Engine Mechanical Cylinder Head: Removal & Installation Toyota Prius I рестайлинг

INSTALLATION

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

Scheme 118

Taping Valve Stem Tip To Ensure A Proper Fit. Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. Place Cylinder Head On Cylinder Block NOTE: Be careful of the installation direction. Place a new cylinder head gasket on the cylinder block surface with the Lod No. stamp upward. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head. (Scheme 120): Placing Cylinder Head Gasket On Cylinder Block Surface With Lod No. Stamp Upward
2. Install Cylinder Head Bolts Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown. (Scheme 121): Installing 10 Cylinder Head Bolts And Plate Washers Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. Mark the front of the cylinder head bolt with paint. Retighten the cylinder head bolts by 90° and 90° in the numerical order shown. Check that the paint mark is now at a 180° angle to the front. Install the bolt holding the water bypass pipe to the cylinder head. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) (Scheme 122): Retightening Cylinder Head Bolts By 90° And 90° Connect the upper radiator hose to the water hose unions. Connect the heater hose to the water hose unions.
3. Install Camshafts Place the 2 camshafts on the cylinder head with the No.1 cam lobes facing as shown the illustration. (Scheme 123): Placing 2 Camshafts On Cylinder Head With No.1 Cam Lobes Facing NOTE: No. 2 camshaft bearing cap has a number and front mark. Install the bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (Scheme 124): Identifying Camshaft Bearing Cap Number And Front Mark Install and uniformly tighten the 19 bearing cap bolts. After tightening the No.1 camshaft bearing cap, tighten then in several passes, in the sequence shown. (Scheme 125): Installing And Uniformly Tightening Bearing Cap Bolts Torque: No. 1 23 N.m (235 kgf.cm, 17 ft.lbf) No. 2 12.7 N.m (130 kgf.cm, 10 ft.lbf)
4. Install Valve Timing Controller Assembly And Camshaft Timing Sprocket Apply engine oil in the rage from the tip of the intake camshaft to 16 mm from that tip. NOTE: Do not push valve timing controller assembly to the camshaft forcibly when installing it. Except leaded gasoline spec: Align the timing mark on the valve timing controller assembly with the knock pin, and install the value timing controller assembly to the camshaft. Align the knock pin hole in the camshaft timing sprocket with the knock pin of the camshaft, and install the sprocket to the camshaft. Temporarily install the timing sprocket bolt. Hold the hexagon head portion of the camshaft with a wrench, and install the bolt. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
5. Check And Adjust Valve Clearance Adjustment See VALVE CLEARANCE ADJUSTMENT.
6. Install Cylinder Head Cover
7. Install Oil Control Valve.
8. Install Oil Filter Cap.
9. Install PCV Valve.
10. Install ECT SENSOR.
11. Install CAMSHAFT POSITION SENSOR.
12. Install TIMING CHAIN COVER.
13. Install Exhaust Manifold Install a new gasket and the exhaust manifold with the 3 bolts 2 nuts. Uniformly tighten the bolts and nuts in several passes. (Scheme 126): Installing Gasket And Exhaust Manifold With 3 Bolts 2 Nuts Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) Install the upper heat insulator with the 4 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
14. Install Exhaust Manifold Stay Install the manifold stay with the 3 bolts. Alternately tighten the bolts. (Scheme 127): Installing Manifold Stay With 3 Bolts Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
15. Connect Front Exhaust Pipe To Exhaust Manifold (Scheme 128): Connecting Front Exhaust Pipe To Exhaust Manifold Place a new gasket to the exhaust manifold. Install the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold. Torque: 62 N.m (630 kgf.cm, 46 ft.lbf)
16. Install Intake Manifold Install a new gasket, the intake manifold and 2 brackets with the 2 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. (Scheme 129): Installing Gasket, Intake Manifold And 2 Brackets With 2 Bolts And 2 Nuts Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
17. Connect Engine Wire To Cylinder Head Install the engine wire protector to the cylinder head cover with the 2 bolts. Connect the water ECT sensor connector. Connect the camshaft position sensor connector. Connect the oil control valve connector. Connect the 4 injector connectors.
18. Install THROTTLE BODY.
19. Install PCV Hoses see scheme 74: Connecting Engine Wire To Cylinder Head
20. Install SPARK PLUGS.
21. Install IGNITION COILS.
22. Install Air Cleaner Assembly Install the air cleaner assembly with the 2 bolts. see scheme 75: Installing Air Cleaner Assembly Tighten the 2 hose clamps. Connect the EVAP hose to the air cleaner case. Connect the MAF meter connector.
23. Install CONVERTER AND INVERTER ASSEMBLY.
24. Install OUTER FR COWL TOP PANEL ASSEMBLY.
25. Fill With Engine Coolant.
26. Fill With HV Coolant.
27. Install Engine Under Covers
28. Connect BATTERY NEGATIVE (-) TERMINAL AND HV BATTERY SERVICE PLUG.
29. Road Test Vehicle Check for abnormal noises, shock slippage, correct shift points and smooth operation.
30. Recheck Engine Coolant And HV Coolant.