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CAMSHAFT INSTALLATION

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  1. Click here

    INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note:

      Be careful not to damage the camshaft.

    2. A0158R0E01

      Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.

      Table 1. Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note:

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

    4. Check that there is no clearance between the camshaft timing gear assembly flange and camshaft.

    5. A015AUT

      Tighten the flange bolt while holding the camshaft.

      100 N*m 1020 kgf*cm 74 ft.*lbf

    6. Check the lock of the camshaft timing gear assembly.


      1. Fix the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note:

        Be careful not to damage the camshaft.

    7. A0158WGE01

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Table 2. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Open
        *4 Close
        A0155U9 Rubber
        A015DBF Vinyl Tape
        Tip:

        The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path as shown in the illustration.

      3. A015DMKE01

        Apply air at approximately 200 kPa (2.0 kgf/cm2, 28 psi) to the 2 open paths.

        Table 3. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. A015AK2E01

        Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

        Table 4. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Hold Pressure
        *4 Decompress
        Tip:

        This operation releases the lock pin at the most retarded position.

      5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path.

        Note:

        Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    8. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note:

        Do not use air pressure to perform the smooth operation check.

    9. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear assembly locks at the most retarded position.

    10. A0159Z4E01

      Remove the flange bolt and camshaft timing gear assembly.

      Table 5. Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt
      Note:

      • Do not remove the other 3 bolts.

      • If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

  2. Click here

    INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note:

      Be careful not to damage the camshaft.

    2. A0156L0E01

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.

      Table 6. Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note:

      Be sure not to turn the camshaft timing exhaust gear in the advanced direction.

    4. Check that there is no clearance between the gear flange and camshaft.

    5. A015DWN

      Tighten the flange bolt while holding the camshaft.

      100 N*m 1020 kgf*cm 74 ft.*lbf

    6. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear assembly locks.

    7. A0156ZNE01

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Table 7. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Open
        *4 Close
        A0155U9 Rubber
        A015DBF Vinyl Tape
        Tip:

        The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path as shown in the illustration.

      3. A015CUQE01

        Apply air at approximately 200 kPa (2.0 kgf/cm2, 28 psi) to the 2 open paths (the advance side path and retard side path).

        Table 8. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. A015CTOE01

        Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

        Table 9. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Hold Pressure
        *4 Decompress
        Tip:

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

      5. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path.

        Note:

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    8. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly.

        Note:

        When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    9. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

    10. A0155DVE01

      Remove the flange bolt and camshaft timing exhaust gear assembly.

      Table 10. Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt
      Note:

      • Be sure not to remove the other 4 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

  3. Click here

    INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note:

      Be careful not to damage the camshaft.

    2. A0158R0E01

      Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.

      Table 11. Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note:

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

    4. Check that there is no clearance between the camshaft timing gear assembly flange and camshaft.

    5. A015AUT

      Install the flange bolt while holding the camshaft.

      100 N*m 1020 kgf*cm 74 ft.*lbf

    6. Check the lock of the camshaft timing gear assembly.


      1. Fix the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note:

        Be careful not to damage the camshaft.

  4. Click here

    INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note:

      Be careful not to damage the camshaft.

    2. A0156L0E01

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.

      Table 12. Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note:

      Be sure not to turn the camshaft timing exhaust gear in the advanced direction.

    4. Check that there is no clearance between the gear flange and camshaft.

    5. A015DWN

      Install the flange bolt while holding the camshaft.

      100 N*m 1020 kgf*cm 74 ft.*lbf

    6. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear assembly locks.

  5. Click here

    INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Check that the notch is aligned with the "0" timing mark of the timing chain cover.

    2. A0157EIE01

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear.

      Table 13. Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align

    3. Clean the camshaft housing LH and camshaft journals and apply engine oil to them.

    4. A0158OXE01

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

      Table 14. Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
    5. A015CEVE01

      Install the chain to the No. 3 camshaft, and then install the camshaft to the camshaft housing LH.

      Table 15. Text in Illustration
      *a Place on camshaft timing gear
      Tip:

      • Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain.

      • Install the camshaft so that the timing mark is facing upward.

  6. Click here

    INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Clean the camshaft housing LH and camshaft journals and apply engine oil to them.

