Installing the cylinder head [Toyota Carina T170]

Engine 4A-F/FE

• Place the new cylinder head gasket on the cylinder block. Both centering pins must pass through the gasket.
• Place the cylinder head on the cylinder block.
• Lubricate the threaded portion and the underside of the cylinder head bolt heads with engine oil.
• Using a special key, tighten the cylinder head bolts in the reverse order to that shown in Figure 19 in three passes until the tightening torque reaches 60 Nm.
• Clamp the intake camshaft hexagon in a vice and install all the parts shown in Figure 45 on the shaft. Install the retaining ring as shown in Figure 62.

• According to Fig. 43, insert bolts (1) and (2) into the holes of the secondary gear wheel and turn the wheel with a screwdriver so that you can insert bolt (3) into both gear wheels and fix them in this position. Do not damage the camshaft.
• Install the exhaust camshaft into the bearing holes and turn it to the position shown in Figure 63. In this position, the cams of the first and third cylinders press the tappets.

• Apply sealant to the surfaces under the bearing caps on the toothed belt side.
• Place 4 bearing caps on the camshaft in the cylinder head in accordance with Fig. 64. Observe the directions of the arrows on the caps.

• Tighten all bearing cap bolts one by one from the center outward to a tightening torque of 13 Nm.
• Lubricate the lips of the new seal and press the seal into the cylinder head without damaging the seal.
• After this, turn the camshaft until the pin shown on the left in Figure 63 is installed. In this position, the cams of the fourth cylinder press the tappets.
• Install the intake camshaft into the cylinder head. In doing so, align the marks shown in Figure 65 and engage both gears. In this position, the cams of the first and third cylinders press the tappets.

• Lubricate the camshaft bearing areas.
• Install bearing caps in accordance with their markings (see fig. 63) and tighten the bolts. Do not install bearing cap #1 yet. Tighten all bearing cap bolts one by one from the center outward to a tightening torque of 13 Nm.
• Remove the bolt previously inserted to hold the drive gear.
• Install bearing cover No.1. If you have difficulty, press the camshaft gear back and insert a screwdriver between the gear and the cylinder head. Tighten both bolts alternately to a torque of 13 Nm.
• Using the method shown in Figure 66, turn the camshaft one revolution from the TDC position back to the TDC position so that the pin is in the position shown in the figure. After installing the gears in the original position, check the alignment of the marks in accordance with Figure 67.

• Align the camshaft gear with the pin and place it on the camshaft in the manner shown in Figure 68. Hold the camshaft from turning and tighten the gear bolt to a torque of 47 Nm.

The timing belt can now be installed according to the following instructions:

• Check that the mark on the camshaft bearing cap matches the small hole in the gear wheel (see fig. 68) and place the toothed belt on the toothed wheel so that the marks made when removing the belt match. Do not allow the belt to come off the crankshaft wheel.
• Loosen the timing belt tensioner roller bolt in accordance with Figure 69 and turn the crankshaft two revolutions from TDC to TDC. Turn the crankshaft only to the right.

• Check the valve timing in accordance with Figure 70. If the marks do not match, remove the toothed belt and move it one or two teeth.

• Align the camshaft gear with the pin and place it on the camshaft in the manner shown in Figure 68. Hold the camshaft from turning and tighten the gear bolt to a torque of 47 Nm.
• Tighten the tension roller bolt in Figure 69 to a tightening torque of 37 Nm.
• Check the tension of the toothed belt at the location shown in Figure 71. If the belt does not deflect to the specified size, the tension roller must be adjusted.

• Check the valve clearances as described in the next chapter.
• Install the timing belt cover.
• Clean the areas shown in Figure 72 from sealant and apply sealant with a brush.

• Apply the gasket and install the cylinder head cover. Secure the cylinder head cover with rubber tips and nuts.
• Screw in the spark plugs and tighten them to a torque of 18 Nm.
• Install the drive belt and water pump pulleys. Adjust the belt tension as described in chapter 4.3.2.
• Install the intake manifold with a new gasket. Tighten the bolts and nuts to a torque of 19 Nm. Install the intake manifold support. Tighten the upper bolt to a torque of 19 Nm and the lower bolt to a torque of 40 Nm.
• Connect the water hose and crankcase ventilation spar.
• Install the fuel pump with two new gaskets and an insulating flange and tighten both bolts (carburetor engine).
• Apply a 2 to 3 mm thick layer of sealant to the thoroughly cleaned surface of the filler housing. A special sealant is used here, which is available at the TOYOTA service station. Do not allow the sealant to get into the holes. The housing must be installed within 15 minutes. Otherwise, you will have to apply the sealant again. Tighten the bolts with a torque of 20 Nm. Connect both water hoses.
• Install the ignition distributor.
• Install the exhaust manifold (with a new gasket. Tighten the bolts and nuts to 25 Nm. Install the upper heat shield and manifold support.
• Install the drain pipe in the same way. Tighten the bolts to 20 Nm.

