Engine Mechanical (Service Information): Removal & Installation Lexus ES XV60

INSTALLATION [06/2012 - ]

HINT

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, No. 3 camshaft, No. 4 camshaft, camshaft timing gear assembly or camshaft timing exhaust gear assembly. Refer to INITIALIZATION [06/2012 - ] .

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1. INSTALL NO. 3 CAMSHAFT Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH. Install the No. 3 camshaft to the camshaft housing sub-assembly LH. HINT: Perform "Inspection After Repair" after replacing the No. 3 camshaft. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
2. INSTALL NO. 4 CAMSHAFT Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH. Install the No. 4 camshaft to the camshaft housing sub-assembly LH. HINT: Perform "Inspection After Repair" after replacing the No. 4 camshaft. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
3. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Apply engine oil to the camshaft bearing caps. 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)
4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Make sure that the valve rocker arm is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap Apply seal packing in a continuous line as shown in the illustration. TEXT IN ILLUSTRATION *a Seal packing diameter (3.5 to 4.5 mm) Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard 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 and tighten the bolts. Do not start the engine for at least 2 hours after installing. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration. TEXT IN ILLUSTRATION *1 Knock Pin *a Front View Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing sub-assembly 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, valve contact with a piston at TDC will occur. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly LH 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)
5. INSTALL CAMSHAFT Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH. Install the camshaft to the camshaft housing sub-assembly RH. HINT: Perform "Inspection After Repair" after replacing the camshaft. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
6. INSTALL NO. 2 CAMSHAFT Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH. Install the No. 2 camshaft to the camshaft housing sub-assembly RH. HINT: Perform "Inspection After Repair" after replacing the No. 2 camshaft. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
7. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Apply engine oil to the camshaft bearing caps. 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 bearing cap bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap Apply seal packing in a continuous line as shown in the illustration. TEXT IN ILLUSTRATION *a Seal packing diameter (3.5 to 4.5 mm) Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard 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 and tighten the bolts. Do not start the engine for at least 2 hours after installing. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration. TEXT IN ILLUSTRATION *1 Knock Pin *a Front View Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing sub-assembly 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, valve contact with a piston at TDC will occur. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly RH 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)
9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Install the No. 3 chain tensioner assembly with the bolt. TEXT IN ILLUSTRATION *1 Plunger *2 Pin *a Push Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
10. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate 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 assemblies. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. TEXT IN ILLUSTRATION *a Turn *b Hold SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the pin from the No. 3 chain tensioner assembly. HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Install the No. 2 chain tensioner assembly with the bolt. TEXT IN ILLUSTRATION *1 Plunger *2 Pin *a Push Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
12. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate 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 assemblies. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. TEXT IN ILLUSTRATION *a Turn *b Hold SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the pin from the No. 2 chain tensioner assembly. HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
13. INSTALL IDLE SPROCKET ASSEMBLY See step 26
14. INSTALL CHAIN SUB-ASSEMBLY See step 27
15. INSTALL CHAIN TENSIONER SLIPPER See step 28
16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 29
17. INSPECT VALVE TIMING See step 30
18. INSTALL TIMING CHAIN CASE OIL SEAL . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598589-S10652622422014021400000)
19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598589-S10652622422014021400000)
20. INSTALL OIL PAN SUB-ASSEMBLY See step 37
21. INSTALL OIL STRAINER SUB-ASSEMBLY See step 38
22. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY See step 39
23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY See step 41
24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 42
25. INSTALL WATER INLET HOUSING See step 34
26. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH See step 35
27. INSTALL CRANKSHAFT PULLEY See step 2
28. INSTALL NO. 1 OIL PIPE See step 48
29. INSTALL OIL PIPE See step 49
30. INSTALL CRANK POSITION SENSOR . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598604-S31216901122014021400000)
31. INSTALL NO. 1 VACUUM SWITCHING VALVE See step 6
32. INSTALL WATER PUMP PULLEY See step 7
33. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY See step 8
34. INSTALL NO. 2 TIMING GEAR COVER See step 9
35. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE See step 44
36. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY See step 10
37. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH See step 11
38. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «INSTALLATION [06/2012 - ] - Step 3»(ref-598608-S19976171092014021400000)
39. INSTALL NO. 2 MANIFOLD STAY . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598608-S19976171092014021400000)
40. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE See step 14
41. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH See step 15
42. INSTALL INTAKE MANIFOLD See step 16
43. INSTALL NO. 2 ENGINE MOUNTING STAY RH See step 17
44. INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598604-S27411255502014021400000)
45. INSTALL THROTTLE BODY BRACKET See step 20
46. INSTALL NO. 1 SURGE TANK STAY See step 19
47. INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 6»(ref-598608-S15471234952014021400000)
48. INSTALL ENGINE HANGERS See step 22
49. REMOVE ENGINE STAND
50. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2
51. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Refer to «INSTALLATION [06/2012 - ]»(ref-598611-S29268603132014021400000)

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1. REMOVE CAMSHAFT Refer to «REMOVAL [06/2012 - ]»(ref-598588-S36386653072014021400000)
2. REMOVE NO. 2 CAMSHAFT See step 44
3. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 45
4. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) See step 46
5. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 47
6. REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 48
7. REMOVE NO. 3 CAMSHAFT See step 49
8. REMOVE NO. 4 CAMSHAFT See step 50
9. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 51
10. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 24 No. 1 valve rocker arm assemblies. HINT: Arrange the removed parts in the correct order.
11. REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 24 valve lash adjuster assemblies from the cylinder head sub-assembly. HINT: Arrange the removed parts in the correct order.
12. REMOVE VALVE STEM CAP Remove the 24 valve stem caps.
13. REMOVE WATER OUTLET See step 16
14. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head set bolts in the sequence shown in the illustration. Remove the 8 cylinder head set bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head sub-assembly RH. Cylinder head sub-assembly RH warpage or cracking could result from removing bolts in the incorrect order. HINT: Arrange the removed parts in the correct order. Remove the cylinder head sub-assembly RH.
15. REMOVE CYLINDER HEAD GASKET RH Remove the cylinder head gasket RH.
16. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Uniformly loosen and remove the 2 cylinder head set bolts in several steps and 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 set bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head sub-assembly LH. Cylinder head sub-assembly LH warpage or cracking could result from removing bolts in the incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head sub-assembly LH.
17. REMOVE CYLINDER HEAD GASKET LH Remove the cylinder head gasket LH.

HINT

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly RH or cylinder head sub-assembly LH. Refer to INITIALIZATION [06/2012 - ] .

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1. INSTALL CYLINDER HEAD GASKET RH Place a new cylinder head gasket RH on the cylinder block sub-assembly surface with the lot No. stamp facing upward. TEXT IN ILLUSTRATION *a Lot No. Engine Front NOTE: Be careful of the installation direction.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH Place the cylinder head sub-assembly RH on the cylinder block sub-assembly. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly RH. Gently lower the cylinder head sub-assembly RH in order not to damage the gasket with the bottom part of the head. HINT: The cylinder head set 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 set bolts. Step 1 Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head set 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 TEXT IN ILLUSTRATION *a Turn 90° *b Painted Mark Engine Front Mark each cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head set bolts 90° in the sequence shown in step 1. Step 3 Tighten the cylinder head set bolts an additional 90° in the sequence shown in step 1. Check that the painted mark is now facing rearward. HINT: Perform "Inspection After Repair" after replacing the cylinder head sub-assembly RH. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
3. INSTALL CYLINDER HEAD GASKET LH Place a new cylinder head gasket LH on the cylinder block sub-assembly surface with the lot No. stamp facing upward. TEXT IN ILLUSTRATION *a Lot No. Engine Front NOTE: Be careful of the installation direction.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH Place the cylinder head sub-assembly LH on the cylinder block sub-assembly. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly LH. Gently lower the cylinder head sub-assembly LH in order not to damage the gasket with the bottom part of the head. HINT: The cylinder head set 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 set bolts. Step 1 Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head set bolts with the plate washers in several steps in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2 TEXT IN ILLUSTRATION *a Turn 90° *b Painted Mark Engine Front Mark each cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head set bolts 90° in the sequence shown in step 1. Step 3 Tighten the cylinder head set bolts an additional 90° in the sequence shown in step 1. 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) HINT: Perform "Inspection After Repair" after replacing the cylinder head sub-assembly LH. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
5. INSTALL WATER OUTLET See step 43
6. INSTALL VALVE STEM CAP Install the 24 valve stem caps.
7. INSTALL VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the lash adjuster free of dirt and foreign matter. Only use clean engine oil. Place the valve lash adjuster assembly into a container filled with engine oil. Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger. TEXT IN ILLUSTRATION *1 Tapered Part *2 Plunger *3 Check Ball *a Correct *b Incorrect *c Low Pressure Chamber *d High Pressure Chamber SST: 09276-75010 Squeeze SST and valve lash adjuster assembly 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 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 SST. Then, try to press the plunger quickly and firmly by hand. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster assembly. Install the valve lash adjuster assemblies. NOTE: Install each valve lash adjuster assembly to the same place it was removed from.
8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the valve lash adjuster assembly tip and valve stem cap end. Install the No. 1 valve rocker arm assemblies as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap
9. INSTALL NO. 3 CAMSHAFT See step 1
10. INSTALL NO. 4 CAMSHAFT See step 2
11. INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 3
12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 4
13. INSTALL CAMSHAFT See step 5
14. INSTALL NO. 2 CAMSHAFT See step 6
15. INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 7
16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 8

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1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FRONT FENDER APRON SEAL RH
5. REMOVE V-RIBBED BELT See step 5
6. REMOVE CRANKSHAFT PULLEY Using SST, loosen the crankshaft pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 TEXT IN ILLUSTRATION *a Hold Turn Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021 TEXT IN ILLUSTRATION *a Hold Turn Remove the pulley set key from the crankshaft.
7. REMOVE TIMING CHAIN CASE OIL SEAL Using a knife, cut off the timing chain case oil seal lip. TEXT IN ILLUSTRATION *1 Protective Tape *a Cut Position Using a screwdriver, pry out the timing chain case oil seal. NOTE: After removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. HINT: Tape the screwdriver tip before use.

