ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL OIL SPACER LH


    1. A004I3J

      Install the oil spacer LH with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  2. INSTALL OIL CONTROL VALVE FILTER (for Bank 2)


    1. A004HG3E02
      Text in Illustration
      *a 0 to 0.5 mm (0 to 0.0197 in.) from the face of the camshaft housing sub-assembly LH

      Install 2 new oil control valve filters to the camshaft housing sub-assembly LH as shown in the illustration.

  3. INSTALL CAMSHAFT (for Bank 2)

    Click here

  4. INSTALL CAMSHAFT CAP (for Bank 2)

    Click here

  5. INSTALL HOLE PLUG (for Manual Transmission)


    1. A004JBF

      Install a new gasket and the hole plug to the camshaft housing sub-assembly RH.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  6. INSTALL CAMSHAFT OIL FEED PIPE SUB-ASSEMBLY (for Automatic Transmission)


    1. Temporarily install 2 new gaskets and the camshaft oil feed pipe sub-assembly with the bolt and 2 union bolts.

    2. A004KM9

      Tighten the 2 union bolts to the specified torque.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

    3. Tighten the bolt to the specified torque.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  7. INSTALL OIL SPACER RH


    1. A004IVD

      Install the oil spacer RH with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  8. INSTALL OIL CONTROL VALVE FILTER (for Bank 1)


    1. A004HL0E01
      Text in Illustration
      *a 0 to 0.5 mm (0 to 0.0197 in.) from the face of the camshaft housing sub-assembly RH

      Install 2 new oil control valve filters to the camshaft housing sub-assembly RH as shown in the illustration.

  9. INSTALL CAMSHAFT (for Bank 1)

    Click here

  10. INSTALL CAMSHAFT CAP (for Bank 1)

    Click here

  11. INSTALL OIL PAN SUB-ASSEMBLY


    1. A004J6LE01

      Install the 2 stud bolts to the oil pan sub-assembly.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard height (A)
      70.0 mm (2.756 in.)
    2. A004I8F

      Install the baffle plate to the oil pan sub-assembly with the 4 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }
    3. A004KEKE03
      Text in Illustration
      *a Seal Packing
      *b φ4.0 to 6.0 mm (0.158 to 0.236 in.)
      *c 1.5 mm (0.059 in.)
      *d Chamfer edge

      Using a sealer gun, apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent

      Note


      • Clean and degrease the contact surface.

      • Install the oil pan sub-assembly within 5 minutes of applying seal packing.

      • Apply seal packing 1.5 mm (0.0591 in.) away from the outer side of the chamfer edge. However, it is allowed to apply the seal packing on the chamfer around the bolt hole.

    4. A004I7I

      Install 3 new O-rings to the cylinder block.

    5. A004I2JE01

      Tighten the 13 bolts in the order shown in the illustration to install the oil pan sub-assembly to the cylinder block.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Text in Illustration
      A004I9S Bolt A
      A004KUZ Bolt B
      Length of bolt A
      25.0 mm (0.984 in.)
      Length of bolt B
      75.0 mm (2.953 in.)

      Tech Tips

      After tightening the bolts, if the seal packing is squeezed out onto the seal surface of the chain cover, completely remove it.

  12. INSTALL OIL STRAINER SUB-ASSEMBLY

    A004HAV

    1. Install a new O-ring.

    2. Install the oil strainer sub-assembly to the oil pan sub-assembly with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  13. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A004J69

      Install 2 new oil pan seal rings to the No. 2 oil pan sub-assembly.

    2. A004KOCE03
      Text in Illustration
      *a Seal Packing
      *b 9.5 mm (0.374 in.)
      *c φ4.0 to 6.0 mm (0.158 to 0.236 in.)

      Using a sealer gun, apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent

      Note


      • Clean and degrease the contact surface.

      • Install the No. 2 oil pan sub-assembly within 5 minutes of applying seal packing.

    3. A004HVSE03

      Tighten the 11 bolts in the order shown in the illustration to install the No. 2 oil pan sub-assembly.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    4. Install a new gasket and the drain plug.

