

4wd And Prerunner-Bank 1

1. Before servicing the vehicle, refer to the Precautions Section.
2. Properly discharge the fuel system pressure.
3. Properly disarm the SRS system.
4. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
5. Remove the power steering gear assembly.
6. Remove the front differential carrier assembly.
7. Remove the timing chain or belt cover subassembly.
8. Remove the chain subassembly.
9. Remove the number one cool inlet. Remove the front exhaust pipe assembly. Remove the three bolts and remove the exhaust manifold stay.
10. Disconnect the air fuel ratio sensor connector. Remove the six nuts; remove the exhaust manifold and gasket.
11. Disconnect the number one fuel pipe subassembly. Disconnect the number two fuel pipe subassembly.
12. Disconnect the fuel injector connectors. Remove the ten intake manifold retaining bolts. Remove the intake manifold from the engine.
13. Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the two bolts and four nuts, and then remove the water bypass joint RR and two gaskets. Remove the O-ring from the water outlet hose.
14. While raising the chain tensioner number two, insert a 0.039 inch diameter pin, into the hole. Hold the hexagonal portion of the camshaft in place, using a wrench.
    
    NOTE

    Be careful not to damage the cylinder head and valve lifter with the wrench.
15. Remove the two bolts. Remove the camshaft timing gear, camshaft timing gear assembly and timing chain number two.
    
    NOTE

    Do not disassemble the camshaft timing gear assembly.
16. Remove the bolt and then remove the chain tensioner number two.
17. Remove the camshafts.
18. Remove the two bolts. Separate the two ground cables.
19. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    
    NOTE

    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.
20. Lift the cylinder head from the dowels on the cylinder block and remove it from the engine.

To install:

1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage. Remove any old packing material. Be careful not to drop any oil on the contact surfaces of the cylinder head or engine block.
2. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder head gasket. Bead width should be 0.098-0.118 inch.
   
   NOTE

   Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing.
3. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
   
   NOTE

   Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.
4. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
   
   NOTE

   Replace defective bolts, as required.
5. Continue the installation in the reverse of the removal procedure.
6. Be sure to fill the cooling system with the proper grade and type engine coolant.
7. Be sure to fill the engine oil with the proper grade and type oil.
   
   NOTE

   Do not fill the engine with oil for at least four hours after the cylinder head has been installed.
8. Start the engine and check for leaks. Correct as required.

4wd And Prerunner-Bank 2

1. Before servicing the vehicle, refer to the Precautions Section.
2. Properly discharge the fuel system pressure.
3. Properly disarm the SRS system.
4. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
5. Remove the power steering gear assembly.
6. Remove the front differential carrier assembly.
7. Remove the timing chain or belt cover subassembly.
8. Remove the chain subassembly.
9. Remove the number one cool inlet. Remove the number two front exhaust pipe assembly. Remove the three bolts and remove the exhaust manifold stay.
10. Disconnect the air fuel ratio sensor connector. Remove the six nuts; remove the exhaust manifold and gasket.
11. Disconnect the fuel injector connectors. Remove the ten intake manifold retaining bolts. Remove the intake manifold from the engine.
12. Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the two bolts and four nuts, and then remove the water bypass joint RR and two gaskets. Remove the O-ring from the water outlet hose.
13. Remove the two bolts and then remove the chain vibration damper number one.
14. While pushing down on chain tensioner number two, insert a 0.039 inch diameter pin, into the hole. Hold the hexagonal portion of the camshaft in place, using a wrench.
    
    NOTE

    Be careful not to damage the cylinder head and valve lifter with the wrench.
15. Remove the two bolts. Remove the camshaft timing gear, camshaft timing gear assembly and timing chain number two.
    
    NOTE

    Do not disassemble the camshaft timing gear assembly.
16. Remove the bolt and then remove the chain tensioner number three.
17. Remove the camshafts.
18. Remove the two bolts. Separate the two ground cables.
19. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    
    NOTE

    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.
20. Lift the cylinder head from the dowels on the cylinder block and remove it from the engine.

To install:

1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage. Remove any old packing material. Be careful not to drop any oil on the contact surfaces of the cylinder head or engine block.
2. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder head gasket. Bead width should be 0.098-0.118 inch.
   
