Cylinder head (3S-GTE)¶

Components¶

Removal of cylinder head¶

(See Cylinder head (3S-GTE))

Disconnect cable from negative terminal of battery.

Caution

Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery.
Drain engine coolant. (See page CO-6)
Remove engine under covers.
Remove engine hood side panels.
Remove suspension upper brace. (See Cylinder block (3S-GTE) › Removal of engine, step 8)
Disconnect accelerator cable from throttle body.
Remove cruise control actuator (w/ cruise control system) and accelerator linkage. (See Cylinder block (3S-GTE) › Removal of engine, step 13)
Remove air cleaner cap. (See Cylinder block (3S-GTE) › Removal of engine, step 9)
Disconnect ground strap connector.
Disconnect hoses.
1. Brake booster vacuum hose from intake manifold
2. Turbocharging pressure sensor hose from intake manifold
3. A/C VSV vacuum hose from intake manifold
4. A/C VSV air hose from No.2 air tube
Remove RH front engine hanger.

Remove the three bolts and engine hanger.
Remove intercooler. (See Intercooler, steps 4, 5, 7, 8, 10–13)
Remove front exhaust pipe. (See Cylinder block (3S-GTE) › Removal of engine, steps 30, 31)
Remove catalytic converter.
1. Remove the four bolts and RH converter stay.
2. Remove the three bolts and LH converter stay.
3. Remove the three bolts, two nuts and catalytic converter. Remove the gasket, retainer and cushion.
4. Remove the five bolts and front heat insulator.
5. Remove the four bolts and rear heat insulator.
Remove turbocharger. (See Turbocharger › Removal of turbocharger, steps 8, 11, 12, 18–24)
Remove throttle body. (See steps 5 to 8, 10 and 11 on pages FI-135 and 136)
Remove cold start injector. (See steps 2 to 4 on pages FI-99 and 100)
Remove exhaust manifold.
1. Remove the seven nuts, exhaust manifold and gasket.
2. Remove the bolt, nut and heat insulator.
Remove distributor. (See Distributor (3S-GTE))
Remove No.2 air tube.
1. Disconnect the following hose:
  1. Air hose from No.1 air tube
  2. Air hose from intake manifold
2. Remove the bolt and No.2 air tube.
Remove LH engine hanger.

Remove the two bolts and engine hanger.
Remove EGR vacuum modulator and VSV.
1. Disconnect the EGR VSV connector.
2. Disconnect the following hoses:
  1. Vacuum hose from EGR valve
  2. Vacuum hose from EGR vacuum modulator
3. Remove the bolt, vacuum modulator and VSV assembly.
Remove vacuum pipe.
1. Disconnect the vacuum hose from the vacuum pipe.
2. Remove the bolt and vacuum pipe.
Remove EGR valve and pipe.
1. Disconnect the vacuum hose from the EGR valve.
2. Remove the four bolts, the EGR valve, pipe assembly and two gaskets.
Remove water outlet and housing.
1. Disconnect the following connectors:
  - Water temperature sender gauge connector
  - Water temperature sensor
  - Cold start injector time switch connector
2. Remove the bolt, and disconnect the fuel inlet hose.
3. Remove the bolt, and disconnect the fuel return hose.
4. Disconnect the following hoses:
  1. Water filler hose
  2. Radiator hose
  3. Water by-pass pipe hose from ISC valve
  4. Heater water hose
  5. Water by-pass hose from water by-pass pipe
  6. Two EVAP VSV vacuum hoses
5. Remove the two bolts, the water outlet, housing assembly and gasket.
Remove oil pressure switch.
Remove oil cooler. (See steps 7 to 10 on pages LU-18 and 19)
Remove water by-pass pipe.
1. Disconnect the following hoses:
  1. Water by-pass hose from cylinder block
  2. Water by-pass hoses from No.1 air tube
  3. Vacuum hose from turbocharging pressure VSV
  4. Heater water hose
2. Remove the two bolts, two nuts, water by-pass pipe, gasket and O-ring.
Remove intake manifold stays.
1. Disconnect the alternator wire clamp from the wire bracket.
2. Remove the two bolts and manifold stay. Remove the two manifold stays.
Remove No.1 air tube.
1. Disconnect the vacuum hose from the turbocharging pressure VSV.
2. Disconnect the alternator wire clamp from the wire bracket.
3. Remove the two bolts, wire bracket and air tube.
Remove T-VIS vacuum tank, T-VIS VSV, turbocharging pressure VSV and bracket.
1. Disconnect the following connectors:
  - T-VIS VSV connector
  - Turbocharging pressure VSV connector
2. Disconnect the following hoses:
  1. Vacuum hose (from T-VIS VSV) from T-VIS actuator
  2. Vacuum hose (from T-VIS vacuum tank) from intake manifold
3. Remove the two bolts, the T-VIS vacuum tank, T-VIS VSV, turbocharging pressure VSV and bracket assembly.
Disconnect engine wire from intake manifold.
1. Disconnect the two engine wire clamps from the mount bolts on the No.2 timing belt covers.
2. Disconnect the injector connector.
3. Remove the bolt, and disconnect the ground strap.
4. Disconnect the knock sensor connector.
5. Disconnect the alternator connector.
6. Disconnect the vacuum sensing hose from the intake manifold.
7. Remove the two bolts, and disconnect the engine wire from the intake manifold.
Remove intake manifold and T-VIS valve.

