Engine Mechanical: Overhaul Lexus ES XV40

DISASSEMBLY

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1. REMOVE OIL FILLER CAP SUB-ASSEMBLY Remove the oil filler cap and gasket.
2. REMOVE SPARK PLUG Remove the spark plugs.
3. REMOVE OIL PAN DRAIN PLUG Remove the drain plug and gasket.
4. REMOVE VENTILATION VALVE SUB-ASSEMBLY Remove the ventilation valve.
5. REMOVE CAMSHAFT POSITION SENSOR Remove the 4 bolts and 4 sensors.
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Remove the 4 bolts and 4 oil control valves.
7. REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and sensor.
8. REMOVE NO. 1 OIL PIPE Remove the 2 oil pipe unions and oil pipe. Remove the oil control valve filter LH and gaskets.
9. REMOVE OIL PIPE Remove the bolt. Remove the 2 oil pipe unions and oil pipe. Remove the oil control valve filter RH and gaskets.
10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Remove the water drain cocks from the cylinder block. Remove the water drain cock plugs from the water drain cocks.
11. REMOVE OIL FILTER ELEMENT Remove the drain plug. NOTE: Do not remove the O-ring from the oil filter cap. Connect the hose to the pipe. Insert the pipe with the hose into the oil filter cap. Make sure that the oil is completely drained and remove the pipe and O-ring. Using SST, remove the oil filter cap. SST 09228-06501 Remove the oil filter element and O-ring from the oil filter cap. NOTE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.
12. REMOVE CRANKSHAFT PULLEY Using SST, loosen the crankshaft pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
13. REMOVE FRONT ENGINE MOUNTING BRACKET NO. 1 LH Remove the 6 bolts and engine mounting bracket. Using a "TORX" socket wrench E8, remove the 2 stud bolts.
14. REMOVE WATER INLET HOUSING Remove the 2 nuts, water inlet, and thermostat. Remove the gasket. Remove the 2 stud bolts. Separate the No. 1 water by-pass hose. Remove the 2 bolts, nut, and water inlet housing. Remove the drain cock plug. Remove the drain cock. Remove the 2 O-rings.
15. REMOVE WATER OUTLET Remove the 2 bolts, 4 nuts, and water outlet. Remove the 2 gaskets and O-ring.
16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) Remove the 12 bolts, seal washer, head cover, and gasket. Remove the 3 gaskets.
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) Remove the 12 bolts, seal washer, head cover, and gasket. NOTE: The baffle plate is located on the back of the portion shown in the illustration. do not damage the baffle plate when removing the head cover. Remove the 3 gaskets.
18. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Remove the 16 bolts and 2 nuts. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly. SST 09032-00100 NOTE: Be careful not to damage the contact surfaces of the oil pans. Using a "TORX" socket wrench E6, remove the 2 stud bolts.
19. REMOVE OIL STRAINER SUB-ASSEMBLY Remove the bolt, 2 nuts, oil strainer, and gasket. Using a "TORX" socket wrench E6, remove the 2 stud bolts.
20. REMOVE OIL PAN SUB-ASSEMBLY Remove the 16 bolts and 2 nuts. HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. HINT: Tape the screwdriver tip before use. Remove the 2 O-rings. Using a "TORX" socket wrench E8, remove the 2 stud bolts.
21. REMOVE OIL PAN BAFFLE PLATE Remove the 7 bolts and baffle plate.
22. REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 6 bolts. Using a screwdriver, pry out the oil seal retainer. NOTE: Be careful not to damage the engine rear oil seal retainer. HINT: Tape the screwdriver tip before use.
23. REMOVE ENGINE REAR OIL SEAL Place the oil seal retainer on wooden blocks. NOTE: Be careful not to damage the engine rear oil seal retainer. Using a screwdriver and a hammer, tap out the oil seal. HINT: Tape the screwdriver tip before use.
24. REMOVE WATER PUMP ASSEMBLY Remove the 16 bolts, water pump, and gasket.
25. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Remove the 15 bolts and 2 nuts as shown in the illustration. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block, and chain cover. HINT: Tape the screwdriver tip before use. Remove the 4 bolts, chain cover plate, and gasket. Remove the gasket.
26. REMOVE TIMING CHAIN CASE OIL SEAL Using a screwdriver, pry out the oil seal. HINT: Tape the screwdriver tip before use.
27. SET NO. 1 CYLINDER TO TDC / COMPRESSION CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE VALVE TIMING PROCEDURE . Temporarily tighten the pulley set bolt. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression). Check that the timing marks of the camshaft timing gears are aligned with those of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.
28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. Move the stopper plate downward to set the lock, and insert a pin of ø1.27 mm (0.05 in.) into the stopper plate's hole. Remove the 2 bolts and chain tensioner.
29. REMOVE CHAIN TENSIONER SLIPPER Remove the chain tensioner slipper.
30. REMOVE CHAIN SUB-ASSEMBLY Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket. Remove the pulley set bolt. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft. Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks. Remove the chain.
31. REMOVE IDLE SPROCKET ASSEMBLY Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, sprocket, and No. 1 idle gear shaft.
32. REMOVE NO. 1 CHAIN VIBRATION DAMPER Remove the 2 bolts and vibration damper.
33. REMOVE NO. 2 CHAIN VIBRATION DAMPER Remove the 2 vibration dampers.
34. REMOVE CRANKSHAFT TIMING SPROCKET Remove the crankshaft timing sprocket from the crankshaft. Remove the 2 pulley set keys from the crankshaft.
35. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) While raising the No. 2 chain tensioner, insert a pin of ø 1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies. NOTE: Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear assemblies. Remove the No. 2 chain.
36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 2 chain tensioner.
37. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Check that the camshafts are positioned as shown in the illustration. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 5 bearing caps.
38. REMOVE CAMSHAFT Remove the camshaft.
39. REMOVE NO. 2 CAMSHAFT Remove the No. 2 camshaft.
40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use.
41. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) While pushing down the No. 3 chain tensioner, insert a pin of ø 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies. NOTE: Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear assemblies. Remove the No. 2 chain.
42. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 3 chain tensioner.
43. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Check that the camshafts are positioned as shown in the illustration. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 5 bearing caps.
44. REMOVE NO. 3 CAMSHAFT Remove the No. 3 camshaft.
45. REMOVE NO. 4 CAMSHAFT Remove the No. 4 camshaft.
46. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use.
47. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 24 valve rocker arms. HINT: Arrange the removed parts in the correct order.
48. REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 24 valve lash adjusters from the cylinder head. HINT: Arrange the removed parts in the correct order.
49. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop the washers into the cylinder head. Cylinder head warpage or cracking could result from removing the bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head and gasket.
50. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Uniformly loosen and remove the bolts in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop the washers into the cylinder head. Cylinder head warpage or cracking could result from removing the bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head and gasket.
51. REMOVE WATER INLET PIPE Separate the No. 1 water by-pass hose. Remove the 2 bolts and water inlet pipe.
52. REMOVE VALVE STEM CAP Remove the valve stem caps from the cylinder heads. HINT: Arrange the removed parts in the correct order.
53. REMOVE INTAKE VALVE Using SST, compress the compression spring and remove the valve spring retainer locks. SST 09202-70020 (09202-00010) Remove the retainer, compression spring, and valve. HINT: Arrange the removed parts in the correct order.
54. REMOVE EXHAUST VALVE Using SST, compress the compression spring and remove the valve spring retainer locks. SST 09202-70020(09202-00010) Remove the retainer, compression spring, and valve. HINT: Arrange the removed parts in the correct order.
55. REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the oil seals.
56. REMOVE VALVE SPRING SEAT Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.
57. REMOVE NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets. NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
58. REMOVE NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, remove the screw plugs and gaskets. NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
59. REMOVE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced.
60. REMOVE STUD BOLT NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
61. REMOVE INTAKE VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the guide bushes. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
62. REMOVE EXHAUST VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the guide bushes. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
63. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD Check that the matchmarks on the connecting rod and cap are aligned. HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearing, connecting rod, and cap together. Arrange the piston and connecting rod assemblies in the correct order.
64. REMOVE CONNECTING ROD BEARING HINT: Arrange the removed parts in the correct order.
65. REMOVE CRANKSHAFT Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in several steps and in the sequence shown in the illustration. Uniformly loosen the 16 bearing cap bolts in several steps and in the sequence shown in the illustration. Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings. NOTE: Push up on the cap little by little, from the right and left side alternately so that the cap can be removed. Be careful not to damage the joint surface of the cylinder block and the main bearing cap. Remove the crankshaft.
66. REMOVE CRANKSHAFT BEARING HINT: Arrange the removed parts in the correct order.
67. REMOVE CRANKSHAFT THRUST WASHER SET Remove the upper bearings and upper thrust washers from the cylinder block.
68. REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Remove the oil ring expander and 2 side rails by hand. HINT: Arrange the removed parts in the correct order.
69. REMOVE PISTON SUB-ASSEMBLY WITH PIN Check the fitting condition between the piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. Disconnect the connecting rod from the piston. Using a screwdriver, pry off the snap rings from the piston. Gradually heat the piston to approximately 80°C(176°F). Using a brass bar and plastic hammer, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: do not use a wire brush.
70. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the bolts and oil nozzles. Check the 3 oil nozzles for damage or clogging. If necessary, replace the oil nozzle.
71. CLEAN CYLINDER BLOCK

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1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Turn the roller by hand to check that it turns smoothly. HINT: If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.
2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the lash adjuster free of dirt and foreign objects. Only use clean engine oil. Place the lash adjuster into a container filled with engine oil. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger. SST 09276-75010 Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times. Check the movement of the plunger and bleed the air. OK: Plunger moves up and down. NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed. After bleeding the air, remove the SST. Then try to quickly and firmly press the plunger with a finger. OK: Plunger is very difficult to move. If the result is not as specified, replace the lash adjuster.
3. INSPECT CAMSHAFT Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.0016 in.) If the circle runout is greater than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. Using a micrometer, measure the cam lobe height. Standard cam lobe height CAM LOBE HEIGHT SPECIFICATION Item Specification Intake camshaft 44.316 to 44.416 mm (1.7447 to 1.7487 in.) Exhaust camshaft 44.262 to 44.362 mm (1.7426 to 1.7465 in.) Maximum cam lobe height CAM LOBE HEIGHT SPECIFICATION Item Specification Intake camshaft 44.166 mm (1.7388 in.) Exhaust camshaft 44.112 mm (1.7367 in.) Using a micrometer, measure the journal diameter. Standard journal diameter STANDARD JOURNAL DIAMETER SPECIFICATION Item Specification No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25. 975 mm (1.0220 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance.