    2. A0159Z1E01

      Pass the No. 4 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear.

      Table 16. Text in Illustration
      *1 Mark Plate (yellow)
      *2 Timing Mark
      Tip:

      The mark plate is yellow.

    3. A015DGP

      While lifting up the No. 4 camshaft, pass the No. 3 chain tensioner assembly through the No. 2 chain and set it in place.

    4. Install the No. 4 camshaft to the camshaft housing LH, and then install the No. 3 chain tensioner assembly with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  7. Click here

    INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Clean the camshaft bearing caps and apply engine oil to them.

    2. A0158OXE01

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

      Table 17. Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
    3. A0155ADE01

      Check the marks and numbers on the camshaft bearing caps, and then remove the replacement bolts and washers in the order shown in the illustration. Immediately after removing the bolts and washers for temporary installation of the camshaft housing in the location for a bearing cap, install the bearing cap with the bolts in the order shown in the illustration.

      for bolt A
      28 N*m 286 kgf*cm 21 ft.*lbf
      for bolt B
      16 N*m 163 kgf*cm 12 ft.*lbf
      Table 18. Text in Illustration
      *1 Bolt
      *2 Washer
      *a Installation of Bolts and Washers for Temporary Installation of Camshaft Housing
      *b Part Installation
      A015DIT Bolt A
      A015CC1 Bolt B
      Note:

      • Be sure to follow the numerical order when performing this procedure.

      • Do not drop bolts and washers for temporary installation of the camshaft housing into the cylinder head.

    4. Check the torque of each bolt again.

  8. Click here

    CONNECT CHAIN SUB-ASSEMBLY (for Bank 2)


    1. A015B67E01

      Align the paint marks on the camshaft timing gear and No. 1 chain and install the No. 1 chain to the camshaft timing gear.

      Table 19. Text in Illustration
      *1 Paint Mark
      Tip:

      If the paint marks are not aligned, align them by turning the camshaft slightly.

  9. Click here

    INSTALL CAMSHAFT


    1. A0157UIE03

      Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be installed easily.

      Table 20. Text in Illustration
      *a 5° to 10°
      Note:

      When turning the crankshaft, engine oil may spray out of the oil holes.

    2. A015DYVE01

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear.

      Table 21. Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align

    3. Clean the camshaft housing RH and camshaft journals and apply engine oil to them.

    4. A0158OXE01

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

      Table 22. Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
    5. A015BFVE01

      Install the chain to the camshaft, and then install the camshaft to the camshaft housing RH.

      Table 23. Text in Illustration
      *a Place on camshaft timing gear
      Tip:

      • Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain.

      • Install the camshaft so that the timing mark is facing upward.

  10. Click here

    INSTALL NO. 2 CAMSHAFT


    1. Clean the camshaft housing RH and camshaft journals and apply engine oil to them.

    2. A015AY8E01

      Pass the No. 2 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear.

      Table 24. Text in Illustration
      *1 Mark Plate (yellow)
      *2 Timing Mark
      Tip:

      The mark plate is yellow.

    3. A015AF4

      While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain and set it in place.

    4. Install the No. 2 camshaft to the camshaft housing RH, and then install the No. 2 chain tensioner assembly with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  11. Click here

    INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Clean the camshaft bearing caps and apply engine oil to them.

    2. A0158OXE01

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

      Table 25. Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
    3. A0159URE01

      Check the marks and numbers on the camshaft bearing caps, and then remove the replacement bolts and washers in the order shown in the illustration. Immediately after removing the bolts and washers for temporary installation of the camshaft housing in the location for a bearing cap, install the bearing cap with the bolts in the order shown in the illustration.

      for bolt A
      28 N*m 286 kgf*cm 21 ft.*lbf
      for bolt B
      16 N*m 163 kgf*cm 12 ft.*lbf
      Table 26. Text in Illustration
      *1 Bolt
      *2 Washer
      *a Installation of Bolts and Washers for Temporary Installation of Camshaft Housing
      *b Part Installation
      A015DIT Bolt A
      A015CC1 Bolt B
      Note:

      • Be sure to follow the numerical order when performing this procedure.

