Engine Mechanical (Service Information): Removal & Installation

INSTALLATION [03/2012 - ]

HINT

Perform "Inspection After Repairs" after replacing the camshaft (intake or exhaust side) or camshaft timing gear assembly (intake or exhaust side). Refer to INITIALIZATION [03/2012 - ] .

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Scheme 84: INSTALLATION [03/2012 - ]

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INSTALL CAMSHAFT TIMING GEAR ASSEMBLY HINT: Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly. Refer to «INITIALIZATION [03/2012 - ]»(ref-600436-S34722863312014022400000) . 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 pin hole and straight pin. TEXT IN ILLUSTRATION *1 Pin Hole *2 Straight Pin Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole. NOTE: Be sure not to turn the camshaft timing gear assembly in the retard direction. Check that there is no clearance between the camshaft timing gear assembly flange and camshaft. Install the flange bolt while holding the camshaft. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Check the lock of the camshaft timing gear assembly. Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked. NOTE: Be careful not to damage the camshaft.
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY HINT: Perform "Inspection After Repairs" after replacing the camshaft timing exhaust gear assembly. Refer to «INITIALIZATION [03/2012 - ]»(ref-600436-S34722863312014022400000) . 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 pin hole and straight pin. TEXT IN ILLUSTRATION *1 Pin Hole *2 Straight Pin Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole. NOTE: Be sure not to turn the camshaft timing exhaust gear in the advanced direction. Check that there is no clearance between the gear flange and camshaft. Install the flange bolt while holding the camshaft. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Check the camshaft timing exhaust gear lock. Make sure that the camshaft timing exhaust gear assembly locks.
INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY HINT: Perform "Inspection After Repairs" after replacing the No. 3 camshaft sub-assembly. Refer to «INITIALIZATION [03/2012 - ]»(ref-600436-S34722863312014022400000) . Check that the notch is aligned with the "0" timing mark of the timing chain cover. Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate (yellow) Clean the camshaft housing LH and camshaft journals, and apply engine oil to them. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Install the chain to the No. 3 camshaft, and then install the camshaft to the camshaft housing LH. TEXT IN ILLUSTRATION *a Place on camshaft timing gear HINT: Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain. Install the camshaft so that the timing mark is facing upward.
INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY HINT: Perform "Inspection After Repairs" after replacing the No. 4 camshaft sub-assembly. Refer to «INITIALIZATION [03/2012 - ]»(ref-600436-S34722863312014022400000) . Clean the camshaft housing LH and camshaft journals, and apply engine oil to them. Pass the No. 4 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear. TEXT IN ILLUSTRATION *1 Mark Plate (yellow) *2 Timing Mark While lifting up the No. 4 camshaft, pass the No. 3 chain tensioner through the No. 2 chain and set it in place. Install the No. 4 camshaft to the camshaft housing LH, and then install the No. 3 chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL CAMSHAFT BEARING CAP (for Bank 2) Clean the camshaft bearing caps and apply engine oil to them. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration. Immediately after removing the service bolts and washers in the locations for the bearing caps, install the bearing caps with the bolts in the order shown in the illustration. for bolt A Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) for bolt B Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) TEXT IN ILLUSTRATION *1 Service Bolts and Washers (used to temporarily secure the camshaft housing) *a Remove the service bolts and washers used to temporarily secure the camshaft housing *b Part to be installed Bolt A Bolt B NOTE: Be sure to follow the numerical order when performing this procedure. Do not drop the service bolts and washers into the cylinder head. Check the torque of each bolt again.
INSTALL CHAIN SUB-ASSEMBLY Align the paint marks on the camshaft timing gear and No. 1 chain, and install the No. 1 chain to the camshaft timing gear. TEXT IN ILLUSTRATION *1 Paint Mark HINT: If the paint marks are not aligned, align them by turning the camshaft slightly.
INSTALL CAMSHAFT HINT: Perform "Inspection After Repairs" after replacing the camshaft. Refer to «INITIALIZATION [03/2012 - ]»(ref-600436-S34722863312014022400000) . Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be installed easily. TEXT IN ILLUSTRATION *a 5 to 10° HINT: When turning the crankshaft, engine oil may spray out of the oil holes. Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate (yellow) Clean the camshaft housing RH and camshaft journals and apply engine oil to them. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Install the chain to the camshaft, and then install the camshaft to the camshaft housing RH. TEXT IN ILLUSTRATION *a Place on camshaft timing gear HINT: Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain. Install the camshaft so that the timing mark is facing upward.
INSTALL NO. 2 CAMSHAFT HINT: Perform "Inspection After Repairs" after replacing the No. 2 camshaft. Refer to «INITIALIZATION [03/2012 - ]»(ref-600436-S34722863312014022400000) . Clean the camshaft housing RH and camshaft journals, and apply engine oil to them. Pass the No. 2 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear. TEXT IN ILLUSTRATION *1 Mark Plate (yellow) *2 Timing Mark While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner through the No. 2 chain and set it in place. Install the No. 2 camshaft to the camshaft housing RH, and then install the No. 2 chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL CAMSHAFT BEARING CAP (for Bank 1) Clean the camshaft bearing caps and apply engine oil to them. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration. Immediately after removing the service bolts and washers in the locations for the bearing caps, install the bearing caps with the bolts in the order shown in the illustration. for bolt A Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) for bolt B Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) TEXT IN ILLUSTRATION *1 Service Bolt and Washers (used to temporarily secure the camshaft housing) *a Remove the service bolts and washers to temporarily secure the camshaft housing *b Part to be installed Bolt A Bolt B NOTE: Be sure to follow the numerical order when performing this procedure. Do not drop the service bolts and washers into the cylinder head. Check the torque of each bolt again.
INSTALL CHAIN SUB-ASSEMBLY Align the paint marks on the camshaft timing gear and chain, and install the chain to the camshaft timing gear. TEXT IN ILLUSTRATION *1 Paint Mark HINT: If the paint marks are not aligned, align them by turning the camshaft slightly.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark. Turn the crankshaft slightly to eliminate the slack in the chain. HINT: Make sure there is some slack in the chain around the area where the chain tensioner is installed. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. TEXT IN ILLUSTRATION *1 Stopper Plate *a Push While turning the stopper plate of the tensioner counterclockwise, insert a pin of 1.27 mm (0.0500 in.) diameter into the holes in the stopper plate and tensioner to secure the stopper plate in place. Install the No. 1 chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the pin from the No. 1 chain tensioner.
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 *1 Timing Mark - - *a Viewpoint - - HINT: For Intake 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 timing chain. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.
INSTALL TIMING CHAIN COVER PLATE Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
INSTALL SPARK PLUG TUBE GASKET See step 46
POUR ENGINE OIL HINT: Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Before applying seal packing black, completely remove any old seal packing adhering to the sealed areas. NOTE: The seal packing black cannot be wiped off. It can only be removed with a scraper. Clean and degrease the areas where the cylinder head cover, timing chain cover and camshaft housing RH contact each other with brake cleaner or non-residue solvent so that there is no oil, water or other foreign matter adhering to those areas. TEXT IN ILLUSTRATION *1 Seal Packing Black Application Area *a Part Contact Areas *b 4.0 to 10.0 mm (0.157 to 0.394 in.) Apply seal packing black (diameter: 2.0 to 3.0 mm (0.0787 to 0.118 in.)) to the areas shown in the illustration and install the cylinder head cover. 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 within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install 5 new gaskets to the camshaft bearing caps. Install a new gasket to the cylinder head cover. Apply adhesive to the threads of the 13 bolts shown in the illustration, and then using 2 new seal washers for each bolt, install the cylinder head cover with the 15 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Standard Bolt Item Length A 25 mm (0.984 in.) B 60 mm (2.36 in.) TEXT IN ILLUSTRATION *a Apply adhesive to these bolts Bolt A Bolt B Attach the clamps and connect the connectors to connect the cylinder head cover.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Before applying seal packing black, completely remove any old seal packing adhering to the sealed areas. NOTE: The seal packing black cannot be wiped off. It can only be removed with a scraper. Clean and degrease the areas where the cylinder head cover LH, timing chain cover and camshaft housing LH contact each other with brake cleaner or non-residue solvent so that there is no oil, water or other foreign matter adhering to those areas. TEXT IN ILLUSTRATION *1 Seal Packing Black Application Area *a Part Contact Areas *b 4.0 to 10.0 mm (0.157 to 0.394 in.) Apply seal packing black (diameter: 2.0 to 3.0 mm (0.0787 to 0.118 in.)) to the areas shown in the illustration and install the cylinder head cover LH. 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 LH within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install 5 new gaskets to the camshaft bearing caps. Install a new gasket to the cylinder head cover. Apply adhesive to the threads of the 14 bolts shown in the illustration, and then using 2 new seal washers for each bolt, install the cylinder head cover LH with the 16 bolts. for bolt A and B Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt C and D Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Standard Bolt Item Length A 25 mm (0.984 in.) B 60 mm (2.36 in.) C 35 mm (1.38 in.) D 70 mm (2.76 in.) TEXT IN ILLUSTRATION *a Apply adhesive to these bolts Bolt A Bolt B Bolt C Bolt D Attach the clamps and connect the connectors to connect the cylinder head cover LH.
INSTALL NO. 2 OIL LEVEL DIPSTICK GUIDE . Refer to «INSTALLATION [03/2012 - ] - Step 11»(ref-600587-S36596734442014022400000)
INSTALL SPARK PLUG . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600565-S23506956452014022400000)
INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600565-S23506956452014022400000)
CONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY NOTE: Make sure the pipe claw does not come off the separator connection point. When replacing the separator, also replace the pipe. While keeping the pipe stay aligned with the guide rail of the separator, push the stay in downwards at an angle until the stay contacts the stopper as shown in the illustration, and then connect the No. 2 water by-pass pipe sub-assembly and install the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) TEXT IN ILLUSTRATION *1 Pipe Claw *2 Separator Connection Point *3 Separator Guide Rail *4 Separator Stopper *a Insert at an angle *b Insert until stay contacts stopper
INSTALL PCV VALVE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600566-S25553525242014022400000)
INSTALL ENGINE COVER . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600566-S25553525242014022400000)
INSTALL INJECTOR DRIVER . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600584-S14428337192014022400000)
INSTALL NO. 1 ENGINE COVER . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600584-S14428337192014022400000)
INSTALL FUEL PUMP ASSEMBLY Refer to «INSTALLATION [03/2012 - ]»(ref-600584-S33738359992014022400000)
INSTALL ECM Refer to «INSTALLATION [03/2012 - ]»(ref-600565-S10234760722014022400000)
INSTALL INVERTER WITH CONVERTER ASSEMBLY Refer to «INSTALLATION [03/2012 - ]»(ref-600413-S25887079982014022400000)

