ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Note

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click here

PROCEDURE


  1. INSTALL STRAIGHT PIN

    Note

    It is not necessary to remove the straight pins unless they are being replaced.


    1. Using a plastic hammer, tap in 4 new straight pins to the No. 2 timing gear cover assembly.

      B0070XQC01
      *a Protrusion Height - -
      Standard Protrusion Height
      Straight Pin (A)
      3.0 to 5.0 mm (0.118 to 0.197 in.)
      Straight Pin (B)
      5.0 to 7.0 mm (0.197 to 0.276 in.)

  2. INSTALL RING PIN

    Note

    It is not necessary to remove the ring pins unless they are being replaced.


    1. B007140C01
      *a Protrusion Height

      Using a plastic hammer, tap in 6 new ring pins to the stiffening crankcase assembly.

      Standard Protrusion Height
      Ring Pin (A)
      3.5 to 4.5 mm (0.138 to 0.177 in.)
      Ring Pin (B)
      4.3 to 5.3 mm (0.169 to 0.209 in.)

  3. INSTALL STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. B0070HKC01
      *a 9 mm (0.354 in.)
      *b 19 mm (0.748 in.)

      Using an E6 "TORX" socket wrench, install the 2 stud bolts to the stiffening crankcase assembly.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. B0071R7C01
      *a 21 mm (0.827 in.)
      *b 9 mm (0.354 in.)
      *c 34 mm (1.34 in.)

      Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  4. INSTALL WIRE HARNESS CLAMP BRACKET


    1. B0071RP

      Install the wire harness clamp bracket to the stiffening crankcase assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. INSTALL STRAIGHT SCREW PLUG


    1. B006Z6N

      Using a 10 mm hexagon socket wrench, install the 3 straight screw plugs and 3 new gaskets to the stiffening crankcase assembly.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  6. INSTALL ENGINE BALANCER ASSEMBLY


    1. B006YLJ

      Install the engine balancer assembly to the stiffening crankcase assembly with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  7. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. B006YFKC01
      *1 Crankshaft Timing Gear Key
      *a 270°

      Rotate the crankshaft clockwise so that the crankshaft timing gear key is at the position 270° from the bottom as shown in the illustration.

    2. B0070DOC01
      *a Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Dimension
      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after the installation.

      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).

    3. B006YDZC01
      *a Cutout

      Check that the rear cutouts are as shown in the illustration.

    4. Clean the bolts and bolt holes.

    5. B006YT8C01
      *a Bolt Type

      Temporarily install the stiffening crankcase assembly with the 11 bolts.

      Bolt Length
      Item Length
      Bolt (A) 40 mm (1.57 in.)
      Bolt (B) 90 mm (3.54 in.)
      Bolt (C) 170 mm (6.69 in.)
    6. B0071L2C01
      *a Tightening Order

      Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  8. INSTALL OIL PUMP ASSEMBLY

    Click here

  9. INSTALL OIL PUMP BRACKET


    1. B006XKQC01
      *a Front Mark

      Install the oil pump bracket with the 2 bolts as shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  10. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  11. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to a new oil strainer gasket.

    2. B0071JR

      Using an 8 mm socket wrench, install the oil strainer sub-assembly and oil strainer gasket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  12. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. B00713TC01
      *a Seal Packing
      *b 4.5 mm (0.177 in.)
      *c 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Apply seal packing in a continuous line as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Diameter
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).

    2. B0071RZC01
      *a Nut

      Install the No. 2 oil pan sub-assembly with the 11 bolts and 2 nuts in several steps in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  13. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and the oil pan drain plug to the No. 2 oil pan sub-assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  14. INSTALL OIL FILTER UNION


    1. B006ZGW

      Using a 12 mm hexagon socket wrench, install the oil filter union to the stiffening crankcase assembly.

      Torque:
      29.5 N*m  { 301 kgf*cm, 22 ft.*lbf }

  15. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  16. INSTALL REAR ENGINE OIL SEAL

    Click here

  17. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. B006YU3

      Install the cylinder block water jacket spacer to the exhaust side of the cylinder block sub-assembly.