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1. INSTALL TIMING CHAIN CASE OIL SEAL Apply MP grease to a new timing chain case oil seal lip. Using SST and a hammer, tap in the timing chain case oil seal until its surface is flush with the timing chain cover edge. TEXT IN ILLUSTRATION *a Oil seal tap in depth (0 to 1.0 mm) SST: 09223-22010 SST: 09506-35010 Oil seal tap in depth 0 to 1.0 mm (0 to 0.0394 in.) NOTE: Keep the lip free of foreign matter. Do not tap the timing chain case oil seal at an angle.
2. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the crankshaft pulley, and slide on the crankshaft pulley. Using SST, install the pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 Torque: 250 N*m (2549 kgf*cm, 184 ft.*lbf) TEXT IN ILLUSTRATION *a Hold Turn
3. INSTALL V-RIBBED BELT See step 1
4. INSTALL FRONT FENDER APRON SEAL RH
5. INSTALL ENGINE UNDER COVER RH
6. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
7. INSTALL FRONT WHEEL RH Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)

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1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Refer to «REMOVAL [06/2012 - ]»(ref-598611-S38337276292014021400000)
2. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly and rear drive plate spacer.
3. REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the engine rear oil seal lip. TEXT IN ILLUSTRATION *1 Protective Tape *a Cut Position Using a screwdriver, pry out the engine rear oil seal. NOTE: Be careful not to damage the crankshaft. HINT: Tape the screwdriver tip before use.

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1. INSTALL ENGINE REAR OIL SEAL Apply MP grease to a new engine rear oil seal lip. TEXT IN ILLUSTRATION *1 Retainer *a Oil seal tap in depth (-0.5 to 0.5 mm) Using SST and a hammer, tap in the engine rear oil seal. SST: 09223-15030 SST: 09950-70010 09951-07150 Oil seal tap in depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Clean the 8 bolts and 8 bolt holes. Install the front drive plate spacer. HINT: Align the pin of the front drive plate spacer with the pin hole of the crankshaft. Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft. TEXT IN ILLUSTRATION *1 Drive Plate *2 Rear Spacer Transaxle Side Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 8 bolts. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install and uniformly tighten the 8 bolts in several steps in the sequence shown in the illustration. Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf) NOTE: Do not start the engine for at least an hour after installing the drive plate and ring gear sub-assembly.
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Refer to «INSTALLATION [06/2012 - ]»(ref-598611-S29268603132014021400000)

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1. PRECAUTION WARNING: The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop. NOTE: After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to «PRECAUTION [06/2012 - ]»(ref-598449-S42461431542014021400000) .
2. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . Refer to «REPLACEMENT [06/2012 - ] - Step 1»(ref-598598-S20753311472014021400000)
3. DISCHARGE FUEL SYSTEM PRESSURE Refer to «PRECAUTION [06/2012 - ]»(ref-598600-S24641911262014021400000)
4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [06/2012 - ]»(ref-598449-S08309221792014021400000) .
6. REMOVE FRONT WHEELS
7. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
8. REMOVE ENGINE UNDER COVER RH
9. REMOVE FRONT FENDER APRON SEAL RH
10. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
11. REMOVE ENGINE UNDER COVER LH
12. REMOVE FRONT FENDER APRON SEAL LH
13. DRAIN ENGINE OIL . Refer to «REPLACEMENT [06/2012 - ] - Step 1»(ref-598589-S19481969902014021400000)
14. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT [06/2012 - ] - Step 1»(ref-598590-S28562218122014021400000)
15. DRAIN AUTOMATIC TRANSAXLE FLUID . Refer to «REPLACEMENT [06/2012 - ] - Step 1»(ref-598611-S31387069152014021400000)
16. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL [06/2012 - ] - Step 1»(ref-598617-S32838744702014021400000)
17. REMOVE V-BANK COVER SUB-ASSEMBLY Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the retainer on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly. NOTE: Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.
18. REMOVE INLET NO. 2 AIR CLEANER Disconnect the 2 wire harness clamps and vacuum hose clamp. Remove the 2 bolts and inlet No. 2 air cleaner.
19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 7»(ref-598604-S35516938872014021400000)
20. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Disconnect the 3 wire harness clamps, connector, vacuum hose and No. 1 fuel vapor feed hose. Remove the 2 bolts and air cleaner case sub-assembly.
22. REMOVE BATTERY Disconnect the positive (+) cable from the positive (+) battery terminal. Loosen the nut and remove the bolt. Remove the battery clamp, battery and battery tray.
23. REMOVE INLET NO. 1 AIR CLEANER Disengage the pin and remove the inlet No. 1 air cleaner.
24. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY Disengage the clamp and disconnect the 2 vacuum hoses. Remove the 2 bolts and intake air resonator sub-assembly.
25. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
26. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY Remove the 4 bolts and engine moving control rod sub-assembly.
27. REMOVE NO. 3 ENGINE MOUNTING STAY RH HINT: Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary. Remove the 2 bolts, engine moving control rod and No. 3 engine mounting stay RH from the engine moving control rod bracket. TEXT IN ILLUSTRATION *1 Engine Moving Control Rod *2 No. 3 Engine Mounting Stay RH *3 Engine Moving Control Rod Bracket
28. SEPARATE EARTH WIRE Remove the 2 bolts and separate the earth wire from the engine assembly.
29. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE Disconnect the No. 1 fuel vapor feed hose.
30. DISCONNECT UNION TO CHECK VALVE HOSE Disconnect the union to check valve hose from the brake booster.
31. DISCONNECT NO. 1 RADIATOR HOSE Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose. Disconnect the No. 1 radiator hose.
32. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the No. 2 radiator hose.
33. DISCONNECT NO. 3 WATER BY-PASS HOSE Disconnect the No. 3 water by-pass hose from the transmission oil cooler.
34. DISCONNECT INLET HEATER WATER HOSE Disconnect the inlet heater water hose.
35. DISCONNECT WATER HOSE SUB-ASSEMBLY Disconnect the water hose sub-assembly.
36. REMOVE STARTER ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 11»(ref-598603-S29742264412014021400000)
37. DISCONNECT ENGINE WIRE Remove the No. 1 relay block cover. Remove the 2 nuts and disconnect the wire clamp. Using a screwdriver, unlock the clamp and separate the engine wire from the engine room relay block. Disconnect the 4 connectors. Using a screwdriver, unlock the clamp and separate the engine wire from the engine room relay block. Pull up the lever to disconnect the ECM connector. Disconnect the 2 wire clamps.
38. REMOVE AIR CLEANER BRACKET Disconnect the 2 wire clamps. Remove the bolt and air cleaner bracket from the battery carrier.
39. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 6»(ref-598611-S38465168952014021400000)
40. DISCONNECT FUEL TUBE SUB-ASSEMBLY Remove the fuel pipe clamp. Disconnect the connector from the tube by hand. When the connector and the tube are stuck, push in and pull on the connector to release it. Pull the connector out of the tube carefully. TEXT IN ILLUSTRATION Push Pull NOTE: Check for any dirt and foreign matter in the tube and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the tube and connector. Do not use any tools to separate the tube and connector. Do not forcibly bend or twist the nylon tube. Check for any dirt and foreign matter on the tube seal surface. Clean if necessary. Cover the tube and connector ends with plastic bags to prevent damage and dirt contamination. If the tube and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.
41. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to «REMOVAL [06/2012 - ] - Step 4»(ref-598598-S13270348472014021400000)
42. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE . Refer to «REMOVAL [06/2012 - ] - Step 5»(ref-598598-S13270348472014021400000)
43. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET . Refer to «REMOVAL [06/2012 - ] - Step 7»(ref-598608-S20638794302014021400000)
44. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 5»(ref-598608-S13092153322014021400000)
45. SECURE STEERING WHEEL . Refer to «REMOVAL [06/2012 - ] - Step 3»(ref-598619-S32083608112014021400000)
46. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 4»(ref-598619-S32083608112014021400000)
47. REMOVE FRONT AXLE SHAFT NUT LH . Refer to «REMOVAL [06/2012 - ] - Step 9»(ref-598620-S06848924362014021400000)
48. REMOVE FRONT AXLE SHAFT NUT RH HINT: Perform the same procedure as for the LH side.
49. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH . Refer to «REMOVAL [06/2012 - ] - Step 4»(ref-598621-S14357130422014021400000)
50. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
51. SEPARATE FRONT SPEED SENSOR LH . Refer to «REMOVAL [06/2012 - ] - Step 3»(ref-598622-S08187446612014021400000)
52. SEPARATE FRONT SPEED SENSOR RH HINT: Perform the same procedure as for the LH side.
53. SEPARATE TIE ROD ASSEMBLY LH . Refer to «REMOVAL [06/2012 - ] - Step 5»(ref-598619-S32083608112014021400000)
54. SEPARATE TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
55. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to «REMOVAL [06/2012 - ] - Step 8»(ref-598622-S08187446612014021400000)
56. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
57. SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 7»(ref-598622-S08187446612014021400000)
58. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to «REMOVAL [06/2012 - ] - Step 15»(ref-598620-S06848924362014021400000)
59. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to «REMOVAL [06/2012 - ] - Step 17»(ref-598620-S06848924362014021400000)
60. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to «REMOVAL [06/2012 - ] - Step 16»(ref-598620-S06848924362014021400000)
61. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET Remove the bolt and No. 1 exhaust pipe support bracket.
62. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY Remove the 2 bolts and No. 1 exhaust pipe support bracket sub-assembly.
63. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT . Refer to «REMOVAL [06/2012 - ] - Step 2»(ref-598611-S22530277632014021400000)
64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Set the engine lifter. TEXT IN ILLUSTRATION Attachment Installation Position NOTE: Place the height adjustment and plate lift attachments under the engine assembly with transaxle. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand. Remove the 4 bolts, 2 nuts and frame side rail plates RH and LH. Remove the 4 bolts, 2 nuts and front suspension member rear braces RH and LH. Operate the engine lifter, then remove the engine assembly with transaxle from the vehicle. NOTE: Make sure that the engine assembly with transaxle is clear of all wiring and hoses. While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle. Install the engine hangers See step 22 .
65. REMOVE V-RIBBED BELT See step 5
66. REMOVE GENERATOR ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 6»(ref-598623-S13510758962014021400000)
67. REMOVE COMPRESSOR AND MAGNETIC CLUTCH . Refer to «REMOVAL [06/2012 - ] - Step 6»(ref-598598-S13270348472014021400000)
68. REMOVE TRANSMISSION OIL COOLER
69. REMOVE FRONT FRAME ASSEMBLY Disconnect the 2 clamps. Disconnect the 2 clamps and vacuum switching valve connector. Remove the bolt and disconnect the front engine mounting insulator assembly. Remove the nut and disconnect the engine mounting insulator LH. Remove the nut and disconnect the engine mounting insulator RH. Remove the front frame assembly.
70. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Remove the 3 nuts and front engine mounting insulator assembly. HINT: Perform this procedure only when replacement of the front engine mounting insulator assembly is necessary.
71. REMOVE ENGINE MOUNTING INSULATOR LH Remove the 2 hole plugs from the front frame assembly. Remove the 3 nuts and engine mounting insulator LH. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
72. REMOVE ENGINE MOUNTING INSULATOR RH Remove the 2 hole plugs from the front frame assembly. Remove the 3 nuts and engine mounting insulator RH. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
73. REMOVE ENGINE WIRE Remove the engine wire from the engine with transaxle.
74. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 8»(ref-598611-S22530277632014021400000)
75. REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and engine mounting bracket RH.
76. REMOVE DRIVE SHAFT BEARING BRACKET Remove the 3 bolts and drive shaft bearing bracket.
77. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2
78. INSTALL ENGINE TO ENGINE STAND Install the engine to an engine stand with the bolts.