   NOTE

   Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing.
3. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
   
   NOTE

   Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.
4. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
   
   NOTE

   Replace defective bolts, as required.
5. Continue the installation in the reverse of the removal procedure.
6. Be sure to fill the cooling system with the proper grade and type engine coolant.
7. Be sure to fill the engine oil with the proper grade and type oil.
   
   NOTE

   Do not fill the engine with oil for at least four hours after the cylinder head has been installed.
8. Start the engine and check for leaks. Correct as required.

2RZ-FE & 3RZ-FE Engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Release the fuel system pressure.
3. Disconnect the negative battery cable.
4. Drain the engine coolant.
5. Remove or disconnect the following:
   
   
   Air cleaner cap
   

   Mass Air Flow (MAF) meter and resonator
   

   Accelerator cable from the throttle body, if equipped with a manual transmission
   

   Accelerator and throttle cables from the throttle body, if equipped with an automatic transmission
   

   Cruise control cable from the actuator, if equipped with cruise control
   

   Intake air connector
   

   Air hose for Idle Air Control (IAC)
   

   Vacuum sensing hose
   

   Wire clamp for the engine wiring harness
   

   Oil dipstick guide
   

   Power steering belt
   

   Power steering pulley pump and bracket
   

   Positive Crankcase Ventilation (PCV) hoses
   

   Distributor
   

   Spark plug wires from the spark plugs
   

   Engine wiring harness
   

   Air conditioning compressor, if equipped with air conditioning
   

   Oil pressure sensor
   

   Engine Coolant Temperature (ECT) sensor connector
   

   ECT sender gauge connector
   

   Exhaust Gas Recirculation (EGR) gas temperature sensor connector
   

   Vacuum Switching Valve (VSV) connector
   

   2 vacuum hose from the VSV
   

   Ground strap from the cowl top panel
   

   Engine wiring harness from the air intake chamber
   

   Throttle Position (TP) sensor connector
   

   IAC valve connector
   

   Crankshaft Position (CKP) sensor connector
   

   Knock Sensor (KS) connector
   

   Data Link Connector 1 (DLC1) from the bracket
   

   Engine wiring harness clamp
   

   EGR pipe
   

   Intake chamber stay
   

   Air intake chamber assembly
   
6. Disconnect the following hoses:
   
   
   Evaporative Emissions (EVAP) hose from the throttle body
   

   Brake booster vacuum hose from the union
   

   Water bypass hose from the water bypass pipe
   

   Water bypass hose from the cylinder head rear cover
   
7. Remove or disconnect the following:
   
   
   Injector connectors
   

   Fuel inlet pipe
   

   Hoses and the fuel return pipe
   

   Delivery pipe and injectors
   

   Intake manifold
   

   Front exhaust pipe
   

   Exhaust manifold and gasket
   

   Water outlet
   

   Cylinder head rear cover
   

   Spark plugs
   

   Front engine hanger
   

   Engine wiring harness brackets
   

   Cylinder head cover
   
8. Set No. 1 cylinder to Top Dead Center (TDC) of the compression stroke. The groove on the crankshaft pulley should align with the 0 mark on the timing chain cover and the timing marks (1 and 2 dots) of the camshaft gears should form a straight line in respect to the cylinder head surface. If not, turn the crankshaft 1 revolution (360 degrees).
9. Remove or disconnect the following:
   
   
   Chain tensioner and gasket
   

   Camshaft timing gear
   

   Exhaust camshafts
   
10. Remove the intake camshaft, as follows:
    
    
    
    
    1. Uniformly, loosen and remove the bearing cap bolts in the reverse order of the tightening in several passes, in sequence.
    2. Remove the bearing caps and camshaft. Make a note of the bearing cap positions for proper installation.
       
       NOTE

       If the camshaft is not being lifted out straight and level, reinstall the No. 3 bearing cap with the 2 bolts. Then, alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.
11. Remove or disconnect the following:
    
    NOTE

    Arrange the valve lifters and shims in correct order.
    
    
    
    
    Valve lifters and shims
    
    
    
    
    
    Cylinder head, by uniformly loosen and remove the cylinder head bolts in the reverse order of the tightening, in sequence, using several passes
    

To install:

1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage.
2. Apply sealant (PN 08826-00080) to the 2 locations. Place a new head gasket on the block and install the cylinder head. 
   