Remove the four bolts, three nuts, intake manifold, T-VIS VSV and two gaskets.
Remove delivery pipe and injectors. (See steps 9, 13 to 15 on pages FI-111 and 112)
Remove cylinder head cover.

Remove the ten screws, seal washers, head cover and two gaskets.
Remove camshaft timing pulleys. (See Timing belt (3S-GTE) › Removal of timing belt, steps 9–21)
Remove No.1 idler pulley. (See Timing belt (3S-GTE) › Removal of timing belt, step 26)
Remove No.3 timing belt cover.

Remove the five bolts and timing belt cover.
Hint
- Support the timing belt, so that the meshing of the crankshaft timing pulley and timing belt does not shift.
- Be careful not to drop anything inside the timing belt cover.
- Do not allow the timing belt to come into contact with oil, water or dust.
Remove camshafts.

Uniformly loosen and remove the ten bearing cap bolts in several passes in the sequence shown, and remove the five bearing caps, oil seal and camshaft. Remove the intake and exhaust camshafts.
Remove cylinder head.
1. Using SST, uniformly loosen and remove the ten cylinder head bolts in several passes in the sequence shown.
  
  SST 09043-38100
  
  Hint
  
  Cylinder head warpage or cracking could result from removing in the incorrect order.
2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.
  
  Hint
  
  If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.
  
  Notice
  
  Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

Disassembly of cylinder head¶

(See Cylinder head (3S-GTE))

Remove valve lifters and shims.

Hint

Arrange the valve lifters and shims in correct order.
Remove valves.
1. Using SST, compress the valve spring and remove the two keepers.
  
  SST 09202-70010
2. Remove the spring retainer, valve spring, valve and spring seat.
  
  Hint
  
  Arrange the valves, valve springs, spring seats and spring retainers in correct order.
3. Using needle-nose pliers, remove the oil seal.

Inspection, cleaning and repair of cylinder head components¶

Clean top surfaces of pistons and cylinder block.
1. Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface.
2. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
3. Using compressed air, blow carbon and oil from the bolt holes.
  
  Caution
  
  Protect your eyes when using high-compressed air.
Clean cylinder head.
1. Remove gasket material
  
  Using a gasket scraper, remove all the gasket material from the cylinder block surface.
  
  Notice
  
  Be careful not to scratch the cylinder block contact surface.
2. Clean combustion chambers
  
  Using a wire brush, remove all the carbon from the combustion chambers.
  
  Notice
  
  Be careful not to scratch the cylinder block contact surface.
3. Clean valve guide bushings
  
  Using a valve guide bushing brush and solvent, clean all the guide bushings.
4. Clean cylinder head
  
  Using a soft brush and solvent, thoroughly clean the cylinder head.
Inspect cylinder head.
1. Inspect for flatness
  
  Using precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block, T-VIS valve and exhaust manifold for warpage.
  