4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Clamp the camshaft in a vise. NOTE: Be careful not to damage the camshaft in the vise. Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove. NOTE: Be sure not to turn the camshaft timing gear in the retard direction (the right angle). Check that there is no clearance between the gear's flange and the camshaft. Tighten the flange bolt with the camshaft timing gear fixed. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) Check the lock of the camshaft timing gear. Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked. NOTE: Be careful not to damage the camshaft. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece. Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 broken paths. CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path. HINT: This operation releases the lock pin for the most retarded position. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path in that order. NOTE: do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. Check for smooth rotation. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. NOTE: do not use air pressure to perform the smooth operation check. Check the lock in the most retarded position. Confirm that the camshaft timing gear is locked at the most retarded position. Remove the flange bolt and camshaft timing gear. NOTE: Do not remove the other 3 bolts. If the gear will be reused, be sure to release the straight pin lock before installing the gear.
5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Clamp the camshaft in a vise. NOTE: Be careful not to damage the camshaft in the vise. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin. Lightly press the gear against the camshaft and turn the gear. Push further at the position where the pin enters the groove. NOTE: Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle). Check that there is no clearance between the gear's flange and the camshaft. Tighten the flange bolt with the camshaft timing exhaust gear fixed. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) Check the camshaft timing exhaust gear lock. Make sure that the camshaft timing exhaust gear is locked. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: 4 oil paths are provided in the groove. Plug 2 paths with rubber pieces. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 broken paths (the advance side path and the retard side path). CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. Make sure that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path. HINT: The lock pin is released and the camshaft timing exhaust gear turns in the retard direction. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path. NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts. Check for smooth rotation. Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly. NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check. Check the lock at the most advanced position. Make sure that the camshaft timing exhaust gear is locked at the most advanced position. Remove the flange bolt and camshaft timing exhaust gear. NOTE: Be sure not to remove the other 4 bolts. If the gear will be reused, be sure to release the straight pin lock before installing the gear.
6. INSPECT CYLINDER HEADSET BOLT Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point. Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 in.) Minimum outside diameter: 10.70 mm (0.4213 in.) Measuring Point: 103 mm (4.06 in.) HINT: If no excessively thin areas are found in a visual check, check the center of the bolt and find the area that has the lowest diameter. If the diameter is less than the minimum, replace the cylinder head bolt.
7. INSPECT CHAIN SUB-ASSEMBLY Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration. Using vernier calipers, measure the length of 15 links. Maximum chain elongation: 136.9 mm (5.390 in.) NOTE: Perform the measurement at 3 random places. Use the average of the measurements. If the elongation is greater than the maximum, replace the chain.
8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration. Using vernier calipers, measure the length of 15 links. Maximum chain elongation: 137.6 mm (5.417 in.) NOTE: Perform the measurement at 3 random places. Use the average of the measurements. If the elongation is greater than the maximum, replace the chain.
9. INSPECT CRANKSHAFT TIMING SPROCKET Wrap the chain around the sprocket. Using vernier calipers, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 61.4 mm (2.417 in.) HINT: The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
10. INSPECT IDLE SPROCKET ASSEMBLY Wrap the chain around the sprocket. Using vernier calipers, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 61.4 mm (2.417 in.) HINT: The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE Using a micrometer, measure the idle gear shaft diameter. Idle gear shaft diameter: 22.987 to 23.000 mm (0.9050 to 0.9055 in.) Using a caliper gauge, measure the inside diameter of the idle gear. Idle gear inside diameter: 23.020 to 23.030 mm (0.9063 to 0.9067 in.) Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement. Standard oil clearance: 0.020 to 0.043 mm (0.0008 to 0.0017 in.) Maximum oil clearance: 0.093 mm (0.0037 in.) If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle gear.
12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. If necessary, replace the chain tensioner assembly.
13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner. Maximum Depth: 0.9 mm (0.035 in.) If the depth is greater than the maximum, replace the chain tensioner assembly.
14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner. Maximum Depth: 0.9 mm (0.035 in.) If the depth is greater than the maximum, replace the chain tensioner assembly.
15. INSPECT CHAIN TENSIONER SLIPPER Measure the worn depth of the chain tensioner slipper. Maximum Depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain tensioner slipper.
16. INSPECT NO. 1 CHAIN VIBRATION DAMPER Measure the worn depth of the chain vibration damper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain vibration damper.
17. INSPECT NO. 2 CHAIN VIBRATION DAMPER Measure the worn depth of the chain vibration damper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain vibration damper.
18. INSPECT CYLINDER HEAD ASSEMBLY Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds. Standard warpage STANDARD WARPAGE SPECIFICATION Item Warpage Cylinder head lower 0.05 mm (0.0020 in.) Intake 0.08 mm (0.0031 in.) Exhaust 0.08 mm (0.0031 in.) Maximum warpage MAXIMUM WARPAGE SPECIFICATION Item Warpage Cylinder head lower 0.10 mm (0.0039 in.) Intake 0.10 mm (0.0039 in.) Exhaust 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace the cylinder head assembly. Using a dye penetrant, check the intake ports, exhaust ports, and cylinder surface for cracks. If cracked, replace the cylinder head assembly.
19. INSPECT INTAKE VALVE Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) If the valve stem is not as specified, check the oil clearance. Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.0394 in.) Minimum margin thickness: 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the intake valve. Using vernier calipers, measure the valve's overall length. Standard overall length: 105.85 mm (4.1673 in.) Minimum overall length: 105.35 mm (4.1476 in.) If the overall length is less than the minimum, replace the intake valve.
20. INSPECT EXHAUST VALVE Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2151 to 0.2157 in.) If the valve stem is not as specified, check the oil clearance. Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.0394 in.) Minimum margin thickness: 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the exhaust valve. Using vernier calipers, measure the valve's overall length. Standard overall length: 110.40 mm (4.3464 in.) Minimum overall length: 109.90 mm (4.3268 in.) If the overall length is less than the minimum, replace the exhaust valve.