   
   
   Fig. Cylinder head bolt torque sequence-2.4L and 2.7L (3RZ-FE/M) engines
3. Install the cylinder head as follows:
   
   
   
   
   1. Lightly coat the cylinder head bolts with engine oil.
   2. Install the bolts and tighten, in several passes, in the sequence. Tighten all bolts to 29 ft. lbs. (39 Nm).
   3. Mark the front of the bolt with paint and retighten bolts 90 degrees in the proper sequence.
   4. Retighten an additional 90 degrees. Check that the painted mark is now facing rearward.
4. Install or connect the following:
   
   
   Tighten the 2 front mounting bolts to 15 ft. lbs. (21 Nm).
   

   Valve lifters and shims in their proper locations. Check that the valve lifter rotates smoothly by hand.
   

   Intake and exhaust camshafts
   
5. Set No. 1 cylinder to TDC compression stroke. The groove on the crankshaft pulley should align with the 0 mark on the timing chain cover and the timing marks (1 and 2 dots) of the camshaft gears should form a straight line in respect to the cylinder head surface. If not, turn the crankshaft 1 revolution (360 degrees).
6. Install the timing gear, as follows:
   1. Place the gear over the straight pin of the intake camshaft.
   2. Hold the intake camshaft with a wrench. Install and tighten the bolt to 54 ft. lbs. (74 Nm).
   3. Hold the exhaust camshaft and install the bolt and distributor gear. Tighten the bolt to 34 ft. lbs. (46 Nm).
7. Install or connect the following:
   
   
   Chain tensioner, using a new gasket (mark toward the front)
   

   Recheck the valve timing
   

   Check and adjust the valve clearance
   

   Spark plugs
   

   Semi-circular plug
   
8. Recheck the engine for proper valve timing.
9. Install or connect the following:
   
   
   Cylinder head cover, using a new gasket
   

   Engine wiring harness brackets
   

   Front engine hanger. Tighten the bolts to 30 ft. lbs. (42 Nm).
   

   Cylinder head rear cover. Tighten the bolts to 10 ft. lbs. (13 Nm).
   

   Water outlet, using a new gasket. Tighten the bolts to 14 ft. lbs. (20 Nm).
   

   Upper radiator hose
   

   Exhaust manifold. Tighten the bolts to 36 ft. lbs. (49 Nm).
   

   Remaining components
   

   Negative battery cable
   
10. Fill the engine and radiator with engine coolant.
11. Start the engine and check for leaks.
12. Check the ignition timing. Road test the vehicle for proper operation.
13. Recheck all fluid levels.

2TR-FE Engine

NOTE

The engine must first be removed from the vehicle.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Properly discharge the fuel system pressure.
3. Properly disarm the SRS system.
4. Disconnect the negative battery cable.
5. Remove the hood subassembly.
6. Remove the engine from the vehicle and position it in a suitable holding fixture.
7. Remove the intake air connector. Remove the alternator.
8. Remove the number one exhaust manifold heat insulator. Remove the air switching valve assembly.
9. Remove the exhaust manifold.
10. Remove the belt tensioner assembly. Remove the number one idler pulley subassembly. Remove the idle pulley assembly and bracket.
11. Remove the crankshaft position sensor. Remove the camshaft position sensor.
12. Remove the number one intake manifold.
13. Remove the cylinder head cover. Remove the crankshaft pulley. Remove the oil gauge subassembly.
14. Remove the number two oil pan subassembly. Remove the oil strainer. Remove the oil pap subassembly.
15. Remove the timing chain cover. Remove the timing chain guide. Remove the number one chain tensioner assembly.
16. Remove the chain tensioner slipper. Remove the number one chain vibration damper. Remove the chain subassembly.
17. Remove the camshaft. Remove the valve rocker arms.
18. Remove the valve lash adjuster assembly.
19. Disconnect the water hoses. Disconnect the engine coolant temperature sensor wire. Remove the bolts and separate the wire from the harnesses. Remove the bolt, and then separate the wire harness bracket.
20. Loosen the cylinder head retaining bolts in several steps and in the proper removal sequence. Remove the bolts.
    
    NOTE

    Be careful not to drop the washers into the cylinder head. Head warpage and cracking could result in removing the bolts in the wrong order.
    
