Engine: Diagnosis Toyota Paseo L40

Inspection

1. Inspect cylinder head warpage at cylinder block and manifold areas. Replace cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(ref-49065-S22268377962001011500000) table under ENGINE SPECIFICATIONS.
2. Inspect intake manifold-to-cylinder head surfaces for warpage. Replace intake manifold if warpage exceeds .0039" (.099 mm).
3. Inspect exhaust manifold-to-cylinder head surface warpage. Replace exhaust manifold if warpage exceeds .0079" (.200 mm).
4. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck warpage exceeds specification. See «CYLINDER BLOCK»(ref-49065-S16853097632001011500000) table under ENGINE SPECIFICATIONS. Inspect camshaft and components. See CAMSHAFT under «REMOVAL & INSTALLATION»(ref-49065-S21547183592001011500000) .

Scheme 8

1. Install NEW cylinder head gasket on cylinder block. Ensure all holes in cylinder head gasket align with holes in cylinder block. Install cylinder head. Apply engine oil on cylinder head bolt threads and cylinder head bolt-to-cylinder head contact surfaces.
2. Install and tighten cylinder head bolts to specification in sequence. see scheme 10 See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000). Install camshafts using proper procedure. See CAMSHAFT under «REMOVAL & INSTALLATION»(ref-49065-S21547183592001011500000).
3. To install remaining components, reverse removal procedure using NEW gaskets and NEW "O" rings. If camshaft or cylinder head components are serviced, adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-49065-S13161886812001011500000) under ADJUSTMENTS.
4. If spark plug tube gasket in valve cover requires replacement, pry spark plug tube gasket from valve cover. Use care not to scratch valve cover sealing surface.
5. Using Handle (SST 09552-10010) and Gasket/Seal Installer (SST 09556-10010), install spark plug tube gasket until it is even with upper edge of valve cover surface. Coat spark plug tube gasket sealing area with grease.
6. Before installing valve cover and gasket, apply sealant at indicated valve cover sealing areas on cylinder head. see scheme 3 Using NEW gasket, install valve cover and sealing washers. Install and tighten retaining nuts to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000). CAUTION: Install spacers below delivery pipe with plastic end away from cylinder head and metal area toward cylinder head.
7. If injector was removed from delivery pipe, coat NEW "O" ring with gasoline. Install NEW "O" ring and NEW grommet on injector. Ensure injectors rotate smoothly after delivery pipe is installed. If injector does not rotate smoothly, check for damaged "O" rings.
8. When installing throttle body (if removed), ensure NEW throttle body gasket is positioned with protrusion in proper location. (Scheme 8)
9. Before installing air control valve, install NEW "O" ring on air control valve. Coat "O" ring with soapy water solution. Install air control valve. Install and tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000).
10. Use NEW nuts when installing exhaust manifold. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000).
11. When installing coolant housing, apply sealant in groove on rear of coolant housing before installing. Ensure excessive sealant is not applied on rear of coolant housing so sealant does not enter passages on cylinder head.
12. Install NEW "O" ring on distributor and coat with engine oil. When installing distributor, rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine.
13. Ensure timing mark on crankshaft pulley aligns with "0" mark on timing belt cover. Ensure slot area on intake camshaft is properly position. (Scheme 9)
14. Position cutout area on coupling with groove on distributor housing. (Scheme 9) Install distributor. Position center of flange on distributor with bolt hole on cylinder head. Install and tighten distributor hold-down bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000).
15. Install remaining components. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000). Adjust fluid levels, control cables and ignition timing.

Scheme 9