      • Do not drop bolts and washers for temporary installation of the camshaft housing into the cylinder head.

    4. Check the torque of each bolt again.

  12. Click here

    CONNECT CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A015D32E01

      Align the paint marks on the camshaft timing gear and No. 1 chain and install the No. 1 chain to the camshaft timing gear.

      Table 27. Text in Illustration
      *1 Paint Mark
      Tip:

      If the paint marks are not aligned, align them by turning the camshaft slightly.

  13. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A0155CBE01

      Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark.

    2. Turn the crankshaft slightly to eliminate the slack in the chain.

      Tip:

      Make sure there is some slack in the chain around the area where the chain tensioner is installed.

    3. A015DBWE01

      While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

      Table 28. Text in Illustration
      *1 Stopper Plate
      *a Push

    4. While turning the stopper plate of the tensioner counterclockwise, insert a pin with a diameter of 1.27 mm (0.0500 in.) into the holes in the stopper plate and tensioner to fix the stopper plate in place.

    5. Install the chain tensioner with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    6. Remove the pin from the No. 1 chain tensioner.

  14. Click here

    INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note:

      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

    2. A0159MGE01

      Check that each camshaft timing mark is positioned as shown in the illustration.

      Table 29. Text in Illustration
      *1 Timing Mark - -
      *a Viewpoint - -
      A0159QCE01
      Tip:

      for Intake Camshaft:

      Be sure to check mark A at the point when marks B, C and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

    3. If the valve timing is misaligned, reinstall the timing chain.

    4. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.

  15. Click here

    INSTALL TIMING CHAIN COVER PLATE


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

      9.0 N*m 92 kgf*cm 80 in.*lbf
  16. Click here

    POUR ENGINE OIL

    Tip:

    Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.

  17. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the camshaft housing, timing chain cover and cylinder head cover.

    2. A015E8A

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Table 30. Text in Illustration
      A015DIT Seal Packing
      Note:

      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. Install 3 new gaskets.

    4. Install a new gasket to the cylinder head cover.

    5. Install new seal washers to the bolts.

    6. A015AMTE01

      Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

      for bolt A and D
      10 N*m 102 kgf*cm 7 ft.*lbf
      for bolt B and C
      21 N*m 214 kgf*cm 15 ft.*lbf
      Standard Bolt
      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 65 mm (2.56 in.)
      D 60 mm (2.36 in.)
      Table 31. Text in Illustration
      A015DIT Bolt A
      A015CC1 Bolt B
      A0158FK Bolt C
      A015719 Bolt D
      Note:

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

  18. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the camshaft housing, timing chain cover and cylinder head cover.

    2. A0155II

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Table 32. Text in Illustration
      A015DIT Seal Packing
      Note:

      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. Install 3 new gaskets.

    4. Install a new gasket to the cylinder head cover.

    5. Install new seal washers to the bolts.

    6. A0156B3E01

      Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

      for bolt A and D
      10 N*m 102 kgf*cm 7 ft.*lbf
      for bolt B and C
      21 N*m 214 kgf*cm 15 ft.*lbf
      Standard Bolt
      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 70 mm (2.76 in.)
      D 60 mm (2.36 in.)
      Table 33. Text in Illustration
      A015DIT Bolt A
      A015CC1 Bolt B
      A0158FK Bolt C
      A015719 Bolt D
      Note:

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

  19. Click here

    CONNECT FUEL PIPE SUB-ASSEMBLY


    1. Connect the fuel pipe with the 2 bolts.

      9.0 N*m 92 kgf*cm 80 in.*lbf
  20. Click here

    INSTALL NO. 2 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.

    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

    3. 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).

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

      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.

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

      65 N*m 663 kgf*cm 48 ft.*lbf
  21. Click here

    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.

    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

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

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

      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.

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

      65 N*m 663 kgf*cm 48 ft.*lbf
  22. Click here

    INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A0156MBE01

      Install the water by-pass pipe with the 3 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Connect the 2 hoses.

      Table 34. Text in Illustration
      *a Upward
      *b Rearward
      Tip:

      The direction of the hose clamp is indicated in the illustration.

  23. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A015BW2E01

      Install a new O-ring to the engine oil level dipstick guide.