  Surface Maximum warpage
  
  Cylinder block side 0.20 mm (0.0079 in.)
  
  T-VIS valve side 0.20 mm (0.0079 in.)
  
  Exhaust manifold side 0.30 mm (0.0118 in.)
  
  If warpage is greater than maximum, replace the cylinder head.
2. Inspect for cracks
  
  Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
  
  If cracked, replace the cylinder head.
Clean valves.
1. Using a gasket scraper, chip off any carbon from the valve head.
2. Using a wire brush, thoroughly clean the valve.
Inspect valve stems and guide bushings.
1. Using a caliper gauge, measure the inside diameter of the guide bushing.
  
  Bushing inside diameter: 6.000 – 6.018 mm (0.2362 – 0.2369 in.)
2. Using a micrometer, measure the diameter of the valve stem.
  
  Valve stem diameter:
  - Intake – 5.960 – 5.975 mm (0.2346 – 0.2352 in.)
  - Exhaust – 5.955 – 5.970 mm (0.2344 – 0.2350 in.)
3. Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.
  
  Standard oil clearance:
  - Intake – 0.025 – 0.058 mm (0.0010 – 0.0023 in.)
  - Exhaust – 0.030 – 0.063 mm (0.0012 – 0.0025 in.)
  Maximum oil clearance:
  - Intake – 0.08 mm (0.0031 in.)
  - Exhaust – 0.10 mm (0.0039 in.)
  If the clearance is greater than maximum, replace the valve and guide bushing.
If necessary, replace valve guide bushings.
1. (w/ Snap Ring)
  
  Insert an old valve wrapped with tape into the valve guide bushing, and break off the valve guide bushing by hitting it with a hammer. Remove the snap ring.
  
  Hint
  
  Wrap the tape approx. 13 mm (0.51 in.) from the valve stem end.
  
  Notice
  
  Be careful not to damage the valve lifter hole.
2. Gradually heat the cylinder head to 80 – 100°C (176 – 212°F).
3. Using SST and a hammer, tap out the guide bushing.
  
  SST 09201-70010
4. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
5. Select a new guide bushing (STD size or O/S 0.05).
  
  Both intake and exhaust
  
  Bushing bore diameter mm (in.) Bushing size
  
  10.988 – 11.006 (0.4326 – 0.4333) Use STD
  
  11.038 – 11.056 (0.4346 – 0.4353) Use O/S 0.05
  
  If the bushing bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bushing bore to the following dimension:
  
  11.038 – 11.056 mm (0.4346 – 0.4353 in.)
  
  If the bushing bore diameter of the cylinder head is greater than 11.056 mm (0.4353 in.), replace the cylinder head.
6. Gradually heat the cylinder head to 80 – 100°C (176 – 212°F).
7. Using SST and a hammer, tap in a new guide bushing until the snap ring makes contact with the cylinder head.
  
  SST 09201-70010
8. Using a sharp 6 mm reamer, ream the guide bushing to obtain the standard specified clearance (See Inspection, cleaning and repair of cylinder head components) between the guide bushing and valve stem.
Inspect and grind valves.
1. Grind the valve enough to remove pits and carbon.
2. Check that the valve is ground to the correct valve face angle.
  
  Valve face angle: 44.5°
3. Check the valve head margin thickness.
  
  Standard margin thickness: 0.8 – 1.2 mm (0.031 – 0.047 in.)
  
  Minimum margin thickness: 0.5 mm (0.020 in.)
  
  If the margin thickness is less than minimum, replace the valve.
4. Check the valve overall length.
  
  Standard overall length:
  - Intake – 105.50 mm (4.1535 in.)
  - Exhaust – 99.55 mm (3.9193 in.)
  Minimum overall length:
  - Intake – 104.80 mm (4.1260 in.)
  - Exhaust – 98.85 mm (3.8917 in.)
  If the overall length is less than minimum, replace the valve.
5. Check the surface of the valve stem tip for wear.
  
  If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.
  
  Notice
  
  Do not grind off more than the minimum.
Inspect and clean valve seats.
1. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.
2. Check the valve seating position.
  
