Reassembly [06/2016 - ]: Procedure
- INSTALL OIL SPACER LH
- INSTALL OIL CONTROL VALVE FILTER (for Bank 2)
- INSTALL CAMSHAFT (for Bank 2)
See step 1
- INSTALL CAMSHAFT CAP (for Bank 2)
See step 2
- INSTALL HOLE PLUG (for Manual Transmission)
- INSTALL CAMSHAFT OIL FEED PIPE SUB-ASSEMBLY (for Automatic Transmission)
- INSTALL OIL SPACER RH
- INSTALL OIL CONTROL VALVE FILTER (for Bank 1)
- INSTALL CAMSHAFT (for Bank 1)
See step 3
- INSTALL CAMSHAFT CAP (for Bank 1)
See step 4
- INSTALL OIL PAN SUB-ASSEMBLY
- 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.)
- 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)
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Three Bond 1217G, 1217H or equivalent
TEXT IN ILLUSTRATION*a Seal Packing *b 4.0 to 6.0 mm (0.158 to 0.236 in.) *c 1.5 mm (0.059 in.) *d Chamfer edge 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.
- Install 3 new O-rings to the cylinder block.
- 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*a Use a TORX Socket Wrench T45 Bolt A Bolt B Bolt C Length of bolt A
25.0 mm (0.984 in.)
Length of bolt B
75.0 mm (2.953 in.)
Length of bolt C
30.0 mm (1.181 in.)
HINT:
After tightening the bolts, if the seal packing is squeezed out onto the seal surface of the chain cover, completely remove it.
- Install the 2 stud bolts to the oil pan sub-assembly.
- INSTALL OIL STRAINER SUB-ASSEMBLY
- Install a new O-ring.
- 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)
- INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
- Install 2 new oil pan seal rings to the No. 2 oil pan sub-assembly.
- 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.
TEXT IN ILLUSTRATION*a Seal Packing *b 9.5 mm (0.374 in.) *c 4.0 to 6.0 mm (0.158 to 0.236 in.) - 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)
- Install a new gasket and the drain plug.
Torque: 42 N*m (425 kgf*cm, 31 ft.*lbf)
- Install 2 new oil pan seal rings to the No. 2 oil pan sub-assembly.
- INSTALL NO. 2 ENGINE HANGER
- INSTALL NO. 2 CYLINDER HEAD GASKET
See step 1
- INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
See step 2
- INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
- 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.
HINT:
Be sure to install the removed parts in their original locations.
- 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.
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Three Bond 1217G, 1217H or equivalent
TEXT IN ILLUSTRATION*a Chamfer edge *b Range of B-B *c within 1.0 mm (0.0394 in.) *d 2.5 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.
- 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)
HINT:
Set the intake camshaft LH and the exhaust camshaft LH to the zero-lift position.
- Loosen the 3 bolts by 180° in the order shown in the illustration.
- Tighten the 3 bolts in the order shown in the illustration.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
- Loosen the 3 bolts by 180° in the order shown in the illustration.
- Tighten the 3 bolts in the order shown in the illustration.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
- Loosen the 3 bolts by 180° in the order shown in the illustration.
- Tighten the 3 bolts in the order shown in the illustration.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
HINT:
After tightening the bolts, if the seal packing is squeezed out onto the seal surface of the chain cover, completely remove it.
- 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.
- 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).
- 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.
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
HINT:
- 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.
- 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.
- ADJUST VALVE CLEARANCE (for Bank 2)
- Remove the camshaft housing sub-assembly LH.
- Remove the No. 1 valve rocker arm sub-assemblies.
- Remove the valve adjusting shims.
- Using a micrometer, measure the thickness of the valve adjusting shims.
- 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 1.69
Exhaust side
A = B + (C - 0.22 mm (0.00866 in.) x 1.87
A
Required valve adjusting shim thickness
B
Removed valve adjusting shim thickness
C
Measured valve clearance
- 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.
