A) Install a new cylinder head gasket, taking into account the position of the guides on the block.
b) Lower the cylinder head onto the gasket.
Note: Before installing, apply a light coat of engine oil to the bolt threads and under the bolt heads.
V) Using a suitable tool, install and progressively tighten in several passes (at least 3) 10 head bolts in the sequence shown in the figure.
- Tightening torque - 29 Nm
If the required torque is not reached when tightening the bolt, replace the bolt.
Note: The block head bolts have different lengths of 90mm and 108mm. When installing, be careful not to mix them up.
G) Mark the edge of the bolt facing the front of the engine (side opposite the power take-off) paint as shown in the picture.
d) Tighten all bolts in the sequence noted above by turning them 90°.
e) Tighten all bolts again in the sequence noted above by another 90°.
and) Make sure all bolt marks are oriented 180°from the original position.
2. (4A-FE, 5A-FE) Lower the engine with a hoist.
3. Assemble the intake camshaft.
A) Secure the camshaft in a vise by clamping it on the hex section.
Note: Be careful not to damage the camshaft.
b) Install the following parts:
(1) camshaft gear spring
(2) auxiliary gear,
(3) wavy puck.
V) Install the retaining ring with pliers.
G) Enter technological bolts (A) And (IN) into the sub camshaft gear locating hole.
d) Using a screwdriver, turn the camshaft sub gear clockwise and align the holes of the camshaft driven gear and the sub gear, then install the access bolt (WITH).
Note: Be careful not to damage the camshaft.
4. Install the intake and exhaust camshafts.
Attention: when installing camshafts, it must be taken into account that the axial clearance is very small, so the shafts must be laid in the bearing bed strictly horizontally, without distortion, in order to avoid jamming and / or damage to the shafts.
A. Install the exhaust camshaft.
A) Apply grease to the end faces of the camshaft.
b) Lay the exhaust camshaft into the cylinder head so that the dowel pin is slightly to the right of the vertical axis of the camshaft as shown. In this position, the cams of the 1st and 3rd cylinders equally press the pushers of the corresponding valves.
V) Remove any remaining old sealant.
G) Apply sealant to the #1 camshaft bearing cap as shown.
d) Install the camshaft bearing caps on the corresponding journals in accordance with the numbers stamped on them, as shown in the figure; the arrows on the bearing caps must point towards the front of the engine (in the direction opposite to the power take-off).
e) Apply engine oil to the threads and back of the bolt heads.
and) Install and evenly tighten the bearing cap bolts in several passes in the order shown in the figure.
- Tightening torque - 13 Nm
h) Apply grease to the seal lip.
and) Using a suitable mandrel, install the camshaft oil seal.
Note:
- - The oil seal must be installed as shown in the figure.
- - The stuffing box is installed in the bore of the block head until it stops.
B. Install the intake camshaft.
A) Install the exhaust camshaft dowel so that it is just above the edge of the cylinder head as shown.
b) Apply grease to the thrust (end) camshaft surface.
V) Engage the gears of the intake and exhaust camshafts, aligning the timing marks on these gears with each other.
Note: The camshaft gears also have "timing marks" or TDC marks; do not confuse them with installation marks.
G) Keeping the gears engaged, lay the intake camshaft in the bearing bed. In this position, the cams of the 1st and 3rd cylinders evenly press the pushers of the respective valves, which facilitates the installation of the camshaft.
d) Install the camshaft bearing caps on the corresponding journals in accordance with the numbers stamped on them, as shown in the figure; the arrows on the bearing caps must point towards the front of the engine (in the direction opposite to the power take-off).
e) Apply engine oil to the threads and back of the camshaft bearing cap bolt heads.
and) Tighten the bearing cap bolts evenly in several passes in the order shown in the figure.
- Tightening torque - 13 Nm
h) Remove the technological bolt connecting the auxiliary and main gears of the intake camshaft.
And) Install the cover of the 1st bearing of the intake camshaft with the arrow forward (towards the timing drive).
Attention: if the cover of the 1st bearing does not sit in place, use a screwdriver to move the camshaft back and forth along its axis.
To) Tighten the bearing cap bolts evenly in several passes.
- Tightening torque - 13 Nm
l) Turn the exhaust camshaft clockwise by its hex part 1 turn (from TDC to BDC) so that the dowel pin is in the position shown in the figure.
m) Make sure the timing marks on the exhaust and intake camshaft gears are correct. are in the extreme upper position, and the TDC marks ("timing marks"), match each other as shown in the figure.
5. Check and adjust valve clearances (see section "Checking and adjusting thermal clearances in valves").
6. Install the exhaust manifold strut.
Torque:
- 4A-FE, 5A-FE - 40 Nm
7A-FE:
- bolt A - 40 Nm
- bolt B - 44 Nm
7. (4A-FE, 5A-FE) Establish a reception pipe of system of release, having wrapped nuts of fastening.
- Tightening torque - 63 Nm
8. (4A-FE, 5A-FE) Install the exhaust pipe bracket.
- Tightening torque - 13 Nm
9. (7A-FE) Install the exhaust pipe.
A) Install the exhaust pipe bracket and tighten the 2 bolts and 2 fastening nuts.
- Tightening torque - 63 Nm
b) Install the downpipe lower bracket by tightening the 2 mounting nuts.
- Tightening torque - 33 Nm
10. Install the generator.
11. Connect the #2 coolant inlet with 2 nuts.
- Tightening torque - 15 Nm
12. (7A-FE) Connect the connectors of the EVAP solenoid valve, idle speed control valve, throttle position sensor, coolant temperature sensor, integrated ignition assembly.
12. Install wire harness guard.
13. Install the oil dipstick assembly with guide.
A) Install a new O-ring on the dipstick guide with a little soapy water on it.
V) Install the dipstick assembly with the guide and secure it with the bolt.
- Tightening torque - 10 Nm
14. Install the power steering pump.
A) Install the pump by tightening the 2 mounting bolts.
- Tightening torque - 19 Nm
b) Tighten the adjusting bolt.
15. Connect the fuel inlet hose and fuel return hose by tightening the bypass bolt.
- Tightening torque - 30 Nm
16. Install the intake manifold strut.
Torque:
- intake manifold mounting bolt - 19 Nm
- bolt of fastening to the cylinder block - 40 Nm
17. Connect the heater hose and coolant hose.
18. Connect the radiator inlet and outlet hoses.
19. Connect a socket of the gauge of position of a cranked shaft.
20. Install the air filter cover with air duct.
21. (4A-FE, 5A-FE) Connect the air hose of the air conditioning solenoid valve.
22. Connect the vacuum hose of the fuel vapor accumulator.
23. Connect a vacuum hose of the amplifier of brakes.
24. Connect the vacuum hose of the absolute pressure sensor in the intake manifold.
25. Connect the power steering air bypass hose.
26. Connect the vacuum reservoir hose.
27. Connect throttle control cable (automatic transmission).
28. Connect the accelerator cable.
29. Install the integrated ignition assembly or distributor.
30. Install the timing belt.
31. Fill in coolant.