БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)

1. Проверьте выступание поршня для каждого цилиндра.

   
   

   1. Почистите блок цилиндров растворителем.

   2. Установите измеряемый поршень цилиндра в положение непосредственно после ВМТ.

2. 

   Прокладку головки блока цилиндров установите на поверхность блока цилиндров штампом "Lot No." (Номер партии) вверх.

   Note:
   

   • Соблюдайте направление установки.

   • Во время установки головки блока цилиндров будьте осторожны, не повредите головку.

3. Установите головку блока цилиндров на блок цилиндров.

   Note:

   Проверьте, чтобы на установочной поверхности головки блока цилиндров отсутствовало масло.

   Tip:

   Болты крепления головки блока цилиндров затягиваются в 3 последовательных этапа.

4. Нанесите тонкий слой моторного масла на резьбы и под головки болтов головки блока цилиндров.

5. 

   Шаг 1:

   
   

   1. С помощью 12-гранного гаечного ключа на 10 мм вверните, предварительно подложив плоские шайбы, и в несколько приемов равномерно затяните 10 болтов головки блока цилиндров в последовательности, показанной на рисунке.

      36 Н*м

      367 кгс*см

      27 фунт-сила-футов

6. 

   Шаг 2:

   
   

   1. Краской отметьте головки болтов головки блока цилиндров, как показано на рисунке.

   2. Затяните болты головок блока цилиндров с поворотом на 90° в той же последовательности, что и в шаге 1.

7. Шаг 3:

   
   

   1. Заново затяните болты головки блока цилиндров с поворотом еще на 90° в той же последовательности, что и на шаге 1.

   2. Убедитесь, что нанесенные краской метки теперь направлены назад.

8. 

   Равномерно затяните 2 болта в последовательности, показанной на рисунке.

   21 Н*м

   214 кгс*см

   15 фунт-сила-футов

INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2)

1. Check the piston protrusions for each cylinder.

   
   

   1. Clean the cylinder block with solvent.

   2. Set the piston of the cylinder to be measured to slightly ATDC.

2. 

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

   Note:
   

   • Be careful of the installation direction.

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

3. Place the cylinder head on the cylinder block.

   Note:

   Ensure that no oil is on the mounting surface of the cylinder head.

   Tip:

   The cylinder head bolts are tightened in 3 progressive steps.

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

5. 

   Step 1:

   
   

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

      36 N*m

      367 kgf*cm

      27 ft.*lbf

6. 

   Step 2:

   
   

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

   2. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

7. Step 3:

   
   

   1. Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.

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

8. 

   Uniformly install the 2 cylinder head bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

INSTALL CAMSHAFT BEARING CAP (for Bank 2)

1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

2. Install the No. 1 and No. 2 camshaft to the camshaft housing.

3. 

   Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper positions and directions.

4. 

   Temporarily install the 8 bolts in the order shown in the illustration.

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2)

1. 

   Make sure that the valve rocker arms are installed as shown in the illustration.

2. 

   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 diameter
   3.5 to 4.0 mm (0.138 to 0.158 in.)

   Note:
   

   • Remove any oil from the contact surface.

   • Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

3. 

   Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

   for bolt A
   10 N*m	1020 kgf*cm	74 ft.*lbf
   except bolt A
   30 N*m	306 kgf*cm	22 ft.*lbf

   Note:

   Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

4. 

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

   16 N*m

   163 kgf*cm

   12 ft.*lbf

   Note:

   Thoroughly wipe clean any seal packing.

INSTALL CAMSHAFT BEARING CAP (for Bank 1)

1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

2. Install the No. 3 and No. 4 camshaft to the camshaft housing.

3. 

   Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper positions and directions.

4. 

   Temporarily install the 8 bolts in the order shown in the illustration.

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1)

1. 

   Make sure that the valve rocker arms are installed as shown in the illustration.

2. 

   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 diameter
   3.5 to 4.0 mm (0.138 to 0.158 in.)

   Note:
   

   • Remove any oil from the contact surface.

   • Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

3. 

   Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

   for bolt A
   10 N*m	102 kgf*cm	7 ft.*lbf
   except bolt A
   30 N*m	306 kgf*cm	22 ft.*lbf

   Note:

   Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

4. 

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

   16 N*m

   163 kgf*cm

   12 ft.*lbf

   Note:

   Thoroughly wipe clean any seal packing.

INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

1. 

   Install the chain tensioner with the 2 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

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

INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)

1. 

   Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

2. 

   Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

3. 

   Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

   Tip:

   The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears.

4. Install the crankshaft timing gear to the crankshaft.

5. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly.

6. Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

7. Remove the pin from the No. 2 chain tensioner.

INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)

1. 

   Install the vibration damper with the 2 bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)

1. 

   Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

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

3. 

   Install the chain tensioner with the 2 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

4. Remove the hexagon wrench from the chain tensioner.

INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

1. 

   Install the chain tensioner with the 2 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

2. While pushing down the No. 3 chain tensioner, insert a pin with a diameter of 1.0 mm (0.039 in.) into the hole to fix it in place.

INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)

1. 

   Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

2. 

   Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

3. 

   Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

   Tip:

   The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears.

4. Install the crankshaft timing gear to the crankshaft.

5. Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly.

6. Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

   Note:

   Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

7. Remove the pin from the No. 2 chain tensioner.

INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)

1. 

   Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

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

3. 

   Install a new gasket and chain tensioner with the 2 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)

1. 

   Install the vibration damper with the 2 bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

2. Remove the hexagon wrench from the No. 1 chain tensioner.

TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY

1. for Bank 1:

   
   
   1. 

      Using a wrench, hold the hexagonal portion of the No. 3 camshaft.

   2. Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.

      79 N*m

      806 kgf*cm

      58 ft.*lbf

   3. 

      Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.

      100 N*m

      1020 kgf*cm

      74 ft.*lbf

2. for Bank 2:

   
   
   1. 

      Using a wrench, hold the hexagonal portion of the No. 1 camshaft.

   2. Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.

      79 N*m

      806 kgf*cm

      58 ft.*lbf

   3. 

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.

      100 N*m

      1020 kgf*cm

      74 ft.*lbf

CHECK NO. 1 CYLINDER TO TDC / COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

3. 

   Remove the crankshaft pulley bolt.

INSTALL WATER INLET PIPE

1. 

   Apply soapy water to 2 new O-rings and install them to the inlet pipe.

2. Install the inlet pipe to the No. 1 heat exchanger cover.

INSTALL WATER PUMP

1. 

   Install the engine water pump and gasket with the 9 bolts as shown in the illustration.

   20 N*m	204 kgf*cm	15 ft.*lbf	for bolt A
   23 N*m	235 kgf*cm	17 ft.*lbf	for bolt B
   47 N*m	479 kgf*cm	35 ft.*lbf	for bolt C

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

1. 

   Install a new oil pump gasket.

2. 

   Install a new O-ring.

3. 

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

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

   
   
   • 

     Apply Seal Packing as Follows
     Area Seal packing diameter Application position from inside edge of cover Continuous Line Area 3.0 to 4.0 mm (0.1181 to 0.1575 in.) 2.5 mm (0.098 in.) Dashed Line Area 6.4 mm (0.2520 in.) or more, or within OK area shown in illustration 0.5 mm (0.020 in.) Diagonal Line Area 3.0 to 4.0 mm (0.1181 to 0.1575 in.) 5.5 mm (0.217 in.)

   Note:
   

   • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

   • Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

4. 

   Align the drive rotor spline of the oil pump and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

5. 

   Temporarily tighten the timing chain cover with the 30 bolts and nut.

   Bolt Length
   Item Length Thread diameter Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.) Bolt B 55 mm (2.165 in.) 8 mm (0.315 in.) Bolt C 70 mm (2.756 in.) 8 mm (0.315 in.) Bolt D 35 mm (1.378 in.) 10 mm (0.394 in.) Bolt E 55 mm (2.165 in.) 10 mm (0.394 in.) Bolt F 80 mm (3.150 in.) 10 mm (0.394 in.)

   Note:

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

6. 

   Tighten the 11 bolts in several steps, in the sequence shown in the illustration.

   47 N*m

   479 kgf*cm

   35 ft.*lbf

7. 

   Temporarily tighten the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

8. 

   Tighten the 21 bolts and nut in several steps, in the sequence shown in the illustration.

   23 N*m

   235 kgf*cm

   17 ft.*lbf

   

   Note:

   After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

9. 

   Install the 2 new gaskets and the 2 plugs.