HINT

Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION [06/2012 - ] .

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Scheme 166

1. REMOVE ENGINE STAND
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2
3. INSTALL DRIVE SHAFT BEARING BRACKET Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
4. INSTALL ENGINE MOUNTING BRACKET RH Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 6»(ref-598611-S18291330762014021400000)
6. INSTALL ENGINE WIRE Install the engine wire to the engine with transaxle.
7. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Temporarily install the front engine mounting insulator assembly with the 3 nuts. HINT: Perform this procedure only when replacement of the front engine mounting insulator assembly is necessary.
8. INSTALL ENGINE MOUNTING INSULATOR LH Temporarily install the engine mounting insulator LH with the 3 nuts. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
9. INSTALL ENGINE MOUNTING INSULATOR RH Temporarily install the engine mounting insulator RH with the 3 nuts. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
10. INSTALL FRONT FRAME ASSEMBLY Install the engine mounting insulator RH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) Install the engine mounting insulator LH with the nut. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) Install the front engine mounting insulator assembly with the bolt. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) Connect the 2 wire clamps and vacuum switching valve connector. Connect the 2 wire clamps. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque. HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary. TEXT IN ILLUSTRATION *1 Front Engine Mounting Insulator Assembly *2 Engine Mounting Insulator RH *3 Engine Mounting Insulator LH - - A Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) B Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) Install the 4 hole plugs. HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary. TEXT IN ILLUSTRATION *1 Engine Mounting Insulator RH *2 Engine Mounting Insulator LH
11. INSTALL TRANSMISSION OIL COOLER
12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598598-S11100292132014021400000)
13. INSTALL GENERATOR ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598623-S26993035132014021400000)
14. INSTALL V-RIBBED BELT See step 1
15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Set the engine assembly with transaxle on an engine lifter. NOTE: Place the height adjustment and plate lift attachments under the engine assembly with transaxle. Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly. Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand. To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle. Make sure to support the engine assembly with transaxle securely to prevent it from falling. Remove the engine hangers See step 1 . Install the engine assembly with transaxle to the vehicle. NOTE: Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up. Make sure that the engine assembly with transaxle is clear of all wiring and hoses. While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts. A Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) B Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) Install the front suspension member rear braces RH and LH with the 4 bolts and 2 nuts. C Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) D Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) HINT: Perform "Inspection After Repair" after replacing the engine assembly. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) .
16. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT . Refer to «INSTALLATION [06/2012 - ] - Step 12»(ref-598611-S18291330762014021400000)
17. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
18. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Install the No. 1 exhaust pipe support bracket with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
19. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH . Refer to «REASSEMBLY [06/2012 - ] - Step 13»(ref-598620-S14383026002014021400000)
20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598620-S12541058962014021400000)
21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598620-S12541058962014021400000)
22. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to «INSTALLATION [06/2012 - ] - Step 8»(ref-598622-S26304413942014021400000)
23. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
24. CONNECT TIE ROD ASSEMBLY LH . Refer to «INSTALLATION [06/2012 - ] - Step 8»(ref-598619-S36902069952014021400000)
25. CONNECT TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
26. INSTALL FRONT SPEED SENSOR LH . Refer to «INSTALLATION [06/2012 - ] - Step 19»(ref-598622-S26304413942014021400000)
27. INSTALL FRONT SPEED SENSOR RH HINT: Perform the same procedure as for the LH side.
28. INSTALL FRONT STABILIZER LINK ASSEMBLY LH . Refer to «INSTALLATION [06/2012 - ] - Step 9»(ref-598621-S25885191382014021400000)
29. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
30. INSTALL FRONT AXLE SHAFT NUT LH . Refer to «INSTALLATION [06/2012 - ] - Step 7»(ref-598620-S12541058962014021400000)
31. INSTALL FRONT AXLE SHAFT NUT RH HINT: Perform the same procedure as for the LH side.
32. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 10»(ref-598619-S36902069952014021400000)
33. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 8»(ref-598608-S19976171092014021400000)
34. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET . Refer to «INSTALLATION [06/2012 - ] - Step 5»(ref-598608-S27490512242014021400000)
35. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE . Refer to «INSTALLATION [06/2012 - ] - Step 3»(ref-598598-S11100292132014021400000)
36. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to «INSTALLATION [06/2012 - ] - Step 4»(ref-598598-S11100292132014021400000)
37. CONNECT FUEL TUBE SUB-ASSEMBLY Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound. NOTE: Check that there is no damage or foreign matter on the fuel tube connector. After connecting, check that the fuel tube connector and the tube are securely connected by pulling on them. Install the fuel pipe clamp. HINT: The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.
38. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598611-S40465022772014021400000)
39. INSTALL AIR CLEANER BRACKET Install the air cleaner bracket to the battery carrier with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the 2 wire clamps.
40. CONNECT ENGINE WIRE Connect the 2 wire clamps. Connect the connector to the ECM with the lock lever. Connect the engine wire to the engine room relay block. Connect the 4 connectors. Connect the engine wire to the engine room relay block. Connect the 2 wire clamps and install the 2 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Install the No. 1 relay block cover.
41. INSTALL STARTER ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598603-S09274318012014021400000)
42. CONNECT WATER HOSE SUB-ASSEMBLY Connect the water hose sub-assembly with the hose clip.
43. CONNECT INLET HEATER WATER HOSE Connect the inlet heater water hose with the hose clip.
44. CONNECT NO. 3 WATER BY-PASS HOSE Connect the No. 3 water by-pass hose to the transmission oil cooler with the hose clip.
45. CONNECT NO. 2 RADIATOR HOSE Connect the No. 2 radiator hose with the hose clip.
46. CONNECT NO. 1 RADIATOR HOSE Connect the No. 1 radiator hose with the hose clip. Install the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.
47. CONNECT UNION TO CHECK VALVE HOSE Connect the union to check valve hose to the brake booster with the hose clip.
48. CONNECT NO. 1 FUEL VAPOR FEED HOSE Connect the No. 1 fuel vapor feed hose with the hose clip.
49. CONNECT EARTH WIRE Install the earth wire with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
