РАСПРЕДВАЛ (для ряда 2) УСТАНОВКА


  1. INSTALL NO. 3 CAMSHAFT

    Note

    As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


    1. A01J50RE02

      Align the mark link (yellow) with the timing mark (2 dot mark) of the camshaft timing gear as shown in the illustration.

    2. Apply new engine oil to the thrust portion and journal of the camshafts.

    3. A01J4VOE01

      Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.

    4. A01J4D5E01

      Align the knock pin hole in the camshaft timing gear with the knock pin of the No. 3 camshaft, and insert the No. 3 camshaft into the camshaft timing gear.

    5. Temporarily install the camshaft timing gear set bolt.

    6. A01J667E01

      Set the No. 3 camshaft onto the LH cylinder head with the cam lobes of the No. 2 cylinder facing downward as shown in the illustration.

    7. A01J4YNE01

      Install the 4 bearing caps in their proper locations.

    8. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

    9. A01J491E03

      Install and uniformly tighten the 8 bearing cap bolts in several passes in the sequence shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
      24 N*m  { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.47 in.) head (A) }
    10. A01J5GGE01

      Set the paint mark of the No. 1 chain between the timing marks of the camshaft timing gear.

    11. A01J5E4E01

      Hold the hexagonal portion of the No. 3 camshaft with a wrench, and tighten the camshaft timing gear set bolt.

      Torque:
      100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

  2. INSTALL NO. 3 CHAIN TENSIONER


    1. A01J6JOE01

      While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it in place.

    2. A01J7L9E01

      Temporarily install the camshaft timing gear and No. 3 chain tensioner, and align the mark links (yellow) with the timing marks (1 dot mark and 2 dot mark) of the camshaft timing gears.

    3. Tighten the No. 3 chain tensioner bolt.

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

  3. INSTALL NO. 4 CAMSHAFT

    Note

    As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


    1. A01J78WE01

      Align the knock pin hole in the camshaft timing gear with the knock pin of the No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing gear.

    2. Temporarily install the camshaft timing gear set bolt.

    3. A01J515E01

      Install the 4 bearing caps in their proper locations.

    4. Apply a light coat of engine oil on the threads of the bearing cap bolts.

    5. A01J36ZE03

      Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
      24 N*m  { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.47 in.) head (A) }
    6. A01J730E01

      Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing gear set bolt.

      Torque:
      100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

    7. Remove the pin from the No. 3 chain tensioner.

    8. A01J5BGE01

      Release the chain tension between the camshaft timing gear (RH bank) and crankshaft timing gear by turning the crankshaft pulley clockwise slightly.

  4. INSTALL NO. 1 CHAIN TENSIONER


    1. A01J3JVE03

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

    2. While rotating the stopper plate of the tensioner counterclockwise, insert a pin of φ3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.

    3. Install the chain tensioner with the 2 bolts.

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

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01J6NCE01

      Turn the crankshaft pulley, and align its groove with the timing mark 0 of timing chain cover.

    2. A01J3ESE05

      Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

      If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as described above.

  6. INSPECT VALVE CLEARANCE


    1. A01J66VE02

      Check the valves indicated in the illustration.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (Cold)
        Item Specified Condition
        Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)
        Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.)

        Tech Tips

        Write down valve clearance measurements that are not within the specified range. They will be used later to determine the required replacement valve lifter.

    2. A01J7OZE02

      Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (Cold)
        Item Specified Condition
        Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)
        Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.)

      2. Write down valve clearance measurements that are not within the specified range. They will be used later to determine the required replacement valve lifter.

    3. A01J78UE03

      Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (Cold)
        Item Specified Condition
        Intake 0.15 to 0.25 mm (0.006 to 0.010 in.)
        Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.)

      2. Write down valve clearance measurements that are not within the specified range. They will be used later to determine the required replacement valve lifter.

  7. ADJUST VALVE CLEARANCE


    1. A01J6NCE01

      Set the No. 1 cylinder to TDC/compression.


      1. Turn the crankshaft pulley, and align the notch with the timing mark 0 of the timing chain cover.

      2. A01J3ESE05

        Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

        If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as described above.

      3. A01J4E9E01

        Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears.

    2. Remove the No. 1 chain tensioner.

      Note


      • Never rotate the crankshaft with the chain tensioner removed.

      • When rotating the camshaft with the timing chain removed, turn the crankshaft counterclockwise 40° from the TDC first.


      1. A01J3EWE01

        Remove the 4 bolts, timing chain cover plate and gasket.

      2. A01J4FQE01

        While rotating the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.