      Torque:
      42 N*m  { 425 kgf*cm, 31 ft.*lbf }

  14. INSTALL NO. 2 ENGINE HANGER


    1. A004J78

      Install the No. 2 engine hanger to the cylinder block (for bank 1) with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }

  15. INSTALL NO. 2 CYLINDER HEAD GASKET

    Click here

  16. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

    Click here

  17. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A004K5L

      Apply engine oil to the 8 valve adjusting shims and 8 roller rocker arm pivots, and then install them to the cylinder head sub-assembly LH.

      Tech Tips

      Be sure to install the removed parts in their original locations.

    2. A004KF2

      Apply engine oil to 2 new O-rings and the 8 No. 1 valve rocker arm sub-assemblies, and then install them to the cylinder head sub-assembly LH.

    3. Using a sealer gun, apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent
      A004IZ8E01
      Text in Illustration
      *a Chamfer edge *b Range of B-B
      *c within 1.0 mm (0.0394 in.) *d φ2.5 to 3.5 mm (0.098 to 0.138 in.)
      *e -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) *f 18.0 mm (0.709 in.)

      Note


      • Clean and degrease the contact surface.

      • Do not apply excessive seal packing.

      • Install the camshaft housing sub-assembly LH within 5 minutes of applying seal packing.

      • After tightening the bolts, if the seal packing is squeezed out onto the seal surface of the chain cover, completely remove it.

    4. A004JJWE03

      Tighten the 9 bolts in the order shown in the illustration to install the camshaft housing sub-assembly LH.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Set the intake camshaft LH and the exhaust camshaft LH to the zero-lift position.

      A004HRO
    5. A004ILOE01

      Loosen the 3 bolts by 180° in the order shown in the illustration.

    6. A004JM8E01

      Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    7. A004JN0E01

      Loosen the 3 bolts by 180° in the order shown in the illustration.

    8. A004J6HE01

      Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    9. A004IXDE01

      Loosen the 3 bolts by 180° in the order shown in the illustration.

    10. A004JALE01

      Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Tech Tips

      After tightening the bolts, if the seal packing is squeezed out onto the seal surface of the chain cover, completely remove it.

  18. INSPECT VALVE CLEARANCE (for Bank 2)

    Note

    With the chain sub-assembly (for bank 2) removed, valve heads may contact each other if the camshafts are turned, causing the valve stems to bend. To avoid this, do not turn the intake camshaft LH and exhaust camshaft LH more than the zero-lift rang (The range where the camshafts can be turned lightly by hand).


    1. Using a feeler gauge, check the valve clearance between the cam base circle and the roller surface of the No. 1 valve rocker arm sub-assembly.

      A004K9U
      Standard valve clearance (cold)
      0.10 to 0.15 mm (0.00394 to 0.00591 in.) for intake
      0.20 to 0.24 mm (0.00787 to 0.00945 in.) for exhaust

      Tech Tips


      • Set the intake camshaft LH and the exhaust camshaft LH to the zero-lift position.

      • If the clearance is not as specified, take notes of the value in order to adjust the valve clearance later on.

  19. ADJUST VALVE CLEARANCE (for Bank 2)


    1. Remove the camshaft housing sub-assembly LH.

    2. Remove the No. 1 valve rocker arm sub-assemblies.

    3. Remove the valve adjusting shims.

    4. A004KY9

      Using a micrometer, measure the thickness of the valve adjusting shims.

    5. Calculate the thickness of the valve adjusting shim so that the valve clearance comes within the specified values.

      Intake side
      A = B + (C - 0.13 mm (0.00512 in.) x 1.54
      Exhaust side
      A = B + (C - 0.22 mm (0.00866 in.) x 1.69
      A
      Required valve adjusting shim thickness
      B
      Removed valve adjusting shim thickness
      C
      Measured valve clearance

    6. Apply engine oil to the inner face of the valve adjusting shims and install them to the valves.

      Note

      Check if the shims can be rotated smoothly on the valves.