  18. INSTALL CYLINDER HEAD GASKET

    Click here

  19. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head set bolts are tightened in 3 progressive steps.


    1. Place the cylinder head sub-assembly on the cylinder block sub-assembly.

      Note


      • Ensure that the contact surface of the cylinder head sub-assembly is free of oil.

      • Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the cylinder head gasket with the bottom of the cylinder head sub-assembly.

    2. B0071Q7C01
      B006ZY0 Front of Engine

      Install the 10 plate washers to the 10 cylinder head set bolts.

      Bolt Length
      Item Length
      Bolt (A) 139.1 to 140.9 mm (5.48 to 5.55 in.)
      Bolt (B) 149.1 to 150.9 mm (5.87 to 5.94 in.)

    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

    4. Step 1:


      1. B0071Q7C02
        B006ZY0 Front of Engine

        Using a 12 mm socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.

        Torque:
        90 N*m  { 918 kgf*cm, 66 ft.*lbf }

        Note

        Be careful not to drop the plate washers into the cylinder head sub-assembly.

    5. Step 2:


      1. B00700FC18
        *a Paint Mark
        B006ZY0 Front of Engine

        Mark each cylinder head set bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head set bolts 90° in the order shown in step 1.

    6. Step 3:


      1. Tighten the cylinder head set bolts another 90° in the order shown in step 1.

      2. Check that the paint marks are now facing rearward.

        Tech Tips

        Perform inspection after repair after replacing the cylinder head sub-assembly.

        Click here

  20. INSTALL WATER SEAL PLATE


    1. B006YL9

      Using an 8 mm socket wrench, install the water seal plate and a new gasket to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  21. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.


    1. B006YSEC01
      *a Protrusion Height

      Using a plastic hammer, tap in 10 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

      Standard Protrusion Height
      3.7 to 4.3 mm (0.146 to 0.169 in.)

  22. INSTALL NO. 2 CAMSHAFT

    Click here

  23. INSTALL CAMSHAFT

    Click here

  24. INSTALL CAMSHAFT BEARING CAP


    1. B006Y48N01

      Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap in their correct locations.

    2. B006Y8AN01

      Uniformly tighten the 8 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    3. Check the torque of each bolt again.

  25. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem cap ends.

    2. B0070GJ

      Install the 16 valve stem caps to the cylinder head sub-assembly.

      Note


      • Install the same parts in the same combination to their original locations.

      • Do not drop the valve stem caps into the cylinder head sub-assembly.

  26. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the 16 valve lash adjuster assemblies before installing them.

      Click here

    2. B006Z27

      Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

      Install the same parts in the same combination to their original locations.

  27. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. B007120C01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note

      Install the same parts in the same combination to their original locations.

  28. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B006Y7KC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Incorrect
      *b Correct

      Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

    2. B00715FC01
      *a Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).

    3. B006YSFC01
      *a 28° to 58°
      *b 43° to 73°

      Position the knock pins of the camshaft and No. 2 camshaft as shown in the illustration.

    4. B006Y2EN02

      Temporarily install the camshaft housing sub-assembly with the 18 bolts.

      Bolt Length
      Item Length
      Bolt (A) 40 mm (1.57 in.)
      Bolt (B) 65 mm (2.56 in.)
    5. B006Y2EN01

      Install the camshaft housing sub-assembly, and then tighten the 18 bolts in several steps in the order shown in the illustration.

      Torque:
      28.5 N*m  { 291 kgf*cm, 21 ft.*lbf }

      Note


      • Do not add engine oil for at least 2 hours after installation.

      • Do not start the engine for at least 2 hours after installation.

      • After installation, if the seal packing has seeped out, wipe it off.

  29. INSTALL FUEL PUMP LIFTER GUIDE


    1. B0070FN

      Using an 8 mm socket wrench, install the fuel pump lifter guide to the No. 4 camshaft bearing cap with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  30. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. B00719Z

      Using a plastic hammer, tap in the 2 crankshaft timing gear keys.

      Tech Tips

      Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

  31. INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY


    1. B0071V6

      Install the oil nozzle valve sub-assembly to the cylinder block sub-assembly.