50. INSTALL NO. 3 ENGINE MOUNTING STAY RH HINT: Perform this procedure only when replacement of the engine moving control rod sub-assembly or No. 3 engine mounting stay RH is necessary. Temporarily install the No. 3 engine mounting stay RH and engine moving control rod sub-assembly to the engine moving control rod bracket with the 2 bolts. TEXT IN ILLUSTRATION *1 Engine Moving Control Rod *2 No. 3 Engine Mounting Stay RH *3 Engine Moving Control Rod Bracket Tighten the bolt A. Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
51. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY When replacing the engine moving control rod sub-assembly or No. 3 engine mounting stay RH. Install the engine moving control rod bracket with engine moving control rod sub-assembly with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) NOTE: Temporarily tighten bolt A and B, and then fully tighten the 4 bolts in the order of C, D, A and B. Tighten the bolt E. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) When not replacing the engine moving control rod sub-assembly or No. 3 engine mounting stay RH. Install the engine moving control rod bracket with engine moving control rod sub-assembly with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) NOTE: Temporarily tighten bolt A and B, and then fully tighten the 4 bolts in the order of C, D, A and B.
52. INSTALL NO. 2 ENGINE MOUNTING STAY RH Install the No. 2 engine mounting stay RH with the bolt. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) Tighten the 2 nuts. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
53. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY Install the intake air resonator sub-assembly with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the 2 vacuum hoses and engage the claw.
54. INSTALL INLET NO. 1 AIR CLEANER Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly. Engage the pin to the radiator support.
55. INSTALL BATTERY Install the battery and battery tray. Install the battery clamp with the bolt and nut. Bolt Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Nut Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) Connect the positive (+) cable to the positive (+) battery terminal. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Install the air cleaner case sub-assembly to the inlet No. 1 air cleaner. Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration. TEXT IN ILLUSTRATION *1 Air Cleaner Case Sub-assembly *2 Inlet No. 1 Air Cleaner *a Projection *b Hole Tighten the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Connect the 3 wire harness clamps, connector, vacuum hose and No. 1 fuel vapor feed hose.
57. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly. NOTE: Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.
58. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598604-S00398347632014021400000)
59. INSTALL INLET NO. 2 AIR CLEANER Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the 2 wire harness clamps and vacuum hose clamp.
60. INSPECT VACUUM HOSES Inspect the vacuum hoses.
61. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Connect the negative (-) cable to the negative (-) battery terminal. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [06/2012 - ]»(ref-598449-S08309221792014021400000) .
62. INSTALL FRONT WHEELS Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf)
63. ADD ENGINE OIL . Refer to «REPLACEMENT [06/2012 - ] - Step 4»(ref-598589-S19481969902014021400000)
64. ADD ENGINE COOLANT Refer to «REPLACEMENT [06/2012 - ] - Step 2»(ref-598590-S28562218122014021400000)
65. ADD AUTOMATIC TRANSAXLE FLUID Refer to «REPLACEMENT [06/2012 - ] - Step 13»(ref-598611-S31387069152014021400000)
66. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . Refer to «REPLACEMENT [06/2012 - ] - Step 2»(ref-598598-S20753311472014021400000)
67. WARM UP ENGINE . Refer to «REPLACEMENT [06/2012 - ] - Step 3»(ref-598598-S20753311472014021400000)
68. INSPECT FOR REFRIGERANT LEAK . Refer to «REPLACEMENT [06/2012 - ] - Step 4»(ref-598598-S20753311472014021400000)
69. INSPECT ENGINE OIL LEVEL . Refer to «ON-VEHICLE INSPECTION [06/2012 - ] - Step 1»(ref-598618-S31689299242014021400000)
70. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR . Refer to «ON-VEHICLE INSPECTION [06/2012 - ] - Step 2»(ref-598616-S28605636602014021400000)
71. INSPECT FOR FUEL LEAK . Refer to «ON-VEHICLE INSPECTION [06/2012 - ] - Step 1»(ref-598600-S10138120432014021400000)
72. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION [06/2012 - ] - Step 1»(ref-598616-S28605636602014021400000)
73. INSPECT FOR OIL LEAK
74. INSPECT FOR EXHAUST GAS LEAK
75. INSPECT IGNITION TIMING See step 9
76. INSPECT ENGINE IDLE SPEED See step 10
77. INSPECT CO/HC See step 12
78. CHECK FOR SPEED SENSOR SIGNAL Refer to «TEST MODE PROCEDURE [06/2012 - ]»(ref-598453-S15409214192014021400000)
79. INSPECT SHIFT LEVER POSITION . Refer to «ADJUSTMENT [06/2012 - ] - Step 1»(ref-598611-S41237994182014021400000)
80. ADJUST SHIFT LEVER POSITION . Refer to «ADJUSTMENT [06/2012 - ] - Step 2»(ref-598611-S41237994182014021400000)
81. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to «ADJUSTMENT [06/2012 - ]»(ref-598597-S14006087262014021400000)
82. INSTALL V-BANK COVER SUB-ASSEMBLY Fit the 3 retainers and install the V-bank cover sub-assembly.
83. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION [06/2012 - ] - Step 3»(ref-598617-S39604734002014021400000)
84. INSTALL FRONT FENDER APRON SEAL LH
85. INSTALL ENGINE UNDER COVER LH
86. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
87. INSTALL FRONT FENDER APRON SEAL RH
88. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
89. INSTALL ENGINE UNDER COVER RH

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1. REMOVE ENGINE HANGERS Remove the 4 bolts and 2 engine hangers. TEXT IN ILLUSTRATION *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger *a Bank 1 *b Bank 2
2. REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 9»(ref-598608-S22920243232014021400000)
3. REMOVE NO. 1 SURGE TANK STAY Remove the bolt and No. 1 surge tank stay.
4. REMOVE THROTTLE BODY BRACKET Remove the bolt and throttle body bracket.
5. REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 3»(ref-598604-S07961549372014021400000)
6. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt and No. 2 engine mounting stay RH.
7. REMOVE INTAKE MANIFOLD Uniformly loosen and remove the 6 bolts and 4 nuts. TEXT IN ILLUSTRATION *1 nut Remove the intake manifold and 2 gaskets.
8. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Uniformly loosen and remove the 6 nuts. Remove the exhaust manifold sub-assembly RH and gasket.
9. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Remove the engine oil level dipstick. Remove the bolt and No. 2 engine oil level dipstick guide. Remove the O-ring from the No. 2 engine oil level dipstick guide.
10. REMOVE NO. 2 MANIFOLD STAY . Refer to «REMOVAL [06/2012 - ] - Step 11»(ref-598608-S13092153322014021400000)
11. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «REMOVAL [06/2012 - ] - Step 10»(ref-598608-S13092153322014021400000)
12. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Uniformly loosen and remove the 6 nuts. Remove the exhaust manifold sub-assembly LH and gasket.
13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the 5 bolts and V-ribbed belt tensioner assembly.
14. REMOVE NO. 2 TIMING GEAR COVER Remove the 2 bolts and No. 2 timing gear cover.
15. REMOVE WATER PUMP PULLEY Using SST, hold the water pump pulley. SST: 09960-10010 09962-01000 09963-00700 Remove the 4 bolts and water pump pulley.
16. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the bolt, No. 2 idler pulley cover plate, No. 2 idler pulley sub-assembly and idler pulley cover plate.
17. REMOVE NO. 1 VACUUM SWITCHING VALVE Remove the bolt and No. 1 vacuum switching valve.
18. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
19. REMOVE KNOCK CONTROL SENSOR . Refer to «REMOVAL [06/2012 - ] - Step 2»(ref-598604-S37001065802014021400000)
20. REMOVE KNOCK SENSOR WIRE Disconnect the 3 clamps and remove the knock sensor wire from the engine assembly.
21. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.
22. REMOVE ENGINE OIL LEVEL SENSOR Remove the 4 bolts and engine oil level sensor and gasket.