    7. Install the No. 1 valve rocker arm sub-assemblies.

    8. Install the camshaft housing sub-assembly LH.

  20. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A004IV8E01
      Text in Illustration
      *a Spark plug tube edge

      Apply a light layer of engine oil to 2 new spark plug tube gaskets and install them to the spark plug tubes as shown in the illustration.

    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH.

    3. A004KFZE03
      Text in Illustration
      *a Arch starting point
      *b φ2,0 to 4.0 mm (0.079 to 0.158 in.)

      Using a sealer gun, apply seal packing to the mating surface of cylinder head cover sub-assembly LH as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent
      Area Application Length
      A 10.0 mm (0.394 in.) or more
      B 18.8 mm (0.740 in.) or more
      C 63.0 mm (2.480 in.) or more
    4. A004K99E03

      Tighten the 8 bolts in the order shown in the illustration and install the cylinder head cover sub-assembly LH.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  21. INSTALL CYLINDER HEAD GASKET

    Click here

  22. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

    Click here

  23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A004KM5

      Apply engine oil to the 8 valve adjusting shims and 8 roller rocker arm pivots, and then install them to the cylinder head sub-assembly.

      Tech Tips

      Be sure to install the removed parts in their original locations.

    2. A004HYC

      Apply engine oil to 2 new O-rings and the 8 No. 1 valve rocker arm sub-assemblies, and then install them to the cylinder head sub-assembly.

    3. Using a sealer gun, apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent
      A004HIHE03
      Text in Illustration
      *a Range of B-B *b 0 to 1.0 mm (0 to 0.0394 in.)
      *c φ2.5 to 3.5 mm (0.098 to 0.138 in.) *d -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
      *e Chamfer edge *f 18.0 mm (0.709 in.)

      Note


      • Clean and degrease the contact surface.

      • Do not apply excessive seal packing.

      • Install the camshaft housing sub-assembly RH within 5 minutes of applying seal packing.


      • After tightening the bolts, if the seal packing is squeezed out onto the seal surface of the chain cover, completely remove it.

    4. A004J96E03

      Tighten the 9 bolts in the order shown in the illustration to install the camshaft housing sub-assembly RH.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Set the intake camshaft RH and the exhaust camshaft RH to the zero-lift position.

      A004H10
    5. A004KVRE01

      Loosen the 3 bolts by 180° in the order shown in the illustration.

    6. A004HTWE01

      Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    7. A004JOTE01

      Loosen the 3 bolts by 180° in the order shown in the illustration.

    8. A004HQBE01

      Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    9. A004H4ZE03

      Loosen the 3 bolts by 180° in the order shown in the illustration.

    10. A004JPLE01

      Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Tech Tips

      After tightening the bolts, if the seal packing is squeezed out onto the seal surface of the chain cover, completely remove it.

  24. INSPECT VALVE CLEARANCE (for Bank 1)

    Note

    With the chain sub-assembly (for bank 1) removed, valve heads may contact each other if the camshafts are turned, causing the valve stems to bend. To avoid this, do not turn the intake camshaft RH and exhaust camshaft RH more than the zero-lift rang (The range where the camshafts can be turned lightly by hand).


    1. Using a feeler gauge, check the valve clearance between the cam base circle and the roller surface of the No. 1 valve rocker arm sub-assembly.

      A004K9U
      Standard valve clearance (cold)
      0.10 to 0.15 mm (0.00394 to 0.00591 in.) for intake
      0.20 to 0.24 mm (0.00787 to 0.00945 in.) for exhaust

      Tech Tips


      • Set the intake camshaft RH and the exhaust camshaft RH to the zero-lift position.

      • If the clearance is not as specified, take notes of the value in order to adjust the valve clearance later on.

  25. ADJUST VALVE CLEARANCE (for Bank 1)


    1. Remove the camshaft housing sub-assembly RH.

    2. Remove the No. 1 valve rocker arm sub-assemblies.

    3. Remove the valve adjusting shims.

    4. A004KY9

      Using a micrometer, measure the thickness of the valve adjusting shims.