21. INSPECT INTAKE VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. Check the valve face and valve seat by using the following procedure. If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat. Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 in.).
22. INSPECT EXHAUST VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. Check the valve face and valve seat by using the following procedure. If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat. Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 in.).
23. REPAIR INTAKE VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Width: 1.1 to 1.5 mm (0.043 to 0.059 in.) Handrub the valve and valve seat with an abrasive compound. Check the valve seating position.
24. REPAIR EXHAUST VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Width: 1.1 to 1.5 mm (0.043 to 0.059 in.) Handrub the valve and valve seat with an abrasive compound. Check the valve seating position.
25. INSPECT COMPRESSION SPRING Using vernier calipers, measure the free length of the compression spring. Free length: 45.46 mm (1.7898 in.) If the free length is not as specified, replace the spring. Using a steel square, measure the deviation of the inner compression spring. Maximum deviation: 1.0 mm (0.039 in.) Maximum angle (reference): 2° If the deviation is greater than the maximum, replace the spring.
26. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard clearance STANDARD CLEARANCE SPECIFICATION Item Clearance Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance MAXIMUM OIL CLEARANCE SPECIFICATION Item Clearance Intake 0.08 mm (0.0032 in.) Exhaust 0.10 mm (0.0039 in.) For intake side: If the clearance is greater than the maximum, replace the intake valve and intake guide bush. For exhaust side: If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush.
27. INSPECT CAMSHAFT THRUST CLEARANCE Inspect the RH bank camshaft thrust clearance. Install the RH bank camshafts (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) Maximum thrust clearance: 0.15 mm (0.006 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. Inspect the LH bank camshaft thrust clearance. Install the LH bank camshafts (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 in.) Maximum thrust clearance: 0.15 mm (0.006 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
28. INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps, camshaft housing, and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each of the camshaft journals. Install the bearing caps (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). NOTE: do not turn the camshaft. Remove the bearing caps (See «DISASSEMBLY»(ref-283093-S08438412342008041700000) ). Measure the Plastigage at its widest point. Standard oil clearance STANDARD OIL CLEARANCE SPECIFICATION Item Oil Clearance No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.0024 in.) Maximum oil clearance MAXIMUM OIL CLEARANCE SPECIFICATION Item Oil Clearance No. 1 journal 0.10 mm (0.0039 in.) Other journals 0.09 mm (0.0035 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing. Clean the bearing caps, camshaft housing, and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each of the camshaft journals. Install the bearing caps (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). NOTE: do not turn the camshaft. Remove the bearing caps (See «DISASSEMBLY»(ref-283093-S08438412342008041700000) ). Measure the Plastigage at Its widest point. Standard oil clearance STANDARD OIL CLEARANCE SPECIFICATION Item Oil Clearance No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.0024 in.) Maximum oil clearance MAXIMUM OIL CLEARANCE SPECIFICATION Item Oil Clearance No. 1 journal 0.10 mm (0.0039 in.) Other journals 0.09 mm (0.0035 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
29. INSPECT CONNECTING ROD THRUST CLEARANCE Install the connecting rod cap (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 to 0.40 mm (0.0059 to 0.0157 in.) Maximum thrust clearance: 0.50 mm (0.020 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.
30. INSPECT CONNECTING ROD OIL CLEARANCE Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. Check that the front mark of the connecting rod cap is facing forward. Install the connecting rod cap (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). NOTE: Do not turn the crankshaft. Remove the 2 bolts and connecting rod cap (See «DISASSEMBLY»(ref-283093-S08438412342008041700000) ). Measure the Plastigage at its widest point. Standard oil clearance: 0.045 to 0.067 mm (0.0018 to 0.0026 in.) Maximum oil clearance: 0.070 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3, or 4 mark on its surface. Connecting rod diameter CONNECTING ROD DIAMETER SPECIFICATION Mark Diameter 1 56.000 to 56.006 mm (2.2047 to 2.2050 in.) 2 56.007 to 56.012 mm (2.2050 to 2.2052 in.) 3 56.013 to 56.018 mm (2.2052 to 2.2054 in.) 4 56.019 to 56.024 mm (2.2055 to 2.2057 in.) Connecting rod bearing center wall thickness CONNECTING ROD BEARING CENTER WALL THICKNESS SPECIFICATION Mark Thickness 1 1.481 to 1.484 mm (0.0583 to 0.0584 in.) 2 1.484 to 1.487 mm (0.0584 to 0.0585 in.) 3 1.487 to 1.490 mm (0.0585 to 0.0587 in.) 4 1.490 to 1.493 mm (0.0587 to 0.0588 in.) Crankshaft pin diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.) NOTE: Completely remove the Plastigage after the measurement.
31. INSPECT CRANKSHAFT THRUST CLEARANCE Install the main bearing cap (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
32. INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket. Maximum warpage: 0.07 mm (0.0028 in.) If the warpage is greater than the maximum, replace the cylinder block.
33. INSPECT CYLINDER BORE Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter: 94.200 mm (3.7087 in.) If the average diameter of 4 positions is greater than the maximum, replace the cylinder block.
34. INSPECT PISTON SUB-ASSEMBLY WITH PIN Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified. Distance: 9.8 mm (0.3858 in.) Standard diameter: 93.960 to 93.980 mm (3.6992 to 3.7000 in.) Maximum diameter: 93.830 mm (3.6941 in.)
35. INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust directions. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.020 to 0.052 mm (0.0008 to 0.0020 in.) Maximum oil clearance: 0.060 mm (0.0024 in.) If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.
36. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring groove clearance RING GROOVE CLEARANCE SPECIFICATION Item Clearance No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.) Oil 0.070 to 0.150 mm (0.0028 to 0.0059 in.) If the clearance is not as specified, replace the piston.
37. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard end gap STANDARD END GAP SPECIFICATION Item End Gap No. 1 0.25 to 0.35 mm (0.0098 to 0.0138 in.) No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.) Oil 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum end gap MAXIMUM END GAP SPECIFICATION Item End Gap No. 1 0.50 mm (0.0197 in.) No. 2 0.85 mm (0.0335 in.) Oil 0.60 mm (0.0236 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, rebore all the 6 cylinders or replace the cylinder block.
38. INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston pin hole. Piston pin hole inside diameter PISTON PIN HOLE INSIDE DIAMETER SPECIFICATION Mark Diameter A 22.001 to 22.004 mm (0.8662 to 0.8663 in.) B 22.004 to 22.007 mm (0.8663 to 0.8664 in.) C 22.007 to 22.010 mm (0.8664 to 0.8665 in.) Using a micrometer, measure the piston pin diameter. Piston pin diameter PISTON PIN DIAMETER SPECIFICATION Mark Diameter A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.000 to 22.003 mm (0.8661 to 0.8663 in.) C 22.003 to 22.006 mm (0.8663 to 0.8664 in.) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 in.) Maximum oil clearance: 0.015 mm (0.0006 in.) If the oil clearance is greater than the maximum, replace the piston and piston pin as a set. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter BUSHING INSIDE DIAMETER SPECIFICATION Mark Diameter A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) B 22.009 to 22.011 mm (0.8665 to 0.8666 in.) C 22.012 to 22.014 mm (0.8666 to 0.8667 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.030 mm (0.0012 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.
39. INSPECT CONNECTING ROD Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for out-of-alignment. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the out-of-alignment is greater than the maximum, replace the connecting rod assembly. Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly.
40. INSPECT CONNECTING ROD BOLT Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 to 7.3 mm (0.284 to 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt.
41. INSPECT CRANKSHAFT Inspect for circle runout. Clean the crank journal. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than the maximum, replace the crankshaft. Inspect the main journals. Using a micrometer, measure the diameter of each main journal. Standard journal diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. Inspect the crank pin. Using a micrometer, measure the diameter of each crank pin. Crankshaft pin diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft.
42. INSPECT CRANKSHAFT OIL CLEARANCE Check the crank journal and bearing for pitting and scratches. Install the crankshaft bearing (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. Examine the front marks and numbers and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Install the main bearing cap (See «REASSEMBLY»(ref-283093-S24138485622008041700000) ). NOTE: Do not turn the crankshaft. Remove the main bearing caps (See «DISASSEMBLY»(ref-283093-S08438412342008041700000) ). Measure the Plastigage at its widest point. Standard oil clearance: 0.026 to 0.047 mm (0.0010 to 0.0019 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: Completely remove the Plastigage after the measurement. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly. Journal bearings: JOURNAL BEARINGS Cylinder block + Crankshaft 0 - 5 6 - 11 12 - 17 18 - 23 24 - 28 Bearing to be used "1" "2" "3" "4" "5" HINT: EXAMPLE: Cylinder block "11" + Crankshaft "06" Total number 17 (Use bearing "3") Crankshaft main journal diameter CRANKSHAFT MAIN JOURNAL DIAMETER SPECIFICATION Mark Diameter "00" 60.999 to 61.000 mm (2.4015 to 2.4016 in.) "01" 60.998 to 60.999 mm (2.4015 to 2.4015 in.) "02" 60.997 to 60.998 mm (2.4015 to 2.4015 in.) "03" 60.996 to 60.997 mm (2.4014 to 2.4015 in.) "04" 60.995 to 60.996 mm (2.4014 to 2.4014 in.) "05" 60.994 to 60.995 mm (2.4013 to 2.4014 in.) "06" 60.993 to 60.994 mm (2.4013 to 2.4013 in.) "07" 60.992 to 60.993 mm (2.4013 to 2.4013 in.) "08" 60.991 to 60.992 mm (2.4012 to 2.4013 in.) "09" 60.990 to 60.991 mm (2.4012 to 2.4012 in.) "10" 60.989 to 60.990 mm (2.4011 to 2.4012 in.) "11" 60.988 to 60.989 mm (2.4011 to 2.4011 in.) Standard upper bearing center wall thickness (No. 1 and No. 4 journal) STANDARD UPPER BEARING CENTER WALL THICKNESS (NO. 1 AND NO. 4 JOURNAL) Mark Thickness "1" 2.500 to 2.503 mm (0.0984 to 0.0985 in.) "2" 2.503 to 2.506 mm (0.0985 to 0.0987 in.) "3" 2.506 to 2.509 mm (0.0987 to 0.0988 in.) "4" 2.509 to 2.512 mm (0.0988 to 0.0989 in.) "5" 2.512 to 2.515 mm (0.0989 to 0.0990 in.) Standard lower bearing center wall thickness (No. 1 and No. 4 journal) STANDARD LOWER BEARING CENTER WALL THICKNESS (NO. 1 AND NO. 4 JOURNAL) Mark Thickness "1" 2.478 to 2.481 mm (0.0976 to 0.0977 in.) "2" 2.481 to 2.484 mm (0.0977 to 0.0978 in.) "3" 2.484 to 2.487 mm (0.0978 to 0.0979 in.) "4" 2.487 to 2.490 mm (0.0979 to 0.0980 in.) "5" 2.490 to 2.493 mm (0.0980 to 0.0981 in.) Standard upper bearing center wall thickness (No. 2 and No. 3 journal) STANDARD UPPER BEARING CENTER WALL THICKNESS (NO. 2 AND NO. 3 JOURNAL) Mark Thickness "1" 2.478 to 2.481 mm (0.0976 to 0.0977 in.) "2" 2.481 to 2.484 mm (0.0977 to 0.0978 in.) "3" 2.484 to 2.487 mm (0.0978 to 0.0979 in.) "4" 2.487 to 2.490 mm (0.0979 to 0.0980 in.) "5" 2.490 to 2.493 mm (0.0980 to 0.0981 in.) Standard lower bearing center wall thickness (No. 2 and No. 3 journal) STANDARD LOWER BEARING CENTER WALL THICKNESS (NO. 2 AND NO. 3 JOURNAL) Mark Thickness "1" 2.500 to 2.503 mm (0.0984 to 0.0985 in.) "2" 2.503 to 2.506 mm (0.0985 to 0.0987 in.) "3" 2.506 to 2.509 mm (0.0987 to 0.0988 in.) "4" 2.509 to 2.512 mm (0.0988 to 0.0989 in.) "5" 2.512 to 2.515 mm (0.0989 to 0.0990 in.)
43. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point. Standard diameter: 10.8 to 11.0 mm (0.4252 to 0.4331 in.) Minimum diameter: 10.7 mm (0.4213 in.) Measuring Point: 40 mm (1.57 in.) If the diameter is less than the minimum, replace the bolt.

REASSEMBLY

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1. INSTALL STRAIGHT PIN Using a plastic hammer, tap in new straight pins to the cylinder block. Standard protrusion STRAIGHT PIN DIAMETER Item Protrusion Pin A 23 mm (0.906 in.) Pin B 6 mm (0.236 in.) Pin C 11 mm (0.433 in.) Pin d 9 mm (0.354 in.)
2. INSTALL STUD BOLT Using E8 and E10 "TORX" sockets, install the stud bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 17 N*m (173 kgf*cm, 13 ft.*lbf) for bolt B
3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the oil nozzles. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
4. INSTALL PISTON SUB-ASSEMBLY WITH PIN Using a screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Gradually heat the piston to approximately 80°C (176°F). Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. HINT: The piston and pin are a matched set. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin. Using a screwdriver, install a new snap ring at the other end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
5. INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the oil ring rail as shown in the illustration. Position the piston rings so that the ring ends are as shown in the illustration. NOTE: do not align the ring ends.
6. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the bearing. NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions. Install the upper bearing. Install the upper bearings to the cylinder block as shown in the illustration. NOTE: do not apply engine oil to the bearings and the contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Install the lower bearing. Install the lower bearings to the bearing caps. Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge. dimension (A - B): 0.7 mm (0.0276 in.) or less NOTE: do not apply engine oil to the bearings and the contact surfaces.
7. INSTALL CRANKSHAFT THRUST WASHER SET Apply engine oil to the crankshaft thrust washer. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
8. INSTALL CRANKSHAFT Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block. Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Temporarily install the 8 main bearing cap bolts to the inside positions. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide. Bolt length: 100 to 102 mm (3.94 to 4.02 in.) Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts. Install the 8 main bearing cap bolts to the outside positions. Install the crankshaft bearing cap bolts. HINT: The main bearing cap bolts are tightened in 2 progressive steps. Step 1 Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) If any of the main bearing cap bolts does not meet the specified torque, replace it. Step 2 Mark the front of the bearing cap bolts with paint. Retighten the bearing cap bolts 90° in the order above. Check that the painted mark is now at a 90° angle to the front. Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration. Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf) Bolt length BOLT LENGTH SPECIFICATION Item Length Bolt A 45 mm (1.77 in.) Except bolt A 30 mm (1.18 in.) Check that the crankshaft turns smoothly. Check the crankshaft thrust clearance (See «INSPECTION»(ref-283093-S03920934732008041700000) ).
9. INSTALL CONNECTING ROD BEARING Install the connecting rod bearing to the connecting rod and bearing cap. Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge. Dimension (A - B): 0.7 mm (0.0276 in.) or less NOTE: Do not apply engine oil to the bearings and the contact surfaces.
10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. Position the piston rings so that the ring ends are as shown in the illustration. NOTE: do not align the ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward. NOTE: Match the numbered connecting rod cap with the connecting rod. Check that the front mark of the connecting rod cap is facing forward. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. Install the connecting cap bolts. HINT: The connecting cap bolts are tightened in 2 progressive steps. Step 1 Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) Step 2 Mark the front side of each connecting cap bolt with paint. Retighten the cap bolts 90° as shown in the illustration. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly. Check the connecting rod thrust clearance (See «INSPECTION»(ref-283093-S03920934732008041700000) ).
11. INSTALL INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05). GUIDE BUSH DIAMETER Bush size Bush bore diameter STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST, tap in new valve guide bushes to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0023 in.)
12. INSTALL EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05). GUIDE BUSH DIAMETER Bush size Bush bore diameter STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST, tap in new valve guide bushes to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
13. INSTALL RING PIN Using a plastic hammer, tap in new ring pins to the specified protrusion height. Specified protrusion height: 2.5 to 3.5 mm (0.098 to 0.138 in.)