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REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Refer to «REMOVAL [03/2012 - ]»(ref-600562-S32838646212014022400000)
SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 37
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 38
REMOVE CHAIN TENSIONER SLIPPER See step 39
REMOVE CHAIN SUB-ASSEMBLY See step 40
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) While raising the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner. TEXT IN ILLUSTRATION *1 Pin *2 Plunger *a Push Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH. SST: 09922-10010 TEXT IN ILLUSTRATION *a Turn *b Hold NOTE: Be careful not to damage the cylinder head with SST. Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one. Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain.
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 2 chain tensioner.
REMOVE CAMSHAFT BEARING CAP (for Bank 1) Check that the camshafts are positioned as shown in the illustration. TEXT IN ILLUSTRATION *1 Knock Pin *a IN *b EX Uniformly loosen and remove the 9 bearing cap bolts in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 15 bearing cap bolts in several steps and in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level.
REMOVE FUEL PUMP LIFTER HOUSING Remove the fuel pump lifter housing.
REMOVE CAMSHAFT
REMOVE NO. 2 CAMSHAFT
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Remove the camshaft housing RH by prying between the cylinder head and camshaft housing RH with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing RH. HINT: Tape the screwdriver tip before use.
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner. TEXT IN ILLUSTRATION *1 Pin *2 Plunger *a Push Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH. SST: 09922-10010 TEXT IN ILLUSTRATION *a Turn *b Hold NOTE: Be careful not to damage the cylinder head with SST. Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one. Remove the 2 bolts and the camshaft timing gear together with the No. 2 chain.
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 3 chain tensioner.
REMOVE CAMSHAFT BEARING CAP (for Bank 2) Check that the camshafts are positioned as shown in the illustration. TEXT IN ILLUSTRATION *1 Knock Pin *a IN *b EX Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 5 camshaft bearing caps.
REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY
REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Remove the camshaft housing LH by prying between the cylinder head LH and camshaft housing LH with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing LH. HINT: Tape the screwdriver tip before use.
REMOVE NO. 1 CHAIN VIBRATION DAMPER See step 42
REMOVE NO. 2 CHAIN VIBRATION DAMPER See step 43
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 24 No. 1 valve rocker arms. HINT: Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 24 valve lash adjusters from the cylinder head. HINT: Arrange the removed parts in the correct order.
REMOVE VALVE STEM CAP Remove the 24 valve stem caps. HINT: Arrange the removed parts in the correct order.
REMOVE REAR WATER BY-PASS JOINT See step 23
REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600584-S35908823442014022400000)
REMOVE FUEL DELIVERY PIPE LH . Refer to «REMOVAL [03/2012 - ] - Step 3»(ref-600584-S35908823442014022400000)
REMOVE FUEL DELIVERY PIPE RH . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600584-S35908823442014022400000)
REMOVE FUEL INJECTOR ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 5»(ref-600584-S35908823442014022400000)
REMOVE FUEL INJECTOR SEAL . Refer to «REMOVAL [03/2012 - ] - Step 6»(ref-600584-S35908823442014022400000)
REMOVE CYLINDER HEAD SUB-ASSEMBLY Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head.
REMOVE CYLINDER HEAD GASKET
REMOVE CYLINDER HEAD LH Uniformly loosen and remove the bolts in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head LH.
REMOVE NO. 2 CYLINDER HEAD GASKET
INSPECT CYLINDER HEAD SET BOLT See step 6

HINT

Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly or cylinder head LH. Refer to INITIALIZATION [03/2012 - ] .

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INSTALL CYLINDER HEAD GASKET Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 2.5 to 3.0 mm (0.0984 to 0.118 in.) Seal Packing Application Range A 10 to 15 mm (0.394 to 0.591 in.) B 1.25 to 1.50 mm (0.0492 to 0.0591 in.) TEXT IN ILLUSTRATION *1 Seal Packing *2 Gasket NOTE: Remove any oil from the contact surface. Install the cylinder head gasket within 3 minutes after applying the seal packing. Do not apply engine oil within 2 hours of installation. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. TEXT IN ILLUSTRATION *1 Lot No. Engine Front NOTE: Be careful of the installation direction. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly. Refer to «INITIALIZATION [03/2012 - ]»(ref-600436-S34722863312014022400000) . Place the cylinder head on the cylinder block. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1: Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2: Mark the front side of each cylinder head bolt head with paint. Tighten the cylinder head bolts another 90°. Step 3: Tighten the cylinder head bolts an additional 90°. Check that the paint marks are now at a 180° angle to the front. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine. TEXT IN ILLUSTRATION *1 Cylinder Head *2 Cylinder Head Gasket *3 Cylinder Block *a Wipe Clean
INSTALL NO. 2 CYLINDER HEAD GASKET Apply a continuous line of seal packing to a new No. 2 cylinder head gasket as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 2.5 to 3.0 mm (0.0984 to 0.118 in.) Seal Packing Application Range A 10 to 15 mm (0.394 to 0.591 in.) B 1.25 to 1.50 mm (0.0492 to 0.0591 in.) TEXT IN ILLUSTRATION *1 Seal Packing *2 Gasket NOTE: Remove any oil from the contact surface. Install the No. 2 cylinder head gasket within 3 minutes after applying the seal packing. Do not start the engine for at least 2 hours after installation. Place the No. 2 cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. TEXT IN ILLUSTRATION *1 Lot No. Engine Front NOTE: Be careful of the installation direction. Gently place the cylinder head LH in order not to damage the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD LH HINT: Perform "Inspection After Repairs" after replacing the cylinder head LH. Refer to «INITIALIZATION [03/2012 - ]»(ref-600436-S34722863312014022400000) . Place the cylinder head LH on the cylinder block. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head LH. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1: Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2: Mark the front side of each cylinder head bolt head with paint. Tighten the cylinder head bolts another 90°. Step 3: Tighten the cylinder head bolts an additional 90°. Check that the paint marks are now at a 180° angle to the front. Tighten the 2 bolts in the order shown in the illustration. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) Thoroughly wipe off seal packing that has seeped out onto the front side of the engine. TEXT IN ILLUSTRATION *1 Cylinder Head LH *2 No. 2 Cylinder Head Gasket *3 Cylinder Block *a Wipe Clean
INSTALL FUEL INJECTOR SEAL . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600584-S32920619542014022400000)
INSTALL FUEL INJECTOR ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600584-S32920619542014022400000)
INSTALL FUEL DELIVERY PIPE RH . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600584-S32920619542014022400000)
INSTALL FUEL DELIVERY PIPE LH . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600584-S32920619542014022400000)
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 5»(ref-600584-S32920619542014022400000)
INSTALL REAR WATER BY-PASS JOINT See step 51
INSTALL VALVE STEM CAP Apply a light coat of engine oil to the valve stem caps. Install the 24 valve stem caps to the cylinder head. NOTE: Install the valve stem cap to the same place it was removed from.
INSTALL VALVE LASH ADJUSTER ASSEMBLY Inspect the valve lash adjuster See step 2 . Install the 24 valve lash adjusters to the cylinder head. NOTE: Install the lash adjuster to the same place it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the lash adjuster tips and valve stem cap ends. NOTE: Install the No. 1 valve rocker arm to the same place it was removed from. Install the 24 No. 1 valve rocker arms as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap
INSTALL NO. 1 CHAIN VIBRATION DAMPER See step 31
INSTALL NO. 2 CHAIN VIBRATION DAMPER See step 32
INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing LH. Install the No. 3 camshaft to the camshaft housing LH.
INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing LH. Install the No. 4 camshaft to the camshaft housing LH.
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 each in the proper position and direction. Temporarily install and tighten the 8 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Make sure that the No. 1 valve rocker arm is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap *a CORRECT *b INCORRECT Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent TEXT IN ILLUSTRATION *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.) *b Diameter 4.0 to 4.5 mm (0.158 to 0.177 in.) Seal Packing NOTE: Remove any oil from the contact surface. Install the camshaft housing LH within 3 minutes. Do not start the engine for at least 2 hours after installation. Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) Standard Bolt Item Length A 68 mm (2.68 in.) B 48 mm (1.89 in.) TEXT IN ILLUSTRATION *1 Knock Pin *a IN *b EX Bolt A Bolt B NOTE: When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing LH, clean the installation surfaces, and reapply seal packing. If the camshaft housing 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) Remove any protruding seal packing black.
INSTALL CAMSHAFT Apply a light coat of engine oil to the camshaft journals and camshaft housing RH. Install the camshaft to the camshaft housing RH.
INSTALL NO. 2 CAMSHAFT Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing RH. Install the No. 2 camshaft to the camshaft housing RH.
INSTALL FUEL PUMP LIFTER HOUSING Install the fuel pump lifter housing.
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 each in the proper position and direction. Temporarily install and tighten the 9 bearing cap bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Standard Bolt Item Length A 40 mm (1.57 in.) B 58 mm (2.28 in.) TEXT IN ILLUSTRATION Bolt A Bolt B
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Make sure that the No. 1 valve rocker arm is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap *a CORRECT *b INCORRECT Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent TEXT IN ILLUSTRATION *a Diameter 3.0 to 4.0 mm (0.118 to 0.158 in.) Seal Packing NOTE: Remove any oil from the contact surface. Install the camshaft housing RH within 3 minutes. Do not start the engine for at least 2 hours after installation. Install the camshaft housing RH and tighten the 15 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) Standard Bolt Item Length A 68 mm (2.68 in.) B 48 mm (1.89 in.) TEXT IN ILLUSTRATION *1 Knock Pin *a EX *b IN Bolt A Bolt B NOTE: When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing RH, clean the installation surfaces, and reapply seal packing. If the camshaft housing 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 9 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) Remove any protruding seal packing black.
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Install the No. 3 chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) TEXT IN ILLUSTRATION *1 Plunger *2 Pin *a Push While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix the tensioner in place.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (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 assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain installed. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH. SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) TEXT IN ILLUSTRATION *a Turn *b Hold Remove the pin from the No. 3 chain tensioner.
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Install the No. 2 chain tensioner with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) TEXT IN ILLUSTRATION *1 Plunger *2 Pin *a Push While pushing in the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix the tensioner in place.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (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 assembly. 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 flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH. SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) TEXT IN ILLUSTRATION *a Turn *b Hold Remove the pin from the No. 2 chain tensioner.
INSTALL CHAIN SUB-ASSEMBLY See step 35
INSTALL CHAIN TENSIONER SLIPPER See step 36
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 37
INSPECT VALVE TIMING See step 38
POUR ENGINE OIL See step 15
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Refer to «INSTALLATION [03/2012 - ]»(ref-600562-S02134450322014022400000)

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Scheme 158: ILLUSTRATION

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Scheme 159: REMOVAL [03/2012 - ]

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Scheme 162

Scheme 163

REMOVE FAN SHROUD Refer to «REMOVAL [03/2012 - ]»(ref-600564-S20447706282014022400000)
REMOVE FAN AND GENERATOR V BELT See step 5
DISCONNECT WIRE HARNESS Disconnect the engine oil pressure switch connector. Remove the bolt and disconnect the wire harness bracket.
REMOVE CRANKSHAFT PULLEY Using SST, loosen the pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 TEXT IN ILLUSTRATION *a Hold *b Turn Tighten the pulley bolt to 2 or 3 threads of the crankshaft. Using SST, remove the pulley bolt and pulley. SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021 TEXT IN ILLUSTRATION *a Hold *b Turn HINT: Apply grease to the threads and tip of SST (center bolt) prior to use.
REMOVE CRANKSHAFT TIMING GEAR KEY Remove the pulley set key of the key groove.
REMOVE TIMING CHAIN CASE OIL SEAL Using a screwdriver with its tip taped, pry out the oil seal. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. HINT: Tape the screwdriver tip before use.