Engine 3S-FE

• Place a new cylinder head gasket on the cylinder block. Both centering pins must pass through the gasket. Check the position of the gasket.
• Place the cylinder head on the cylinder block.
• Lubricate the threaded portion and the underside of the heads of all cylinder head bolts with engine oil.
• Using a special key, tighten the cylinder head bolts in the reverse order to that shown (Fig. 19) in three passes until the final tightening torque of 65 Nm.
• Clamp the intake camshaft hexagon in a vice and install all the parts shown in Figure 45 on the shaft. Install the retaining ring as shown in Figure 62.
• According to Fig. 44, insert bolt (1) into the hole of the secondary gear and turn the gear with a screwdriver so that bolt (2) can be inserted into both gears to fix them in this position. Do not damage the camshaft.
• Insert the exhaust camshaft into the bearing holes and turn it to the position shown in Figure 73. In this position, the cams of the first and third cylinders press the tappets.

• Apply a 2-3 mm thick layer of sealant to the surface of the front bearing cover in accordance with Figure 74.

• Install 4 camshaft bearing caps according to Fig. 75 on the camshaft in the cylinder head. Also install the front bearing cap on the toothed belt side. Observe the directions of the arrows on the caps.

• Tighten all bearing cap bolts in turn from the center outward in the sequence shown in Figure 76 to a tightening torque of 19 Nm.

• Lubricate the lips of the new seal and press the seal into the cylinder head without damaging the seal.
• After this, turn the camshaft so that the pin shown in Figure 77 is in position 10 before TDC.

• Install the intake camshaft into the cylinder head. In doing so, align both marks shown in Figure 78 and engage both gear wheels. In this position, the cams of the first and third cylinders press the corresponding tappets. It should be taken into account that there are several marks on the gear wheels of the camshafts, i.e., the required marks should be aligned. The figure shows how the marks should be located after installation. In doing so, slowly turn the exhaust camshaft with the gears engaged. In doing so, slowly turn the intake camshaft step by step to the left or right until the exhaust camshaft fits into the bearing holes without protruding.
• Lubricate the camshaft bearing areas, as well as the threaded parts and the undersides of the bolt heads.
• Install bearing caps in accordance with their markings (same as shown in figure 75 for intake camshaft) and screw in the bearing cap bolts in accordance with Fig. 76, but in a mirror image, i.e. for this shaft, the bearing cap bolts on the front side are tightened last. The tightening torque is 19 Nm. All bearing caps must be marked "E". Otherwise, the wrong cap was installed on the intake camshaft.
• Remove the bolt inserted to lock the drive gear.
• Turn the camshaft one revolution from the TDC position back to the TDC position so that the marks again coincide, as shown in Figure 78 after installing the gears in their original position.

• Align the camshaft gear with the pin and place it on the camshaft. The marks shown in Figure 26 should be located at the top. Hold the camshaft and tighten the gear bolt to a torque of 54 Nm.

Now install and tension the timing belt according to the following instructions:

• Place the toothed belt on the toothed wheel so that the marks made when removing the belt match. Do not allow the belt to slip off the crankshaft wheel. The belt must be tensioned between the places indicated by the arrows in Figure 79.

• Loosen the timing belt tensioner roller bolt (this is the top roller in figure 79) and turn the crankshaft two revolutions from TDC to TDC. Turn the crankshaft only clockwise.
• Check the marks on the camshaft gear again and tighten the timing belt tensioner bolt to 42 Nm. If the marks do not match, remove the timing belt and put it on again without disengaging it from the crankshaft gear. When installing the removed belt, the marks made during removal must match.
• Check the tension of the toothed belt at the location shown in Figure 80. If the belt is tight at this location, the adjustment is correct. Otherwise, adjust the tension by loosening and tightening the tensioner bolt. When tightening the bolt, hold the tension roller in the new position.

• Check and adjust valve clearances and install timing belt cover.
• Clean the sealant from the places indicated in Figure 81 and apply the sealant. Place the gasket on the cylinder head cover and install the cylinder head cover. Secure the cylinder head cover with rubber tips and nuts in accordance with Figure 82. First insert the tips at the indicated angle and then install them in their original position.

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• Screw in the spark plugs and tighten them to a torque of 18 Nm.
• Install the intake manifold with a new gasket. Tighten the bolts and nuts to a torque of 19 Nm. Install the intake manifold support. Tighten the upper bolt to a torque of 19 Nm and the lower bolt to a torque of 40 Nm.
• Install the air pipe on the two bolts and connect the air hoses. Also install the pressure pipes of the cold engine starting device, the throttle body and the components of the exhaust gas return device. Connect all vacuum hoses.
• Install a new sealing ring on the drain pipe, lubricate the ring with engine oil and install the pipe with a new gasket. Tighten the pipe (two nuts and bolts) torque of 9 Nm.
• Remove old sealant from coolant drain nipple and apply new sealant to housing surface. Connect water and vacuum hoses.
• Install the ignition distributor.
• Install the exhaust manifold with a new gasket, heat shield, etc.
• Install the alternator and adjust the V-belt tension as described in Chapter "Electrical equipment".