      3. While rotating the stopper plate of the tensioner downward, insert a pin of φ3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.

      4. Remove the 2 bolts and chain tensioner.

    3. Remove the No. 2 camshaft.

      Note

      As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


      1. A01J4QQE02

        While raising up the No. 2 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

      2. A01J6R6E02

        Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing gear set bolt.

        Note

        Be careful not to damage the cylinder head and valve lifter with the wrench.

      3. Separate the camshaft timing gear from the No. 2 camshaft.

      4. A01J3JLE01

        Rotate the camshaft counterclockwise using the wrench so that the cam lobes of the No. 1 cylinder face upward as shown in the illustration.

      5. A01J66WE01

        Uniformly loosen and remove the 8 bearing cap bolts in several passes in the sequence shown in the illustration.

      6. Remove the 4 bearing caps and No. 2 camshaft.

    4. A01J73UE01

      Remove the No. 2 chain tensioner.


      1. Remove the No. 2 chain tensioner bolt, and then remove the No. 2 chain tensioner and camshaft timing gear.

    5. Remove the No. 1 camshaft.

      Note

      As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


      1. A01J4OOE01

        Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear set bolt.

        Note


        • Be careful not to damage the cylinder head and valve lifter with the wrench.

        • Do not disassemble the camshaft timing gear assembly.

      2. A01J4AUE01

        Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear.

      3. A01J5Q6E01

        Rotate the No. 1 camshaft counterclockwise using the wrench so that the cam lobes of No. 1 cylinder face downward as shown in the illustration.

      4. A01J5P1E01

        Uniformly loosen and remove the 8 bearing cap bolts in several passes in the sequence shown in the illustration.

      5. Remove the 4 bearing caps.

      6. A01J5B0E01

        Remove the camshaft timing gear set bolt with the No. 1 camshaft lifted up, and then remove the No. 1 camshaft and camshaft timing gear with No. 2 chain.

      7. A01J5WCE01

        Tie the No. 1 chain with a string as shown in the illustration.

        Note

        Be careful not to drop anything inside the timing chain cover.

    6. Remove the No. 4 camshaft.

      Note

      As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


      1. A01J32TE01

        While pushing down the No. 3 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

      2. A01J730E01

        Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing gear set bolt.

        Note

        Be careful not to damage the cylinder head and valve lifter with the wrench.

      3. Separate the camshaft timing gear from the No. 4 camshaft.

      4. A01J36ZE01

        Uniformly loosen and remove the 8 bearing cap bolts in several passes in the sequence shown in the illustration.

      5. Remove the 4 bearing caps and No. 4 camshaft.

    7. A01J58GE01

      Remove the No. 3 chain tensioner assembly.


      1. Remove the No. 3 chain tensioner bolt, and then remove the No. 3 chain tensioner and camshaft timing gear.

    8. Remove the No. 3 camshaft sub-assembly.

      Note

      As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


      1. A01J4NNE01

        Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration.

      2. Remove the 4 bearing caps.

      3. A01J52EE01

        Hold the No. 1 chain, and remove the No. 3 camshaft, camshaft timing gear and No. 2 chain.

      4. A01J3EYE01

        Tie the No. 1 chain with a string as shown in the illustration.

        Note

        Be careful not to drop anything inside the timing chain cover.

    9. Remove the valve lifters.

    10. Determine the replacement valve lifter size by following the procedures below.


      1. Using a micrometer, measure the thickness of the removed lifter.

      2. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

        T Thickness of removed lifter
        A Measured valve clearance
        N Thickness of new lifter
        New lifter thickness
        Item Thickness
        Intake N = T + (A to 0.20 mm (0.008 in.))
        Exhaust N = T + (A to 0.30 mm (0.012 in.))

      3. Select a new intake side lifter with a thickness as close as possible to the calculated value.

        Tech Tips

        Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

      4. Valve lifter selection chart (intake).

        A01J5QOE04

      5. Valve lifter selection chart (intake) (continued).

        A01J5VLE04
        New lifter thickness
        No. Thickness No. Thickness No. Thickness
        06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
        08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
        10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
        12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
        14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
        16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
        18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2189 in.)
        20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
        22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
        24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
        26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
        28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -
        Standard intake valve clearance (Cold)
        0.15 to 0.25 mm (0.006 to 0.010 in.)

        Example:

        The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.)

        Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.