Scheme 164

Scheme 164: INSTALLATION [03/2012 - ]

Scheme 165

INSTALL TIMING CHAIN CASE OIL SEAL Apply MP grease to the lip of a new oil seal. NOTE: Keep the lip free of foreign matter. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain case edge. SST: 09223-22010 SST: 09506-35010 Standard depth 0 to 1.0 mm (0 to 0.0394 in.) TEXT IN ILLUSTRATION *1 Depth NOTE: Keep the lip free of foreign matter. Do not tap the oil seal at an angle.
INSTALL CRANKSHAFT TIMING GEAR KEY Install the pulley set key to the key groove.
INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the crankshaft 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 *b Turn
CONNECT WIRE HARNESS Install the wire harness bracket with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the engine oil pressure switch connector.
INSTALL FAN AND GENERATOR V BELT See step 1
INSTALL FAN SHROUD Refer to «INSTALLATION [03/2012 - ]»(ref-600564-S13974000572014022400000)
INSPECT FOR OIL LEAK . Refer to «REPLACEMENT [03/2012 - ] - Step 6»(ref-600562-S02225467592014022400000)

Scheme 166

Scheme 166: ILLUSTRATION

Scheme 167

Scheme 167: REMOVAL [03/2012 - ]

Scheme 168

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Scheme 170

REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY Refer to «REMOVAL [03/2012 - ]»(ref-600573-S17309851462014022400000)
REMOVE TRANSMISSION INPUT DAMPER COVER ASSEMBLY Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Remove the 9 bolts and transmission input damper cover assembly.
REMOVE FLYWHEEL SUB-ASSEMBLY Remove the 8 bolts and flywheel sub-assembly.
REMOVE REAR ENGINE OIL SEAL Using a knife, cut through the oil seal lip. TEXT IN ILLUSTRATION *1 Cut Position *2 Protective Tape Using a screwdriver with its tip taped, pry out the oil seal. NOTE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. HINT: Tape the screwdriver tip before use.

Scheme 171

Scheme 171: INSTALLATION [03/2012 - ]

Scheme 172

Scheme 173

INSTALL REAR ENGINE OIL SEAL Apply MP grease to the lip of a new oil seal. NOTE: Keep the lip free of foreign matter. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST: 09223-15030 SST: 09950-70010 09951-07150 Standard depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) TEXT IN ILLUSTRATION *1 Depth NOTE: Wipe off any excess grease on the crankshaft. Keep the lip free of foreign matter. Do not tap on the oil seal at an angle.
INSTALL FLYWHEEL SUB-ASSEMBLY Using SST, hold the crankshaft pulley. SST: 09213-70010 09213-70020 SST: 09330-00021 Clean the 8 bolts and 8 bolt holes. Apply a few drops of adhesive to 2 or 3 threads of the 6 bolt tips. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf)
INSTALL TRANSMISSION INPUT DAMPER COVER ASSEMBLY Install the damper cover with the 9 bolts. Torque: 49 N*m (504 kgf*cm, 36 ft.*lbf) TEXT IN ILLUSTRATION Flywheel Side NOTE: Make sure to insert the damper cover in the correct direction.
INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY Refer to «INSTALLATION [03/2012 - ]»(ref-600573-S33925572772014022400000)
INSPECT FOR OIL LEAK . Refer to «REPLACEMENT [03/2012 - ] - Step 6»(ref-600562-S02225467592014022400000)

Scheme 174

Scheme 174: ILLUSTRATION

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Scheme 175: ILLUSTRATION

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Scheme 176: ILLUSTRATION

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Scheme 177: ILLUSTRATION

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Scheme 178: ILLUSTRATION

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Scheme 179: ILLUSTRATION

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Scheme 180: ILLUSTRATION

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Scheme 181: ILLUSTRATION

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Scheme 182: ILLUSTRATION

Scheme 183

Scheme 183: ILLUSTRATION

Scheme 184

Scheme 184: ILLUSTRATION

REMOVAL [03/2012 - ]

WARNING

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the service information are not followed. Therefore, always follow the instructions listed in the service information when performing this procedure.

