CYLINDER HEAD GASKET (for Bank 1) INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET


    1. A017FK3E01

      Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

      Note


      • Be careful of the installation direction.

      • Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


    1. Place the cylinder head on the cylinder block.

      Note

      Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

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

    3. Step 1


      1. A017FOYE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    4. A017F4AE02

      Step 2


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

      2. Tighten the cylinder head bolts another 90°.

    5. Step 3


      1. Tighten the cylinder head bolts an additional 90°.

      2. Check that the painted mark is now facing rearward.

  3. INSTALL VALVE STEM CAP


    1. Install the 12 valve stem caps.

  4. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the lash adjuster free of dirt and foreign objects.

    • Only use clean engine oil.


    1. Place the lash adjuster into a container filled with engine oil.

    2. A017BTWE06

      Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed the air.

      OK
      Plunger moves up and down.

      Note

      When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

    5. After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly with by hand.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster.

    6. Install the valve lash adjusters.

      Note

      Install the valve lash adjuster to the same place where it was removed from.

  5. INSTALL CAMSHAFT BEARING CAP


    1. Apply engine oil to the camshaft journals, camshaft housing sub-assembly RH and camshaft bearing caps.

    2. Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly RH.

    3. A017C1E

      Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

    4. A017E93E01

      Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.

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

  6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A017BLZE01

      Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

    2. A017CSQE06

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      3.5 to 4.5 mm (0.138 to 0.177 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly RH within 3 minutes.

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

    3. A017CTOE01

      Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration.

        Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

    4. A017CEQE02

      Tighten the 8 bolts in the order shown in the illustration.

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

  7. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A017DHNE02

      Install the No. 2 chain tensioner assembly with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.039 in.) diameter into the hole to fix it.

  8. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)


    1. A017ESIE09

      Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. install the camshaft timing gear assembly and camshaft timing exhaust timing gear assembly and camshaft timing exhaust gear RH with the No. 2 chain sub-assembly installed.

    4. A017B01E01

      Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts and camshaft timing gear assemblies.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 2 chain tensioner assembly.

  9. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. Install the 2 No. 2 chain vibration dampers.

  10. INSTALL IDLE SPROCKET ASSEMBLY


    1. A017DMBE01

      Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

    2. Temporarily install the No. 1 idle gear shaft and idle sprocket assembly with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

      Note

      Be careful of the idle gear installation position.

      Tech Tips

      Check that no foreign matter is on the No. 1 or No. 2 idle gear shafts.

    3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Tech Tips

      After installing the idle sprocket assembly, check that it turns smoothly.

  11. INSTALL CHAIN SUB-ASSEMBLY


    1. A017D57E02

      Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly.

      Tech Tips

      The camshaft mark plates are orange.

    2. A017D6Y

      Do not pass the chain sub-assembly over the crankshaft, just temporarily place it on the crankshaft.

    3. A017CPCE04

      Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain sub-assembly between the banks.

      Note

      When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain sub-assembly between the banks.

    4. A017BKGE03

      Align the mark plate and timing marks as shown in the illustration and install the chain sub-assembly onto the crankshaft timing sprocket.

      Tech Tips

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the pulley set bolt.

    6. A017BSAE04

      Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

  12. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A017CI1E01

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

    2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

    3. A017FY1

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A017CZZE05

      Remove the hexagon wrench from the No. 1 chain tensioner assembly. Check that each timing mark is aligned with the crankshaft at the TDC/compression.

    5. Remove the pulley set bolt.

  14. INSTALL TIMING CHAIN CASE OIL SEAL


    1. A017DW1E04

      Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing chain cover sub-assembly edge.

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free of foreign matter.

      • Do not tap the timing chain case oil seal at an angle.

      • Make sure that the oil seal edge does not stick out of the timing chain cover sub-assembly.

  15. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

      A017G4RE13
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      3.0 mm (0.118 in.)

      Note


      • Be sure to clean the contact surfaces, especially the surfaces indicated by B in the illustration.

      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain cover sub-assembly within 3 minutes of applying seal packing.

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

    2. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.

      A017BR8E13
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain 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.

      Seal Packing Application Chart
      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Alternate Long and Dashed Line Area 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.079 to 0.118 in.)
      Dashed Line Area 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Diagonal Line Area 6.0 mm (0.236 in.) or more 5.0 mm (0.197 in.)
    3. A017F8XE01

      Install a new gasket.

    4. A017ED2E04

      Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and timing chain cover sub-assembly to the crankshaft.