14. INSTALL NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
15. INSTALL NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
16. INSTALL STUD BOLT NOTE: If the stud bolt is deformed or the threads are damaged, replace it. Using E6 and E8 "TORX" sockets, install the stud bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts A and B 4.0 N*m (41 kgf*cm, 35 in.*lbf) for bolt C
17. INSTALL STRAIGHT PIN Using a plastic hammer, tap in new straight pins as shown in the illustration. Protrusion height: 17.5 to 19.5 mm (0.689 to 0.768 in.)
18. INSTALL VALVE SPRING SEAT Install the valve spring seats to the cylinder head.
19. INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to new oil seals. NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later. HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. Using SST, push in the oil seals. SST 09201-41020 NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
20. INSTALL EXHAUST VALVE Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. Install the valve, compression spring, and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to the original locations. Using SST, compress the spring and install the 2 retainer locks. SST 09202-70020 (09202-00010) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
21. INSTALL INTAKE VALVE Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. Install the valve, compression spring, and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to the original locations. Using SST, compress the spring and install the 2 retainer locks. SST 09202-70020 (09202-00010) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
22. INSTALL VALVE STEM CAP Apply a light coat of engine oil to the valve stem caps. Install the valve stem caps on the valves.
23. INSTALL ENGINE REAR OIL SEAL Place the oil seal retainer on wooden blocks. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTE: Keep the lip free of foreign matter. Do not tap on the oil seal at an angle.
24. INSTALL ENGINE REAR OIL SEAL RETAINER Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 2.0 to 3.0 mm (0.079 to 0.118 in.) NOTE: Remove any oil from the contact surface. Install the oil seal retainer within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install the oil seal retainer with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
25. INSTALL WATER INLET PIPE Install the water inlet pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the No. 1 water by-pass hose.
26. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Be sure to install the gasket in the correct direction. Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder head. Place the cylinder head on the cylinder block. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1 Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2 Mark the cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts another 90°. Step 3 Tighten the cylinder head bolts an additional 90°. Check that the painted mark is now facing rearward.
27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Be sure to install the gasket in the correct direction. Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder head. Place the cylinder head on the cylinder block. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1 Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2 Mark the cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts another 90°. Step 3 Tighten the cylinder head bolts an additional 90°. Check that the painted mark is now facing rearward. Tighten the 2 bolts in the order shown in the illustration. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
28. INSTALL VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the lash adjuster free of dirt and foreign objects. Only use clean engine oil. Place the lash adjuster into a container filled with engine oil. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger. SST 09276-75010 Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times. Check the movement of the plunger and bleed the air. OK: Plunger moves up and down. NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not be bled. After bleeding the air, remove the SST. Then, try to press the plunger quickly and firmly with a finger. OK: Plunger is very difficult to move. If the result is not as specified, replace the lash adjuster. Install the lash adjusters. NOTE: Install the lash adjuster to the same place where it was removed from.
29. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the lash adjuster tip and valve stem cap end. Make sure that the valve rocker arms are installed as shown in the illustration.
30. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Apply engine oil to the camshaft journals, camshaft housing, and bearing caps. Install the camshaft and No. 2 camshaft to the camshaft housing RH. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. Temporarily tighten the 8 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
31. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Make sure that the valve rocker arm is installed as shown in the illustration. Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing sub-assembly RH within 3 minutes. Do not start the engine for at least 2 hours after installing. Install the camshaft housing RH and tighten the 12 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing. If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
32. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Apply engine oil to the camshaft journals, camshaft housing, and bearing caps. Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing LH. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. Temporarily tighten the 8 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Make sure that the valve rocker arm is installed as shown in the illustration. Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing sub-assembly LH within 3 minutes. Do not start the engine for at least 2 hours after installing. Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing. If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
34. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Install the No. 2 chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the tensioner, insert a pin of (J) 1.0 mm (0.039 in.) into the hole to fix it.
35. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE VALVE TIMING PROCEDURE . Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration. Apply a light coat of engine oil to the bolt threads and bolt-seating surface. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) Remove the pin from the chain tensioner.
36. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Install the chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the tensioner, insert a pin of ø 1.0 mm (0.039 in.) into the hole to hold it.
37. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE VALVE TIMING PROCEDURE . Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration. Apply a light coat of engine oil to the bolt threads and bolt-seating surface. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) Remove the pin from the chain tensioner.
38. INSTALL NO. 1 CHAIN VIBRATION DAMPER Install the chain vibration damper with the 2 bolts. Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
39. INSTALL NO. 2 CHAIN VIBRATION DAMPER Install the 2 chain vibration dampers.
40. INSTALL CRANKSHAFT TIMING SPROCKET Install the 2 timing gear set keys and timing sprocket as shown in the illustration.
41. INSTALL IDLE SPROCKET ASSEMBLY Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block. NOTE: Be sure to install the idle gear shaft in the correct direction. HINT: Check that no foreign objects are on the idle gear shafts No. 1 and No. 2. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) HINT: After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
42. INSTALL CHAIN SUB-ASSEMBLY Align the mark plate and timing marks as shown in the illustration and install the chain. HINT: The color of the camshaft mark plate is orange. Do not pass the chain over the crankshaft, just put it on it. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks. NOTE: When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks. Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket. HINT: The color of the crankshaft mark plate is yellow. Temporarily tighten the pulley set bolt. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
43. INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper.
44. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the hexagon wrench of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression. Remove the pulley set bolt.