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Scheme 224

Scheme 225

REMOVE ENGINE ROOM SIDE COVER Remove the 4 clips and engine room side cover.
REMOVE COOL AIR INTAKE DUCT SEAL Remove the 7 clips and cool air intake duct seal.
REMOVE V-BANK COVER SUB-ASSEMBLY Place both hands on the sides of the cover as shown in the illustration, lift the cover to detach the 2 clips near the front in the order shown in the illustration, and then lift the cover further to detach the rear clip and remove the cover. TEXT IN ILLUSTRATION Areas to place hands when lifting cover NOTE: If the cover is lifted rearward or forward and to the right or left at the same time, the cover may be damaged.
RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM . Refer to «REPLACEMENT [03/2012 - ] - Step 1»(ref-600577-S29202516282014022400000)
DISCHARGE FUEL SYSTEM PRESSURE Refer to «PRECAUTION [03/2012 - ]»(ref-600579-S11839162022014022400000)
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
REMOVE LUGGAGE COMPARTMENT FLOOR MAT . Refer to «REMOVAL [03/2012 - ] - Step 1»(ref-600591-S42295782952014022400000)
REMOVE LUGGAGE COMPARTMENT TRIM COVER LH . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600591-S42295782952014022400000)
PRECAUTION WARNING: Be sure to read Precaution thoroughly before servicing. Refer to «PRECAUTION [03/2012 - ]»(ref-600593-S38793126432014022400000) . NOTE: After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery terminal notice before proceeding with work. Refer to «PRECAUTION [03/2012 - ]»(ref-600412-S33693534232014022400000) .
DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [03/2012 - ]»(ref-600412-S41156157812014022400000) .
REMOVE NO. 1 SEAT ARMREST CAP . Refer to «DISASSEMBLY [03/2012 - ] - Step 7»(ref-600608-S38377318282014022400000)
REMOVE LOWER HYBRID VEHICLE BATTERY COVER PANEL . Refer to «REMOVAL [03/2012 - ] - Step 7»(ref-600413-S10416066482014022400000)
REMOVE SERVICE PLUG GRIP . Refer to «REMOVAL [03/2012 - ] - Step 8»(ref-600413-S10416066482014022400000)
REMOVE INVERTER COVER . Refer to «REMOVAL [03/2012 - ] - Step 15»(ref-600413-S23644527292014022400000)
REMOVE CONNECTOR COVER ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 16»(ref-600413-S23644527292014022400000)
CHECK TERMINAL VOLTAGE . Refer to «REMOVAL [03/2012 - ] - Step 17»(ref-600413-S23644527292014022400000)
TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 18»(ref-600413-S23644527292014022400000)
REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 19»(ref-600413-S23644527292014022400000)
REMOVE INVERTER TERMINAL COVER . Refer to «REMOVAL [03/2012 - ] - Step 20»(ref-600413-S23644527292014022400000)
REMOVE FRONT WHEEL
REMOVE ENGINE UNDER COVER Remove the 13 screws, 3 clips and engine under cover.
REMOVE REAR ENGINE UNDER COVER LH Remove the screw and rear engine under cover LH.
REMOVE REAR ENGINE UNDER COVER RH HINT: Remove the RH side following the same procedure as for the LH side.
REMOVE FRONT SUSPENSION MEMBER BRACE Remove the 4 bolts, and then turn the clip and remove the front suspension member brace. HINT: Do not remove the clip from the front suspension member brace.
REMOVE NO. 2 ENGINE UNDER COVER Remove the 4 screws, 2 grommets and No. 2 engine under cover.
DRAIN ENGINE OIL . Refer to «REPLACEMENT [03/2012 - ] - Step 1»(ref-600562-S02225467592014022400000)
DRAIN ENGINE COOLANT . Refer to «REPLACEMENT [03/2012 - ] - Step 4»(ref-600564-S07414681062014022400000)
DRAIN COOLANT (for Inverter) . Refer to «REPLACEMENT [03/2012 - ] - Step 4»(ref-600413-S09979707372014022400000)
REMOVE NO. 1 AIR CLEANER INLET Remove the bolt and No. 1 air cleaner inlet.
REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE . Refer to «REMOVAL [03/2012 - ] - Step 7»(ref-600565-S03651640162014022400000)
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
REMOVE AIR CLEANER CASE SUB-ASSEMBLY Remove the 2 bolts, 2 clamps and air cleaner case sub-assembly. NOTE: When removing the air cleaner case sub-assembly, be careful not to lose the grommet on the underside of the air cleaner case.
DISCONNECT WIRE HARNESS . Refer to «REMOVAL [03/2012 - ] - Step 13»(ref-600573-S38918554282014022400000)
REMOVE OIL PUMP MOTOR CONTROLLER . Refer to «REMOVAL [03/2012 - ] - Step 14»(ref-600573-S38918554282014022400000)
REMOVE WIRING HARNESS PROTECTOR . Refer to «REMOVAL [03/2012 - ] - Step 9»(ref-600573-S19955461162014022400000)
REMOVE HEATER ACCESSORY ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 15»(ref-600577-S17817199662014022400000)
DISCONNECT PURGE LINE HOSE Remove the clamp and disconnect the purge line hose.
DISCONNECT NO. 3 FUEL TUBE SUB-ASSEMBLY Disconnect the No. 3 fuel tube sub-assembly. Refer to «PRECAUTION [03/2012 - ]»(ref-600579-S11839162022014022400000) .
DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY Disconnect the No. 2 fuel tube sub-assembly. Refer to «PRECAUTION [03/2012 - ]»(ref-600579-S11839162022014022400000) .
DISCONNECT FUEL TUBE SUB-ASSEMBLY Disconnect the fuel tube sub-assembly. Refer to «PRECAUTION [03/2012 - ]»(ref-600579-S11839162022014022400000) .
REMOVE NO. 1 RADIATOR HOSE . Refer to «REMOVAL [03/2012 - ] - Step 12»(ref-600564-S13032995062014022400000)
DISCONNECT NO. 2 RADIATOR HOSE . Refer to «REMOVAL [03/2012 - ] - Step 6»(ref-600564-S29728736322014022400000)
DISCONNECT INLET HEATER WATER HOSE Remove the water hose set. Disconnect the inlet heater water hose.
DISCONNECT OUTLET HEATER WATER HOSE Remove the water hose set. Disconnect the outlet heater water hose.
DISCONNECT AIR CONDITIONING HARNESS Release the green-colored lock and disconnect the connector as shown in the illustration. TEXT IN ILLUSTRATION *1 Green-colored Lock WARNING: Wear insulated gloves when performing the procedure. NOTE: Insulate the connector by sealing it with tape. Remove the bolt and 3 wire harness clamps to disconnect the air conditioning harness.
DISCONNECT NO. 2 OIL COOLER INLET HOSE . Refer to «REMOVAL [03/2012 - ] - Step 15»(ref-600564-S13032995062014022400000)
DISCONNECT NO. 2 OIL COOLER OUTLET HOSE . Refer to «REMOVAL [03/2012 - ] - Step 16»(ref-600564-S13032995062014022400000)
DISCONNECT NO. 5 INVERTER COOLING HOSE Disconnect the No. 5 inverter cooling hose.
REMOVE NO. 1 INVERTER COOLING PIPE Disconnect the 2 connectors, 2 wire harness clamps and wire harness. Remove the bolt and disconnect the 2 hoses to remove the No. 1 inverter cooling pipe.
DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to «REMOVAL [03/2012 - ] - Step 14»(ref-600577-S11260502662014022400000)
DISCONNECT SUCTION HOSE . Refer to «REMOVAL [03/2012 - ] - Step 13»(ref-600577-S11260502662014022400000)
REMOVE ECM . Refer to «REMOVAL [03/2012 - ] - Step 7»(ref-600565-S38319377392014022400000)
DISCONNECT MOTOR CABLE . Refer to «REMOVAL [03/2012 - ] - Step 22»(ref-600413-S23644527292014022400000)
DISCONNECT GENERATOR CABLE . Refer to «REMOVAL [03/2012 - ] - Step 21»(ref-600413-S23644527292014022400000)
REMOVE INVERTER RESERVOIR TANK ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 10»(ref-600587-S37811566882014022400000)
DISCONNECT ENGINE WIRE Engine Room LH Side: Remove the No. 1 engine room relay block cover. Disconnect the 3 connectors from the No. 2 connector holder. Detach the clamp and 3 claws, and then disconnect the No. 2 connector holder. Engine Room RH Side: Remove the bolt, clamp and No. 3 engine wire.
REMOVE NO. 1 REAR FLOOR BOARD SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 1»(ref-600587-S32961584102014022400000)
REMOVE NO. 2 REAR FLOOR BOARD SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600587-S32961584102014022400000)
REMOVE FRONT CENTER FLOOR BRACE . Refer to «REMOVAL [03/2012 - ] - Step 3»(ref-600587-S32961584102014022400000)
DISCONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600587-S32961584102014022400000)
DISCONNECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) . Refer to «REMOVAL [03/2012 - ] - Step 18»(ref-600587-S37811566882014022400000)
REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 6»(ref-600587-S32961584102014022400000)
REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 20»(ref-600587-S37811566882014022400000)
REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY Remove the 4 bolts and front center floor brace sub-assembly.
REMOVE NO. 1 FUEL TANK PROTECTOR . Refer to «REMOVAL [03/2012 - ] - Step 3»(ref-600415-S02806654642014022400000)
REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600415-S02806654642014022400000)
REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600415-S02806654642014022400000)
DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 14»(ref-600613-S38941821072014022400000)
DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH Loosen the bolt while holding the nut. Disconnect the lower part of the front shock absorber from the front suspension lower arm. NOTE: Support the steering knuckle using a rubber attachment or other similar object to prevent excessive force from being applied to the flexible hose.
DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH HINT: Remove the RH side following the same procedure as for the LH side.
DISCONNECT FRONT LOWER BALL JOINT ASSEMBLY LH . Refer to «REMOVAL [03/2012 - ] - Step 6»(ref-600574-S00185771582014022400000)
DISCONNECT FRONT LOWER BALL JOINT ASSEMBLY RH HINT: Remove the RH side following the same procedure as for the LH side.
DISCONNECT POWER STEERING LINK WIRE HARNESS Disconnect the 2 wire harness clamps from the bracket. Disconnect the 2 connectors (A) and (B) from the power steering link assembly. Release the lock of connector (C) and disconnect the connector from the power steering link assembly.
DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 7»(ref-600573-S04923291292014022400000)
REMOVE FRONT NO. 2 UPPER SUSPENSION MEMBER Remove the 6 bolts and front No. 2 upper suspension member.
REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR Remove the 4 bolts and suspension member protector.
INSTALL ENGINE HANGER Install the 2 No. 1 engine hangers with the 4 bolts as shown in the illustration. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) TEXT IN ILLUSTRATION *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger HINT: No. 1 engine hanger 12281 - 31130 No. 2 engine hanger 12282 - 31140 Bolt 91671 - F0822
REMOVE ENGINE AND TRANSMISSION ASSEMBLY Remove the nut and disconnect the wire harness. Set the engine on an engine lifter. TEXT IN ILLUSTRATION *a Place Wooden Block or Plate Attachments NOTE: Place wooden blocks or plate lift attachments so that the engine is level. With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous. Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan. Remove the 4 bolts, and then disconnect the rear engine mounting member. Remove the 10 bolts and 2 nuts shown in the illustration. TEXT IN ILLUSTRATION Bolt Nut Operate the engine lifter, and then slowly remove the engine from the vehicle. NOTE: Make sure the engine is clear of all wiring and hoses. While lowering the engine from the vehicle, do not allow it to contact the vehicle. Attach an engine sling device and hang the engine with a chain block. NOTE: Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to «REMOVAL [03/2012 - ] - Step 13»(ref-600587-S37811566882014022400000)
REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE Remove the bolt and engine oil level dipstick guide. Remove the O-ring from the engine oil level dipstick guide.
REMOVE ENGINE UNDER COVER SUB-ASSEMBLY LH Remove the engine under cover sub-assembly LH.
REMOVE ENGINE UNDER COVER SUB-ASSEMBLY RH Remove the engine under cover sub-assembly RH.
REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH . Refer to «REMOVAL [03/2012 - ] - Step 22»(ref-600587-S37811566882014022400000)
REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH . Refer to «REMOVAL [03/2012 - ] - Step 21»(ref-600587-S37811566882014022400000)
REMOVE CONNECTOR . Refer to «REMOVAL [03/2012 - ] - Step 3»(ref-600573-S38659998332014022400000)
REMOVE WIRE HARNESS . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600573-S38659998332014022400000)
REMOVE OIL COOLER HOSE TUBE SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 10»(ref-600573-S38659998332014022400000)
REMOVE WATER PIPE AND HOSE SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 11»(ref-600573-S38659998332014022400000)
REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 13»(ref-600573-S38659998332014022400000)
SUPPORT HYBRID VEHICLE TRANSMISSION ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 14»(ref-600573-S38659998332014022400000)
REMOVE STARTER HOLE INSULATOR . Refer to «REMOVAL [03/2012 - ] - Step 15»(ref-600573-S38659998332014022400000)
REMOVE FLYWHEEL HOUSING SIDE COVER . Refer to «REMOVAL [03/2012 - ] - Step 16»(ref-600573-S38659998332014022400000)
REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 17»(ref-600573-S38659998332014022400000)
REMOVE TRANSMISSION INPUT DAMPER COVER ASSEMBLY See step 2
REMOVE FLYWHEEL SUB-ASSEMBLY See step 3
REMOVE COMPRESSOR WITH MOTOR ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 15»(ref-600577-S11260502662014022400000)
REMOVE FAN AND GENERATOR V BELT See step 5
REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Remove the 2 bolts, and then disconnect the front suspension crossmember sub-assembly from the engine. TEXT IN ILLUSTRATION *a LH Side *b RH Side
INSTALL ENGINE ON ENGINE STAND Install the engine to an engine stand with bolts. NOTE: Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect. With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous. Remove the 4 bolts and 2 engine hangers.
REMOVE FRONT ENGINE MOUNTING INSULATOR HINT: Only perform this procedure when replacement of the engine mounting insulator is necessary. Remove the 2 nuts and front engine mounting insulator RH and LH. TEXT IN ILLUSTRATION *a LH Side *b RH Side
REMOVE REAR ENGINE MOUNTING MEMBER Remove the 4 nuts and rear engine mounting member from the rear No. 1 engine mounting insulator.
REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR HINT: Only perform this procedure when replacement of the engine mounting insulator is necessary. Remove the 4 bolts and rear No. 1 engine mounting insulator from the hybrid vehicle transmission assembly.