- Install the No. 1 valve rocker arm sub-assemblies.
- Install the camshaft housing sub-assembly LH.
- Check that the No. 1 valve rocker arm sub-assemblies are correctly installed.
- INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
- 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.TEXT IN ILLUSTRATION
*a Spark plug tube edge - Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH.
- 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 TEXT IN ILLUSTRATION*a Arch starting point *b 2, 0 to 4.0 mm (0.079 to 0.158 in.) - 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)
- 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.
- INSTALL CYLINDER HEAD GASKET
See step 4
- INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
See step 5
- INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
- 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.
HINT:
Be sure to install the removed parts in their original locations.
- 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.
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Three Bond 1217G, 1217H or equivalent
TEXT IN ILLUSTRATION*a Range of B-B *b 0 to 1.0 mm (0 to 0.0394 in.) *c 2.5 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.
- 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)
HINT:
Set the intake camshaft RH and the exhaust camshaft RH to the zero-lift position.
- Loosen the 3 bolts by 180° in the order shown in the illustration.
- Tighten the 3 bolts in the order shown in the illustration.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
- Loosen the 3 bolts by 180° in the order shown in the illustration.
- Tighten the 3 bolts in the order shown in the illustration.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
- Loosen the 3 bolts by 180° in the order shown in the illustration.
- Tighten the 3 bolts in the order shown in the illustration.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
HINT:
After tightening the bolts, if the seal packing is squeezed out onto the seal surface of the chain cover, completely remove it.
- 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.
- 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).
- 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.
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
HINT:
- 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.
- 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.
- ADJUST VALVE CLEARANCE (for Bank 1)
- Remove the camshaft housing sub-assembly RH.
- Remove the No. 1 valve rocker arm sub-assemblies.
- Remove the valve adjusting shims.
- Using a micrometer, measure the thickness of the valve adjusting shims.
- 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 1.69
Exhaust side
A = B + (C - 0.22 mm (0.00866 in.) x 1.87
A
Required valve adjusting shim thickness
B
Removed valve adjusting shim thickness
C
Measured valve clearance
- 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.
- Install the No. 1 valve rocker arm sub-assemblies.
- Install the camshaft housing sub-assembly RH.
- Check that the No. 1 valve rocker arm sub-assemblies are correctly installed.
- INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
- 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.TEXT IN ILLUSTRATION
*a Spark plug tube edge - Install a new cylinder head cover gasket to the cylinder head cover sub-assembly RH.
- 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 TEXT IN ILLUSTRATION*a Arch starting point *b 2, 0 to 4.0 mm (0.079 to 0.158 in.) - 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)
- 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.
- INSTALL INJECTOR DRIVER BRACKET
- INSTALL SPARK PLUG
- Using a 14 mm spark plug wrench, install the 4 spark plugs.
Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
- Using a 14 mm spark plug wrench, install the 4 spark plugs.
- INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH
See step 14
- INSTALL CAMSHAFT TIMING INTAKE GEAR ASSEMBLY LH
See step 15
- INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH
See step 16
- INSTALL CAMSHAFT TIMING INTAKE GEAR ASSEMBLY RH
See step 17
- INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
- 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.
HINT:
Apply engine oil to all component parts of the chain sub-assembly.
- Move the link plate in the direction of the arrow in the illustration to press in the plunger.TEXT IN ILLUSTRATION
*1 Link Plate *2 Plunger - 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.TEXT IN ILLUSTRATION
*1 First notch of the plunger rack *2 Stopper Tooth HINT:
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.
- Temporarily install the crankshaft pulley spacer and crankshaft pulley.
- Using SST, set the crankshaft pulley pin hole at the position shown in the illustration.
- SST: 09960-10010
- 09962-01000
- 09963-01000
TEXT IN ILLUSTRATION*a Crankshaft Pulley Pin Hole *b Alignment Mark *c Crankshaft Timing Gear key NOTE:Make sure to perform this operation to prevent the valves and pistons from contacting each other.