      6. Valve lifter selection chart (exhaust).

        A01J4IKE02

      7. Valve lifter selection chart (exhaust) (continued).

        A01J5ZKE02
        New lifter thickness mm (in.)
        No. Thickness No. Thickness No. Thickness
        06 5.060 mm . (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
        08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
        10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
        12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
        14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
        16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
        18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2189 in.)
        20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
        22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
        24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252)
        26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260)
        28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -
        Standard exhaust valve clearance (Cold)
        0.29 to 0.39 mm (0.011 to 0.015 in.)

        Example:

        The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.)

        Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.

        Tech Tips

        Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

    11. Install the No. 3 camshaft.

      Note

      As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


      1. A01J50RE02

        Align the mark link (yellow) with the timing mark (2 dot mark) of the camshaft timing gear as shown in the illustration.

      2. Apply new engine oil to the thrust portion and journal of the camshafts.

      3. A01J3HAE01

        Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.

      4. A01J667E01

        Set the No. 3 camshaft onto the LH cylinder head with the cam lobes of the No. 2 cylinder facing downward as shown in the illustration.

      5. A01J4YNE01

        Install the 4 bearing caps in their proper locations.

      6. Apply a light coat of engine oil on the threads of the bearing cap bolts.

      7. A01J491E03

        Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
        24 N*m  { 245 kgf*cm, 18 in.*lbf, for 12 mm (0.47 in.) head (A) }
      8. A01J5GGE01

        Set the paint mark of the No. 1 chain between the timing marks of the camshaft timing gear.

    12. A01J6JOE01

      Install the No. 3 chain tensioner.


      1. While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it in place.

      2. A01J7L9E01

        Temporarily install the camshaft timing gear and No. 3 chain tensioner, and align the mark links (yellow) with the timing marks (1 dot mark and 2 dot mark) of the camshaft timing gears.

      3. Tighten the No. 3 chain tensioner bolt.

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

    13. Install the No. 4 camshaft sub-assembly.

      Note

      As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


      1. A01J78WE01

        Align the knock pin hole in the camshaft timing gear with the knock pin of the No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing gear.

      2. Temporarily install the camshaft timing gear set bolt.

      3. A01J515E01

        Install the 4 bearing caps in their proper locations.

      4. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

      5. A01J36ZE03

        Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
        24 N*m  { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.47 in.) head (A) }
      6. A01J730E02

        Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing gear set bolt.

        Torque:
        100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

      7. Remove the pin from the No. 3 chain tensioner.

    14. Install the camshaft.

      Note

      As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


      1. A01J578E02

        Align the mark link (yellow) with the timing mark (1 dot mark) of the camshaft timing gear as shown in the illustration.

      2. Apply new engine oil to the thrust portion and journal of the camshafts.

      3. A01J6K6E01

        Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.

      4. A01J5YEE01

        Align the knock pin hole in the camshaft timing gear with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear.

      5. Temporarily install the camshaft timing gear set bolt.

      6. A01J5KAE01

        Set the No. 1 camshaft onto the RH cylinder head with the cam lobes of the No. 1 cylinder facing downward as shown in the illustration.

      7. A01J3Y2E01

        Install the 4 bearing caps in their proper locations.

      8. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

      9. A01J5P1E04

        Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
        24 N*m  { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.39 in.) head (A) }
      10. A01J6G0E01

        Hold the hexagonal portion of the No. 1 camshaft using a wrench. Rotate the No. 1 camshaft so that the timing mark of the camshaft timing gear is aligned with the timing marks of the camshaft bearing cap.

      11. A01J4JXE01

        Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear.

      12. A01J4OOE01

        Hold the hexagonal portion of the No. 1 camshaft with a wrench, and tighten the camshaft timing gear set bolt.

        Torque:
        100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }
    15. A01J50LE01

      Install the No. 2 chain tensioner.


      1. While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it in place.

      2. A01J49SE01

        Temporarily install the camshaft timing gear and No. 2 chain tensioner and align the mark links (yellow) with the timing marks (1 dot mark) of the camshaft timing gears.

      3. Tighten the No. 2 chain tensioner bolt.

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

    16. Install the No. 2 camshaft.

      Note

      As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.


      1. A01J44FE01

        Set the No. 2 camshaft onto the RH cylinder head with the cam lobes of No. 1 cylinder facing upward as shown in the illustration.

      2. A01J5V3E01

        Install the 4 bearing caps in their proper locations.

      3. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

      4. A01J66WE04

        Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
        24 N*m  { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.47 in.) head (A) }
      5. A01J3TUE01

        Rotate the No. 2 camshaft clockwise using a wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing gear.

