БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

Информация добавлена 08-08-2017

PROCEDURE


  1. INSTALL STUD BOLT

    Note

    It is not necessary to remove a stud bolt unless it is being replaced.


    1. Install the oil pan stud bolt.


      1. Using E6 and E8 "TORX" socket wrenches, install the 6 stud bolts as shown in the illustration.

        A01A6YFN02
        Torque:
        for stud bolt A
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
        for stud bolt B and C
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01A7U9N03
      *1 21 mm (0.827 in.)
      *2 34 mm (1.34 in.)
      *3 9 mm (0.354 in.)

      Install the cylinder head cover LH stud bolt.


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

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

  2. INSTALL RING PIN

    Note

    It is not necessary to remove a ring pin unless it is being replaced.


    1. Using a plastic-faced hammer, tap in new ring pins to the camshaft housing.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)
      A01A2JXC02
      *1 Protrusion Height - -
      *a LH *b RH

  3. INSTALL STRAIGHT PIN

    Note

    It is not necessary to remove a straight pin unless it is being replaced.


    1. Using a plastic-faced hammer, tap in new straight pins to the camshaft housing.

      Standard Protrusion Height
      Item Specified Condition
      Ring pin A 7.7 to 8.3 mm (0.303 to 0.327 in.)
      Ring pin B 5.7 to 6.3 mm (0.224 to 0.248 in.)
      A01A3DIC02
      *1 Protrusion Height - -
      *a LH *b RH

  4. INSTALL TAPER SCREW PLUG

    Note

    It is not necessary to remove a taper screw plug unless it is being replaced.


    1. Clean the taper screw plug and the screw hole.

    2. Apply adhesive to 2 or 3 threads of the taper screw plug end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A01A8HL

      Install the taper screw plug.

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

      Note


      • Install the taper screw plug within 3 minutes after applying adhesive.

      • Do not expose the taper screw plug to coolant within 1 hour of the installation.

  5. INSTALL REAR CRANKSHAFT OIL SEAL


    1. A01A54RN01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.

      SST
      09223-78010

      Note


      • Keep the lip free of foreign matter.

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

    2. Apply MP grease to the lip of the oil seal.

  6. INSTALL ENGINE REAR OIL SEAL RETAINER


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer or cylinder block.

    2. A01A4TRC01
      *1 Seal Packing

      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
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil seal retainer within 3 minutes after applying seal packing.

    3. Install the oil seal retainer with the 5 bolts and 2 nuts.

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

      Note


      • When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.

      • When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.

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

  7. INSTALL CYLINDER BLOCK WATER JACKET SPACER

    A01A3XNC01
    *1 UP Mark
    *2 L Mark
    *3 R Mark

    1. Install the 2 water jacket spacers as shown in the illustration.

      Note

      Make sure that face the "L mark", "R mark" and "UP mark" are oriented as shown in the illustration.

  8. INSTALL KNOCK SENSOR

    Click here

  9. INSTALL NO. 1 WATER OUTLET PIPE

    Click here

  10. INSTALL CYLINDER HEAD GASKET

    Click here

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  12. INSTALL NO. 2 CYLINDER HEAD GASKET

    Click here

  13. INSTALL CYLINDER HEAD LH

    Click here

  14. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem caps.

    2. Install the 24 valve stem caps to the cylinder head.

  15. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster Click here.

    2. Install the 24 valve lash adjusters to the cylinder head.

      Note

      Install the lash adjuster at the same place it was removed from.

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


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

    2. A01A7TOC05
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Install the 24 valve rocker arms as shown in the illustration.

  17. 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. 3 camshaft and No. 4 camshaft to the camshaft housing.

    3. A01A40K

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

    4. A01A6HFN01

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

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

  18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01A7TOC06
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. A01A4R0C01
      *1 Seal Packing

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

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

      Note


      • Remove any oil from the contact surface.

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

    3. A01A63XC01
      *1 Knock Pin
      *a Front View

      Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

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

      Note


      • When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

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

      • If the camshaft housing sub-assembly LH 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.

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

    4. A01A6AJN02

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

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

      Note

      Thoroughly wipe clean any seal packing.

  19. 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 camshaft and No. 2 camshaft to the camshaft housing.

    3. A01A438

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

    4. A01A4BSN01

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

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

  20. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01A7TOC07
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. A01A30IC01
      *1 Seal Packing

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

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

      Note


      • Remove any oil from the contact surface.

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

    3. A01A6CBC01
      *1 Knock Pin
      *a Front View

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

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

      Note


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

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

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

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

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

    4. A01A70VN02

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

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

      Note

      Thoroughly wipe clean any seal packing.

  21. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (for Bank 2)


    1. A01A2REC01
      *1 Pin
      *2 Plunger
      *a Push

      Install the No. 3 chain tensioner assembly with the bolt.

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

    2. Push in the tensioner and insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the tensioner.

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


    1. A01A4CDC01
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

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

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

    4. A01A74PC02
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 3 chain tensioner assembly.

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


    1. A01A5BXC01
      *1 Pin
      *2 Plunger
      *a Push

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

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

    2. Push in the No. 2 chain tensioner assembly and insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the tensioner.

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


    1. A01A2GLC01
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

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

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

    4. A01A7PSC02
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

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

  25. INSTALL NO. 1 CHAIN VIBRATION DAMPER


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

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

  26. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

  27. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01A372C01
      *a Inward

      Align the key groove of the timing sprocket with the timing sprocket set key.