WARNING

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR HINT: Only perform this procedure when replacement of the engine mounting insulator is necessary. Install the rear No. 1 engine mounting insulator to the hybrid vehicle transmission assembly with the 4 bolts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) HINT: Make sure that the paint mark faces toward the rear of the vehicle. TEXT IN ILLUSTRATION *1 Paint Mark Rear of Vehicle
INSTALL FRONT ENGINE MOUNTING INSULATOR HINT: Only perform this procedure when replacement of the engine mounting insulator is necessary. Install the front engine mounting insulator RH and LH with the 2 nuts. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf)
INSTALL ENGINE HANGER See step 77
REMOVE ENGINE STAND Attach an engine sling device and hang the engine with a chain block. NOTE: Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect. Lift the engine and remove it from the engine stand. NOTE: With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous. Place the engine onto a work bench.
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Install the front suspension crossmember sub-assembly with the 2 bolts. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
INSTALL FAN AND GENERATOR V BELT See step 1
INSTALL COMPRESSOR WITH MOTOR ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600577-S03561472472014022400000)
INSTALL FLYWHEEL SUB-ASSEMBLY See step 2
INSTALL TRANSMISSION INPUT DAMPER COVER ASSEMBLY See step 3
INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600573-S35908886782014022400000)
INSTALL FLYWHEEL HOUSING SIDE COVER . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600573-S35908886782014022400000)
INSTALL STARTER HOLE INSULATOR . Refer to «INSTALLATION [03/2012 - ] - Step 5»(ref-600573-S35908886782014022400000)
INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 6»(ref-600573-S35908886782014022400000)
INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 8»(ref-600573-S35908886782014022400000)
INSTALL OIL COOLER HOSE TUBE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 9»(ref-600573-S35908886782014022400000)
CONNECT WIRE HARNESS . Refer to «INSTALLATION [03/2012 - ] - Step 15»(ref-600573-S35908886782014022400000)
CONNECT CONNECTOR . Refer to «INSTALLATION [03/2012 - ] - Step 16»(ref-600573-S35908886782014022400000)
INSTALL REAR ENGINE MOUNTING MEMBER Install the engine rear mounting member to the hybrid vehicle transmission assembly with the 4 nuts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600587-S36596734442014022400000)
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600587-S36596734442014022400000)
INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH Install the engine under cover sub-assembly LH.
INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH Install the engine under cover sub-assembly RH.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Install a new O-ring to the engine oil level dipstick guide. Apply a light coat of engine oil to the O-ring. Push in the engine oil level dipstick guide end into the guide hole. Install the engine oil level dipstick guide with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to «INSTALLATION [03/2012 - ] - Step 11»(ref-600587-S36596734442014022400000)
INSTALL ENGINE AND TRANSMISSION ASSEMBLY Set the engine on an engine lifter. NOTE: Place wooden blocks or plate lift attachments so that the engine is level. With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous. Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan. Remove the 4 bolts and 2 No. 1 engine hangers. Operate the engine lifter and install the engine to the vehicle. NOTE: Make sure that the engine is clear of all wiring and hoses. Install the engine and transmission assembly with crossmember with the 6 bolts, 4 new bolts and 2 nuts. for bolt A Torque: 194 N*m (1978 kgf*cm, 143 ft.*lbf) for bolt B Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt C Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) for nut Torque: 151 N*m (1540 kgf*cm, 111 ft.*lbf) TEXT IN ILLUSTRATION Bolt Nut HINT: Use new bolts for the bolts labeled C. Install the rear engine mounting member with the 4 bolts. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) Connect the wire harness with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR Install the front lower suspension member protector with the 4 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
INSTALL FRONT NO. 2 UPPER SUSPENSION MEMBER Install the 2 front No. 2 upper suspension members with the 6 bolts. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600573-S14032559372014022400000)
CONNECT POWER STEERING LINK WIRE HARNESS Connect the wire harness connector (C) to the power steering link assembly and securely lock the connector. TEXT IN ILLUSTRATION Front Connect the 2 wire harness connectors (A) and (B) to the power steering link assembly. Connect the 2 wire harness clamps to the bracket.
CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600574-S03651589032014022400000)
CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH HINT: Install the RH side following the same procedure as for the LH side.
CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH Install the bolt on the lower side of the front shock absorber while holding the nut. Torque: 108 N*m (1101 kgf*cm, 80 ft.*lbf)
CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH HINT: Install the RH side following the same procedure as for the LH side.
CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 5»(ref-600613-S42023091832014022400000)
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600415-S28614099402014022400000)
FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600415-S28614099402014022400000)
INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600415-S28614099402014022400000)
INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR . Refer to «INSTALLATION [03/2012 - ] - Step 5»(ref-600415-S28614099402014022400000)
INSTALL NO. 1 FUEL TANK PROTECTOR . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600415-S28614099402014022400000)
INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY Install the front center floor brace sub-assembly with the 4 bolts. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600587-S36596734442014022400000)
INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600587-S40439511072014022400000)
CONNECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) . Refer to «INSTALLATION [03/2012 - ] - Step 6»(ref-600587-S36596734442014022400000)
CONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600587-S40439511072014022400000)
INSTALL FRONT CENTER FLOOR BRACE . Refer to «INSTALLATION [03/2012 - ] - Step 6»(ref-600587-S40439511072014022400000)
INSTALL NO. 2 REAR FLOOR BOARD SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 7»(ref-600587-S40439511072014022400000)
INSTALL NO. 1 REAR FLOOR BOARD SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 8»(ref-600587-S40439511072014022400000)
CONNECT ENGINE WIRE Engine Room LH Side: Connect the No. 2 connector holder with the clamp and 3 claws. Connect the 3 connectors from the No. 2 connector holder. Install the No. 1 engine room relay block cover. Engine Room RH Side: Install the bolt, clamp and No. 3 engine wire. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
CONNECT INVERTER RESERVOIR TANK ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 14»(ref-600587-S36596734442014022400000)
CONNECT MOTOR CABLE . Refer to «INSTALLATION [03/2012 - ] - Step 10»(ref-600413-S37662380792014022400000)
CONNECT GENERATOR CABLE . Refer to «INSTALLATION [03/2012 - ] - Step 11»(ref-600413-S37662380792014022400000)
INSTALL ECM . Refer to «INSTALLATION [03/2012 - ] - Step 5»(ref-600565-S08986112232014022400000)
CONNECT SUCTION HOSE . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600577-S03561472472014022400000)
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600577-S03561472472014022400000)
INSTALL NO. 1 INVERTER COOLING PIPE Install the No. 1 inverter cooling pipe with the bolt. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) Connect the 2 hoses. Connect the 2 connectors and 2 wire harness clamps.
CONNECT NO. 5 INVERTER COOLING HOSE Connect the No. 5 inverter cooling hose.
CONNECT NO. 2 OIL COOLER OUTLET HOSE . Refer to «INSTALLATION [03/2012 - ] - Step 6»(ref-600564-S01433370552014022400000)
CONNECT NO. 2 OIL COOLER INLET HOSE . Refer to «INSTALLATION [03/2012 - ] - Step 7»(ref-600564-S01433370552014022400000)
CONNECT AIR CONDITIONING HARNESS Connect the white tape part of the air conditioning harness to the clamp as shown in the illustration. TEXT IN ILLUSTRATION *1 White Tape *2 Air Conditioning Harness NOTE: Make sure that the air conditioning harness is securely connected. Connect the 2 wire harness clamps to each bracket. Connect the bracket with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the connector and lock the green-colored lock as shown in the illustration. TEXT IN ILLUSTRATION *1 Green-colored Lock WARNING: Wear insulated gloves when performing the procedure.
CONNECT OUTLET HEATER WATER HOSE Connect the outlet heater water hose. Install the water hose set.
CONNECT INLET HEATER WATER HOSE Connect the inlet heater water hose. Install the water hose set.
CONNECT NO. 2 RADIATOR HOSE . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600564-S32191971532014022400000)
INSTALL NO. 1 RADIATOR HOSE . Refer to «INSTALLATION [03/2012 - ] - Step 10»(ref-600564-S01433370552014022400000)
CONNECT FUEL TUBE SUB-ASSEMBLY Connect the fuel tube sub-assembly. Refer to «PRECAUTION [03/2012 - ]»(ref-600579-S11839162022014022400000) .
CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY Connect the No. 2 fuel tube sub-assembly. Refer to «PRECAUTION [03/2012 - ]»(ref-600579-S11839162022014022400000) .
CONNECT NO. 3 FUEL TUBE SUB-ASSEMBLY Connect the No. 3 fuel tube sub-assembly. Refer to «PRECAUTION [03/2012 - ]»(ref-600579-S11839162022014022400000) .
CONNECT PURGE LINE HOSE Install the clamp and connect the purge line hose.
INSTALL HEATER ACCESSORY ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600577-S40391211832014022400000)
CONNECT WIRING HARNESS PROTECTOR . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600573-S14811841162014022400000)
INSTALL OIL PUMP MOTOR CONTROLLER . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600573-S00992824072014022400000)
CONNECT WIRE HARNESS . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600573-S00992824072014022400000)
INSTALL AIR CLEANER CASE SUB-ASSEMBLY Insert the pin on the lower side of the air cleaner case into the grommet. TEXT IN ILLUSTRATION *1 Pin *2 Grommet Install the air cleaner case, 2 clamps and 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) NOTE: During removal, do not lose the grommet on the underside of the air cleaner case.
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600565-S34117039542014022400000)
INSTALL NO. 1 AIR CLEANER INLET Install the No. 1 air cleaner inlet with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
ADD ENGINE OIL . Refer to «REPLACEMENT [03/2012 - ] - Step 5»(ref-600562-S02225467592014022400000)
INSTALL CONNECTOR COVER ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 9»(ref-600413-S37662380792014022400000)
INSTALL INVERTER TERMINAL COVER . Refer to «INSTALLATION [03/2012 - ] - Step 12»(ref-600413-S37662380792014022400000)
INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 13»(ref-600413-S37662380792014022400000)
INSTALL INVERTER COVER . Refer to «INSTALLATION [03/2012 - ] - Step 20»(ref-600413-S37662380792014022400000)
INSTALL SERVICE PLUG GRIP . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600413-S00900170522014022400000)
INSTALL LOWER HYBRID VEHICLE BATTERY COVER PANEL . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600413-S00900170522014022400000)
INSTALL NO. 1 SEAT ARMREST CAP . Refer to «REASSEMBLY [03/2012 - ] - Step 18»(ref-600608-S21916465962014022400000)
CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [03/2012 - ]»(ref-600412-S41156157812014022400000) .
INSTALL LUGGAGE COMPARTMENT TRIM COVER LH . Refer to «INSTALLATION [03/2012 - ] - Step 24»(ref-600591-S24662608162014022400000)
INSTALL LUGGAGE COMPARTMENT FLOOR MAT . Refer to «INSTALLATION [03/2012 - ] - Step 26»(ref-600591-S24662608162014022400000)
PERFORM INITIALIZATION Refer to «INITIALIZATION [03/2012 - ]»(ref-600412-S41156157812014022400000)
ADJUST SHIFT LEVER POSITION . Refer to «ADJUSTMENT [03/2012 - ] - Step 2»(ref-600573-S16638884742014022400000)
INSPECT SHIFT LEVER POSITION . Refer to «ADJUSTMENT [03/2012 - ] - Step 1»(ref-600573-S16638884742014022400000)
ADD ENGINE COOLANT . Refer to «REPLACEMENT [03/2012 - ] - Step 5»(ref-600564-S07414681062014022400000)
ADD COOLANT (for Inverter) . Refer to «REPLACEMENT [03/2012 - ] - Step 5»(ref-600413-S09979707372014022400000)
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . Refer to «REPLACEMENT [03/2012 - ] - Step 2»(ref-600577-S29202516282014022400000)
INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION [03/2012 - ] - Step 1»(ref-600563-S26066385202014022400000)
INSPECT COOLANT LEAK (for Inverter) . Refer to «ON-VEHICLE INSPECTION [03/2012 - ] - Step 1»(ref-600413-S30119265742014022400000)
INSPECT FOR OIL LEAK . Refer to «REPLACEMENT [03/2012 - ] - Step 6»(ref-600562-S02225467592014022400000)
INSPECT FOR FUEL LEAK . Refer to «ON-VEHICLE INSPECTION [03/2012 - ] - Step 1»(ref-600579-S34995337152014022400000)
INSPECT FOR EXHAUST GAS LEAK . Refer to «INSTALLATION [03/2012 - ] - Step 9»(ref-600587-S40439511072014022400000)
CHECK FOR REFRIGERANT GAS LEAK . Refer to «REPLACEMENT [03/2012 - ] - Step 4»(ref-600577-S29202516282014022400000)
INSTALL FRONT WHEEL Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
CHECK AND ADJUST FRONT WHEEL ALIGNMENT Refer to «ADJUSTMENT [03/2012 - ]»(ref-600576-S35749324442014022400000)
ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) . Refer to «ADJUSTMENT [03/2012 - ] - Step 1»(ref-600437-S08511103972014022400000)
ADJUST NIGHT VIEW CAMERA ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 8»(ref-600443-S16157810062014022400000)
INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 6»(ref-600565-S34117039542014022400000)
INSPECT IGNITION TIMING See step 8
INSPECT ENGINE IDLE SPEED See step 9
INSPECT CO/HC See step 11
INSPECT ENGINE COOLANT LEVEL . Refer to «ON-VEHICLE INSPECTION [03/2012 - ] - Step 2»(ref-600563-S26066385202014022400000)
INSPECT COOLANT LEVEL IN RESERVOIR TANK (for Inverter) . Refer to «ON-VEHICLE INSPECTION [03/2012 - ] - Step 2»(ref-600413-S30119265742014022400000)
INSPECT ENGINE OIL LEVEL . Refer to «ON-VEHICLE INSPECTION [03/2012 - ] - Step 2»(ref-600561-S01448690112014022400000)
INSTALL NO. 2 ENGINE UNDER COVER Install the No. 2 engine under cover with the 4 screws and 2 grommets.
INSTALL FRONT SUSPENSION MEMBER BRACE Install the front suspension member brace with the clip and 4 bolts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
INSTALL REAR ENGINE UNDER COVER LH Install the rear engine under cover LH with the screw.
INSTALL REAR ENGINE UNDER COVER RH HINT: Install the RH side following the same procedure as for the LH side.
INSTALL ENGINE UNDER COVER Install the engine under cover with the 13 screws and 3 clips.
INSTALL V-BANK COVER SUB-ASSEMBLY Attach the 3 clips in the order shown in the illustration to install the V-bank cover. TEXT IN ILLUSTRATION *1 Tip (Round Portion) NOTE: Securely attach the clips. If the clips are forcibly attached or struck with an object, they may be damaged. Do not apply any oil to the tips (round portions).
INSTALL COOL AIR INTAKE DUCT SEAL Install the cool air intake duct seal with the 7 clips.
INSTALL ENGINE ROOM SIDE COVER Install the engine room side cover with the 4 clips.

