РАСПРЕДВАЛ УСТАНОВКА

  1. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    1. Inspect each valve lash adjuster before installing it Click here.

    2. Install the 16 valve lash adjusters to the cylinder head.

      Note

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

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

    1. Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

      A00DQ7XE07

    2. Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.

      Text in Illustration
      *1 Lash Adjuster
      *2 Valve Rocker Arm
      *3 Valve Stem
      *4 Valve Stem Cap

  3. INSTALL NO. 2 CAMSHAFT

    1. Clean the camshaft journals.

      A00DUDB

    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing.

    3. Install the camshaft to the camshaft housing.

  4. INSTALL CAMSHAFT

    1. Clean the camshaft journals.

      A00DPOO

    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing.

    3. Install the camshaft to the camshaft housing.

  5. INSTALL CAMSHAFT BEARING CAP

    1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.

      A00DQ7SE01

    2. Check the marks and numbers on the camshaft bearing caps and place the bearing caps in the proper position and direction.

      Tech Tips

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

    3. Install the 10 bolts in the order shown in the illustration.

      A00DTT8E01
      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    1. Make sure that the valve rocker arm is installed as shown in the illustration.

      A00DQ7XE07
      Text in Illustration
      *1 Lash Adjuster
      *2 Valve Rocker Arm
      *3 Valve Stem
      *4 Valve Stem Cap

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

      A00DQY2E01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Diameter
      Area Specified Condition
      Continuous Line 3.5 to 4.5 mm (0.138 to 0.177 in.)
      A 8.0 mm (0.315 in.)
      B 7.0 mm (0.276 in.)
      Application Length A and B
      15 mm (0.591 in.)

      Note

      • Remove any oil from the contact surfaces.

      • Install the camshaft housing 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.

    3. Set the camshaft and No. 2 camshaft as shown in the illustration.

      A00DS4PE01

    4. Install the camshaft housing with the 17 bolts and tighten them in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

      Note

      • After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.

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

      • If the camshaft housing 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.

      • After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and cylinder head.

  7. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned as shown in the illustration.

      A00DPLNE02
      Text in Illustration
      *1 Straight Pin
      *2 Key Groove

      Note

      Do not forcefully push in the camshaft timing gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear.

    2. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

      A00DTCOE02
      Text in Illustration
      *1 Straight Pin
      *2 Key Groove

      Note

      Do not turn the camshaft timing gear in the retard direction (clockwise).

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

      A00DTR9E01

    4. Tighten the flange bolt with the camshaft timing gear secured in place.

      A00DUC3
      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

    5. Check that the camshaft timing gear can move in the retard direction (clockwise) and is locked in the most retarded position.

      A00DSF6E02
      Text in Illustration
      *1 Lock

  8. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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

      A00DRHSE05
      Text in Illustration
      *1 Straight Pin
      *2 Pin Hole

      Note

      Do not forcefully push in the camshaft timing exhaust gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing exhaust gear.

    2. Lightly press the gear against the camshaft and turn the gear. Push further at the position where the pin enters the hole.

      Note

      Be sure not to turn the camshaft timing exhaust gear in the retard direction (clockwise).

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

      A00DTR9E01

    4. Tighten the flange bolt with the camshaft timing exhaust gear secured in place.

      A00DT2S
      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

    5. Check the camshaft timing exhaust gear lock.

      1. Make sure that the camshaft timing exhaust gear is locked.

  9. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    1. Install the chain vibration damper with the 2 bolts.

      A00DUAW
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  10. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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

      A00DTKS
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  11. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Temporarily install the crankshaft pulley bolt.

      A00DS2FE02

    2. Turn the crankshaft counterclockwise to position the timing gear key at the top.

      Text in Illustration
      *1 Timing Gear Key

    3. Check that the timing marks on the camshaft timing gears are aligned as shown in the illustration.

      A00DSWBE02
      Text in Illustration
      *1 Timing Mark

    4. Remove the crankshaft pulley bolt.

  12. INSTALL CHAIN SUB-ASSEMBLY

    1. Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

      A00DTM2E01

      Tech Tips

      • Be sure to position the mark plate at the front of the engine.

      • The mark plate on the camshaft side is colored orange.

      • Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.

      • Pass the chain through the No. 1 vibration damper.

    2. Place the chain on the crankshaft without passing it around the shaft.

      A00DSJ6

    3. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plates (orange) and timing mark, and then install the chain.

      A00DTDHE01

      Tech Tips

      • Be sure to position the mark plates at the front of the engine.

      • The mark plates on the camshaft side are colored orange.

    4. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.

      Tech Tips

      To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.

    5. Align the mark plates (yellow) and timing marks and install the chain to the crankshaft timing gear.

      A00DTLQE02
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (Yellow)

      Tech Tips

      The mark plates on the crankshaft side are colored yellow.

  13. INSTALL CHAIN TENSIONER SLIPPER

    1. Install the chain tensioner slipper to the cylinder block.

      A00DQN3E01

  14. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Check each timing mark at TDC/compression.

      A00DRPEE02
      Text in Illustration
      *1 Timing Mark *2 Mark Plate (Orange)
      *3 Mark Plate (Yellow) -

  15. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    1. Install a new gasket.