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1. REMOVE OIL FILLER CAP SUB-ASSEMBLY Remove the oil filler cap sub-assembly and oil filler cap gasket.
2. REMOVE SPARK PLUG . Refer to «REMOVAL [06/2012 - ] - Step 4»(ref-598604-S07961549372014021400000)
3. REMOVE OIL PAN DRAIN PLUG Remove the oil pan drain plug and oil pan drain plug gasket.
4. REMOVE VENTILATION VALVE SUB-ASSEMBLY Remove the ventilation valve sub-assembly.
5. REMOVE VVT SENSOR . Refer to «REMOVAL [06/2012 - ] - Step 2»(ref-598604-S20700095802014021400000)
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to «REMOVAL [06/2012 - ] - Step 3»(ref-598604-S05338819362014021400000)
7. REMOVE CRANK POSITION SENSOR . Refer to «REMOVAL [06/2012 - ] - Step 2»(ref-598604-S14117346562014021400000)
8. REMOVE NO. 1 OIL PIPE Remove the 2 oil pipe unions, 3 gaskets and No. 1 oil pipe. TEXT IN ILLUSTRATION *1 Oil Pipe Union Remove the oil control valve filter LH.
9. REMOVE OIL PIPE Remove the bolt. TEXT IN ILLUSTRATION *1 Oil Pipe Union *2 Bolt Remove the 2 oil pipe unions, 3 gaskets and oil pipe. Remove the oil control valve filter RH.
10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY TEXT IN ILLUSTRATION *a for Bank 1 *b for Bank 2 Remove the 2 cylinder block water drain cock sub-assemblies from the cylinder block sub-assembly. Remove the 2 cylinder block water drain cock plugs from the 2 cylinder block water drain cock sub-assemblies.
11. REMOVE OIL FILTER CAP ASSEMBLY . Refer to «REPLACEMENT [06/2012 - ] - Step 2»(ref-598589-S19481969902014021400000)
12. REMOVE CRANKSHAFT PULLEY See step 6
13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE Remove the bolt and engine oil level dipstick guide. Remove the O-ring.
14. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH Remove the 6 bolts and No. 1 front engine mounting bracket LH. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
15. 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 from the water inlet housing. Remove the drain cock plug. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Remove the drain cock assembly. Remove the 2 bolts, nut, and water inlet housing. Remove the 2 O-rings.
16. REMOVE WATER OUTLET Remove the 2 bolts, 4 nuts and water outlet. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Remove the 2 gaskets and O-ring.
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket. TEXT IN ILLUSTRATION *1 Seal Washer Remove the 3 gaskets.
18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and No. 2 cylinder head cover gasket. TEXT IN ILLUSTRATION *1 Baffle Plate *2 Seal Washer 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 cylinder head cover sub-assembly LH. Remove the 3 gaskets.
19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Remove the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Insert the blade of the oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly. NOTE: Be careful not to damage the contact surfaces of the oil pans. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
20. REMOVE OIL STRAINER SUB-ASSEMBLY Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket. TEXT IN ILLUSTRATION *1 Bolt *2 Nut Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
21. REMOVE OIL PAN SUB-ASSEMBLY Remove the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder block sub-assembly and oil pan sub-assembly. HINT: Tape the screwdriver tip before use. Remove the 2 O-rings. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
22. REMOVE NO. 1 OIL PAN BAFFLE PLATE Remove the 7 bolts and No. 1 oil pan baffle plate.
23. REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 6 bolts. Using a screwdriver, pry out the engine rear oil seal retainer. TEXT IN ILLUSTRATION *1 Protective Tape Pry NOTE: Be careful not to damage the engine rear oil seal retainer. HINT: Tape the screwdriver tip before use.
24. REMOVE ENGINE REAR OIL SEAL Place the engine rear oil seal retainer on wooden blocks. TEXT IN ILLUSTRATION *1 Protective Tape *2 Wooden Block Using a screwdriver and a hammer, tap out the engine rear oil seal. NOTE: Be careful not to damage the engine rear oil seal retainer. HINT: Tape the screwdriver tip before use.
25. REMOVE ENGINE WATER PUMP ASSEMBLY Remove the 16 bolts, engine water pump assembly and water pump gasket.
26. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Remove the 15 bolts and 2 nuts as shown in the illustration. TEXT IN ILLUSTRATION *1 Nut Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head sub-assembly, cylinder block sub-assembly and timing chain cover sub-assembly. HINT: Tape the screwdriver tip before use. Remove the 4 bolts, timing chain cover plate and timing chain cover plate gasket. Remove the gasket.
27. REMOVE TIMING CHAIN CASE OIL SEAL . Refer to «REMOVAL [06/2012 - ] - Step 32»(ref-598589-S06488733812014021400000)
28. SET NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily tighten the pulley set bolt. Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression). TEXT IN ILLUSTRATION *1 Sensor Plate *a Center Line *b Timing Mark Check that the timing marks of the camshaft timing gear assemblies are aligned with the timing marks of the bearing cap as shown in the illustration. TEXT IN ILLUSTRATION *a Timing Mark If not, turn the crankshaft clockwise 1 revolution (360°) and align the timing marks as above.
29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. TEXT IN ILLUSTRATION *1 Plunger *2 Stopper Plate *3 Pin Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.0500 in.) into the stopper plate hole. Remove the 2 bolts and No. 1 chain tensioner assembly.
30. REMOVE CHAIN TENSIONER SLIPPER Remove the chain tensioner slipper.
31. REMOVE CHAIN SUB-ASSEMBLY Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly of the crankshaft timing sprocket. TEXT IN ILLUSTRATION *1 Sensor Plate *a Center Line *b Timing Mark Remove the pulley set bolt. Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks. TEXT IN ILLUSTRATION *a for Bank 1 Remove the chain sub-assembly.
32. REMOVE IDLE SPROCKET ASSEMBLY Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.
33. REMOVE NO. 1 CHAIN VIBRATION DAMPER Remove the 2 bolts and No. 1 chain vibration damper.
34. REMOVE NO. 2 CHAIN VIBRATION DAMPER Remove the 2 No. 2 chain vibration dampers.
35. REMOVE CRANKSHAFT TIMING SPROCKET Remove the crankshaft timing sprocket from the crankshaft. Remove the 2 keys from the crankshaft.
36. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) See step 40
37. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY See step 41
38. REMOVE CAMSHAFT BEARING CAP (for Bank 1) See step 42
39. REMOVE CAMSHAFT See step 43
40. REMOVE NO. 2 CAMSHAFT See step 44
41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 45
42. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) See step 46
43. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 47
44. REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 48
45. REMOVE NO. 3 CAMSHAFT See step 49
46. REMOVE NO. 4 CAMSHAFT See step 50
47. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 51
48. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 10
49. REMOVE VALVE LASH ADJUSTER ASSEMBLY See step 11
50. REMOVE VALVE STEM CAP See step 12
51. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH See step 14
52. REMOVE CYLINDER HEAD GASKET RH See step 15
53. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH See step 16
54. REMOVE CYLINDER HEAD GASKET LH See step 17
55. REMOVE WATER INLET PIPE Remove the 2 clamps and separate the No. 1 water by-pass hose. Remove the 2 bolts and water inlet pipe.