    
    
    
    

    

    Fig. Cylinder head bolt loosening sequence-2.7L (2TR-FE) engine
    
    
    
    

    

    Fig. Cylinder head gasket sealant application-2.7L (2TR-FE) engine
    
    
    
    

    

    Fig. Cylinder head gasket positioning-2.7L (2TR-FE) engine
    
    
    
    

    

    Fig. Cylinder head bolt torque sequence-2.7L (2TR-FE) engine

To install:

1. Before installing, thoroughly clean the gasket mating surfaces and check for warpage.
2. Apply continuous beads of seal packing, part number 08826-00080 or equivalent, to the cylinder block upper side and cylinder head gasket upper side. Bead width should be 0.15-0.28 inch.
   
   NOTE

   Remove any oil from the contact surface. Install the cylinder head gasket within three minutes after applying the seal packing. Install the cylinder head bolts within fifteen minutes after applying the seal packing. Do not fill the engine with oil for at least four hours.
3. Be sure to position the cylinder head gasket on the engine block with the lot number stamp facing upward.
   
   NOTE

   Be sure that the head gasket is installed in the correct direction. Position the gasket gently in order to avoid damaging the gasket with the bottom part of the cylinder head.
4. Apply a light coat of clean engine oil to the cylinder head bolts. Tighten the cylinder head bolts, in two successive steps, to specification and in the proper sequence.
5. Continue the installation in the reverse of the removal procedure.
6. Be sure to fill the cooling system with the proper grade and type engine coolant.
7. Be sure to fill the engine oil with the proper grade and type oil.
   
   NOTE

   Do not fill the engine with oil for at least four hours after the cylinder head has been installed.
8. Start the engine and check for leaks. Correct as required.

5vz-FE Engine

Fig. Cylinder head and related components-3.4L engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Relieve the fuel system pressure.
4. Remove the engine undercover.
5. Drain the cooling system.
6. Remove or disconnect the following:
   
   
   Front exhaust pipe
   

   Air cleaner cap
   

   Mass Air Flow (MAF) meter and resonator
   
7. Disconnect the following cables:
   
   
   Actuator cable from the bracket, if equipped with cruise control
   

   Accelerator cable
   

   Throttle cable, if equipped with an automatic transmission
   

   Heater hose
   

   Upper radiator hose
   

   Power steering drive belt
   

   Air conditioning drive belt, by loosening the idle pulley nut and adjusting bolt
   

   Loosen the lockbolt, pivot bolt and adjusting bolt and the alternator drive belt
   

   No. 2 fan shroud by removing the 2 clips
   

   Fan with the fluid coupling and fan pulleys
   

   Power steering pump and move it aside without disconnecting the pump lines
   

   Compressor and move it aside without disconnecting the compressor lines, if equipped with air conditioning
   

   Air conditioning bracket, if equipped with air conditioning
   

   Spark plug wires with the ignition coils
   

   Spark plugs
   

   No. 2 timing belt cover
   
8. Remove the fan bracket, as follows:
   1. Remove the power steering adjusting strut by removing the nut.
   2. Remove the fan bracket by removing the bolt and nut.
9. Set the No. 1 cylinder at Top Dead Center (TDC) of the compression stroke.
   1. Turn the crankshaft pulley and align its groove with the timing mark 0on the No. 1 timing belt cover.
   2. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360 degrees).
10. Remove the timing belt tensioner by alternately loosening the 2 bolts.
11. Remove the camshaft timing pulleys, as follows:
    1. Using Variable Pin Wrench Set tool 09960-10010, remove the pulley bolt, the timing pulley and the knock pin.
    2. Remove the 2 timing pulleys with the timing belt.
12. Remove or disconnect the following:
    
    
    Bolt and the No. 2 idler pulley
    

    Alternator
    
13. Remove the Exhaust Gas Recirculation (EGR) pipe and 2 gaskets, if equipped with an EGR valve
14. Remove the intake chamber stay as follows:
    1. Remove the oil filler tube and No. 1 throttle cable clamp by removing the bolt and 2 nuts.
    2. Remove the intake chamber stay by removing the 2 bolts.
15. Remove the following connectors:
    
    
    VSV connector for the fuel pressure control.
    

    Throttle position sensor
    

    IAC valve connector
    

    EGR valve gas temperature sensor, if equipped
    

    Vacuum Switching Valve (VSV) connector for the EGR valve, if equipped
    
16. Disconnect the following hoses:
    
    
    Positive Crankcase Ventilation (PCV) hoses
    

    Water bypass hoses.
    