    5. Calculate the thickness of the valve adjusting shim so that the valve clearance comes within the specified values.

      Intake side
      A = B + (C - 0.13 mm (0.00512 in.) x 1.54
      Exhaust side
      A = B + (C - 0.22 mm (0.00866 in.) x 1.69
      A
      Required valve adjusting shim thickness
      B
      Removed valve adjusting shim thickness
      C
      Measured valve clearance

    6. Apply engine oil to the inner face of the valve adjusting shims and install them to the valves.

      Note

      Check if the shims can be rotated smoothly on the valves.

    7. Install the No. 1 valve rocker arm sub-assemblies.

    8. Install the camshaft housing sub-assembly RH.

  26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A004IGTE01
      Text in Illustration
      *a Spark plug tube edge

      Apply a light layer of engine oil to 2 new spark plug tube gaskets and install them to the spark plug tubes as shown in the illustration.

    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly RH.

    3. A004IUKE03
      Text in Illustration
      *a Arch starting point
      *b φ2,0 to 4.0 mm (0.079 to 0.158 in.)

      Using a sealer gun, apply seal packing to the mating surface of cylinder head cover sub-assembly RH as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent
      Area Application Length
      A 10.0 mm (0.394 in.) or more
      B 68.0 mm (2.677 in.) or more
      C 70.7 mm (2.784 in.) or more
    4. A004IN2E03

      Tighten the 8 bolts in the order shown in the illustration and install the cylinder head cover sub-assembly RH.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  27. INSTALL INJECTOR DRIVER BRACKET


    1. A004JBM

      Install the injector driver bracket with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  28. INSTALL SPARK PLUG


    1. Using a 14 mm spark plug wrench, install the 4 spark plugs.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  29. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH

    Click here

  30. INSTALL CAMSHAFT TIMING INTAKE GEAR ASSEMBLY LH

    Click here

  31. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH

    Click here

  32. INSTALL CAMSHAFT TIMING INTAKE GEAR ASSEMBLY RH

    Click here

  33. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A004ITW

      Install the crankshaft timing gear or sprocket.

  34. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)

    Note

    Do not allow any foreign matter to adhere or to enter into the component parts during installation.

    Tech Tips

    Apply engine oil to all component parts of the chain sub-assembly.


    1. A004JJAE01
      Text in Illustration
      *1 Link Plate
      *2 Plunger

      Move the link plate in the direction of the arrow in the illustration to press in the plunger.

    2. A004J6EE01
      Text in Illustration
      *1 First notch of the plunger rack
      *2 Stopper Tooth

      Insert an approximately 1 mm (0.0394 in.) diameter wire or the like into the chain tensioner assembly through the stopper pin hole, and hold the plunger.

      Tech Tips

      If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner assembly are not aligned, check that the first notch of the plunger rack is engaged with the stopper tooth. If not engaged, retract the plunger a little so that the first notch of the plunger rack is engaged with the stopper tooth.

    3. Temporarily install the crankshaft pulley spacer and crankshaft pulley.

    4. A004KVTE01
      Text in Illustration
      *a Crankshaft Pulley Pin Hole
      *b Alignment Mark
      *c Crankshaft Timing Gear key

      Using SST, set the crankshaft pulley pin hole at the position shown in the illustration.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

      Note

      Make sure to perform this operation to prevent the valves and pistons from contacting each other.

      Tech Tips

      At this time, the alignment mark on the crankshaft timing gear or sprocket and the crankshaft timing gear key are at the positions shown in the illustration.

    5. A004KDKE03
      Text in Illustration
      *a Alignment Mark
      *b 25°to 30°

      Using SST, turn the camshaft timing intake gear assembly LH and align the alignment mark as shown in the illustration.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

      Note

      Do not turn the exhaust camshaft LH. If the exhaust camshaft LH is turned, valve heads may come into contact with each other, causing the valve stems to bend.

    6. A004H8OE03
      Text in Illustration
      *a Crankshaft Pulley Pin Hole
      *b Crankshaft Timing Gear key
      *c Cylinder Block Guide Pin

      Using SST, turn the crankshaft about 200 degrees counterclockwise until the crankshaft pulley pin hole is aligned at the position shown in the illustration.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

      Note

      Never turn the crankshaft clockwise because the valves may come into contact with the piston. Turning the crankshaft clockwise is only allowed when adjusting the key position precisely.