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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 No. 1 valve rocker arm sub-assembly.
2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the valve lash adjuster assembly free of dirt and foreign matter. Only use clean engine oil. Place the valve lash adjuster assembly into a container filled with engine oil. Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger. TEXT IN ILLUSTRATION *1 Tapered Part *2 Plunger *3 Check Ball *a Correct *b Incorrect *c Low Pressure Chamber *d High Pressure Chamber SST: 09276-75010 Squeeze SST and the valve lash adjuster assembly 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 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 SST. Then try to quickly and firmly press the plunger by hand. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster assembly.
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 runout 0.04 mm (0.00157 in.) If the 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 Item Specification Intake camshaft 44.316 to 44.416 mm (1.7448 to 1.7486 in.) Exhaust camshaft 44.262 to 44.362 mm (1.7426 to 1.7465 in.) Minimum Cam Lobe Height Item Specification Intake camshaft 44.166 mm (1.7388 in.) Exhaust camshaft 44.112 mm (1.7366 in.) If the cam lobe height is less than the minimum, replace the camshaft. Using a micrometer, measure the journal diameter. Standard Journal Diameter 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 (1.0221 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 assembly and camshaft together by aligning the key groove and straight pin. TEXT IN ILLUSTRATION *1 Straight Pin *a Key Groove Check that there is no clearance between the camshaft timing gear assembly flange and the camshaft. Tighten the bolt while holding the camshaft. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Check the lock of the camshaft timing gear assembly. Release the lock pin. TEXT IN ILLUSTRATION *1 Advance Side Path *2 Retard Side Path *3 Vinyl Tape *4 Rubber *a Close *b Open Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: There are 4 oil paths in the groove of the camshaft. Plug 2 paths with rubber piece. Break through the tape of the advance side path and the retard side path on the opposite side of the groove as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 29 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path). TEXT IN ILLUSTRATION *1 Advance Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path. TEXT IN ILLUSTRATION *1 Advance Side Path *2 Retard Side Path *a Hold Pressure *b Decompress HINT: The lock pin is released and the camshaft timing gear assembly turns in the advance direction. When the camshaft timing gear assembly moves to the most advance position, release the air pressure first from the retard side path, and then release the air pressure from the advance side path. NOTE: Be sure to release the air pressure from the retard side path first. If the air pressure of the advance side path is released first, the camshaft timing gear assembly may abruptly shift in the advance direction and break the lock pin or other parts. Check for smooth rotation. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly. NOTE: Do not use air pressure to perform the smooth operation check. Check the lock in the most retarded position. Remove the bolt and camshaft timing gear assembly. TEXT IN ILLUSTRATION *1 Straight Pin *2 Bolt *a Do Not Remove NOTE: Do not remove the other 3 bolts. If planning to reuse the camshaft timing gear assembly, be sure to release the straight pin lock before installing the camshaft timing gear assembly.
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 assembly and camshaft together by aligning the key groove and straight pin. TEXT IN ILLUSTRATION *1 Straight Pin *a Key Groove Check that there is no clearance between the camshaft timing exhaust gear assembly flange and the camshaft. Tighten the bolt while holding the camshaft. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Check the lock of the camshaft timing exhaust gear assembly. Release the lock pin. TEXT IN ILLUSTRATION *1 Retard Side Path *2 Advance Side Path *3 Rubber *4 Vinyl Tape *a Open *b Close Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: There are 4 oil paths in the groove of the camshaft. Plug 2 paths with rubber piece. Break through the tape of the advance side path and the retard side path on the opposite side of the groove as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 29 psi) of air pressure to the 2 open paths (the advance side path and the retard side path). TEXT IN ILLUSTRATION *1 Advance Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Check that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path. TEXT IN ILLUSTRATION *1 Advance Side Path *2 Retard Side Path *a Decompress *b Hold Pressure HINT: The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first 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 assembly 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 assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advance position. Make sure that the camshaft timing exhaust gear assembly turns smoothly. NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advance 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 advance position. Remove the bolt and camshaft timing exhaust gear assembly. TEXT IN ILLUSTRATION *1 Straight Pin *2 Bolt *a Do Not Remove NOTE: Be sure not to remove the other 4 bolts. If planning to reuse the camshaft timing exhaust gear assembly, be sure to release the straight pin lock before installing the camshaft timing exhaust gear assembly.
6. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the diameter of the threads at the measurement point. TEXT IN ILLUSTRATION *a Measurement Point Standard diameter 10.85 to 11.00 mm (0.4272 to 0.4330 in.) Minimum diameter 10.70 mm (0.4212 in.) Measurement point (distance from the seat) 103 mm (4.06 in.) HINT: If the diameter is less than the minimum, replace the cylinder head set bolt. Failure to do so may lead to engine damage. If there is any thread deformation, replace the cylinder head set bolt with a new one.
7. INSPECT CHAIN SUB-ASSEMBLY Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 links. TEXT IN ILLUSTRATION *a Measuring Point Maximum chain elongation 136.9 mm (5.389 in.) NOTE: Perform the measurement at 3 random places. Use the average of the measurements. If the average elongation is greater than the maximum, replace the chain sub-assembly.
8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 links. TEXT IN ILLUSTRATION *a Measuring Point 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 average elongation is greater than the maximum, replace the chain sub-assembly.
9. INSPECT CRANKSHAFT TIMING SPROCKET Place the chain around the crankshaft timing sprocket. Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly. Minimum sprocket diameter (with chain) 61.4 mm (2.418 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket.
10. INSPECT IDLE SPROCKET ASSEMBLY Place the chain around the idle sprocket assembly. Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly. Minimum sprocket diameter (with chain) 61.4 mm (2.418 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain chain sub-assembly and idle sprocket assembly.
11. INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE Using a micrometer, measure the No. 1 idle gear shaft diameter. Standard No. 1 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 sprocket assembly. Standard idle gear inside diameter 23.020 to 23.030 mm (0.9063 to 0.9067 in.) Subtract the No. 1 idle gear shaft diameter measurement from the idle sprocket assembly inside diameter measurement. Standard oil clearance 0.020 to 0.043 mm (0.000787 to 0.00169 in.) Maximum oil clearance 0.093 mm (0.00366 in.) If the thrust oil clearance is greater than the maximum, replace the No. 1 idle gear shaft and idle sprocket assembly.
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. TEXT IN ILLUSTRATION *1 Plunger *2 Stopper Plate If necessary, replace the No. 1 chain tensioner assembly.
13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. TEXT IN ILLUSTRATION *a Depth Using a vernier caliper, measure the worn depth of the No. 2 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is greater than the maximum, replace the No. 2 chain tensioner assembly.
14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. TEXT IN ILLUSTRATION *a Depth Using a vernier caliper, measure the worn depth of the No. 3 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is greater than the maximum, replace the No. 3 chain tensioner assembly.
15. INSPECT CHAIN TENSIONER SLIPPER Measure the worn depth of the chain tensioner slipper. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the chain tensioner slipper.
16. INSPECT NO. 1 CHAIN VIBRATION DAMPER Using a vernier caliper, measure the worn depth of the No. 1 chain vibration damper. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the No. 1 chain vibration damper.
17. INSPECT NO. 2 CHAIN VIBRATION DAMPER Using a vernier caliper, measure the worn depth of the No. 2 chain vibration damper. TEXT IN ILLUSTRATION *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the No. 2 chain vibration damper.
18. INSPECT CAMSHAFT THRUST CLEARANCE Inspect the bank 1 camshaft thrust clearance. Install the bank 1 camshaft See step 5 . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.08 to 0.13 mm (0.00315 to 0.00512 in.) Maximum thrust clearance 0.15 mm (0.00591 in.) If the thrust clearance is greater than the maximum, replace the camshaft housing sub-assembly RH. If the thrust surface is damaged, replace the camshaft. Inspect the bank 2 camshaft thrust clearance. Install the bank 2 camshaft. Refer to «INSTALLATION [06/2012 - ]»(ref-598588-S13789659252014021400000) . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.08 to 0.13 mm (0.00315 to 0.00512 in.) Maximum thrust clearance 0.15 mm (0.00591 in.) If the thrust clearance is greater than the maximum, replace the camshaft housing sub-assembly LH. If the thrust surface is damaged, replace the camshaft.
19. INSPECT CAMSHAFT OIL CLEARANCE (for Bank 1) Clean the camshaft bearing caps, camshaft housing sub-assembly RH and camshaft journals. Place the camshafts on the camshaft housing sub-assembly RH. Lay a strip of Plastigage across each camshaft journal. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps See step 7 . NOTE: Do not turn the camshaft. Remove the camshaft bearing caps See step 42 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 Other Journals Standard Oil Clearance Item Oil Clearance No. 1 journal 0.032 to 0.063 mm (0.00126 to 0.00248 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance Item Oil Clearance No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly RH.
20. INSPECT CAMSHAFT OIL CLEARANCE (for Bank 2) Clean the camshaft bearing caps, camshaft housing sub-assembly LH and camshaft journals. Place the camshafts on the camshaft housing sub-assembly LH. Lay a strip of Plastigage across each camshaft journal. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps See step 3 . NOTE: Do not turn the camshaft. Remove the camshaft bearing caps See step 48 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 Other Journals Standard Oil Clearance Item Oil Clearance No. 1 journal 0.032 to 0.063 mm (0.00126 to 0.00248 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance Item Oil Clearance No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly LH.
21. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head sub-assembly LH. Maximum warpage 0.7 mm (0.0276 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.). If the warpage is greater than the maximum, replace the exhaust manifold sub-assembly LH.
22. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head sub-assembly RH. Maximum warpage 0.7 mm (0.0276 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.). If the warpage is greater than the maximum, replace the exhaust manifold sub-assembly RH.
23. INSPECT INTAKE MANIFOLD TEXT IN ILLUSTRATION *a Cylinder Head Side *b Surge Tank Side Cylinder head side: Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head sub-assembly for warpage. Maximum warpage 0.1 mm (0.00394 in.) If the warpage is greater than the maximum, replace the intake manifold. Surge tank side: Using a precision straightedge and feeler gauge, measure the surface contacting the surge tank for warpage. Maximum warpage 0.1 mm (0.00394 in.) If the warpage is greater than the maximum, replace the intake manifold.