  32. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  33. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

    Perform inspection after repair after replacing the camshaft timing gear assembly.

    Click here


    1. B006Z3MC01
      *a Knock Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

    2. B006ZLRC01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the camshaft.

      Note


      • Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly or spark plug tube with the wrench.

    3. Using a 10 mm bi-hexagonal wrench, install the camshaft timing gear assembly with the bolt.

      Torque:
      86 N*m  { 877 kgf*cm, 63 ft.*lbf }

  34. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tech Tips

    Perform inspection after repair after replacing the camshaft timing exhaust gear assembly.

    Click here


    1. B006XAQC01
      *a Knock Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.

    2. Using a wrench, hold the hexagonal portion of the No. 2 camshaft.

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

    3. B006WSL

      Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly with the 3 bolts and install the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly).

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  35. SET NO. 1 CYLINDER TO TDC (COMPRESSION)


    1. Temporarily install the crankshaft pulley bolt.

    2. B006ZMNC01
      *1 Crankshaft Timing Gear Key
      *a 44.2°

      Rotate the crankshaft 44.2° counterclockwise to position the crankshaft timing gear key as shown in the illustration.

    3. B006Y3FC01
      *a Timing Mark

      Check that the timing marks of the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

  36. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. B0070X6

      Install the No. 1 chain vibration damper with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  37. INSTALL CHAIN SUB-ASSEMBLY


    1. B006X1KC01
      *1 Crankshaft Timing Gear Key

      Set the crankshaft timing gear key as shown in the illustration.

    2. Remove the crankshaft pulley bolt.

    3. B006Z6B

      Install the crankshaft timing sprocket and chain sub-assembly.

    4. B006YP9C01
      *a Paint Mark (Yellow)
      *b Timing Mark

      Align the paint mark (yellow) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.

    5. Place the chain sub-assembly onto the camshaft timing exhaust gear assembly and camshaft timing gear assembly.

      Tech Tips


      • Make sure the paint mark of the chain sub-assembly is facing away from the engine assembly.

      • It is not necessary to install the chain sub-assembly to the teeth of the gears.

    6. B006ZOUC01
      *a Paint Mark (Pink)
      *b Timing Mark

      Align the paint mark (pink) of the chain sub-assembly with the timing mark of the camshaft timing gear assembly and install the chain sub-assembly to the camshaft timing gear assembly.

    7. B00719OC01
      *a Paint Mark (Pink)
      *b Timing Mark

      Using the hexagonal portion of the No. 2 camshaft, rotate the No. 2 camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing exhaust gear assembly with the paint mark (pink) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

      Tech Tips

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

  38. INSTALL CHAIN TENSIONER SLIPPER


    1. B006ZFB

      Install the chain tensioner slipper with the bolt.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  39. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0070AGC01
      *a Pin

      Using an 8 mm socket wrench, install the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Install the No. 1 chain tensioner assembly with the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Remove the pin from the stopper plate.

  40. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY


    1. Set the crankshaft timing gear key as shown in the illustration.

      B0070FMC01
      *1 Oil Pump Drive Sprocket *2 Oil Pump Drive Shaft Sprocket
      *3 Crankshaft Timing Gear Key *4 Oil Pump Sub-assembly
      *a Mark Plate *b Timing Mark

    2. Turn the oil pump drive shaft so that the flat face is facing upward.

    3. Align the mark plates with the timing marks of the oil pump drive sprocket and oil pump drive shaft sprocket as shown in the illustration.

      Tech Tips

      Make sure the mark plates of the oil pump drive chain sub-assembly are facing away from the engine assembly.

    4. With the oil pump drive chain sub-assembly placed around the oil pump drive sprocket and oil pump drive shaft sprocket, install the oil pump drive sprocket to the crankshaft and temporarily install the oil pump drive shaft sprocket to the oil pump drive shaft.

    5. B006XOKC01
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring

      Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate.

    6. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.

    7. B0070R5N01

      Using SST, hold the crankshaft pulley assembly and tighten the bolt.

      SST
      09213-54015
      09330-00021
      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    8. Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.