HINT:
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.
- SST: 09960-10010
- 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
TEXT IN ILLUSTRATION*a Alignment Mark *b 25° to 30° 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.
- SST: 09960-10010
- 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
TEXT IN ILLUSTRATION*a Crankshaft Pulley Pin Holey *b Crankshaft Timing Gear key *c Cylinder Block Guide Pin 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.
HINT:
At this time, the crankshaft timing gear key is at the position shown in the illustration.
- SST: 09960-10010
- Remove the crankshaft pulley and crankshaft pulley spacer.
- Align the alignment mark on the camshaft timing exhaust gear assembly LH as shown in the illustration.TEXT IN ILLUSTRATION
*a Alignment Mark *b 25° to 30° 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).
- Install the chain sub-assembly in the following order.TEXT IN ILLUSTRATION
*a Alignment Mark (Oval) *b Alignment Mark (Engraved Line) *c Mark plate (Grayish Blue) *d Mark plate (Pink) - Align the mark plate (grayish blue) on the chain sub-assembly with the alignment mark (oval) on the crankshaft timing gear or sprocket.
- Align the mark plate (pink) on the chain sub-assembly with the alignment mark (engraved line) on the camshaft timing exhaust gear assembly LH.
- Align the mark plate (pink) on the chain sub-assembly with the alignment mark (engraved line) on the camshaft timing intake gear assembly LH.
- 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)
HINT:
Apply engine oil to the bolt before install it.
- Install a new O-ring to the cylinder block (for bank 2).
- Install the chain tensioner slipper.
- Install the No. 2 chain tensioner assembly with the 2 bolts.
Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
- Check that the chain is correctly installed.TEXT IN ILLUSTRATION
*a Alignment Mark (Oval) *b Alignment Mark (Engraved Line) *c Mark plate (Grayish Blue) *d Mark plate (Pink) - The mark plate (grayish blue) on the chain sub-assembly is aligned with the alignment mark (oval) on the crankshaft timing gear or sprocket.
- 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.
- 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.
- Pull out the wire or the like from the No. 2 chain tensioner assembly.
- Temporarily install the crankshaft pulley spacer and crankshaft pulley.
- 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.
- SST: 09960-10010
- Move the link plate in the direction of the arrow in the illustration to press in the plunger.
- 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.
HINT:
Apply engine oil to all component parts of the chain sub-assembly.
- Move the link plate in the direction of the arrow in the illustration to press in the plunger.TEXT IN ILLUSTRATION
*1 Link Plate *2 Plunger - 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.TEXT IN ILLUSTRATION
*1 First notch of the plunger rack *2 Stopper Tooth HINT:
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.
- 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
TEXT IN ILLUSTRATION*a Alignment Mark *b Crankshaft Pulley Pin Hole *c Crankshaft Timing Gear Key HINT:
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.
- SST: 09960-10010
- Remove the crankshaft pulley and crankshaft pulley spacer.
- Align the alignment marks of the camshaft timing intake gear assembly RH and camshaft timing exhaust gear assembly RH as shown in the illustration.TEXT IN ILLUSTRATION
*a Alignment Mark 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).
- Install the chain sub-assembly in the following order.TEXT IN ILLUSTRATION
*a Alignment Mark (Oval) *b Alignment Mark (Engraved Line) *c Mark plate (Grayish Blue) *d Mark plate (Pink) - Align the mark plate (grayish blue) on the chain sub-assembly with the alignment mark (oval) on the crankshaft timing gear or sprocket.
- Align the mark plate (pink) on the chain sub-assembly with the alignment mark (engraved line) on the camshaft timing intake gear assembly RH.
- Align the mark plate (pink) on the chain sub-assembly with the alignment mark (engraved line) on the camshaft timing exhaust gear assembly RH.
- 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)
HINT:
Apply engine oil to the bolt before install it.