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1. INSTALL ENGINE REAR OIL SEAL Place the engine rear oil seal retainer on wooden blocks. Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge. SST: 09223-15030 SST: 09950-70010 09951-07100 TEXT IN ILLUSTRATION *a Depth NOTE: Keep the lip free of foreign matter. Do not tap the engine rear oil seal at an angle.
2. INSTALL ENGINE REAR OIL SEAL RETAINER Apply seal packing in a continuous line as shown in the illustration. TEXT IN ILLUSTRATION *a Seal Packing Diameter (2.0 to 3.0 mm (0.0787 to 0.118 in.)) Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.) NOTE: Remove any oil from the contact surfaces. Install the engine rear oil seal retainer within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install the engine rear 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
3. 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.
4. INSTALL CYLINDER HEAD GASKET RH See step 1
5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH See step 2
6. INSTALL CYLINDER HEAD GASKET LH See step 3
7. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH See step 4
8. INSTALL VALVE STEM CAP See step 6
9. INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 7
10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 8
11. INSTALL NO. 3 CAMSHAFT See step 1
12. INSTALL NO. 4 CAMSHAFT See step 2
13. INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 3
14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 4
15. INSTALL CAMSHAFT See step 5
16. INSTALL NO. 2 CAMSHAFT See step 6
17. INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 7
18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 8
19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY See step 9
20. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) See step 10
21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY See step 11
22. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) See step 12
23. INSTALL NO. 1 CHAIN VIBRATION DAMPER Install the No. 1 chain vibration damper with the 2 bolts. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
24. INSTALL NO. 2 CHAIN VIBRATION DAMPER Install the 2 No. 2 chain vibration dampers.
25. INSTALL CRANKSHAFT TIMING SPROCKET Install the 2 keys and crankshaft timing sprocket as shown in the illustration.
26. INSTALL IDLE SPROCKET ASSEMBLY Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. TEXT IN ILLUSTRATION *1 Knock Pin Temporarily install the No. 1 idle gear shaft and idle sprocket assembly with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block sub-assembly. NOTE: Be careful of the idle gear installation position. HINT: Check that no foreign matter is on the No. 1 and No. 2 idle gear shafts. 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.
27. INSTALL CHAIN SUB-ASSEMBLY Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly. TEXT IN ILLUSTRATION *1 Mark Plate *a Timing Mark HINT: The camshaft mark plates are orange. Do not pass the chain sub-assembly over the crankshaft, just temporarily place it on the crankshaft. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks. TEXT IN ILLUSTRATION *1 Mark Plate *a Turn *b When the idle sprocket is reused *c Mark *d Align NOTE: When the idle sprocket assembly 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. TEXT IN ILLUSTRATION *1 Mark Plate *a Timing Mark HINT: 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). TEXT IN ILLUSTRATION *1 Center Line *2 Timing Mark *3 Sensor Plate
28. INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper.
29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. TEXT IN ILLUSTRATION *1 Stopper Plate *2 Plunger Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install the No. 1 chain tensioner assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
30. INSPECT VALVE TIMING Check the camshaft timing marks. NOTE: Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear. If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned. Check that each camshaft timing mark is positioned as shown in the illustration. TEXT IN ILLUSTRATION *a Timing Mark *b Viewpoint HINT: For the camshaft or No. 3 camshaft: Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly. If the valve timing is misaligned, reinstall the chain sub-assembly. Remove the pulley set bolt.
31. INSTALL TIMING CHAIN CASE OIL SEAL . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598589-S10652622422014021400000)
32. INSTALL ENGINE WATER PUMP ASSEMBLY Install a new water pump gasket and the engine water pump assembly with the 8 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Apply seal packing in a continuous line to the engine unit as shown in the following illustration. TEXT IN ILLUSTRATION *a Seal Diameter: 3.0 mm or more Seal Packing 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. If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing. Install the timing chain cover sub-assembly 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 sub-assembly as shown in the following illustration. TEXT IN ILLUSTRATION *a Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) *b Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) *c Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent) *d Diagonal line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) Be sure to apply seal packing - - Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent NOTE: If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing. Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. SEAL PACKING APPLICATION CHART Area Seal Packing Diameter Application Position from Inside Seal Line Continuous Line Area 4.5 mm or more (0.177 in.) 1.0 to 2.0 mm (0.0394 to 0.0787 in.) Alternate Long and Short Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.0787 to 0.118 in.) Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.157 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 timing chain cover sub-assembly to the crankshaft. TEXT IN ILLUSTRATION *1 Drive Rotor Spline *2 Crankshaft Temporarily tighten the timing chain cover sub-assembly with the 23 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut BOLT LENGTH Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 25 mm (0.984 in.) NOTE: Make sure that there is no oil on the threads of bolts B and C. Fully tighten the bolts in this order: Area 1 and Area 2. TEXT IN ILLUSTRATION *a Area 1 *b Area 2 *c Area 3 *d Area 4 Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Fully tighten the bolts and nuts in Area 3. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts and nuts from top to bottom as shown in the illustration. Fully tighten the bolts in Area 4. Bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Except bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts from bottom to top as shown in the illustration. Install a new timing chain cover plate gasket and the timing chain cover plate with the 4 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
34. INSTALL WATER INLET HOUSING Install 2 new O-rings. HINT: Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation. Install the 2 stud bolts. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Install the water inlet housing with the 2 bolts and nut. TEXT IN ILLUSTRATION *1 Nut *2 Bolt 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 assembly. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the drain cock assembly to the water inlet housing. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) Install the drain cock plug to the drain cock assembly. Torque: 13 N*m (133 kgf*cm, 10 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 position. Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH Using an E8 "TORX" socket wrench, install the 2 stud bolts. TEXT IN ILLUSTRATION *1 Stud Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the No. 1 front engine mounting bracket LH with the 6 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) NOTE: Install the water inlet and No. 1 front engine mounting bracket LH within 15 minutes after installing the timing chain cover sub-assembly. Do not start the engine for at least 2 hours after installation.
36. INSTALL NO. 1 OIL PAN BAFFLE PLATE Install the No. 1 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 the 2 bolts (A) shown in the illustration before tightening the other bolts.
37. INSTALL OIL PAN SUB-ASSEMBLY Using an E8 "TORX" socket wrench, install the 2 stud bolts. TEXT IN ILLUSTRATION *a Timing Chain Cover *b Lower Cylinder Block Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt B Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Install 2 new O-rings. Apply seal packing in a continuous line as shown in the illustration. TEXT IN ILLUSTRATION *a Seal Diameter Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the oil pan sub-assembly within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install the oil pan sub-assembly with the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Except bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
38. INSTALL OIL STRAINER SUB-ASSEMBLY Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration. TEXT IN ILLUSTRATION *a Timing Chain Cover Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Using an E6 "TORX" socket wrench, install the 2 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. TEXT IN ILLUSTRATION *a Seal Diameter Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
40. INSTALL OIL PAN DRAIN PLUG Install a new oil pan drain plug gasket and the oil pan drain plug. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Apply seal packing as shown in the illustration. TEXT IN ILLUSTRATION Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover sub-assembly 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 cylinder head cover gasket to the cylinder head cover sub-assembly. Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer. TEXT IN ILLUSTRATION *1 Seal Washer Bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Except bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Apply seal packing as shown in the illustration. TEXT IN ILLUSTRATION Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surfaces. Install the cylinder head cover sub-assembly LH 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 No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly LH. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer. TEXT IN ILLUSTRATION *1 Seal Washer Bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Except bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
43. INSTALL WATER OUTLET Install 2 new gaskets and a new O-ring. HINT: Apply soapy water to the O-ring. Install the water outlet with the 2 bolts and 4 nuts. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful that the O-ring does not get caught between the parts.
44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide. Install the engine oil level dipstick guide with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
45. INSTALL CRANKSHAFT PULLEY See step 2
46. INSTALL OIL FILTER CAP ASSEMBLY . Refer to «REPLACEMENT [06/2012 - ] - Step 3»(ref-598589-S19481969902014021400000)
47. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Apply adhesive around the cylinder block water drain cock sub-assembly. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the cylinder block water drain cock sub-assemblies as shown in the illustration. TEXT IN ILLUSTRATION *a for Bank 1 *b for Bank 2 Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Do not rotate the cylinder block water drain cock sub-assemblies more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assemblies with the specified torque. Install the water drain cock plugs to the cylinder block water drain cock sub-assemblies. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
48. 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 LH. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the No. 1 oil pipe (on the head cover side) with the union. TEXT IN ILLUSTRATION *1 Oil Pipe Union Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head side) with the union. 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 side cutters or a similar tool.
49. 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 RH. 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) with the union. TEXT IN ILLUSTRATION *1 Oil Pipe Union Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union. 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 side cutters or a similar tool.
50. INSTALL CRANK POSITION SENSOR . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598604-S31216901122014021400000)
51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598604-S18131885172014021400000)
52. INSTALL VVT SENSOR . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598604-S42400378402014021400000)
53. INSTALL VENTILATION VALVE SUB-ASSEMBLY Apply adhesive around the ventilation valve sub-assembly. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Using a deep socket wrench 19 mm, install the ventilation valve sub-assembly. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
54. INSTALL SPARK PLUG . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598604-S27411255502014021400000)
55. INSTALL OIL FILLER CAP SUB-ASSEMBLY Install a new oil filler cap gasket. Install the oil filler cap sub-assembly.

HINT

Perform "Inspection After Repair" after replacing the engine assembly. Refer to INITIALIZATION [06/2012 - ] .