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Scheme 235

Scheme 235: ILLUSTRATION

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Scheme 236: ILLUSTRATION

Scheme 237

Scheme 237: ILLUSTRATION

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Scheme 238: ILLUSTRATION

Scheme 239

Scheme 239: ILLUSTRATION

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Scheme 240: ILLUSTRATION

Scheme 241

Scheme 241: ILLUSTRATION

Scheme 242

Scheme 242: ILLUSTRATION

Scheme 243

Scheme 243: ILLUSTRATION

Scheme 244

Scheme 244: ILLUSTRATION

Scheme 245

Scheme 245: ILLUSTRATION

Scheme 246

Scheme 246: ILLUSTRATION

Scheme 247

Scheme 247: REMOVAL [03/2012 - ]

Scheme 248

Scheme 249

Scheme 250

Scheme 251

REMOVE NO. 2 ENGINE COVER Remove the 3 clips and clamp, and then remove the No. 2 engine cover.
REMOVE NO. 1 ENGINE COVER . Refer to «REMOVAL [03/2012 - ] - Step 9»(ref-600584-S30154344742014022400000)
REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH Disconnect the 2 clamps. Remove the 4 bolts and front No. 1 engine mounting bracket LH.
REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH Remove the 4 bolts and front No. 1 engine mounting bracket RH.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the 5 bolts and V-ribbed belt tensioner.
REMOVE WATER PUMP PULLEY . Refer to «REMOVAL [03/2012 - ] - Step 27»(ref-600564-S17689283622014022400000)
REMOVE ENGINE WIRE
REMOVE INJECTOR DRIVER . Refer to «REMOVAL [03/2012 - ] - Step 10»(ref-600584-S30154344742014022400000)
REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 8»(ref-600565-S03651640162014022400000)
REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 10»(ref-600587-S31207887812014022400000)
REMOVE NO. 2 SURGE TANK STAY Remove the bolt and No. 2 surge tank stay.
REMOVE NO. 3 WATER BY-PASS PIPE Remove the bolt, and disconnect the 2 hoses and No. 3 water by-pass pipe.
REMOVE INTAKE MANIFOLD . Refer to «REMOVAL [03/2012 - ] - Step 12»(ref-600587-S31207887812014022400000)
REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600584-S34977463212014022400000)
REMOVE FUEL PUMP ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 5»(ref-600584-S34977463212014022400000)
REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600584-S35908823442014022400000)
REMOVE FUEL DELIVERY PIPE LH . Refer to «REMOVAL [03/2012 - ] - Step 3»(ref-600584-S35908823442014022400000)
REMOVE FUEL DELIVERY PIPE RH . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600584-S35908823442014022400000)
REMOVE FUEL INJECTOR ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 5»(ref-600584-S35908823442014022400000)
REMOVE FUEL INJECTOR SEAL . Refer to «REMOVAL [03/2012 - ] - Step 6»(ref-600584-S35908823442014022400000)
REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY Remove the bolt and V-bank cover bracket.
REMOVE V-BANK COVER BOLT Remove the V-bank cover bolt.
REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 6»(ref-600565-S25351552132014022400000)
REMOVE ENGINE OIL LEVEL SENSOR . Refer to «REMOVAL [03/2012 - ] - Step 6»(ref-600562-S27288152252014022400000)
REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 5»(ref-600562-S32689032272014022400000)
REMOVE ENGINE COOLANT TEMPERATURE SENSOR . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600565-S07336242392014022400000)
REMOVE ENGINE COVER . Refer to «REMOVAL [03/2012 - ] - Step 3»(ref-600566-S14922007972014022400000)

Scheme 252

Scheme 252: DISASSEMBLY [03/2012 - ]

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REMOVE OIL FILLER CAP SUB-ASSEMBLY Remove the oil filler cap and gasket.
REMOVE RADIATOR CAP SUB-ASSEMBLY
REMOVE SPARK PLUG . Refer to «REMOVAL [03/2012 - ] - Step 7»(ref-600565-S25351552132014022400000)
REMOVE OIL PAN DRAIN PLUG Remove the drain plug and gasket.
REMOVE PCV VALVE SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600566-S14922007972014022400000)
DISCONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY See step 8
REMOVE WATER BY-PASS HOSE ASSEMBLY
REMOVE NO. 2 SEPARATOR CASE Remove the 2 nuts, No. 2 separator case and O-ring.
REMOVE VVT SENSOR (for Intake Side of Bank 1) . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600565-S08985638542014022400000)
REMOVE VVT SENSOR (for Exhaust Side of Bank 1) . Refer to «REMOVAL [03/2012 - ] - Step 3»(ref-600565-S08985638542014022400000)
REMOVE VVT SENSOR (for Intake Side of Bank 2) . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600565-S08985638542014022400000)
REMOVE VVT SENSOR (for Exhaust Side of Bank 2) . Refer to «REMOVAL [03/2012 - ] - Step 5»(ref-600565-S08985638542014022400000)
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600565-S03464385342014022400000)
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) . Refer to «REMOVAL [03/2012 - ] - Step 3»(ref-600565-S03464385342014022400000)
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) . Refer to «REMOVAL [03/2012 - ] - Step 5»(ref-600565-S03464385342014022400000)
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) . Refer to «REMOVAL [03/2012 - ] - Step 4»(ref-600565-S03464385342014022400000)
REMOVE CRANKSHAFT POSITION SENSOR . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600565-S32794700962014022400000)
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Remove the water drain cocks from the cylinder block. TEXT IN ILLUSTRATION *a RH Side *b LH Side Remove the water drain cock plugs from the water drain cocks.
REMOVE OIL FILTER ELEMENT . Refer to «REPLACEMENT [03/2012 - ] - Step 3»(ref-600562-S02225467592014022400000)
REMOVE CRANKSHAFT PULLEY See step 4
REMOVE WATER INLET SUB-ASSEMBLY Separate the 3 water by-pass hoses. Remove the 4 bolts, nut and water inlet. Remove the 2 O-rings. Remove the 3 water by-pass hoses.
REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY Remove the 3 nuts and water inlet with thermostat. Remove the gasket from the water inlet.
REMOVE REAR WATER BY-PASS JOINT Remove the 2 bolts, 4 nuts and water by-pass joint. Remove the 2 gaskets and O-ring.
REMOVE FUEL PUMP SPACER GASKET Remove the fuel pump spacer gasket from the cylinder head cover.
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY See step 13
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 12
REMOVE SPARK PLUG TUBE GASKET NOTE: Do not deform the claws of the baffle plate more than necessary. Pry up the claws of the ventilation baffle plate. TEXT IN ILLUSTRATION *1 Claw Remove the 6 gaskets from the cylinder head covers. NOTE: As much as possible prevent the plug tube gaskets from being deformed. The removed gaskets will be used when reinstalling the gaskets. Do not damage the connection of the cylinder head cover.
REMOVE OIL PAN DRAIN PLUG Remove the oil pan drain plug and gasket.
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Remove the 15 bolts and 2 nuts. TEXT IN ILLUSTRATION Bolt Nut Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan. NOTE: Be careful not to damage the contact surfaces of the oil pans.
REMOVE OIL PAN SUB-ASSEMBLY Remove the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION Bolt Nut HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver. TEXT IN ILLUSTRATION *a LH Side *b RH Side NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. HINT: Tape the screwdriver tip before use. Remove the 2 O-rings.
REMOVE OIL STRAINER SUB-ASSEMBLY Remove the 3 nuts, oil strainer and gasket. Remove the 8 bolts and baffle plate.
REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 6 bolts. Using a screwdriver, pry out the oil seal retainer. TEXT IN ILLUSTRATION Pry NOTE: Be careful not to damage the engine rear oil seal retainer. HINT: Tape the screwdriver tip before use.
REMOVE REAR CRANKSHAFT OIL SEAL Place the oil seal retainer on wooden blocks. TEXT IN ILLUSTRATION *1 Wooden Block *2 Protective Tape NOTE: Be careful not to damage the engine rear oil seal retainer. Using a screwdriver and a hammer, tap out the oil seal. HINT: Tape the screwdriver tip before use.
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 17»(ref-600562-S10682002562014022400000)
REMOVE ENGINE WATER PUMP ASSEMBLY . Refer to «REMOVAL [03/2012 - ] - Step 29»(ref-600564-S17689283622014022400000)
REMOVE TIMING CHAIN CASE OIL SEAL . Refer to «REMOVAL [03/2012 - ] - Step 18»(ref-600562-S10682002562014022400000)
SET NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily install the pulley set bolt. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC/compression). TEXT IN ILLUSTRATION *1 Timing Mark *a Center Line Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark If not, turn the crankshaft 1 revolution (360°) and align the timing marks as described above.
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 (0.0500 in.) diameter into the stopper plate's hole. Remove the 2 bolts and chain tensioner.
REMOVE CHAIN TENSIONER SLIPPER Remove the chain tensioner slipper.
REMOVE CHAIN SUB-ASSEMBLY Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket. TEXT IN ILLUSTRATION *1 Timing Mark *a Center Line Remove the pulley set bolt. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks. TEXT IN ILLUSTRATION *A for Bank 1 Remove the chain.
REMOVE IDLE SPROCKET ASSEMBLY Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket and No. 1 idle gear shaft.
REMOVE NO. 1 CHAIN VIBRATION DAMPER Remove the 2 bolts and No. 1 chain vibration damper.
REMOVE NO. 2 CHAIN VIBRATION DAMPER Remove the 2 No. 2 chain vibration dampers.
REMOVE CRANKSHAFT TIMING SPROCKET Remove the crankshaft timing sprocket from the crankshaft. Remove the 2 pulley set keys from the crankshaft.
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 6
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY See step 7
REMOVE CAMSHAFT BEARING CAP (for Bank 1) See step 8
REMOVE FUEL PUMP LIFTER HOUSING See step 9
REMOVE CAMSHAFT
REMOVE NO. 2 CAMSHAFT
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 12
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 13
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 14
REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 15
REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY
REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 18
REMOVE OIL CONTROL VALVE FILTER LH Remove the oil control valve filter LH from the camshaft bearing cap.
REMOVE OIL CONTROL VALVE FILTER RH Remove the oil control valve filter RH from the camshaft bearing cap.
REMOVE OIL CHECK VALVE Remove the oil check valve from the camshaft bearing cap.
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 21
REMOVE VALVE LASH ADJUSTER ASSEMBLY See step 22
REMOVE VALVE STEM CAP See step 23
REMOVE CYLINDER HEAD SUB-ASSEMBLY See step 30
REMOVE CYLINDER HEAD GASKET
REMOVE CYLINDER HEAD LH See step 32
REMOVE NO. 2 CYLINDER HEAD GASKET
REMOVE NO. 5 ENGINE WIRE Detach the clamp and remove the No. 5 engine wire.
REMOVE KNOCK SENSOR . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-600565-S16661786112014022400000)
REMOVE WATER OUTLET PIPE SUB-ASSEMBLY Remove the 2 bolts and water outlet pipe.
REMOVE NO. 1 STRAIGHT PIN NOTE: It is not necessary to remove a No. 1 straight pin unless it is being replaced.
REMOVE RING PIN NOTE: It is not necessary to remove a ring pin unless it is being replaced.