- Install the chain tensioner slipper.
- Install the No. 1 chain tensioner assembly with the 2 bolts.
Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
- Check that the chain is correctly installed.TEXT IN ILLUSTRATION
*a Alignment Mark (Oval) *b Alignment Mark (Engraved Line) *c Mark plate (Grayish Blue) *d Mark plate (Pink) - The mark plate (grayish blue) on the chain sub-assembly is aligned with the alignment mark (oval) on the crankshaft timing gear or sprocket.
- 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.
- 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.
- Pull out the hexagon wrench from the No. 1 chain tensioner assembly.
- Temporarily install the crankshaft pulley spacer and crankshaft pulley.
- 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.
- SST: 09960-10010
- Remove the crankshaft pulley and crankshaft pulley spacer.
- Move the link plate in the direction of the arrow in the illustration to press in the plunger.
- INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
- Apply a light layer of engine oil to 4 new O-rings and attach them to the engine.
- Clean and degrease the contact surface.
- If there are gaps at positions shown in the illustration, fill up with seal packing.
Seal packing
Three Bond 1217G, 1217H or equivalent
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Three Bond 1217G, 1217H or equivalent
TEXT IN ILLUSTRATION*a Area A *b Boss (5 locations) *c Area B *d Other than ranges A and B *e 3.5 to 4.5 mm (0.138 to 0.177 in.) *f 2.0 mm (0.079 in.) *g 12 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 and tighten the bolts within 15 minutes of applying seal packing.
- Do not add engine oil within 30 minutes of installation.
- Do not start the engine within 30 minutes of installation.
- Temporarily install the timing chain or belt cover sub-assembly with the 32 bolts.
- Securely tighten the 32 bolts in the order as shown in the illustration.TEXT IN ILLUSTRATION
Bolt A Bolt B Bolt C Bolt D Bolt A and B
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Bolt C and D
Torque: 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.)
- INSTALL TIMING CHAIN COVER OIL SEAL
- 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 and the outer periphery.
- 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
- SST: 09950-70010
- 09951-07100
NOTE:- Do not tap the oil seal at an angle.
- Do not deform the oil seal.
HINT:
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.
- SST: 09950-60010
- Apply engine oil to a new oil seal lip.
- INSTALL CRANKSHAFT PULLEY
- Install the crankshaft pulley spacer.
- Install a new O-ring to the crankshaft pulley spacer.
- Install the crankshaft pulley while aligning the knock hole of the pulley with the knock pin on the crankshaft pulley spacer.TEXT IN ILLUSTRATION
*1 Knock Hole *2 Knock Pin - Apply engine oil to threads and seat sections of the crankshaft pulley set bolt.
- Install SST to the crankshaft pulley.
- SST: 09213-80010
- 90179-10016
- 09213-08010
- 09213-08110
HINT:
Position the projections on SST in the direction as shown in the illustration to prevent SST from separating from the crankshaft pulley.
TEXT IN ILLUSTRATION*1 Claw - SST: 09213-80010
- 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)
TEXT IN ILLUSTRATION*a Hold *b Turn - SST: 09213-80010
- Using a marker, draw the reference line (A) on the crankshaft pulley set bolt and also the reference line (B) on the crank pulley according to the line engraved around the crankshaft pulley set bolt head as shown in the illustration.TEXT IN ILLUSTRATION
*a Reference Line A *b Reference Line B HINT:
There are carved lines on the crankshaft pulley set bolt head every 90°.
- 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
TEXT IN ILLUSTRATION*a Hold *b Turn *c Reference Line A *d Reference Line B - SST: 09213-80010
- INSTALL THERMOSTAT
- Attach a new gasket to the thermostat.