  Apply a thin coat of prussion blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate the valve.
3. Check the valve face and seat for the following:
  - If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
  - If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
  - Check that the seat contact is in the middle of the valve face with the following width:
    
    1.0 – 1.4 mm (0.039 – 0.055 in.)
  If not, correct the valve seats as follows:
  1. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
  2. If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.
4. Hand-lap the valve and valve seat with an abrasive compound.
5. After hand-lapping, clean the valve and valve seat.
Inspect valve springs.
1. Using a steel square, measure the squareness of the valve spring.
  
  Maximum squareness: 2.0 mm (0.079 in.)
  
  If squareness is greater than maximum, replace the valve spring.
2. Using vernier calipers, measure the free length of the valve spring.
  
  Free length: 44.43 mm (1.7492 in.)
  
  If the free length is not as specified, replace the valve spring.
3. Using a spring tester, measure the tension of the valve spring at the specified installed length.
  
  Installed tension: 20.5 – 24.1 kg (45.2 – 53.1 lb, 201 – 236 N) at 34.4 mm (1.354 in.)
  
  If the installed tension is not as specified, replace the valve spring.
Inspect camshafts and bearings.
1. Inspect camshaft for runout
  1. Place the camshaft on V-blocks.
  2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum circle runout: 0.06 mm (0.0024 in.)
  
  If the circle runout is greater than maximum, replace the camshaft.
2. Inspect cam lobes
  
  Using a micrometer, measure the cam lobe height.
  
  Standard cam lobe height: 41.010 – 41.110 mm (1.6146 – 1.6185 in.)
  
  Minimum cam lobe height: 39.90 mm (1.5709 in.)
  
  If the cam lobe height is greater than minimum, replace the camshaft.
3. Inspect camshaft journals
  
  Using a micrometer, measure the journal diameter.
  
  Journal diameter: 26.959 – 26.975 mm (1.0614 – 1.0620 in.)
  
  If the journal diameter is not as specified, check the oil clearance.
4. Inspect camshaft bearings
  
  Check the bearings for flaking and scoring.
  
  If the bearings are damaged, replace the bearing caps and cylinder head as a set.
5. Inspect camshaft journal oil clearance
  1. Clean the bearing caps and camshaft journals.
  2. Place the camshafts on the cylinder head.
  3. Lay a strip of Plastigage across each of the camshaft journals.
  4. Install the bearing caps. (See Installation of cylinder head, step 2)
    
    Torque: 190 kg-cm (14 ft-lb, 19 N·m)
    
    Notice
    
    Do not turn the camshaft.
  5. Remove the bearing caps.
  6. Measure the Plastigage at its widest point.
    
    Standard oil clearance: 0.025 – 0.062 mm (0.0010 – 0.0024 in.)
    
    Maximum oil clearance: 0.08 mm (0.0031 in.)
    
    If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
  7. Completely remove the Plastigage.
6. Inspect camshaft thrust clearance
  1. Install the camshafts. (See Installation of cylinder head, step 2)
  2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
  Standard thrust clearance: 0.120 – 0.240 mm (0.0047 – 0.0094 in.)
  
  Maximum thrust clearance: 0.30 mm (0.0118 in.)
  
  If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
Inspect valve lifters and lifter bores.
1. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
  
  Lifter bore diameter: 28.000 – 28.021 mm (1.1024 – 1.1032 in.)
2. Using a micrometer, measure the lifter diameter.
  
  Lifter diameter: 27.975 – 27.985 mm (1.1014 – 1.1018 in.)
3. Subtract the lifter diameter measurement from the lifter bore diameter measurement.
  
  Standard oil clearance: 0.015 – 0.046 mm (0.0005 – 0.0018 in.)
  
  Maximum oil clearance: 0.07 mm (0.0028 in.)
  
  If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.
Inspect intake and exhaust manifolds.

(Intake manifold)

Using precision straight edge and feeler gauge, measure the surface contacting the T-VIS valve for warpage.

Maximum warpage: 0.20 mm (0.0079 in.)

If warpage is greater than maximum, replace the intake manifold.

(Exhaust manifold)

Using precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.