    5. Temporarily tighten the timing chain cover sub-assembly with the 23 bolts and 2 nuts.

      A017BG1E05
      Bolt Length
      Item Length
      Bolt A 40 mm (1.57 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 25 mm (0.98 in.)

      Note

      Make sure that there is no oil on the bolt and nut threads.

    6. Fully tighten the bolts in this order: Area 1 and Area 2.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    7. Fully tighten the bolts in Area 3.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Tighten the bolts and nuts from top to bottom as shown in the illustration.

    8. Fully tighten the bolts in Area 4.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf, for bolt A }
      21 N*m  { 214 kgf*cm, 15 ft.*lbf, for bolts except bolt A }

      Tech Tips

      Tighten the bolts from bottom to top as shown in the illustration.

    9. Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.

      Torque:
      9.1 N*m  { 93 kgf*cm, 81 in.*lbf }

  16. INSTALL OIL PAN SUB-ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

      A017EK0E02
      Text in Illustration
      *a Lower Cylinder Block *b Timing Chain Cover
      *c Oil Pan LH Side - -
      Torque:
      Bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    2. A017D6L

      Install 2 new O-rings.

    3. A017EG7E05

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

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

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan sub-assembly within 3 minutes of applying seal packing.

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

    4. A017FQ1E02

      Install the oil pan sub-assembly with the 16 bolts and 2 nuts.

      Torque:
      Bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Except bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  17. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A017BUKE01

      Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A017DJHE01

      Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

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

  18. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A017EWDE01

      Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A017C1JE04

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

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

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan sub-assembly within 3 minutes of applying seal packing.

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

    3. A017B87E01

      Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

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

  19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)


    1. A017G6LE01

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

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

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

    2. A017F2Q

      Install 3 new gaskets as shown in the illustration.

    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

    4. A017CFIE01

      Install a cylinder head cover sub-assembly with the 12 bolts and a new seal washer.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

  20. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A017EYBE01

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

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

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

    2. A017FVT

      Install 3 new gaskets as shown in the illustration.

    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

    4. A017BDFE03

      Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

  21. INSTALL WATER OUTLET


    1. A017DIQ

      Install 2 new gaskets and a new O-ring.

      Tech Tips

      Apply soapy water to the O-ring.

    2. A017B9GE01

      Install the water outlet with the 2 bolts and 4 nuts.

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

      Note

      Be careful that the O-ring does not get caught between the parts.

  22. INSTALL WATER INLET HOUSING


    1. A017E0AE01

      Install 2 new O-rings.

      Tech Tips

      Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.

    2. A017DTGE01

      Install the 2 stud bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A017F72E01

      Install the water inlet housing with the 2 bolts and nut.

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

      Note

      Be careful that the O-ring does not get caught between the parts.

    4. Connect the No. 1 water by-pass hose.

    5. Apply adhesive around the drain cock assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the drain cock assembly to the water inlet housing.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    7. Install the drain cock plug to the drain cock assembly.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    8. Install a new gasket to the thermostat.

    9. A017FNME01

      Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

      Tech Tips

      The jiggle valve may be set within 10° of either side of the prescribed position.

    10. A017ECE

      Install the water inlet with the 2 nuts.

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

  23. INSTALL NO. 1 OIL COOLER BRACKET


    1. A017CTSE01

      Using an E8 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A017BAVE01

      Install a new gasket to the No. 1 oil cooler bracket.

    3. Install the oil cooler pipe with the bolt and 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }
    4. A017FTVE01

      Install a new gasket to the oil pan sub-assembly.

    5. Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }

  24. INSTALL OIL COOLER ASSEMBLY


    1. A017E70

      Install a new O-ring.

    2. Install the oil cooler assembly with the union bolt.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }
    3. A017CAHE04

      Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.

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

  25. INSTALL CRANKSHAFT PULLEY


    1. Align the pulley set key with the key groove of the crankshaft pulley, and slide on the crankshaft pulley.

    2. A017GAJE01

      Using SST, install the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      250 N*m  { 2550 kgf*cm, 184 ft.*lbf }

  26. INSTALL OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

      Note

      Do not touch the mesh when installing the oil control valve filter RH.

    2. A017ETOE02

      Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the cylinder head cover side).

    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.

    4. Install the bolt (A) to the cylinder head.

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

    5. Tighten the oil pipe union (on the cylinder head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    6. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

  27. INSTALL NO. 1 OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

      Note

      Do not touch the mesh when installing the oil control valve filter LH.

    2. A017BIAE01

      Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the No. 1 oil pipe (on the cylinder head cover side).

    3. Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head side) with the oil pipe union.