- INSTALL WATER OUTLET
- INSTALL ENGINE WATER PUMP ASSEMBLY
- INSTALL WATER PUMP PULLEY
- INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
- INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
- INSTALL PCV VALVE SUB-ASSEMBLY
- INSTALL WATER INLET PIPE
- INSTALL REAR CYLINDER HEAD PLATE (for Manual Transmission)
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Three Bond 1217G, 1217H or equivalent
TEXT IN ILLUSTRATION*a 2, 0 to 4.0 mm (0.079 to 0.158 in.) *b Within 1.0 mm (0.0394 in.) *c Chamfer edge NOTE:- Clean and degrease the contact surface.
- Install the rear cylinder head plate within 5 minutes of applying seal packing.
- Install the rear cylinder head plate with the 3 bolts.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
- Apply seal packing in a continuous line as shown in the illustration.
- INSTALL VACUUM PUMP ASSEMBLY (for Automatic Transmission)
Refer to PROCEDURE - Step 1
- INSTALL PCV HOSE CONNECTOR
- INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
- Clean and degrease the threads of the engine oil pressure switch assembly.
- Apply adhesive 1324 to the threads of the engine oil pressure switch assembly.
Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
TEXT IN ILLUSTRATION*1 Adhesive 1324 NOTE:Keep the oil hole free from adhesive.
- Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.TEXT IN ILLUSTRATION
*1 24 mm Deep Socket Wrench Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
NOTE:Do not start the engine for at least 1 hour after installation.
- INSTALL TEMPERATURE SENSOR
- INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
- Install the back-up ring to the camshaft timing oil control valve (for exhaust side of bank 2).TEXT IN ILLUSTRATION
*1 O-ring *2 Back-up ring - Install a new O-ring to the camshaft timing oil control valve (for exhaust side of bank 2).
- Apply a light coat of engine oil to the O-ring.
- 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)
- Install the back-up ring to the camshaft timing oil control valve (for intake side of bank 2).
- Install a new O-ring to the camshaft timing oil control valve (for intake side of bank 2).
- Apply a light coat of engine oil to the O-ring.
- 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)
- Install the back-up ring to the camshaft timing oil control valve (for exhaust side of bank 1).
- Install a new O-ring to the camshaft timing oil control valve (for exhaust side of bank 1).
- Apply a light coat of engine oil to the O-ring.
- 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)
- Install the back-up ring to the camshaft timing oil control valve (for intake side of bank 1).
- Install a new O-ring to the camshaft timing oil control valve (for intake side of bank 1).
- Apply a light coat of engine oil to the O-ring.
- 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)
- Install the back-up ring to the camshaft timing oil control valve (for exhaust side of bank 2).
- INSTALL VVT SENSOR
- Install a new O-ring to the VVT sensor (for exhaust side of bank 2).
- Apply a light coat of engine oil to the O-ring.
- Install the VVT sensor (for exhaust side of bank 2) with the bolt.
Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
- Install a new O-ring to the VVT sensor (for intake side of bank 2).
- Apply a light coat of engine oil to the O-ring.
- Install the VVT sensor (for intake side of bank 2) with the bolt.
Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
- Install a new O-ring to the VVT sensor (for exhaust side of bank 1).
- Apply a light coat of engine oil to the O-ring.
- Install the VVT sensor (for exhaust side of bank 1) with the bolt.
Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
- Install a new O-ring to the VVT sensor (for intake side of bank 1).
- Apply a light coat of engine oil to the O-ring.
- Install the VVT sensor (for intake side of bank 1) with the bolt.
Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
- INSTALL CRANK POSITION SENSOR
- INSTALL KNOCK CONTROL SENSOR
- INSTALL E.F.I. WATER TEMPERATURE SENSOR
- 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 (Refer to PRECAUTION [06/2016 - ] ).
- Using a 19 mm union nut wrench, install a new gasket and the E.F.I. water temperature sensor.
- INSTALL OIL FILTER UNION
- INSTALL OIL FILTER SUB-ASSEMBLY
- INSTALL OIL FILLER CAP ASSEMBLY
- Install the oil filler cap assembly.