      Tech Tips

      At this time, the crankshaft timing gear key is at the position shown in the illustration.

    7. Remove the crankshaft pulley and crankshaft pulley spacer.

    8. A004K5ZE04
      Text in Illustration
      *a Alignment Mark
      *b 25° to 30°

      Align the alignment mark on the camshaft timing exhaust gear assembly LH as shown in the illustration.

      Note

      To avoid damaging the valves, do not turn the camshaft timing exhaust gear assembly LH more than the zero-lift range (The range where camshaft timing exhaust gear assembly LH can be turned lightly by hand).

    9. A004JPUE04
      Text in Illustration
      *a Alignment Mark (Oval)
      *b Alignment Mark (Engraved Line)
      *c Mark plate (Grayish Blue)
      *d Mark plate (Pink)

      Install the chain sub-assembly in the following order.


      1. Align the mark plate (grayish blue) on the chain sub-assembly with the alignment mark (oval) on the crankshaft timing gear or sprocket.

      2. Align the mark plate (pink) on the chain sub-assembly with the alignment mark (engraved line) on the camshaft timing exhaust gear assembly LH.

      3. Align the mark plate (pink) on the chain sub-assembly with the alignment mark (engraved line) on the camshaft timing intake gear assembly LH.

    10. Using a 5 mm hexagon socket wrench, install the No. 1 chain vibration damper with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

      Tech Tips

      Apply engine oil to the bolt before install it.

    11. A004INR

      Install a new O-ring to the cylinder block (for bank 2).

    12. A004H2S

      Install the chain tensioner slipper.

    13. Install the No. 2 chain tensioner assembly with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }
    14. A004IB3E04
      Text in Illustration
      *a Alignment Mark (Oval)
      *b Alignment Mark (Engraved Line)
      *c Mark plate (Grayish Blue)
      *d Mark plate (Pink)

      Check that the chain is correctly installed.


      1. The mark plate (grayish blue) on the chain sub-assembly is aligned with the alignment mark (oval) on the crankshaft timing gear or sprocket.

      2. The mark plate (pink) on the chain sub-assembly is aligned with the alignment mark (engraved line) on the camshaft timing intake gear assembly LH.

      3. The mark plate (pink) on the chain sub-assembly is aligned with the alignment mark (engraved line) on the camshaft timing exhaust gear assembly LH.

    15. Pull out the wire or the like from the No. 2 chain tensioner assembly.

    16. Temporarily install the crankshaft pulley spacer and crankshaft pulley.

    17. Using SST, turn the crankshaft clockwise to make sure that there are no abnormal conditions.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

      Note

      Be sure to perform this confirmation.

  35. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)

    Note

    Do not allow any foreign matter to adhere or to enter into the component parts during installation.

    Tech Tips

    Apply engine oil to all component parts of the chain sub-assembly.


    1. A004I1AE01
      Text in Illustration
      *1 Link Plate
      *2 Plunger

      Move the link plate in the direction of the arrow in the illustration to press in the plunger.

    2. A004IBEE03
      Text in Illustration
      *1 First notch of the plunger rack
      *2 Stopper Tooth

      Insert a 2.5 mm (0.098 in.) diameter hexagon wrench into the No. 1 chain tensioner assembly through the stopper pin hole, and hold the plunger.

      Tech Tips

      If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner assembly are not aligned, check that the first notch of the plunger rack is engaged with the stopper tooth. If not engaged, retract the plunger a little so that the first notch of the plunger rack is engaged with the stopper tooth.

    3. A004J2GE03
      Text in Illustration
      *a Alignment Mark
      *b Crankshaft Pulley Pin Hole
      *c Crankshaft Timing Gear Key

      Using SST, turn the crankshaft pulley until the alignment marks on the camshaft timing intake gear assembly LH and the camshaft timing exhaust gear assembly LH, and the crankshaft pulley pin hole are aligned at the positions shown in the illustration.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

      Tech Tips

      At this time, the alignment mark on the crankshaft timing gear or sprocket and the crankshaft timing gear key are at the positions shown in the illustration.