    Air assist hose from the intake air connector
    

    2 vacuum sensing hoses from the VSV
    

    Evaporative Emissions (EVAP) hose
    

    Air hose, from the power steering
    

    Air hose from the air conditioning idle up valve, if equipped with air conditioning
    
17. Remove or disconnect the following:
    
    
    4 bolts, 2 nuts and the air intake chamber assembly
    

    Intake air connector
    
18. Disconnect the engine wiring harness from the intake manifold, as follows:
    
    
    Oil pressure sensor connector
    

    Crankshaft position sensor connector
    

    6 injector connectors
    

    Engine Coolant Temperature (ECT) sender gauge connector
    

    ECT sensor connector
    

    Knock (KS) sensor connector
    

    Camshaft Position (CMP) sensor connector
    

    3 engine wiring harness clamps
    

    3 bolts and the engine wiring harness from the cylinder head
    
19. Remove or disconnect the following:
    
    
    CMP sensor
    

    No. 3 (rear) timing belt cover, by removing the 6 bolts
    
    

    

    

    Fig. Rear timing belt cover bolt locations-3.4L engine

    
    
    

    

    

    Fig. Intake manifold bolt locations-3.4L engine
    
    
    
    
    Fuel pressure regulator
    

    Intake manifold assembly
    

    Power steering pump bracket
    

    Oil dipstick and guide
    

    Exhaust crossover pipe and gaskets, by removing the 6 nuts
    

    Left-hand exhaust manifold, by removing the heat insulator and 6 nuts
    

    Right-hand exhaust manifold, by removing the heat insulator and 6 nuts
    

    8 bolts, seal washers, cylinder head cover and gasket
    

    Both cylinder head covers
    

    Semi-circular plugs
    

    Right exhaust camshafts
    

    Right-hand intake camshaft
    

    Left exhaust camshafts
    
    

    

    

    Fig. Drive gear service bolt (right side)-3.4L engine

    
    
    

    

    

    Fig. Aligning the timing mark (1 dot mark) of the left camshafts-3.4L engine

    
    
    

    

    

    Fig. Drive gear service bolt (left side)-3.4L engine
    
    
    
    
    Left-hand intake camshaft
    

    Valve lifters and shims from the cylinder head; arrange the valve lifters and shims in correct order
    
20. Remove the cylinder heads, as follows:
    
    
    Bolt and disconnect the ground strap
    

    Cylinder head (recessed head) bolt on each cylinder head, using an 8mm hexagon wrench; then repeat for the other side
    

    8 cylinder head (12-pointed head) bolts on each cylinder head, by loosening the bolts in several passes and in the reverse order of the tightening sequence
    

    16 cylinder head bolts and plate washers.
    

    Cylinder head
    
    

    

    

    Fig. Cylinder head recessed bolts-3.4L engine

To install:

Fig. Cylinder head bolt torque sequence-3.4L engine

1. Clean all surfaces.
2. Install or connect the following:
   
   
   New cylinder head gaskets
   

   Cylinder heads
   
3. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
4. Tighten the cylinder head bolts, in sequence, using several passes, as follows:
   
   
   Step 1: 25 ft. lbs. (34 Nm)
   

   Step 2: Mark the front of the cylinder head bolt with paint
   

   Step 3: An additional 90 degrees
   

   Step 4: Check that the painted mark is now at a 90 degrees angle to the front
   
5. Install the recessed head cylinder head bolts, as follows:
   
   
   Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts
   

   Cylinder head bolt on each cylinder head, using a 8mm hexagon wrench; then, repeat for the other side, as shown. Tighten the bolts to 13 ft. lbs. (18 Nm).
   

   Bolt and the ground strap
   
6. Install or connect the following:
   
   NOTE

   Check that the valve lifter rotates smoothly by hand.
   
   
   
   
   Valve lifters and shims
   
   
   
   
   
   Camshafts
   
   

   

   

   Fig. Aligning the right camshafts for installation-3.4L engine

   Check and adjust the valve clearance
   

   Semi-circular plugs
   

   Cylinder head covers. Tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).
   

   Exhaust manifolds, with new gaskets. Tighten the nuts to 30 ft. lbs. (40 Nm).
   