      A00DU13E03

      Note

      Remove any oil from the contact surface.

    2. Install the water pump with the 3 bolts.

      A00DQKR
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

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

      A00DTT9E03

    4. Install 3 new O-rings.

      A00DROX

    5. Apply seal packing as shown in the illustration.

      A00DUU7E04
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      5.0 mm (0.197 in.)

      Note

      • Remove any oil from the contact surface.

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

      • Do not add engine oil for at least 2 hours after installing the timing chain cover sub-assembly.

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

      A00DPROE01
      Seal Packing
      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Application Specification
      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.0 mm (0.0984 to 0.118 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -
      A - A 2.5 to 3.0 mm (0.0984 to 0.118 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      B - B 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Opposite edge of seal packing

      5.0 mm (0.197 in.)

      		 - -
      C - C 7.0 to 8.0 mm (0.276 to 0.315 in.)

      Opposite edge of seal packing

      7.5 mm (0.295 in.)

      		 - -
      F 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.8 mm (0.622 in.) 50.1 mm (1.97 in.)
      G 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 155.1 mm (6.11 in.)
      H 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 165.4 mm (6.51 in.)
      I 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (1.31 ft.)
      J 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      K 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 133.9 mm (5.27 in.)
      L 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 159.2 mm (6.28 in.)
      M 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.0 mm (0.197 in.) 185.0 mm (7.28 in.)
      N 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (1.31 ft.)
      O 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -

      Note

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

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

      • After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.

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

    7. Clean the bolts and their installation holes.

    8. Install the timing chain cover.

    9. Temporarily install the engine mounting bracket with the 3 bolts.

      A00DRLH

      Note

      • Install the mounting bracket within 10 minutes after installing the timing chain cover.

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

    10. Install 2 new O-rings.

      A00DPKQ

    11. Temporarily install the oil filter bracket with the 4 bolts.

      A00DUZI

      Note

      • Install the oil filter bracket within 10 minutes after installing the timing chain cover.

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

    12. Apply adhesive to 5 and a half threads or more of the end of bolt E.

      A00DQ3SE07
      Text in Illustration
      *1 Adhesive
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the timing chain cover with the 26 bolts and seal washer in the order shown in the illustration.

      A00DPQ9E01
      Torque:
      for bolt A, E
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }
      for bolt B
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt C
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

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

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

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

      Bolt Length
      Item Length Thread Diameter
      Bolt A, E 35 mm (1.38 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt C 80 mm (3.15 in.) 10 mm (0.394 in.)
      Bolt D 40 mm (1.57 in.) 6 mm (0.236 in.)

      Tech Tips

      Apply adhesive to bolt E before installing it.

  16. INSTALL TIMING CHAIN COVER OIL SEAL

    1. Apply MP grease to the lip of a new oil seal.

      A00OIPDE01

      Note

      • Do not allow foreign matter to contact the lip of the oil seal.

      • Do not allow MP grease to contact the dust seal.

    2. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.

      SST
      09223-22010

      Note

      • Wipe off any extra grease from the crankshaft.

      • Do not tap in the oil seal at an angle.

  17. INSTALL CRANKSHAFT PULLEY

    1. Align the key groove of the pulley with the pulley set key.

      A00OK87E01

    2. Temporarily install the pulley with the pulley bolt.

    3. Using SST, hold the pulley in place and tighten the bolt.

      Text in Illustration
      *1 Hold
      *2 Turn
      SST
      09330-00021
      09213-58014   ( 91551-80840 )
      Torque:
      190 N*m  { 1940 kgf*cm, 140 ft.*lbf }

  18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

      A00DUQOE01

      Note

      Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

    2. Install a new gasket, the chain tensioner and bracket with the 2 nuts.

      A00DPIV
      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

    3. Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.

      A00DSWME02
      Text in Illustration
      *1 Release
      *2 Pin
      *3 Hook
      *4 Turn

    4. Turn the crankshaft clockwise and check that the plunger is extended.

      A00DTXME03
      Text in Illustration
      *1 Plunger
      *2 Plunger Extended
      *3 Turn

  19. INSTALL SPARK PLUG TUBE GASKET

    1. Using a cutter knife, cut off the seal part of the removed gasket.

      A00DU3AE01
      Text in Illustration
      *1 Part to Cut Off

    2. Using a hammer and a plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.

      A00DUMPE03
      Text in Illustration
      *1 Plug Tube Gasket without Sealing Part
      *2 New Plug Tube Gasket
      *3 Claw

      Tech Tips

      If a plug tube gasket that will be used to install a new gasket is deformed and cannot be positioned on a new gasket, correct the deformation using pliers.

      Note

      • Keep the lip free of foreign matter.

      • Do not tap in the plug tube gasket at an angle.

    3. Return the claws of the ventilation baffle plate to their original positions.

  20. INSTALL CYLINDER HEAD COVER GASKET

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

      A00DT9X

      Note

      Remove any oil from the contact surfaces.

  21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. Install 3 new gaskets to the camshaft bearing cap.