    4. Remove the crankshaft pulley and crankshaft pulley spacer.

    5. A004J7SE01
      Text in Illustration
      *a Alignment Mark

      Align the alignment marks of the camshaft timing intake gear assembly RH and camshaft timing exhaust gear assembly RH as shown in the illustration.

      Note

      To avoid damaging the valves, do not turn the camshaft timing intake gear assembly RH and camshaft timing exhaust gear assembly RH more than the zero-lift range (The range where the camshafts can be turned lightly by hand).

    6. A004KHHE03
      Text in Illustration
      *a Alignment Mark (Oval)
      *b Alignment Mark (Engraved Line)
      *c Mark plate (Grayish Blue)
      *d Mark plate (Pink)

      Install the chain sub-assembly in the following order.


      1. Align the mark plate (grayish blue) on the chain sub-assembly with the alignment mark (oval) on the crankshaft timing gear or sprocket.

      2. Align the mark plate (pink) on the chain sub-assembly with the alignment mark (engraved line) on the camshaft timing intake gear assembly RH.

      3. Align the mark plate (pink) on the chain sub-assembly with the alignment mark (engraved line) on the camshaft timing exhaust gear assembly RH.

    7. Using a 5 mm hexagon socket wrench, install the No. 1 chain vibration damper with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

      Tech Tips

      Apply engine oil to the bolt before install it.

    8. A004HNR

      Install the chain tensioner slipper.

    9. Install the No. 1 chain tensioner assembly with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }
    10. A004JGWE01
      Text in Illustration
      *a Alignment Mark (Oval)
      *b Alignment Mark (Engraved Line)
      *c Mark plate (Grayish Blue)
      *d Mark plate (Pink)

      Check that the chain is correctly installed.


      1. The mark plate (grayish blue) on the chain sub-assembly is aligned with the alignment mark (oval) on the crankshaft timing gear or sprocket.

      2. The mark plate (pink) on the chain sub-assembly is aligned with the alignment mark (engraved line) on the camshaft timing intake gear assembly RH.

      3. The mark plate (pink) on the chain sub-assembly is aligned with the alignment mark (engraved line) on the camshaft timing exhaust gear assembly RH.

    11. Pull out the hexagon wrench from the No. 1 chain tensioner assembly.

    12. Temporarily install the crankshaft pulley spacer and crankshaft pulley.

    13. Using SST, turn the crankshaft clockwise to make sure that there are no abnormal conditions.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

      Note

      Be sure to perform this confirmation.

    14. Remove the crankshaft pulley and crankshaft pulley spacer.

  36. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. Apply a light layer of engine oil to 4 new O-rings and attach them to the engine.

    2. Clean and degrease the contact surface.

    3. If there are gaps at positions shown in the illustration, fill up with seal packing by using a sealer gun.

      Seal packing
      Three Bond 1217G, 1217H or equivalent
      A004KJU

    4. Using a sealer gun, apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent
      A004HSYE04
      Text in Illustration
      *a Area A *b Boss (5 locations)
      *c Area B *d Other than ranges A and B
      *e φ3.5 to 4.5 mm (0.138 to 0.177 in.) *f 2.0 mm (0.079 in.)
      *g φ12 mm (0.472 in.) *h 2.5 mm (0.098 in.)
      *i 0.5 mm (0.0197 in.) - -

      Note


      • Clean and degrease the contact surface.

      • Install the chain cover within 5 minutes of applying seal packing.

    5. Temporarily install the timing chain or belt cover sub-assembly with the 32 bolts.

    6. Securely tighten the 32 bolts in the order as shown in the illustration.

      A004HI3E01
      Text in Illustration
      A004I9S Bolt A A004KUZ Bolt B
      A004HPD Bolt C A004KY1 Bolt D
      Torque:
      Bolt A and B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt C and D
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Bolt Length
      Item Length Item Length
      Bolt A 20 mm (0.787 in.) Bolt B 50 mm (1.969 in.)
      Bolt C 25 mm (0.984 in.) Bolt D 60 mm (2.362 in.)