45. INSTALL TIMING CHAIN CASE OIL SEAL Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge. SST 09223-22010,09506-35010 NOTE: Keep the lip free of foreign matter. Do not tap on the oil seal at an angle. Make sure that the oil seal edge does not stick out of the timing chain case.
46. INSTALL WATER PUMP ASSEMBLY Install a new gasket and the water pump with the 8 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
47. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Apply seal packing in a continuous line to the engine unit as shown in the following illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 mm (0.118 in.) NOTE: Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes. Do not start the engine for at least 2 hours after installing. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent NOTE: When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. Install the chain cover 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 installing. Apply seal packing as follows SEAL PACKING DIAMETER Area Seal Packing diameter Application Position from Inside Seal Line Continuous Line Area 4.5 mm or more (0.177 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Alternate Long and Short dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.) Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.) Install a new gasket. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft. Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts. Bolt length BOLT LENGTH SPECIFICATION Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 25 mm (0.98 in.) NOTE: Make sure that there is no oil on the bolt and nut threads. Fully tighten the bolts in this order: Area 1 and Area 2. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Fully tighten the bolts in Area 3. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts and nuts in the order of upper to lower as shown in the illustration. Fully tighten the bolts in Area 4. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except bolt A HINT: Tighten the bolts in the order of lower to upper as shown in the illustration. Install a new gasket and the chain cover plate with the 4 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
48. INSTALL WATER INLET HOUSING Install 2 new O-rings. HINT: Apply a small amount of water or soapy water to O-ring (A) in the illustration before installing it. Install the stud bolts. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Install the water inlet with the 2 bolts and nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful that the O-ring does not get caught between the parts. Connect the No. 1 water by-pass hose. Apply adhesive around the drain cock. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the drain cock to the water inlet housing. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) Install the drain cock plug to the water drain cock. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Install a new gasket to the thermostat. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 10° of either side of the prescribed positions. Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
49. INSTALL FRONT ENGINE MOUNTING BRACKET NO. 1 LH Install the engine mounting bracket with the 6 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) NOTE: Install the water inlet and mounting bracket within 15 minutes after installing the chain cover. Do not start the engine for at least 2 hours after installation. When replacing a stud bolt, install it by using an E8 "TORX" socket wrench. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
50. INSTALL OIL PAN BAFFLE PLATE Install the oil pan baffle plate with the 7 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Temporarily tighten the 7 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.
51. INSTALL OIL PAN SUB-ASSEMBLY When replacing a stud bolt, install it by using an E8 "TORX" socket wrench. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install 2 new O-rings. Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.) NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install the oil pan with the 16 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A
52. INSTALL OIL STRAINER SUB-ASSEMBLY Using an E6 "TORX" socket, install the stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
53. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Using an E6 "TORX" socket, install the stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.) NOTE: Remove any oil from the contact surface. Install the oil pan No. 2 within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install the oil pan with the 16 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
54. INSTALL OIL PAN DRAIN PLUG Install a new gasket and the drain plug. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
55. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the head cover within 3 minutes after applying seal packing. do not start the engine for at least 2 hours after installing. Install 3 new gaskets as shown in the illustration. Install a new gasket to the head cover. Install a head cover with the 12 bolts and a new washer. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A HINT: After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the head cover within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install 3 new gaskets as shown in the illustration. Install a new gasket to the head cover. Install the head cover with the 12 bolts and a new washer. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A HINT: After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
57. INSTALL WATER OUTLET Install 2 new gaskets and a new O-ring. HINT: Apply soapy water to the O-ring. Install the water by-pass joint with the 2 bolts and 4 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts 10 N*m (103 kgf*cm, 7 ft.*lbf) for nuts NOTE: Be careful that the O-ring does not get caught between the parts.
58. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide it on the pulley. Using SST, install the pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf)
59. INSTALL OIL FILTER ELEMENT Clean the inside of the oil filter cap, the threads and O-ring groove. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap. Set a new oil filter element to the oil filter cap. Remove dirt or foreign matter from the installation surface of the engine. Apply a light coat of engine oil to the O-ring again and install the oil filter cap. NOTE: Be careful that the O-ring does not get caught between the parts. The O-ring must not be twisted on the groove. Using SST, tighten the oil filter cap. SST 09228-06501 Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Make sure that the oil filter is installed securely as shown in the illustration. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap. NOTE: Remove all dirt and foreign matter from the installation surface. Install the oil filter drain plug to the oil filter cap. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) NOTE: Make sure that the O-ring does not get caught between the parts.
60. INSTALL CYLINdER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Apply adhesive around the drain cocks. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the water drain cocks as shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque. Install the water drain cock plugs to the water drain cocks. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
61. INSTALL NO. 1 OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. NOTE: do not touch the mesh when installing the oil control valve filter. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side). Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt. Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
62. INSTALL OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter RH. NOTE: do not touch the mesh when installing the oil control valve filter. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side). Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt. Install the bolt (A) to the cylinder head. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
63. INSTALL CRANKSHAFT POSITION SENSOR Install the sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
64. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Install the 4 oil control valves with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
65. INSTALL CAMSHAFT POSITION SENSOR Install the 4 sensors with the 4 bolts. Torque: 1b N*m (102 kgf*cm, 7 ft.*lbf)
66. INSTALL VENTILATION VALVE SUB-ASSEMBLY Apply adhesive around the ventilation valve. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the ventilation valve. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
67. INSTALL SPARK PLUG Install the 6 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
68. INSTALL OIL FILLER CAP SUB-ASSEMBLY Install a new gasket. Install the oil filler cap.