   Exhaust manifold heat insulators. Tighten the nuts to 71 inch lbs. (8 Nm).
   

   Exhaust crossover pipe. Tighten the nuts to 33 ft. lbs. (45 Nm).
   

   Alternator bracket. Tighten to 14 ft. lbs. (18 Nm).
   

   Oil dipstick and guide, using a new O-ring
   

   Power steering bracket. Tighten the fasteners to 14 ft. lbs. (18 Nm).
   

   New gaskets and the intake manifold assembly. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
   

   Intake manifold stay with the 2 bolts. Tighten the bolts to 14 ft. lbs. (18 Nm).
   

   Fuel inlet hose
   

   Fuel pressure regulator
   

   No. 3 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).
   

   CMP sensor. Tighten to 71 inch lbs. (8 Nm).
   

   Engine wiring harness
   
7. Install or connect the intake air connector, as follows:
   
   
   Intake manifold. Tighten the bolts and nuts to 14 ft. lbs. (19 Nm).
   

   DLC1 to the bracket on the intake manifold
   

   Ground strap to the intake manifold
   

   Brake booster vacuum hose to the intake air connector
   

   2 fuel return hoses
   

   Engine wiring harness to the intake manifold
   

   Idle up valve connector, if equipped with air conditioning
   
8. Install or connect the following:
   
   
   Air intake chamber assembly. Tighten the bolts and nuts to 14 ft. lbs. (18.5 Nm).
   

   Hoses
   
9. Attach the following connectors:
   
   NOTE

   Check that the pulley bracket moves smoothly.
   
   
   
   
   VSV connector for the fuel pressure control
   

   TP sensor connector
   

   IAC valve connector
   

   EGR gas temperature connector, if equipped with an EGR valve
   

   VSV connector, if equipped with an EGR valve
   

   Intake chamber stay
   

   New gaskets and the EGR pipe. Tighten the clamp nuts to 71 inch lbs. (8 Nm) and the EGR pipe nuts to 14 ft. lbs. (18 Nm).
   

   Alternator but do not tighten the bolts and nuts at this time.
   

   No. 2 timing belt idler. Tighten the bolt to 30 ft. lbs. (40 Nm).
   
   
   
   
   
   Left camshaft timing pulley
   
10. Set the No. 1 cylinder to TDC of the compression stroke, as follows:
    1. Turn the crankshaft pulley and align its groove with the timing mark 0on the No. 1 timing belt cover.
    2. Turn the camshaft, align the knock pin hole of the camshaft with the timing mark of the No. 3 timing belt cover.
    3. Turn the camshaft timing pulley, align the timing marks of the camshaft timing pulley and the No. 3 timing belt cover.
11. Connect the timing belt to the left camshaft timing pulley, as follows:
    1. Check that the installation mark on the timing belt is aligned with the end of the No. 1 timing belt cover.
    2. Using Variable Pin Wrench Set 09960-01000, slightly turn the left camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left camshaft timing pulley.
    3. Align the timing marks of the left camshaft pulley and the No. 3 timing belt cover.
    4. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft timing pulley.
12. Install the right camshaft timing pulley and the timing belt, as follows:
    1. Align the installation mark on the timing belt with the timing mark of the right camshaft timing pulley, and hang the timing belt on the right camshaft timing pulley with the flange side facing inward.
    2. Slide the right camshaft timing pulley on the camshaft. Align the timing marks on the right camshaft timing pulley and the No. 3 timing belt cover.
    3. Align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the knock pin. Install the bolt and tighten to 81 ft. lbs. (110 Nm).
13. Set the timing belt tensioner as follows:
    1. Using a press, slowly press in the pushrod using 220-2,205 lbs. (981-9,807 N) of force.
    2. Align the holes of the pushrod and housing, pass a 1.5mm hexagon wrench through the holes to keep the setting position of the pushrod.
    3. Release the press and install the dust boot to the tensioner.
14. Install the timing belt tensioner. Tighten the bolts alternately to 20 ft. lbs. (28 Nm).
15. Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
16. Check the valve timing.
17. Install or connect the following:
    
    
    Remaining components
    

    Negative battery cable
    
18. Fill the radiator with engine coolant.
19. Start the engine and check for leaks.
20. Check the ignition timing.
21. Install the engine undercover.
22. Road test the vehicle.
23. Recheck all fluid levels.

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html