  37. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A004HPAE01

      Apply engine oil to a new oil seal lip.

      Note


      • Keep the lip free from foreign matter.

      • Do not apply engine oil to the dust seal section.

    2. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain or belt cover sub-assembly edge.

      SST
      09950-60010   ( 09951-00460, 09951-00610, 09952-06010 )
      09950-70010   ( 09951-07100 )

      Note


      • Do not tap the oil seal at an angle.

      • Do not deform the oil seal.

      Tech Tips

      Alternatively, the tapping depth of the timing chain cover oil seal can be 0 to -1.0 mm (0 to -0.0394 in.) from the timing chain cover end surface.

  38. INSTALL CRANKSHAFT PULLEY


    1. Install the crankshaft pulley spacer.

    2. Install a new O-ring to the crankshaft pulley spacer.

    3. A004I57E01
      Text in Illustration
      *1 Knock Hole
      *2 Knock Pin

      Install the crankshaft pulley while aligning the knock hole of the pulley with the knock pin on the crankshaft pulley spacer.

    4. Apply engine oil to threads and seat sections of the crankshaft pulley set bolt.

    5. A004H9KE03
      Text in Illustration
      *1 Claw

      Install SST to the crankshaft pulley.

      SST
      09213-80010   ( 90179-10016, 09213-08010, 09213-08110 )

      Tech Tips

      Position the projections on SST in the direction as shown in the illustration to prevent SST from separating from the crankshaft pulley.

    6. A004IPTE03
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley and tighten the crankshaft pulley set bolt.

      SST
      09213-80010   ( 90179-10016, 09213-08010, 09213-08110 )
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    7. A004HH2E03
      Text in Illustration
      *a Reference Line A
      *b Reference Line B

      Using a marker, draw the reference line (A) on the crankshaft pulley set bolt and also the reference line (B) on the crankshaft pulley according to the line engraved around the crankshaft pulley set bolt head as shown in the illustration.

      Tech Tips

      There are carved lines on the crankshaft pulley set bolt head every 90°.

    8. A004JGVE03
      Text in Illustration
      *a Hold
      *b Turn
      *c Reference Line A
      *d Reference Line B

      Using SST, hold the crankshaft pulley, and tighten the crankshaft pulley set bolt by 90° until the reference lines A and B are aligned.

      SST
      09213-80010   ( 90179-10016, 09213-08010, 09213-08110 )

  39. INSTALL THERMOSTAT


    1. Attach a new gasket to the thermostat.

  40. INSTALL WATER OUTLET


    1. A004ICJ

      Install the thermostat and water outlet with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  41. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. A004H8A

      Install a new gasket and the water pump assembly with the 5 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  42. INSTALL WATER PUMP PULLEY


    1. Temporarily install the water pump pulley with the 3 bolts.

    2. A004KSXE01

      Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    3. Securely tighten the 3 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  43. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A004I09

      Install the idler pulley cover and No. 1 idler pulley sub-assembly with the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  44. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A004J6W

      Install the idler pulley cover and No. 1 idler pulley sub-assembly with the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  45. INSTALL PCV VALVE SUB-ASSEMBLY


    1. A004HPIE36
      Text in Illustration
      *1 Adhesive 1141G

      Apply adhesive to 2 or 3 threads of the PCV valve sub-assembly.

      Adhesive
      Three Bond 1141G or equivalent
    2. A004KFN

      Using a 19 mm deep socket wrench, install the PCV valve sub-assembly.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  46. INSTALL WATER INLET PIPE


    1. A004HVW

      Attach 2 new O-rings to the cylinder block.

    2. A004J4E

      Install the water inlet pipe with the 4 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    3. Connect the No. 3 water by-pass hose with the clamp.

  47. INSTALL REAR CYLINDER HEAD PLATE (for Manual Transmission)


    1. A004HJRE03
      Text in Illustration
      *a φ2,0 to 4.0 mm (0.079 to 0.158 in.)
      *b Within 1.0 mm (0.0394 in.)
      *c Chamfer edge

      Using a sealer gun, apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent

      Note


      • Clean and degrease the contact surface.