      A00DQK5

    2. Apply seal packing as shown in the illustration.

      A00DS0Z
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard diameter
      4.0 mm (0.157 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 after applying seal packing.

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

    3. Install the cylinder head cover with a new seal washer and the 13 bolts.

      A00DPL5
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  22. INSTALL RADIO SETTING CONDENSER

    1. Install the setting condenser with the bolt.

      A005TG3
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  23. INSTALL IGNITION COIL ASSEMBLY

    1. Install the 4 ignition coils with the 4 bolts.

      A005U3JE01
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      *1 Cylinder Head Cover
      *2 Spark Plug Tube
      *3 Plug Cap

      Note

      When installing the ignition coil, do not damage the plug cap with the cylinder head cover opening or the upper edge of the spark plug tube.

    2. Connect the 4 ignition coil connectors.

      A005TOB

  24. INSTALL THERMOSTAT

    1. Установите на термостат новую прокладку.

    2. Установите термостат на впускной патрубок охлаждающей жидкости.

      A00OKDCE05

      Note

      Паровыпускной клапан должен быть установлен в пределах 10° от положения, указанного на рисунке.

  25. INSTALL WATER INLET

    1. Установите впускной патрубок охлаждающей жидкости и закрепите его 2 гайками.

      A00OLAP
      Torque:
      10 Н*м  { 102 кгс*см, 7 фунт-сила-дюймов }

  26. INSTALL WATER INLET HOSE

    1. Install the water inlet hose with the 2 clamps.

      A005RB5

  27. CONNECT NO. 3 WATER BY-PASS HOSE

    1. Connect the No. 3 water by-pass hose to the water inlet housing.

      A00DS82

  28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    1. Apply a light coat of engine oil to a new O-ring.

      A005S94

    2. Install the O-ring to the dipstick guide.

    3. Install the dipstick guide with the bolt.

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

    4. Install the oil dipstick.

  29. INSTALL FUEL INJECTOR ASSEMBLY

    1. Install a new injector vibration insulator to the fuel injector.

      A00OJOBE06
      Text in Illustration
      *1 O-Ring
      *2 Injector Vibration Insulator

    2. Apply a light coat of gasoline or spindle oil to the contact surfaces of the O-ring of the fuel injector.

    3. While turning the fuel injector left and right, install it to the fuel delivery pipe.

      A00ONO6

      Note

      • Do not twist the O-ring.

      • After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring with a new one.

  30. INSTALL NO. 1 DELIVERY PIPE SPACER

    1. Install the 2 No. 1 delivery pipe spacers to the cylinder head.

      A00OMYZ

      Note

      Install the No. 1 delivery pipe spacers in the correct direction.

  31. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    1. Install the fuel delivery pipe with the 4 fuel injector assemblies, and then temporarily install the 2 bolts.

      A00OMR1

      Note

      • Do not drop the fuel injectors when installing the fuel delivery pipe.

      • Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe.

    2. Tighten the 2 bolts to the specified torque.

      A00OMR1
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Install the bolt to secure the fuel delivery pipe.

      A00OJ47
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Install the wire harness bracket with the bolt.

      A00OM0R
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  32. INSTALL FUEL TUBE SUB-ASSEMBLY

    1. Push the fuel tube sub-assembly connector onto the fuel delivery pipe until a "click" sound can be heard.

      A00OLTKE04

      Note

      • Check that there are no scratches or foreign matter around the contact surfaces of the fuel tube connector and pipe before performing this step.

      • After connecting the fuel tube, check that the fuel tube connector and pipe are securely connected by pulling on them.

      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 O-Ring

    2. Install a new No. 2 fuel pipe clamp.

      A00OIMOE07
      Text in Illustration
      *1 Claw

  33. INSTALL AIR TUBE

    1. A00OLUF

      Install the air tube with the 2 bolts.

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

    2. Connect the No. 1 vacuum transmitting hose and No. 1 fuel vapor feed hose.

    3. Connect the union to connector tube hose.

    4. Connect the fuel vapor feed hose to the purge VSV.

  34. INSTALL INTAKE MANIFOLD

    1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

      A00OIZJ
      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Install the wire harness clamp bracket to the intake manifold with the bolt.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    3. Install a new gasket to the intake manifold.

      A00OJG7

    4. Install the intake manifold and intake manifold stay with the 5 bolts and 2 nuts.

      A00OIIH
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    5. Connect the fuel vapor feed hose, ventilation hose and vacuum transmitting hose.

      A00OIM9

    6. Attach the 5 clamps to the intake manifold.

      A00OJP8

    7. Install the wire harness clamp bracket with the bolt.

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

  35. INSTALL THROTTLE BODY ASSEMBLY

    1. Установите на впускной коллектор новую прокладку.

    2. Установите корпус дроссельной заслонки и закрепите 2 болтами и 2 гайками.

      A00OLVB
      Torque:
      10 Н*м  { 102 кгс*см, 7 фунт-сила-дюймов }

    3. Подсоедините разъем корпуса дроссельной заслонки и 2 шланга охлаждающей жидкости.

      A00OLBN

  36. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    1. Install the engine assembly with transaxle Click here.