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1. INSTALL ENGINE OIL LEVEL SENSOR Install the engine oil level sensor with the 4 bolts and a new gasket. Torque: 8.2 N*m (84 kgf*cm, 73 in.*lbf)
2. INSTALL ENGINE COOLANT TEMPERATURE SENSOR . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598604-S38913257652014021400000)
3. INSTALL KNOCK SENSOR WIRE Connect the 3 clamps, 2 knock sensor connectors and knock sensor wire connector.
4. INSTALL KNOCK CONTROL SENSOR . Refer to «INSTALLATION [06/2012 - ] - Step 1»(ref-598604-S22008732282014021400000)
5. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Clean the threads of the engine oil pressure switch assembly. Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE: Do not start the engine within 1 hour after installation to prevent oil leaks.
6. INSTALL NO. 1 VACUUM SWITCHING VALVE Install the No. 1 vacuum switching valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
7. INSTALL WATER PUMP PULLEY Temporarily install the water pump pulley with the 4 bolts. Using SST, hold the water pump pulley. SST: 09960-10010 09962-01000 09963-00700 Tighten the 4 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
9. INSTALL NO. 2 TIMING GEAR COVER Install the No. 2 timing gear cover with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts. HINT: Each bolt length is as follows: A: 70 mm (2.76 in.) B: 33 mm (1.30 in.) Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Tighten the other bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Install a new gasket as shown in the illustration. TEXT IN ILLUSTRATION Engine Front Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
12. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «INSTALLATION [06/2012 - ] - Step 3»(ref-598608-S19976171092014021400000)
13. INSTALL NO. 2 MANIFOLD STAY . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598608-S19976171092014021400000)
14. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Install a new O-ring to the No. 2 engine oil level dipstick guide. Apply a light coat of engine oil to the O-ring. Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide. Install the No. 2 engine oil level dipstick guide with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Install the engine oil level dipstick.
15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Install a new gasket as shown in the illustration. TEXT IN ILLUSTRATION Engine Front Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
16. INSTALL INTAKE MANIFOLD Set 2 new gaskets on each cylinder head sub-assembly. NOTE: Align the port holes of the gasket and cylinder head sub-assembly. Make sure that the gasket is installed in the correct direction. Set the intake manifold on the cylinder head sub-assembly. Install and tighten the 6 bolts and 4 nuts uniformly in several steps. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
17. INSTALL NO. 2 ENGINE MOUNTING STAY RH Install the No. 2 engine mounting stay RH with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
18. INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 2»(ref-598604-S27411255502014021400000)
19. INSTALL NO. 1 SURGE TANK STAY NOTE: Do not apply oil to the bolt as listed below: Oil Application Prohibited Bolt Bolt for No. 1 surge tank stay and cylinder head cover Install the No. 1 surge tank stay with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
20. INSTALL THROTTLE BODY BRACKET NOTE: Do not apply oil to the bolt as listed below: Oil Application Prohibited Bolt Bolt for throttle body bracket and cylinder head cover Install the throttle body bracket with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
21. INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to «INSTALLATION [06/2012 - ] - Step 6»(ref-598608-S15471234952014021400000)
22. INSTALL ENGINE HANGERS Install the 2 engine hangers with the 4 bolts. PART NO. Item Part No. No. 1 Engine Hanger 12281-31120 No. 2 Engine Hanger 12282-31100 Bolt 91671-10825 Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) Attach an engine sling device and hang the engine with a chain block.

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1. REMOVE VALVE STEM CAP Remove the valve stem caps from the cylinder head sub-assembly. HINT: Arrange the removed parts in the correct order.
2. REMOVE INTAKE VALVE Using SST, compress the inner compression spring and remove the valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Remove the valve spring retainer, inner compression spring and intake valve. HINT: Arrange the removed parts in the correct order.
3. REMOVE EXHAUST VALVE Using SST, compress the inner compression spring and remove the valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Remove the valve spring retainer, inner compression spring and exhaust valve. HINT: Arrange the removed parts in the correct order.
4. REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the valve stem oil seals.
5. REMOVE VALVE SPRING SEAT Using compressed air and a Magnet Hand, remove the valve spring seats by blowing air onto them.
6. REMOVE NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, remove the 4 No. 1 straight screw plugs and 4 gaskets. TEXT IN ILLUSTRATION *a for Bank 1 *b for Bank 2 NOTE: If water leaks from a straight screw plug or the plug is corroded, replace it.
7. REMOVE NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, remove the 2 No. 2 straight screw plugs and 2 gaskets. TEXT IN ILLUSTRATION *a for Bank 1 *b for Bank 2 NOTE: If water leaks from a straight screw plug or the plug is corroded, replace it.

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1. INSPECT CYLINDER HEAD SUB-ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder block sub-assembly and manifolds. TEXT IN ILLUSTRATION *a Cylinder Head Lower Side *b Intake Side *c Exhaust Side Standard Warpage Item Warpage Cylinder head lower 0.05 mm (0.00197 in.) Intake 0.08 mm (0.00315 in.) Exhaust 0.08 mm (0.00315 in.) Maximum Warpage Item Warpage Cylinder head lower 0.10 mm (0.00394 in.) Intake 0.10 mm (0.00394 in.) Exhaust 0.10 mm (0.00394 in.) If the warpage is greater than the maximum, replace the cylinder head sub-assembly.
2. INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head sub-assembly.
3. 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 a vernier caliper, measure the valve head margin thickness. TEXT IN ILLUSTRATION *a 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 a vernier caliper, measure the valve overall length. TEXT IN ILLUSTRATION *a 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.
4. INSPECT EXHAUST VALVE Using a micrometer, measure the diameter of the valve stem. Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2157 in.) If the valve stem is not as specified, check the oil clearance. Using a vernier caliper, measure the valve head margin thickness. TEXT IN ILLUSTRATION *a 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 a vernier caliper, measure the valve overall length. TEXT IN ILLUSTRATION *a 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.
5. INSPECT INTAKE VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the intake valve seat. Check the valve face and intake valve seat by using the following procedure: TEXT IN ILLUSTRATION *a Width If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the intake valve. If Prussian blue appears around the entire intake valve seat, the intake valve seat and valve face are concentric. If not, resurface the intake valve seat. Check that the intake valve seat contacts the middle of the valve face with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.).
6. INSPECT EXHAUST VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the exhaust valve seat. Check the valve face and exhaust valve seat by using the following procedure: TEXT IN ILLUSTRATION *a Width If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the exhaust valve. If Prussian blue appears around the entire exhaust valve seat, the exhaust valve seat and valve face are concentric. If not, resurface the exhaust valve seat. Check that the exhaust valve seat contacts the middle of the valve face with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.).
7. INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the inner compression spring. Free length 45.91 mm (1.8075 in.) If the free length is not as specified, replace the inner compression spring. Using a steel square, measure the deviation of the inner compression spring. TEXT IN ILLUSTRATION *a Deviation Maximum deviation 1.0 mm (0.0394 in.) Maximum angle (reference) 2° If the deviation is greater than the maximum, replace the inner compression spring.
8. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve 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 valve guide bush inside diameter measurement. Standard Oil Clearance Item Clearance Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.) Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.) Maximum Oil Clearance Item Clearance Intake 0.08 mm (0.00315 in.) Exhaust 0.10 mm (0.00394 in.) If the clearance is greater than the maximum, replace the valve and valve guide bush.

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1. REPLACE INTAKE VALVE GUIDE BUSH Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F). Place the cylinder head sub-assembly on wooden blocks. Using SST and a hammer, tap out the intake valve guide bushes. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the bush bore diameter of the cylinder head sub-assembly. 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) Bush Size Bush Bore Diameter STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) If the bush bore diameter of the cylinder head sub-assembly 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 sub-assembly is greater than 10.356 mm (0.4077 in.), replace the cylinder head sub-assembly. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F). Place the cylinder head sub-assembly on wooden blocks. Using SST, tap in new intake valve guide bushes to the specified protrusion height. TEXT IN ILLUSTRATION *a Protrusion Height SST: 09201-10000 09201-01050 SST: 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 intake valve guide bushings to obtain the specified clearance. Standard oil clearance 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
2. REPLACE EXHAUST VALVE GUIDE BUSH Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F). Place the cylinder head sub-assembly on wooden blocks. Using SST and a hammer, tap out the exhaust valve guide bushes. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the bush bore diameter of the cylinder head sub-assembly. 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) Bush Size Bush Bore Diameter STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) If the bush bore diameter of the cylinder head sub-assembly 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 sub-assembly is greater than 10.356 mm (0.4077 in.), replace the cylinder head sub-assembly. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F). Place the cylinder head sub-assembly on wooden blocks. Using SST, tap in new exhaust valve guide bushes to the specified protrusion height. TEXT IN ILLUSTRATION *a Protrusion Height SST: 09201-10000 09201-01050 SST: 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 exhaust valve guide bushings to obtain the specified clearance. Standard oil clearance 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
3. REPLACE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Using a plastic hammer, tap in new ring pins to the specified protrusion height. TEXT IN ILLUSTRATION *a for Bank 1 *b for Bank 2 Specified protrusion height 2.5 to 3.5 mm (0.0984 to 0.138 in.)
4. REPLACE STUD BOLT NOTE: If a stud bolt is deformed or the threads are damaged, replace it. Using an E6 and E8 "TORX" socket wrench, install the stud bolts. TEXT IN ILLUSTRATION *a Bank 1 Rear Side *b Bank 1 Intake Side *c Bank 2 Intake Side *d Bank 1 Exhaust Side *e Bank 2 Exhaust Side *f Bank 2 Rear Side Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt B Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
5. REPLACE STRAIGHT PIN NOTE: If a straight pin is deformed, replace it. Using a plastic hammer, tap in new straight pins as shown in the illustration. TEXT IN ILLUSTRATION *a for Bank 1 *b for Bank 2 Protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.)