      • Install the rear cylinder head plate within 5 minutes of applying seal packing.

    2. A004JR8

      Install the rear cylinder head plate with the 3 bolts.

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

  48. INSTALL VACUUM PUMP ASSEMBLY (for Automatic Transmission)

    Click here

  49. INSTALL PCV HOSE CONNECTOR


    1. A004H0J

      Connect the No. 2 water by-pass hose to the PCV hose connector and water inlet pipe with the clips.

    2. Install the PCV hose connector with the 3 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  50. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Clean and degrease the threads of the engine oil pressure switch assembly.

    2. A004KH4E05
      Text in Illustration
      *1 Adhesive 1324

      Apply adhesive 1324 to the threads of the engine oil pressure switch assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Keep the oil hole free from adhesive.

    3. A004HAKE01
      Text in Illustration
      *1 24 mm Deep Socket Wrench

      Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      Do not start the engine for at least 1 hour after installation.

  51. INSTALL ENGINE OIL TEMPERATURE SENSOR


    1. Attach a new gasket to the engine oil temperature sensor.

    2. A004H5RE01
      Text in Illustration
      *1 19 mm Deep Socket Wrench

      Using a 19 mm deep socket wrench, install the engine oil temperature sensor.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  52. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE


    1. A004HVEE05
      Text in Illustration
      *1 O-ring
      *2 Back-up ring

      Install the back-up ring to the camshaft timing oil control valve (for exhaust side of bank 2).

    2. Install a new O-ring to the camshaft timing oil control valve (for exhaust side of bank 2).

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

    4. A004K04

      Install the camshaft timing oil control valve (for exhaust side of bank 2) with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    5. Install the back-up ring to the camshaft timing oil control valve (for intake side of bank 2).

    6. Install a new O-ring to the camshaft timing oil control valve (for intake side of bank 2).

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

    8. A004JGM

      Install the camshaft timing oil control valve (for intake side of bank 2) with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    9. Install the back-up ring to the camshaft timing oil control valve (for exhaust side of bank 1).

    10. Install a new O-ring to the camshaft timing oil control valve (for exhaust side of bank 1).

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

    12. A004IPV

      Install the camshaft timing oil control valve (for exhaust side of bank 1) with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    13. Install the back-up ring to the camshaft timing oil control valve (for intake side of bank 1).

    14. Install a new O-ring to the camshaft timing oil control valve (for intake side of bank 1).

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

    16. A004ITD

      Install the camshaft timing oil control valve (for intake side of bank 1) with the 2 bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  53. INSTALL VVT SENSOR


    1. Install a new O-ring to the VVT sensor (for exhaust side of bank 2).

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

    3. A004JZT

      Install the VVT sensor (for exhaust side of bank 2) with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    4. Install a new O-ring to the VVT sensor (for intake side of bank 2).

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

    6. A004HCI

      Install the VVT sensor (for intake side of bank 2) with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    7. Install a new O-ring to the VVT sensor (for exhaust side of bank 1).

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

    9. A004JTQ

      Install the VVT sensor (for exhaust side of bank 1) with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    10. Install a new O-ring to the VVT sensor (for intake side of bank 1).

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

    12. A004IYS

      Install the VVT sensor (for intake side of bank 1) with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  54. INSTALL CRANK POSITION SENSOR


    1. A004IFK

      Install the crank position sensor with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  55. INSTALL KNOCK CONTROL SENSOR


    1. A004H90

      Install the 2 knock control sensors onto the cylinder block with the 2 bolts as shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Text in Illustration
      A004KUZ Engine front

  56. INSTALL E.F.I. WATER TEMPERATURE SENSOR


    1. A004KXY

      Using a 19 mm union nut wrench, install a new gasket and the E.F.I. water temperature sensor.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  57. INSTALL OIL FILTER UNION


    1. A004KQZ

      Install the oil filter union.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  58. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Apply engine oil to the installation surface of the oil filter sub-assembly.

    2. A004JMME04

      Using SST, install the oil filter sub-assembly.

      SST
      09228-22020
      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  59. INSTALL OIL FILLER CAP


    1. Install the oil filler cap.