Maximum warpage: 0.20 mm (0.0079 in.)

If warpage is greater than maximum, replace the exhaust manifold.

Inspection of Toyota – variable induction system (T-VIS) components¶

Inspect T-VIS valve.
1. Inspect for flatness
  
  Using precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and intake manifold for warpage.
  
  Maximum warpage: 0.20 mm (0.0079 in.)
  
  If warpage is greater than maximum, replace the T-VIS valve.
2. Inspect for operation
  1. With 400 mmHg (15.75 in.Hg, 53.3 kPa) of vacuum applied to the actuator, check that the control valve moves smoothly to the fully closed position.
  2. With the vacuum released, check that the control valve fully opens quickly.
  If operation is not as specified, replace the T-VIS valve.
Inspect vacuum tank.
1. Check that air flows from ports A to B.
2. Check that air does not flow from ports B to A.
3. Apply 500 mmHg (19.69 in.Hg, 66.7 kPa) of vacuum to port A, and check that there is no change in vacuum after one minute.
  
  If operation is not as specified, replace the vacuum tank.
Inspect T-VIS VSV. (See page FI-163)

Assembly of cylinder head¶

(See Cylinder head (3S-GTE))

Hint

Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
Replace all gaskets and oil seals with new ones.

Install valves.
1. Using SST, push in a new oil seal.
  
  SST 09201-41020
  
  Hint
  
  The intake valve oil seal is brown and the exhaust valve oil seal is black.
2. Install the following parts:
  1. Valve
  2. Spring seat
  3. Valve spring
  4. Spring retainer
  Hint
  
  Install the valve spring, facing the white painted mark upward.
3. Using SST, compress the valve spring and place the two keepers around the valve stem.
  
  SST 09202-70010
4. Using a plastic-faced hammer, lightly tap the valve stem tip to assure proper fit.
Install valve lifters and shims.
1. Install the valve lifter and shim.
2. Check that the valve lifter rotates smoothly by hand.

Installation of cylinder head¶

(See Cylinder head (3S-GTE))

Install cylinder head.
1. Place cylinder head on cylinder block
  1. Place a new cylinder head gasket in position on the cylinder block.
    
    Notice
    
    Be careful of the installation direction.
  2. Place the cylinder head in position on the cylinder head gasket.
2. Install cylinder head bolts
  Hint
  - The cylinder head bolts are tightened in two progressive steps (steps (b) and (d)).
  - If any cylinder head bolt is broken or deformed, replace it.
  1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  2. Using SST, install and uniformly tighten the ten cylinder head bolts in several passes in the sequence shown.
    
    SST 09043-38100
    
    Torque: 500 kg-cm (36 ft-lb, 49 N·m)
    
    If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
  3. Mark the front of the cylinder head bolt head with paint.
  4. Retighten the cylinder head bolts 90° in the numerical order shown.
  5. Check that the painted mark is now at a 90° angle to front.
Install camshafts.
1. Place the camshaft on the cylinder head with the No.1 cam lobe facing outward as shown.
2. Apply seal packing to the No.1 bearing cap as shown.
  
  Seal packing: Part No. 08826-00080 or equivalent
3. Install the bearing caps in their proper locations.
  
  Hint
  
  Each bearing cap has a number and front mark.
4. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
5. Install and uniformly tighten the ten bearing cap bolts on one side in several passes in the sequence shown.
  
  Torque: 190 kg-cm (14 ft-lb, 19 N·m)
6. Apply MP grease to a new oil seal lip.
7. Using SST, tap in the two camshaft oil seals.
  
  SST 09223-50010
Adjust valve clearance. (See Engine tune-up › Inspection and adjustment of valve clearance (3S-GTE))

Turn the camshaft and position the cam lobe upward, check and adjust the valve clearance.

Valve clearance (cold):
- Intake – 0.15 – 0.25 mm (0.006 – 0.010 in.)
- Exhaust – 0.20 – 0.30 mm (0.008 – 0.012 in.)
Install No.3 timing belt cover.

Install the No.3 belt cover with the five bolts.