    4. Tighten the oil pipe union (on the cylinder head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    5. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

  28. INSTALL CRANKSHAFT POSITION SENSOR


    1. A017CZI

      Install the crankshaft position sensor with the bolt.

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

  29. INSTALL KNOCK CONTROL SENSOR


    1. A017GBNE03

      Install the 2 knock control sensors with the 2 bolts as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the 2 knock control sensor connectors.

  30. INSTALL KNOCK CONTROL SENSOR WIRE


    1. A017BWL

      Connect the 2 knock control sensor connectors and 3 clamps.

  31. INSTALL NO. 1 VACUUM SWITCHING VALVE


    1. A017D52

      Install the bolt and No. 1 vacuum switching valve.

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

  32. INSTALL RADIO SETTING CONDENSER


    1. A017G35

      Install the 2 bolts and 2 radio setting condensers.

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

  33. INSTALL NO. 1 ENGINE FRONT MOUNTING BRACKET LH


    1. A017FNW

      Install the No. 1 front engine mounting bracket LH with the 6 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

      Note


      • Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.

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

  34. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A017EJRE01

      Install the No. 2 idler pulley sub-assembly and cover plate with the bolt.

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

  35. INSTALL NO. 2 TIMING GEAR COVER


    1. A017FIY

      Install the No. 2 timing gear cover with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  36. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A017CLXE01

      Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.

      Tech Tips

      Each bolt length is as follows:

      A: 70 mm (2.76 in.)

      B: 33 mm (1.30 in.)

    2. Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

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

    3. Tighten the other bolts.

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

  37. INSTALL GENERATOR ASSEMBLY


    1. A017BV6

      Install the wire harness clamp bracket with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A017FOZ

      Connect the generator bracket with the wire harness clamp.

    3. A017CS4

      Install generator assembly with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    4. A017D5C

      Temporarily install the 2 bolts.

    5. A017D5C

      Fully tighten the 2bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A017FW6

      Connect the generator connector to the generator assembly.

    7. Install the generator wire with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    8. Install the terminal cap.

    9. Connect the 3 wire harness clamps.

    10. Connect the magnetic clutch connector to the compressor and magnetic clutch.

  38. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET


    1. A017FPL

      Install the engine mounting bracket RH with the 3 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  39. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A017DARE01

      Install a new gasket as shown in the illustration.

    2. A017F8NE01

      Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  40. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A017F06

      Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  41. INSTALL NO. 2 MANIFOLD STAY


    1. A017EFSE01

      Install the No. 2 manifold stay with the bolt and nut in the order shown in the illustration.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  42. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A017D2Q

      Install a new O-ring to the No. 2 engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the O-rings.

    3. Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.

    4. A017F23

      Install the No. 2 engine oil level dipstick guide with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    5. Install the engine oil level dipstick.

  43. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A017B6ZE01

      Install a new gasket as shown in the illustration.

    2. A017F6NE01

      Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  44. INSTALL INTAKE MANIFOLD

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Parts
    Intake Manifold and Cylinder Head Sub-assembly RH
    Intake Manifold and Cylinder Head Sub-assembly LH

    1. A017C5D

      Set a new gasket on each cylinder head.

      Note


      • Align the port holes of the gasket and cylinder head.

      • Make sure that the gasket is installed in the correct direction.

    2. Set the intake manifold on the cylinder heads.

    3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  45. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A017B2S

      Install the No. 2 mounting stay RH with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  46. INSTALL IGNITION COIL ASSEMBLY (for LHD)


    1. A017CHVE01

      Install the 6 ignition coils with the 6 bolts.

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

    2. Connect the 6 ignition coil connectors.

    3. A017DVRE01

      Install the 4 bolts [A].

      Torque:
      8.3 N*m  { 84 kgf*cm, 73 in.*lbf }

    4. Install the nut [B].

      Torque:
      8.3 N*m  { 84 kgf*cm, 73 in.*lbf }

    5. Install the 2 clamps [C].

  47. INSTALL IGNITION COIL ASSEMBLY (for RHD)


    1. A017CHVE01

      Install the 6 ignition coils with the 6 bolts.

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

    2. Connect the 6 ignition coil connectors.

    3. A017BKFE01

      Install the 2 bolts [D].

      Torque:
      8.3 N*m  { 84 kgf*cm, 73 in.*lbf }

    4. Install the nut [E].

      Torque:
      8.3 N*m  { 84 kgf*cm, 73 in.*lbf }

    5. Install the 2 clamps [F].

  48. REMOVE ENGINE STAND

  49. INSTALL ENGINE ASSEMBLY

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