      6. A01J6R6E01

        Hold the hexagonal portion of the No. 2 camshaft with a wrench, and install the camshaft timing gear set bolt.

        Torque:
        100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

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

    17. A01J3JVE01

      Install the No. 1 chain tensioner.


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

      2. While turning the stopper plate of the tensioner counterclockwise, insert a pin of φ3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.

      3. Install the chain tensioner with the 2 bolts.

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

      4. Remove the pin from the chain tensioner.

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

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      6. A01J6NCE01

        Slowly turn the crankshaft pulley 2 complete revolutions, and align the notch with timing mark 0 of the timing chain cover.

      7. A01J3ESE05

        Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

  8. INSTALL CYLINDER HEAD COVER LH


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

    2. A01J5VFE04

      Apply seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2 to 3 mm (0.08 to 0.12 in.)

      Note

      Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

    3. Install the seal washers to the bolts.

    4. A01J3NWE04

      Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf, for bolt A }
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for bolt B }
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for nut }

  9. INSTALL CYLINDER HEAD COVER RH


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

    2. A01J4ZSE05

      Apply seal packing to the cylinder head and timing chain cover as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2 to 3 mm (0.08 to 0.12 in.)

      Note

      Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

    3. Install the seal washers to the bolts.

    4. A01J5VDE04

      Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf, for bolt A }
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for bolt B }
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for nut }

  10. INSTALL IGNITION COIL

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

  11. INSTALL INTAKE AIR SURGE TANK


    1. A01J7FME01

      Install a new gasket to the intake air surge tank.

    2. Using an 8 mm hexagon socket wrench, install the intake air surge tank with the 4 bolts. Install the 2 nuts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
    3. A01J3SUE01

      Install the 2 surge tank stays with the 4 bolts.

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

    4. Install the oil baffle plate with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    5. A01J78AE01

      Install the throttle body bracket with the 2 bolts.

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

    6. Install the 3 wire harness clamps and hose clamp.

    7. Connect the throttle position sensor and control motor connector.

    8. Connect the 2 VSV connectors.

    9. A01J5ZIE01

      Connect the ventilation hose.

    10. A01J52XE01

      Connect the purge line hose.

    11. A01J68TE02

      Connect the 2 water by-pass hoses.

  12. INSTALL AIR CLEANER

    Torque:
    8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  13. CONNECT NO. 2 VENTILATION HOSE

  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  15. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

  16. ADD ENGINE COOLANT


    1. Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf, for cylinder block drain cock plug }
      Standard capacity
      Item Specified Condition
      A/T 9.8 liters (10.4 US qts, 8.6 Imp. qts)
      M/T 8.5 liters (9.0 US qts, 7.5 Imp. qts)

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

      • Please contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    2. Fill the radiator reservoir with TOYOTA Super Long Life Coolant (SLLC) to the F line.

    3. Install the radiator cap.

    4. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens.

        While the thermostat is open, circulate the coolant for several minutes.

      2. Maintain the engine speed at 2,500 to 3,000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    5. Stop the engine and wait until the coolant cools down to ambient temperature.

      CAUTION:

      Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    6. A01J31CE01

      Check the coolant level in the radiator reservoir.

      If the coolant level is below the L line, add SLLC to the reservoir F line.

  17. CHECK FOR ENGINE COOLANT LEAKS


    1. Check for engine coolant leaks Click here.

  18. INSTALL V-BANK COVER


    1. Install the V-bank cover with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  19. INSPECT IGNITION TIMING


    1. A01J3Z7E01

      When using intelligent tester:

      Check the ignition timing.


      1. Connect the intelligent tester to the DLC3.

        Tech Tips

        Refer to the intelligent tester operator's manual for further details.

        Standard ignition timing
        7 to 24°BTDC @ idle
        (Transmission in neutral position)

      2. Disconnect the intelligent tester from the DLC3.

    2. A01J54ME01

      When not using intelligent tester:

      Check the ignition timing.


      1. Remove the air cleaner cap.

      2. Connect the tester probe of a timing light to the green-red lead wire of the ignition coil connector of the No. 1 cylinder.

      3. A01J664E09

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

        SST
        09843-18040
      4. A01J4U8E01

        Using the timing light, check the ignition timing.

        Standard ignition timing
        10 +-2° BTDC @ idle
        (Transmission in neutral position)

      5. Remove SST from the DLC3.

      6. Check the ignition timing.

        Standard ignition timing
        7 to 24° BTDC @ idle
        (Transmission in neutral position)

      7. Disconnect the timing light from the engine.

      8. Install the air cleaner cap.