CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER INSTALLATION

Tech Tips

Perform "Inspection After Repairs" after replacing the continuously variable valve lift controller assembly Click here.


  1. INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY


    1. A01IQF7E01
      Text in Illustration
      *1 Connector
      *2 Protruding Distance

      Measure the protruding distance of the continuously variable valve lift controller.

      Tech Tips


      • When reinstalling the continuously variable valve lift controller, perform the measurement after the valve lift control actuator connector is installed.

      • It is not necessary to perform this measurement when installing a new continuously variable valve lift controller as the protruding distance is 34.57 to 34.73 mm (1.36 to 1.37 in.).

        Standard protruding distance
        34.57 to 34.73 mm (1.36 to 1.37 in.)

        If the protruding distance of the continuously variable valve lift controller assembly is not 34.57 to 34.73 mm (1.36 to 1.37 in.), perform the Active Test and adjust the protruding distance to the specified value Click here.

    2. A01IUA6E02
      Text in Illustration
      *1 Protrusion
      *2 New O-Ring

      Install a new O-ring to the continuously variable valve lift controller.

      Note


      • Align the protrusion of the O-ring with the protrusion of the continuously variable valve lift controller.

      • Make sure that the O-ring is not protruding from the groove in the continuously variable valve lift controller.

    3. A01IUT1

      Rotate the crankshaft clockwise to retract the valve rocker shaft.

    4. A01IR3X

      Rotate the crankshaft clockwise again until the intake camshaft position at the No. 1 cylinder and No. 3 cylinder is as shown in the illustration.

    5. A01IT8P

      Install the valve lift control actuator connector clip to the valve lift control actuator connector.

      Tech Tips

      When the continuously variable valve lift controller is new, a valve lift control actuator connector is attached to it. Remove the valve lift control actuator connector before performing these procedures.

      Note

      Be sure to insert the protrusions of the valve lift control actuator connector clip into the holes in the valve lift control actuator connector.

    6. A01IUKB

      Install the valve lift control actuator connector to the valve rocker shaft.

      Tech Tips

      There are two types of valve lift control actuator connectors. One type is installed by rotating the connector, and the other type can be installed without being rotated.

    7. Insert the continuously variable valve lift controller into the camshaft housing.

    8. Place the wire harness clamp bracket onto the stud bolts.

    9. A01ITFP

      Install the continuously variable valve lift controller to the camshaft housing with the bolt and 2 nuts.

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

      Note

      Make sure the O-ring is not caught between the parts.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the continuously variable valve lift controller assembly Click here.

    10. A01IRNU

      Using a screwdriver, slide the valve lift control actuator connector clip from the valve lift control actuator connector.

      Note

      Slide only the upper part of the valve lift control actuator connector clip as the straight pin falls out from the bottom if the valve lift control actuator connector clip is completely removed.

    11. A01IRPYE02
      Text in Illustration
      *1 Straight Pin
      *2 Controller Shaft
      *3 Rocker Shaft
      *4 Clip
      *5 Connector

      Using a screwdriver, lightly pry the valve lift control actuator connector and align the hole in the valve lift control actuator connector with the hole in the continuously variable valve lift controller.

      Note


      • Do not forcefully pry the valve lift control actuator connector.

      • Do not damage the camshaft housing or camshaft bearing cap.

    12. A01IU6C

      Insert the straight pin into the valve lift control actuator connector.

      Tech Tips

      If the straight pin is difficult to insert, insert the pin while lightly prying the valve lift control actuator connector.

      Note

      Do not use a tool to insert the straight pin. Insert the straight pin by hand.

    13. A01INVX

      Using a screwdriver, install the valve lift control actuator connector clip to the valve lift control actuator connector.

      Note

      Insert the protrusion of the valve lift control actuator connector clip into the hole in the valve lift control actuator connector.

  2. INSTALL CYLINDER HEAD COVER GASKET


    1. A01IU5J

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

      Note

      Remove any oil from the contact surfaces.

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01IP7C

      Install 3 new gaskets to the camshaft bearing cap.

    2. A01IR75

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard diameter
      4.0 mm (0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

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

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

    3. A01IUMW

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

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


    1. A01IN4RE01

      Install the air tube with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. Connect the No. 2 air hose and No. 1 fuel vapor feed hose.

      Text in Illustration
      *1 Union To Connector Tube Hose
      *2 Vacuum Hose
      *3 No. 2 Air Hose
      *4 No. 1 Fuel Vapor Feed Hose
    3. Connect the union to connector tube hose and vacuum hose.

    4. A01IONW

      Connect the fuel vapor feed hose to the purge VSV.

  5. INSTALL IGNITION COIL ASSEMBLY


    1. A01IPG6

      Install the 4 ignition coils with the 4 bolts.

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


    1. Attach the 10 clamps, and then connect the connectors.

      A01IUAPE01
    2. Connect the engine wire with the 3 bolts and 2 nuts.

      Torque:
      for bolt A
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
      for bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for nut
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
  7. INSTALL BATTERY TRAY

  8. INSTALL BATTERY

  9. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. A01IQN6E01

      Install the battery clamp with the bolt and nut.

      Torque:
      for bolt
      17 N*m  { 169 kgf*cm, 12 ft.*lbf }
      for nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }
    2. Connect the cable to the positive (+) battery terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
  10. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    2. Attach the wire harness clamp to the air cleaner case.

  11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A01IPUC

      Connect the air cleaner cap with the band.

    2. Connect the PCV hose.

    3. A01IP4V

      Connect the 2 clamps.

    4. A01ISEG

      Attach the 2 clamps and connect the wire harness.

    5. Connect the mass air flow meter connector.

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  13. INSTALL NO. 2 CYLINDER HEAD COVER


    1. A01IRS7

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.

  14. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A01IQMS

      Attach the 4 hooks to install the radiator support opening cover.

    2. Install the 3 clips.