  41. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

    Click here

  42. INSTALL NO. 2 TIMING GEAR COVER ASSEMBLY


    1. Clean the contact surfaces of the No. 2 timing gear cover assembly and timing chain cover assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.

      B006ZMZC01
      *a No. 2 Timing Gear Cover Assembly Side *b Timing Chain Cover Assembly Side
    2. B006YAZC01
      B006Y8C Seal Packing

      Apply seal packing in a continuous line to the No. 2 timing gear cover assembly as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Diameter
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Clean the surfaces with non-residue solvent before applying seal packing.

      • Install the No. 2 timing gear cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

      • Do not start the engine for at least 2 hours after installation.

      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).

    3. B006ZTPN01

      Temporarily install the No. 2 timing gear cover assembly to the timing chain cover assembly with the 20 bolts.

      Note

      Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

    4. Tighten the 20 bolts in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    5. Install the engine mounting insulator RH to the engine mounting bracket RH.

    6. B00710HN01

      Install the engine mounting bracket RH with the 3 bolts in the order shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Note

      After applying seal packing to the No. 2 timing gear cover assembly, install the engine mounting bracket RH within 10 minutes.

  43. INSTALL STRAIGHT SCREW PLUG


    1. B0071P6

      Using a 10 mm hexagon wrench, install the straight screw plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  44. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  45. INSTALL SPARK PLUG TUBE GASKET


    1. B0071F9

      Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

  46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0070YX

      Install a new camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.

      Note

      Remove any oil from the contact surfaces.

    2. Install 7 new cylinder head cover gaskets to the cylinder head cover sub-assembly.

      Note

      Remove any oil from the contact surfaces.

    3. B006XMTC01
      *a Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
      *b Mark
      B006YK1 Seal Packing

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

    4. B00701KN01

      Using an 8 mm socket wrench, install the 2 camshaft position sensors (for Exhaust Side and for Intake Side) with 2 new bolts (B) and cylinder head cover sub-assembly with 4 new bolts (C) and the 12 bolts (A) in the order shown in the illustration.

      Bolt Length
      Bolt Length Thread Diameter
      (A) 23.5 mm (0.925 in.) 10 mm (0.394 in.)
      (B), (C) 30 mm (1.18 in.) 8 mm (0.315 in.)
      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note


      • If a camshaft position sensor (for Exhaust Side and for Intake Side) has been struck or dropped, replace it.

      • Make sure that the 2 O-rings are not cracked or moved out of place when installing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

      • Do not start the engine for at least 2 hours after installation.

      Tech Tips

      After tightening all bolts, check the tightening torque of the bolts (7) and (8). Retighten them if necessary.

  47. INSTALL OUTLET WATER BY-PASS SUB-ASSEMBLY


    1. B006ZR0

      Using an 8 mm socket wrench, install the outlet water by-pass sub-assembly and a new outlet water pipe gasket to the cylinder head sub-assembly with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  48. INSTALL WATER OUTLET


    1. B0070Z0

      Using an 8 mm socket wrench, install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  49. INSTALL CRANKSHAFT PULLEY ASSEMBLY


    1. B006ZASC02
      *a Hold
      *b Turn

      Align the crankshaft timing gear key with the key groove of the crankshaft pulley assembly.

    2. Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley bolt.

      SST
      09213-54015
      09330-00021
      Torque:
      260 N*m  { 2651 kgf*cm, 192 ft.*lbf }

  50. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  51. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  52. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  53. INSTALL OIL FILLER CAP GASKET


    1. B006WXB

      Install a new oil filler cap gasket to the oil filler cap sub-assembly.

  54. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. B00701R

      Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  55. INSTALL CAM TIMING CONTROL MOTOR O-RING

    Click here

  56. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

    Click here

  57. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

    Click here

  58. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

    Click here

  59. INSTALL OIL PRESSURE SENSOR (OIL PRESSURE SENDER GAUGE ASSEMBLY)

    Click here

  60. INSTALL ENGINE OIL TEMPERATURE SENSOR

    Click here

  61. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  62. INSTALL KNOCK CONTROL SENSOR

    Click here

  63. INSTALL SPARK PLUG

    Click here