Torque: 90 kg-cm (78 in.-lb, 8.8 N·m)
Install No.1 idler pulley. (See Timing belt (3S-GTE) › Installation of timing belt, step 4)
Install camshaft timing pulleys. (See Timing belt (3S-GTE) › Installation of timing belt, steps 9–23)
Install cylinder head cover.
1. Apply seal packing to the cylinder head as shown in the figure.
  
  Seal packing: Part No. 08826-00080 or equivalent
2. Install the two gaskets to the head cover.
3. Install the head cover with the twelve seal washers and screws. Uniformly tighten the screw in several passes.
  
  Torque: 25 kg-cm (21 in.-lb, 2.5 N·m)
Install delivery pipe and injectors. (See steps 2 to 5 on pages FI-117 and 118)
Install T-VIS valve and intake manifold.
1. Place a new gasket, the T-VIS valve and the other new gasket on the cylinder head.
2. Install the intake manifold with the four bolts and three nuts. Uniformly tighten the bolts and nuts in several passes.
  
  Torque: 195 kg-cm (14 ft-lb, 19 N·m)
Install engine wire to intake manifold.
1. Install the engine wire clamp to the intake manifold with the two bolts.
2. Connect the vacuum sensing hose to the intake manifold.
3. Connect the alternator connector.
4. Connect the knock sensor connector.
5. Connect the ground strap with the bolt.
6. Connect the injector connectors. (See step 6 on page FI-119)
7. Install the two wire clamps to the mount bolts of the No.2 timing belt cover.
Install T-VIS vacuum tank, T-VIS VSV, turbocharging pressure VSV and bracket.
1. Install the T-VIS vacuum tank, T-VIS VSV, turbocharging pressure VSV and bracket assembly with the two bolts.
2. Connect the following hoses:
  1. Vacuum hose (from T-VIS VSV) from T-VIS actuator
  2. Vacuum hose (from T-VIS vacuum tank) from intake manifold
3. Connect the following connectors:
  - T-VIS VSV connector
  - Turbocharging pressure VSV connector
Install No.1 air tube.
1. Install the air tube and wire bracket with the two bolts.
2. Install the alternator wire clamp to the wire bracket.
3. Connect the vacuum hose to turbocharging pressure VSV.
Install intake manifold stays.
1. Install the manifold stay with the two bolts. Install the two manifold stays.
  
  Torque: 260 kg-cm (19 ft-lb, 25 N·m)
2. Install the alternator wire clamp to the wire bracket.
Install water by-pass pipe.
1. Install a new O-ring to the pipe.
2. Apply soapy water on the O-ring.
3. Install a new gasket to the water pump.
4. Install the water by-pass pipe with the two nuts and two bolts.
  
  Torque (nuts): 80 kg-cm (69 in.-lb, 7.8 N·m)
5. Connect the following hoses:
  1. Water by-pass hose from cylinder block
  2. Water by-pass hoses from No.1 air tube
  3. Vacuum hose from turbocharging pressure VSV
  4. Heater water hose
Install oil cooler. (See steps 2 to 4 on pages LU-21 and 22)
Install oil pressure switch.

Apply adhesive to two or three threads.

Adhesive: Part No. 08833-00080, THREE BOND 1324 or equivalent
Install water outlet and housing.
1. Install a new gasket and the water outlet and housing assembly with the two bolts.
  
  Torque: 400 kg-cm (29 ft-lb, 39 N·m)
2. Connect the following hoses:
  1. Water by-pass hose from water by-pass pipe
  2. Two EVAP VSV vacuum hoses
  3. Water filler hose
  4. Radiator hose
  5. Water by-pass pipe hose from ISC valve
  6. Heater water hose
3. Install the fuel inlet hose with the bolt.
4. Install the fuel return hose with the bolt.
5. Connect the following connectors:
  - Water temperature sender gauge connector
  - Water temperature sensor
  - Cold start injector time switch connector
Install EGR valve and pipe.
1. Install two new gaskets, the EGR valve and pipe assembly with the four bolts.
  
