ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL OIL SPACER LH


    1. B0082GZ

      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. B0082EOE03
      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. B0082H0

      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. B0082EI

      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. B0082BX

      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. B0082COE02
      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. B0082E2E01

      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. B0082H6

      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. B0082DWE03
      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. B0082BS

      Install 3 new O-rings to the cylinder block.

    5. B0082G2E01

      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
      B0082HZ Bolt A
      B0082EM 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

    B0082EJ

    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. B0082H3

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

    2. B0082GEE03
      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. B0082CVE03

      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. B0082CJ

      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. B0082DA
      B0082BPE02

      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.

      • The shape of the roller rocker arm pivot used for Bank 1 is different from that of the one for Bank 2. They can be distinguished by whether there is an identification groove or not.

      Text in Illustration
      *1 Identification Groove
      *a for Bank 1
      *b for Bank 2
    2. B0082CH

      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
      B0082HQE01
      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. B0082BME03

      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.

      B0082GU
    5. B0082F1E01

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

    6. B0082DNE01

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

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    7. B0082D0E01

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

    8. B0082GBE01

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

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    9. B0082F3E01

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

    10. B0082HME01

      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.

      B0082FP
      Standard valve clearance (cold)
      0.10 to 0.16 mm (0.0039 to 0.0063 in.) for intake
      0.21 to 0.27 mm (0.0083 to 0.0106 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. B0082DZ

      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 (0.0051 in.) x 1.54
      Exhaust side
      A = B + (C - 0.24 mm (0.0094 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. B0082FSE01
      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. B0082EZE03
      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. B0082FWE03

      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. B0082FI
      B0082BPE02

      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.

      • The shape of the roller rocker arm pivot used for Bank 1 is different from that of the one for Bank 2. They can be distinguished by whether there is an identification groove or not.

      Text in Illustration
      *1 Identification Groove
      *a for Bank 1
      *b for Bank 2
    2. B0082HG

      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
      B0082GIE03
      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. B0082CNE03

      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.

      B0082CD
    5. B0082BHE01

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

    6. B0082HAE01

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

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    7. B0082BFE01

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

    8. B0082CME01

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

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    9. B0082CKE03

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

    10. B0082C4E01

      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.

      B0082FP
      Standard valve clearance (cold)
      0.10 to 0.16 mm (0.0039 to 0.0063 in.) for intake
      0.21 to 0.27 mm (0.0083 to 0.0106 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. B0082DZ

      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 (0.0051 in.) x 1.54
      Exhaust side
      A = B + (C - 0.24 mm (0.0094 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. B0082FBE01
      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. B0082F5E03
      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. B0082BLE03

      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. B0082DY

      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. B0082FY

      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. B0082DIE01
      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. B0082GAE01
      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. B0082BWE01
      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. B0082GKE03
      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. B0082BYE03
      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. B0082GHE04
      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. B0082CCE04
      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. B0082DD

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

    12. B0082E4

      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. B0082EWE04
      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. B0082EAE01
      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. B0082EPE03
      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. B0082I7E03
      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. B0082DVE01
      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. B0082FTE03
      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. B0082GC

      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. B0082HRE01
      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
      B0082ER

    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
      B0082HOE04
      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.

      B0082ETE01
      Text in Illustration
      B0082HZ Bolt A B0082EM Bolt B
      B0082CX Bolt C B0082G4 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. B0082BUE01

      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. B0082G7E01
      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. B0082CZE03
      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. B0082FVE03
      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. B0082E1E03
      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. B0082H2E03
      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. B0082EB

      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. B0082I9

      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. B0082BVE01

      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. B0082BJ

      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. B0082C1

      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. B0082ESE36
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. B0082FQ

      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. B0082DB

      Attach 2 new O-rings to the cylinder block.

    2. B0082DJ

      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. B0082G0E03
      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. B0082GS

      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. B0082GX

      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. B0082D8E05
      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. B0082DGE01
      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. B0082I4E01
      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. B0082DKE05
      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. B0082DH

      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. B0082F8

      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. B0082GT

      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. B0082D9

      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. B0082EK

      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. B0082G5

      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. B0082GN

      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. B0082HC

      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. B0082GV

      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. B0082BN

      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
      B0082EM Engine front

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


    1. B0082DR

      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. B0082I1

      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. B0082G8E04

      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.