      Table 35. Text in Illustration
      *1 New O-Ring

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

    3. Push the engine oil level dipstick guide end into the guide hole.

    4. Install the engine oil level dipstick guide with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf

    5. Install the engine oil level dipstick.

  24. Click here

    INSTALL GENERATOR ASSEMBLY


    1. Install the generator bracket to the generator with the bolt.

      20 N*m 204 kgf*cm 15 ft.*lbf

    2. Install the generator with the 2 bolts.

      43 N*m 438 kgf*cm 32 ft.*lbf

    3. Connect the generator bracket with the bolt.

      20 N*m 204 kgf*cm 15 ft.*lbf

    4. Connect the wire harness clamp bracket with the bolt.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    5. Connect the generator wire to terminal B with the nut.

      9.8 N*m 100 kgf*cm 87 in.*lbf

    6. Close the terminal cap.

    7. Connect the generator connector.

  25. Click here

    INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

      13 N*m 133 kgf*cm 10 ft.*lbf
  26. Click here

    INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the 2 No. 2 idler pulleys with the 2 bolts.

      54 N*m 551 kgf*cm 40 ft.*lbf
  27. Click here

    CONNECT VANE PUMP ASSEMBLY


    1. Connect the vane pump with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    2. Attach the wire harness clamp.

    3. Connect the connector.

  28. Click here

    INSTALL IGNITION COIL ASSEMBLY


    1. Install the 6 ignition coils with the 6 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Connect the 6 ignition coil connectors.

  29. Click here

    INSTALL NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. Install the No. 2 emission control valve set with the 3 nuts.

      21 N*m 214 kgf*cm 15 ft.*lbf
    2. A015C4KE01

      Align the paint mark with the rib and connect the No. 1 air hose.

      Table 36. Text in Illustration
      *1 Paint Mark
      *2 Rib
      *a Top
      *b LH Side
      Tip:

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the No. 2 emission control valve set connector.

  30. Click here

    INSTALL NO. 1 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. Install the No. 1 emission control valve set with the 3 nuts.

      21 N*m 214 kgf*cm 15 ft.*lbf
    2. A015B8PE01

      Align the paint mark with the rib and connect the No. 1 air hose.

      Table 37. Text in Illustration
      *1 Rib
      *2 Paint Mark
      *a RH Side
      *b Top
      Tip:

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the No. 1 emission control valve set connector.

  31. Click here

    INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)


    1. A015ASJE02

      Install 2 new gaskets.

      Table 38. Text in Illustration
      *1 Claw
      *2 No. 2 Air Tube
      Note:

      Make sure the gasket's claws are not caught between the No. 2 emission control valve set and No. 2 air tube.

    2. Install the No. 2 air tube with the 2 bolts and 2 nuts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  32. Click here

    INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. A015DETE02

      Install 2 new gaskets.

      Table 39. Text in Illustration
      *1 Claw
      *2 Air Tube
      Note:

      Make sure the gasket's claws are not caught between the No. 1 emission control valve set and air tube.

    2. Install the air tube with the 2 bolts and 2 nuts.

      10 N*m 102 kgf*cm 7 in.*lbf
  33. Click here

    INSTALL INTAKE AIR SURGE TANK

    (Click here)

  34. Click here

    INSTALL FAN SHROUD

    (Click here)

  35. Click here

    INSPECT IGNITION TIMING

    Note:

    • Turn all electrical systems off.


    • Perform the inspection when the cooling fan motor is turned off.


    1. Warm up the engine.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / IGN Advance.

      3. Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

      4. Check that the ignition timing advances immediately when the engine speed is increased.

    3. A0159JBE05

      When not using the GTS:


      1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

        09843-18040
        Table 40. Text in Illustration
        *a Front view of DLC3
        Note:

        Be sure not to improperly connect the terminals. This may damage the engine.

      2. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.

        Note:

        • Use a timing light that detects primary signals.


        • After the inspection, be sure to wrap the wire harness with tape.

      3. Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

      4. Remove SST from the DLC3.

      5. Inspect the ignition timing during idling.

        Standard ignition timing
        7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

      6. Disconnect the timing light from the engine.