   46 N*m

   469 kgf*cm

   34 ft.*lbf

INSTALL CRANKSHAFT PULLEY

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

2. 

   Using SST, install the pulley bolt.

   09213-54015	90119-08216
   09330-00021

   300 N*m

   3059 kgf*cm

   221 ft.*lbf

INSTALL OIL FILTER BRACKET

1. 

   Install 2 new gaskets and the filter bracket with the 3 bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

INSTALL OIL FILTER ELEMENT

1. Clean the inside of the oil filter cap, the threads and O-ring groove.

2. 

   Apply a small amount of engine oil to a new O-ring for the cap, and then install the O-ring to the groove of the oil filter cap.

   Table 1. Text in Illustration

   *1	O-Ring
   *a	CORRECT
   *b	INCORRECT

   Note:
   

   • Be sure to install the O-ring in the proper location, otherwise oil may leak.

   • Do not twist the O-ring.

3. Set a new oil filter element to the oil filter cap.

4. Remove any dirt or foreign matter from the installation surface of the engine.

5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

   Note:

   Do not pinch the O-ring for the cap.

6. 

   Using SST, tighten the oil filter cap.

   09228-06501

   25 N*m

   255 kgf*cm

   18 ft.*lbf

   Table 2. Text in Illustration

   *1	Oil Filter Bracket
   *2	Oil Filter Cap
   *3	O-Ring
   *4	Oil Filter Bracket
   *a	No Clearance

   Note:
   

   • When tightening the oil filter cap, do not remove the oil filter bracket clip.

   • Make sure that the oil filter is installed securely as shown in the illustration.

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

7. 

   Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

   Table 3. Text in Illustration

   *1

   O-Ring

   Note:

   Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

8. Install the oil filter drain plug.

   13 N*m

   133 kgf*cm

   10 ft.*lbf

   Note:

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

INSTALL CAMSHAFT TIMING CONTROL MOTOR (for Bank 1)

1. 

   Turn the camshaft timing gear assembly's eccentric shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position.

   Tip:
   

   • When the cam of the camshaft lifts the valve, the eccentric shaft becomes difficult to turn.

   • The position where the eccentric shaft stops is the maximum retard angle.

2. Install a new O-ring to the timing chain cover.

3. 

   Align the joint of the camshaft timing control motor LH and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

   Note:
   

   • Check that [L] is printed on the label of the camshaft timing control motor LH.

   • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor LH (connecting surface with timing chain cover sub-assembly).

   • When installing the camshaft timing control motor LH, do not use excessive force.

   • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor LH pin hole to install the camshaft timing control motor LH.

   • Install the camshaft timing control motor LH with the arrow facing upward, as shown in the illustration.

   • Do not drop the camshaft timing control motor LH. If dropped, replace it.

   • Do not disassemble the camshaft timing control motor LH. If disassembled, replace it.

4. 

   Connect the 2 camshaft timing control motor LH connectors and engine wire clamp.

INSTALL CAMSHAFT TIMING CONTROL MOTOR (for Bank 2)

1. 

   Turn the camshaft timing gear assembly's eccentric shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position.

   Tip:
   

   • When the cam of the camshaft lifts the valve, the eccentric shaft becomes difficult to turn.

   • The position where the eccentric shaft stops is the maximum retard angle.

2. Install a new O-ring to the timing chain cover.

3. 

   Align the joint of the camshaft timing control motor RH and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

   Note:
   

   • Check that [R] is printed on the label of the camshaft timing control motor RH.

   • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor RH (connecting surface with timing chain cover sub-assembly).

   • When installing the camshaft timing control motor RH, do not use excessive force.

   • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor RH pin hole to install the camshaft timing control motor RH.

   • Install the camshaft timing control motor RH with the arrow facing upward, as shown in the illustration.

   • Do not drop the camshaft timing control motor RH. If dropped, replace it.

   • Do not disassemble the camshaft timing control motor RH. If disassembled, replace it.

4. 

   Install the engine wire bracket with the bolt.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

5. Connect the 2 camshaft timing control motor RH connectors.

INSTALL SPARK PLUG

1. Закрепите 8 свечей зажигания с помощью свечного ключа на 16 мм.

   21 Н*м

   214 кгс*см

   15 фунт-сила-футов