Scheme 287

Scheme 287: INSPECTION [03/2012 - ]

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INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Turn the roller by hand to check that it turns smoothly. If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.
INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the valve lash adjuster assembly free of dirt and foreign objects. 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. SST: 09276-75010 TEXT IN ILLUSTRATION *1 Tapered Path *2 Plunger *3 Low Pressure Chamber *4 Check Ball *5 High Pressure Chamber *a CORRECT *b INCORRECT 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 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 air, remove SST. Then try to quickly and firmly press the plunger with your fingers. OK Plunger can be pressed 3 times. If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.
INSPECT CAMSHAFT Inspect the camshaft runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout 0.04 mm (0.00157 in.) If the runout is more 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 Specified Condition Intake 44.318 to 44.418 mm (1.7448 to 1.7487 in.) Exhaust 44.341 to 44.441 mm (1.7457 to 1.7496 in.) Minimum Cam Lobe Height Item Specified Condition Intake 44.168 mm (1.7389 in.) Exhaust 44.191 mm (1.7398 in.) 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 (1.0220 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance.
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Install the camshaft timing gear assembly See step 1 . Inspect the camshaft timing gear assembly See step 26 . NOTE: Do not remove the other 3 bolts. If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear. Remove the flange bolt and camshaft timing gear assembly. TEXT IN ILLUSTRATION *1 Flange Bolt *2 Straight Pin *a Do Not Remove
INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Install the camshaft timing exhaust gear assembly See step 2 . Inspect the camshaft timing exhaust gear assembly See step 27 . NOTE: Be sure not to remove the other 4 bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear. Remove the flange bolt and camshaft timing exhaust gear assembly. TEXT IN ILLUSTRATION *1 Flange Bolt *2 Straight Pin *a Do Not Remove
INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end. Standard length 141.3 to 142.7 mm (5.56 to 5.62 in.) Maximum length 143.7 mm (5.66 in.) TEXT IN ILLUSTRATION *1 Measurement Length If the length is more than the maximum, replace the cylinder head set bolt. Using a vernier caliper, measure the diameter of the elongated thread at the narrowest visible area. Standard diameter 10.80 to 11.00 mm (0.425 to 0.433 in.) Minimum diameter 10.70 mm (0.421 in.) If the diameter is less than the minimum, replace the cylinder head set bolt. HINT: If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.
INSPECT CHAIN SUB-ASSEMBLY Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain using a vernier caliper. Maximum chain elongation 136.9 mm (5.39 in.) TEXT IN ILLUSTRATION *1 Measurement Area HINT: Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the chain.
INSPECT NO. 2 CHAIN SUB-ASSEMBLY Using a spring scale, pull the No. 2 chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain using a vernier caliper. Maximum chain elongation 137.6 mm (5.42 in.) HINT: Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the No. 2 chain.
INSPECT CRANKSHAFT TIMING SPROCKET Place the chain around the crankshaft timing sprocket. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain) 61.4 mm (2.42 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
INSPECT IDLE SPROCKET ASSEMBLY Place the chain around the idle sprocket. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain) 61.4 mm (2.42 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
INSPECT IDLE GEAR SHAFT OIL CLEARANCE Using a micrometer, measure the idle gear shaft diameter. Standard idle gear shaft diameter 22.987 to 23.000 mm (0.905 to 0.906 in.) Using a caliper gauge, measure the inside diameter of the idle gear. Standard idle gear inside diameter 23.020 to 23.030 mm (0.906 to 0.907 in.) Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement. Standard oil clearance 0.020 to 0.043 mm (0.000787 to 0.00169 in.) Maximum oil clearance 0.093 mm (0.00366 in.) If the thrust oil clearance is more than the maximum, replace the idle gear shaft and idle gear.
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 *a Moves Smoothly If necessary, replace the No. 1 chain tensioner.
INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. TEXT IN ILLUSTRATION *1 Depth *a Moves Smoothly Measure the depth of wear of the chain tensioner. Maximum depth 0.9 mm (0.0354 in.) If the depth is more than the maximum, replace the No. 2 chain tensioner.
INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. TEXT IN ILLUSTRATION *1 Depth *a Moves Smoothly Measure the depth of wear of the chain tensioner. Maximum depth 0.9 mm (0.0354 in.) If the depth is more than the maximum, replace the No. 3 chain tensioner.
INSPECT CHAIN TENSIONER SLIPPER Measure the depth of wear of the chain tensioner slipper. Maximum depth 1.0 mm (0.0394 in.) TEXT IN ILLUSTRATION *1 Depth If the depth is more than the maximum, replace the chain tensioner slipper.
INSPECT NO. 1 CHAIN VIBRATION DAMPER Measure the depth of wear of the No. 1 chain vibration damper. Maximum depth 1.0 mm (0.0394 in.) TEXT IN ILLUSTRATION *1 Depth If the depth is more than the maximum, replace the No. 1 chain vibration damper.
INSPECT NO. 2 CHAIN VIBRATION DAMPER Measure the depth of wear of the No. 2 chain vibration damper. Maximum depth 1.0 mm (0.0394 in.) TEXT IN ILLUSTRATION *1 Depth If the depth is more than the maximum, replace the No. 2 chain vibration damper.
INSPECT CAMSHAFT OIL CLEARANCE for Bank 1: Clean the camshaft bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each camshaft journal. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps See step 23 . NOTE: Do not turn the camshaft. Remove the camshaft bearing caps See step 8 . Measure the Plastigage at its widest point. Standard Oil Clearance Item Specified Condition No. 1 journal 0.032 to 0.071 mm (0.00122 to 0.00280 in.) No. 2, 3, 4 journals 0.025 to 0.062 mm (0.000984 to 0.00240 in.) No. 5 journal 0.015 to 0.052 mm (0.000591 to 0.00205 in.) Maximum Oil Clearance Item Specified Condition No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 No. 2 Journal *4 No. 3 Journal *5 No. 4 Journal *6 No. 5 Journal If the oil clearance is more than the maximum, inspect the inner compression spring. If necessary, replace the camshaft. If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing. for Bank 2: Clean the camshaft bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each camshaft journal. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps See step 18 . NOTE: Do not turn the camshaft. Remove the camshaft bearing caps See step 15 . Measure the Plastigage at its widest point. Standard Oil Clearance Item Specified Condition No. 1 journal 0.032 to 0.071 mm (0.00122 to 0.00280 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00240 in.) Maximum Oil Clearance Item Specified Condition No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 Other Journals If the oil clearance is more than the maximum, inspect the inner compression spring. If necessary, replace the camshaft. If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing.
INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head. Maximum warpage 0.70 mm (0.0276 in.) If the warpage is more than the maximum, replace the exhaust manifold.
INSPECT INTAKE MANIFOLD Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder head and intake air surge tank. Maximum warpage 0.10 mm (0.00394 in.) TEXT IN ILLUSTRATION *a Surge Tank Side *b Cylinder Head Side If the warpage is more than the maximum, replace the intake manifold.

Scheme 305

Scheme 305: REASSEMBLY [03/2012 - ]