  Torque:
  - Intake manifold side – 195 kg-cm (14 ft-lb, 19 N·m)
  - Cylinder head side – 260 kg-cm (19 ft-lb, 25 N·m)
2. Connect the vacuum hose to the EGR valve.
Install vacuum pipe.
1. Install the vacuum pipe with the bolt.
2. Connect the vacuum hose to the vacuum pipe.
Install EGR vacuum modulator and VSV.
1. Install the EGR vacuum modulator and VSV assembly with the bolt.
2. Connect the following hoses:
  1. Vacuum hose from EGR valve
  2. Vacuum hose from EGR vacuum modulator
3. Connect the EGR VSV connector.
Install LH engine hanger.

Install the LH engine hanger with the two bolts.

Torque:
- 12 mm head bolt – 130 kg-cm (9 ft-lb, 13 N·m)
- 14 mm head bolt – 195 kg-cm (14 ft-lb, 19 N·m)
Install No.2 air tube.
1. Install the No.2 air tube with the bolt.
2. Connect the following hoses:
  1. Air hose from No.1 air tube
  2. Air hose from intake manifold
Install distributor. (See Distributor (3S-GTE) › Installation of distributor, steps 1–7)
Install exhaust manifold.
1. Install the heat insulator with the bolt and nut.
2. Install a new gasket and the exhaust manifold with the seven nuts. Uniformly tighten the nuts in several passes.
  
  Torque: 530 kg-cm (38 ft-lb, 52 N·m)
Install cold start injector. (See steps 1 to 3 on page FI-101)
Install throttle body. (See steps 2, 3 and 4 to 8 on pages FI-138 and 139)
Install turbocharger. (See Turbocharger › Installation of turbocharger, steps 5–11, 17, 18, 21)
Install catalytic converter.
1. Install the front heat insulator with the five bolts.
2. Install the rear heat insulator with the four bolts.
3. Place the cushion, retainer and a new gasket on the catalytic converter.
4. Install the catalytic converter with the three bolts and two nuts.
  
  Torque: 300 kg-cm (22 ft-lb, 29 N·m)
5. Install the RH converter stay with the four bolts.
  
  Torque: 600 kg-cm (43 ft-lb, 59 N·m)
6. Install the LH converter stay with the three bolts.
  
  Torque: 600 kg-cm (43 ft-lb, 59 N·m)
Install front exhaust pipe. (See Cylinder block (3S-GTE) › Installation of engine, steps 18, 19)
Install intercooler. (See Intercooler › Installation of intercooler, steps 2–5, 7, 8, 10, 11)
Install RH front engine hanger.

Install the engine hanger with the three bolts.

Torque: 400 kg-cm (29 ft-lb, 39 N·m)
Connect hoses.
1. A/C VSV vacuum hose from intake manifold
2. A/C VSV air hose from No.2 air tube
3. Turbocharging pressure sensor hose from intake manifold
4. Brake booster vacuum hose from intake manifold
Connect ground strap connector.
Install air cleaner cap. (See Cylinder block (3S-GTE) › Installation of engine, step 40)
Install cruise control actuator (w/ cruise control system) and accelerator linkage. (See Cylinder block (3S-GTE) › Installation of engine, step 36)
Install accelerator cable, and adjust it.
Install suspension upper brace. (See Cylinder block (3S-GTE) › Installation of engine, step 41)
Fill engine with coolant. (See page CO-7)

Capacity (w/ heater): 13.6 liters (14.4 US qts, 12.0 Imp. qts)
Start engine and check for leaks.
Adjust ignition timing. (See Distributor (3S-GTE) › Installation of distributor, steps 9–13)

Ignition timing: 10° BTDC @ idle (w/ terminals TE1 and E1 connected)
Install engine hood side panels.
Install engine under covers.
Perform road test.

Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
Recheck engine coolant and oil levels.

Surface	Maximum warpage
Cylinder block side	0.20 mm (0.0079 in.)
T-VIS valve side	0.20 mm (0.0079 in.)
Exhaust manifold side	0.30 mm (0.0118 in.)

Bushing bore diameter mm (in.)	Bushing size
10.988 – 11.006 (0.4326 – 0.4333)	Use STD
11.038 – 11.056 (0.4346 – 0.4353)	Use O/S 0.05