    2. Install the timing sprocket to the crankshaft with the sprocket facing inward as shown in the illustration.

  28. INSTALL NO. 1 IDLE GEAR SHAFT


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

    2. A01A2INC01
      *1 Knock Pin

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

      Note

      Make sure that the idle gear is installed facing the proper direction.

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

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

    4. Remove the bar from the chain tensioner.

  29. INSTALL NO. 1 CHAIN SUB-ASSEMBLY


    1. A01A8A8C01
      *1 Mark Plate
      *2 Timing Mark

      Align the mark plate and timing marks as shown in the illustration and install the chain.

      Tech Tips

      The camshaft mark plates are orange.

    2. A01A6FB

      Do not pass the chain around the crankshaft, just temporarily place it on the crankshaft.

    3. A01A2CDC02
      *1 Chain Plate
      *a When idle sprocket is reused
      *b Mark
      *c Align
      B001T99 Turn

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

      Note

      When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been when tightening the chain between the banks.

    4. A01A4QQC01
      *1 Mark Plate
      *2 Timing Mark

      Align the mark plate and timing marks as shown in the illustration and install the chain to the crankshaft timing sprocket.

      Tech Tips

      The crankshaft mark plate is yellow.

    5. Temporarily install the pulley set bolt.

    6. A01A8OWC01
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

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

  30. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  31. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B001PW9C02
      *1 Stopper Plate
      *a Push

      Turn the stopper plate of the tensioner clockwise and push in the plunger of the tensioner as shown in the illustration.

    2. Turn the stopper plate of the tensioner counterclockwise and insert a pin with a diameter of 1.27 mm (0.0500 in.) into the holes on the stopper plate and tensioner to fix the stopper plate in place.

    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 No. 1 chain tensioner.

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

      A01A4VCC01
      *1 Timing Mark - -
      *a Viewpoint - -

      Tech Tips

      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.

      A01A8FGN02

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

    4. Remove the pulley set bolt.

  33. INSTALL FRONT CRANKSHAFT OIL SEAL

    Click here

  34. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. Install a new gasket and the engine water pump with the 8 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  36. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. Install the No. 1 oil pan baffle plate with the 6 bolts.

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

  37. INSTALL OIL PAN SUB-ASSEMBLY

    Click here

  38. INSTALL OIL STRAINER SUB-ASSEMBLY

    Click here

  39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  40. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and the drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  41. POUR ENGINE OIL

    A01A387

    Tech Tips

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

  42. INSTALL SPARK PLUG TUBE GASKET


    1. A01A3T8C01
      A01A5MS Area to cut off

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

    2. A01A4DNC01
      *1 Removed Gasket
      *2 New Gasket

      Using the removed gasket and a hammer, tap in a new gasket until it stops.

      Tech Tips

      If the removed gasket does not fit on the new one, correct the removed one with pliers.

    3. Apply a light coat of MP grease to the gasket lip.

    4. Return the ventilation baffle plate claws to their original positions.

  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  45. INSTALL CRANKSHAFT PULLEY

    Click here

  46. INSTALL PCV VALVE SUB-ASSEMBLY

    Click here

  47. INSTALL SPARK PLUG

    Click here

  48. INSTALL REAR WATER BY-PASS JOINT


    1. A01A888C01
      *1 New O-Ring
      *2 New Gasket

      Apply soapy water to a new O-ring and install the O-ring to the water outlet pipe. Then install 2 new gaskets to the water ports LH and RH.

    2. Install the rear water by-pass joint with the 2 bolts and 4 nuts.

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

  49. INSTALL WATER INLET HOUSING

    Click here

  50. INSTALL OIL FILTER BRACKET

    Click here

  51. INSTALL OIL FILTER ELEMENT

    Click here

  52. INSTALL NO. 2 OIL PIPE

    Click here

  53. INSTALL NO. 1 OIL PIPE

    Click here

  54. INSTALL OIL FILLER CAP HOUSING


    1. A01A3SBC01
      *1 New Gasket

      Install a new gasket and the oil filler cap housing with the 2 nuts.

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

    2. Install the oil filler cap.

  55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)

    Click here

  56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)

    Click here

  57. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)

    Click here

  58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)

    Click here

  59. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  60. INSTALL VVT SENSOR (for Exhaust Side of Bank 2)

    Click here

  61. INSTALL VVT SENSOR (for Intake Side of Bank 2)

    Click here

  62. INSTALL VVT SENSOR (for Exhaust Side of Bank 1)

    Click here

  63. INSTALL VVT SENSOR (for Intake Side of Bank 1)

    Click here

  64. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Clean the water drain cock and the screw hole.

    2. Apply adhesive to 2 or 3 threads of the water drain cock end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A01A75MC01
      *a Front

      Install the water drain cock.

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

      Note


      • Install the water drain cock within 3 minutes after applying adhesive.

      • Do not expose the water drain cock to coolant within 1 hour of the installation.

    4. Rotate the water drain cock clockwise to the position shown in the illustration.

      Note


      • Do not rotate the water drain cock by more than 1 revolution (360°) after tightening the water drain cock to the specified torque.

      • Do not loosen the water drain cock after setting it correctly.

    5. Install the water drain cock plug to the water drain cock.

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

  65. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  66. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here