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INSTALL RING PIN NOTE: It is not necessary to remove a ring pin unless it is being replaced. Using a plastic-faced hammer, tap in new ring pins to the camshaft housing. Standard protrusion height 2.7 to 3.3 mm (0.106 to 0.130 in.) TEXT IN ILLUSTRATION *1 Protrusion Height - - *a LH *b RH
INSTALL NO. 1 STRAIGHT PIN NOTE: It is not necessary to remove a No. 1 straight pin unless it is being replaced. Using a plastic-faced hammer, tap in new No. 1 straight pins to the camshaft housing. Standard Protrusion Height Item Specified Condition Straight pin A 7.7 to 8.3 mm (0.303 to 0.327 in.) Straight pin B 5.7 to 6.3 mm (0.224 to 0.248 in.) TEXT IN ILLUSTRATION *1 Protrusion Height - - *a LH *b RH
INSTALL REAR CRANKSHAFT OIL SEAL Place the oil seal retainer on wooden blocks. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge. SST: 09223-15030 SST: 09950-70010 09951-07100 NOTE: Keep the lip free of foreign matter. Do not tap on the oil seal at an angle.
INSTALL ENGINE REAR OIL SEAL RETAINER Apply MP grease to the lip of the oil seal. Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) TEXT IN ILLUSTRATION *1 Seal Packing NOTE: Remove any oil from the contact surface. Install the oil seal retainer within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install the oil seal retainer with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
INSTALL WATER OUTLET PIPE SUB-ASSEMBLY Install the water outlet pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL KNOCK SENSOR . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600565-S08558511322014022400000)
INSTALL NO. 5 ENGINE WIRE Install the No. 5 engine wire with the clamp.
INSTALL CYLINDER HEAD GASKET See step 1
INSTALL CYLINDER HEAD SUB-ASSEMBLY See step 2
INSTALL NO. 2 CYLINDER HEAD GASKET See step 3
INSTALL CYLINDER HEAD LH See step 4
INSTALL VALVE STEM CAP See step 11
INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 12
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 13
INSTALL OIL CHECK VALVE Install the oil check valve to the camshaft bearing cap.
INSTALL OIL CONTROL VALVE FILTER LH Install the oil control valve filter LH to the camshaft bearing cap. NOTE: Make sure the oil control valve filter does not protrude past the camshaft installation surface shown in the illustration. TEXT IN ILLUSTRATION *a Camshaft Installation Surface
INSTALL OIL CONTROL VALVE FILTER RH HINT: Use the same procedure described for the LH side.
INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY See step 16
INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY See step 17
INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 18
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 19
INSTALL CAMSHAFT See step 20
INSTALL NO. 2 CAMSHAFT See step 21
INSTALL FUEL PUMP LIFTER HOUSING See step 22
INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 23
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 24
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY See step 27
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 28
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY See step 25
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 26
INSTALL NO. 1 CHAIN VIBRATION DAMPER Install the No. 1 chain vibration damper with the 2 bolts. Torque: 23 N*m (229 kgf*cm, 17 ft.*lbf)
INSTALL NO. 2 CHAIN VIBRATION DAMPER Install the 2 No. 2 chain vibration dampers.
INSTALL CRANKSHAFT TIMING SPROCKET Install the 2 timing gear set keys and timing sprocket to the crankshaft.
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 No. 1 Idle Gear Shaft *2 Idle Sprocket *3 No. 2 Idle Gear Shaft *4 Knock Pin Apply Engine Oil Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block. NOTE: Make sure that the idle gear is facing the correct direction. HINT: Check that no foreign objects are on the idle gear shafts No. 1 and No. 2. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) HINT: After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
INSTALL CHAIN SUB-ASSEMBLY Check that the camshaft timing gear position on the RH bank and the timing marks on the LH bank and crankshaft are positioned as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark *2 Center Line *a Approximately 10° - - Align the mark plates and timing marks as shown in the illustration and install the chain. TEXT IN ILLUSTRATION *1 Mark Plate (Pink) *2 Timing Mark HINT: The camshaft mark plates are pink. Rest the chain on top of the crankshaft. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks. TEXT IN ILLUSTRATION *1 Chain Plate *a When idle sprocket is reused *b Mark *c Align Turn NOTE: When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks. Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing sprocket. TEXT IN ILLUSTRATION *1 Mark Plate (Yellow) *2 Timing Mark HINT: The crankshaft mark plate is yellow. Temporarily install the pulley set bolt. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression). TEXT IN ILLUSTRATION *1 Timing Mark *a Center Line Turn
INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper.
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 pin of 1.27 mm (0.0500 in.) diameter into the hole of the stopper plate. Install the No. 1 chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the lock pin of the chain tensioner.
INSPECT VALVE TIMING Check the camshaft timing marks. NOTE: Check each timing mark from a viewpoint directly inline 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 *1 Timing Mark - - *a Viewpoint - - HINT: For the intake 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 timing chain. Remove the pulley set bolt.
INSTALL ENGINE WATER PUMP ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600564-S30482544442014022400000)
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600562-S11007923832014022400000)
INSTALL TIMING CHAIN CASE OIL SEAL See step 1
INSTALL OIL STRAINER SUB-ASSEMBLY When replacing a stud bolt, install it by using an E6 "TORX" socket wrench, as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) TEXT IN ILLUSTRATION *a Timing Chain Cover *b Cylinder Block Lower Install the baffle plate with the 8 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Temporarily install the 8 bolts. Tighten the 2 bolts A shown in the illustration before tightening the other bolts. Install a new gasket and the oil strainer with the 3 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install 2 new O-rings.
INSTALL OIL PAN SUB-ASSEMBLY When replacing a stud bolt, install it by using an E6 "TORX" socket wrench. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.156 in.) TEXT IN ILLUSTRATION *1 Seal Packing NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install the oil pan with the 16 bolts and 2 nuts. for bolt A, B and nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt C Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Standard Bolt Item Length Bolt A 25 mm (0.984 in.) Bolt B 45 mm (1.77 in.) Bolt C 16 mm (0.630 in.) TEXT IN ILLUSTRATION Bolt A Bolt B Bolt C Nut
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 4.0 to 6.0 mm (0.156 to 0.236 in.) TEXT IN ILLUSTRATION *1 Seal Packing NOTE: Remove any oil from the contact surface. Install the No. 2 oil pan within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install the oil pan with the 15 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) TEXT IN ILLUSTRATION Bolt Nut
INSTALL OIL PAN DRAIN PLUG Install a new gasket and the oil pan drain plug. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
INSTALL SPARK PLUG TUBE GASKET Using a cutter, cut off the sealing part of the removed plug tube gasket. TEXT IN ILLUSTRATION *a Before cutting off *b After cutting off Area to be cut off Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way. TEXT IN ILLUSTRATION *1 Plug tube gasket without sealing part *2 New plug tube gasket *3 Claw NOTE: Keep the lip free of foreign matter. Do not tap on the oil seal at an angle. HINT: If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers. Return the claws of the ventilation baffle plate to their original positions.
POUR ENGINE OIL See step 15
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY See step 16
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 17
INSTALL FUEL PUMP SPACER GASKET Install a new fuel pump spacer gasket to the cylinder head cover.
INSTALL REAR WATER BY-PASS JOINT Install 2 new gaskets and a new O-ring. HINT: Apply water to the O-ring. Install the water by-pass joint with the 2 bolts and 4 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful that the O-ring does not get caught between the parts.
INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY Install a new gasket and the water inlet with thermostat with the 3 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL WATER INLET SUB-ASSEMBLY Install the 3 water by-pass hoses. Install 2 new O-rings. HINT: Apply a small amount of water to the O-ring (A) shown in the illustration before installing it. Install the water inlet with the 4 bolts and nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful that the O-ring does not get caught between the parts. Install the 3 water by-pass hoses.
INSTALL CRANKSHAFT PULLEY See step 3
INSTALL OIL FILTER ELEMENT . Refer to «REPLACEMENT [03/2012 - ] - Step 4»(ref-600562-S02225467592014022400000)
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Apply adhesive around the drain cocks. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the water drain cocks as shown in the illustration. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) TEXT IN ILLUSTRATION *a RH Side: *b LH Side: NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque. Install the water drain cock plugs to the water drain cocks. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
INSTALL CRANKSHAFT POSITION SENSOR . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600565-S36814740362014022400000)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600565-S38725897392014022400000)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600565-S38725897392014022400000)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600565-S38725897392014022400000)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600565-S38725897392014022400000)
INSTALL VVT SENSOR (for Exhaust Side of Bank 2) . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600565-S37774245832014022400000)
INSTALL VVT SENSOR (for Intake Side of Bank 2) . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600565-S37774245832014022400000)
INSTALL VVT SENSOR (for Exhaust Side of Bank 1) . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600565-S37774245832014022400000)
INSTALL VVT SENSOR (for Intake Side of Bank 1) . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600565-S37774245832014022400000)
INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY See step 21
INSTALL NO. 2 SEPARATOR CASE Apply a light coat of engine oil to a new O-ring and install it to the No. 2 separator case. TEXT IN ILLUSTRATION *1 New O-Ring Install the No. 2 separator case with the bolt and 2 nuts as shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL WATER BY-PASS HOSE ASSEMBLY
INSTALL PCV VALVE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600566-S25553525242014022400000)
INSTALL SPARK PLUG . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600565-S23506956452014022400000)
INSTALL RADIATOR CAP SUB-ASSEMBLY
INSTALL OIL FILLER CAP SUB-ASSEMBLY Install the gasket. Install the oil filler cap.

Scheme 330

Scheme 330: INSTALLATION [03/2012 - ]

INSTALL ENGINE COVER . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600566-S25553525242014022400000)
INSTALL ENGINE COOLANT TEMPERATURE SENSOR . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600565-S19979735562014022400000)
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600562-S10599824592014022400000)
INSTALL ENGINE OIL LEVEL SENSOR . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600562-S13794605352014022400000)
INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600565-S23506956452014022400000)
INSTALL V-BANK COVER BOLT Install the V-bank cover bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL V-BANK COVER BRACKET SUB-ASSEMBLY Install the V-bank cover bracket with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL FUEL INJECTOR SEAL . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600584-S32920619542014022400000)
INSTALL FUEL INJECTOR ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600584-S32920619542014022400000)
INSTALL FUEL DELIVERY PIPE RH . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600584-S32920619542014022400000)
INSTALL FUEL DELIVERY PIPE LH . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600584-S32920619542014022400000)
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 5»(ref-600584-S32920619542014022400000)
SET FUEL PUMP ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600584-S19408205172014022400000)
TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600584-S19408205172014022400000)
INSTALL FUEL PUMP ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600584-S19408205172014022400000)
INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600584-S19408205172014022400000)
INSTALL NO. 3 WATER BY-PASS PIPE Connect the 2 hoses, and install the bolt and No. 3 water by-pass pipe. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL INTAKE MANIFOLD . Refer to «INSTALLATION [03/2012 - ] - Step 4»(ref-600587-S07679077572014022400000)
INSTALL NO. 2 SURGE TANK STAY Install the No. 2 surge tank stay with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 6»(ref-600587-S07679077572014022400000)
INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600565-S34117039542014022400000)
INSTALL INJECTOR DRIVER . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-600584-S14428337192014022400000)
INSTALL ENGINE WIRE
INSTALL WATER PUMP PULLEY . Refer to «INSTALLATION [03/2012 - ] - Step 3»(ref-600564-S30482544442014022400000)
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Temporarily install the V-ribbed belt tensioner with the 5 bolts. Standard Bolt Item Length A 70 mm (2.76 in.) B 35 mm (1.38 in.) Install the V-ribbed belt tensioner 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)
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH Install the front No. 1 engine mounting bracket LH with the 4 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Connect the 2 clamps.
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH Install the front No. 1 engine mounting bracket RH with the 4 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
INSTALL NO. 1 ENGINE COVER . Refer to «INSTALLATION [03/2012 - ] - Step 2»(ref-600584-S14428337192014022400000)
INSTALL NO. 2 ENGINE COVER Install the No. 2 engine cover with the 3 clips. Connect the clamp.

Scheme 331

Scheme 331: ILLUSTRATION

Scheme 332

Scheme 332: DISASSEMBLY [03/2012 - ]

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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.
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.
REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the valve stem oil seals.
REMOVE VALVE SPRING SEAT Using compressed air and a magnet hand, remove the valve spring seats by blowing air onto them.
REMOVE NO. 1 STRAIGHT SCREW PLUG NOTE: If water leaks from a straight screw plug or the plug is corroded, replace it. Using a 10 mm hexagon wrench, remove the 4 No. 1 straight screw plugs and 4 gaskets. TEXT IN ILLUSTRATION *A Bank 1 *B Bank 2
REMOVE NO. 2 STRAIGHT SCREW PLUG NOTE: If water leaks from a straight screw plug or the plug is corroded, replace it. Using a 14 mm hexagon wrench, remove the 2 No. 2 straight screw plugs and 2 gaskets. TEXT IN ILLUSTRATION *A Bank 1 *B Bank 2
REMOVE UNION NOTE: It is not necessary to remove the union unless it is being replaced.
REMOVE STUD BOLT NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
REMOVE NO. 1 STRAIGHT PLUG Remove the 2 No. 1 straight plugs. TEXT IN ILLUSTRATION *A Bank 1 *B Bank 2

Scheme 339

Scheme 339: INSPECTION [03/2012 - ]

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INSPECT CYLINDER HEAD SUB-ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block sub-assembly and manifolds. TEXT IN ILLUSTRATION *a Cylinder Block Side *b Exhaust Side *c Intake Side - - Standard Warpage Item Specified Condition Cylinder Block Side 0 to 0.05 mm (0 to 0.00197 in.) Exhaust Side 0 to 0.08 mm (0 to 0.00315 in.) Intake Side 0 to 0.08 mm (0 to 0.00315 in.) Maximum warpage 0.10 mm (0.00394 in.) If the warpage is more than the maximum, replace the cylinder head sub-assembly.
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.
INSPECT INTAKE VALVE Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter 5.470 to 5.485 mm (0.215 to 0.216 in.) If the valve stem is not as specified, check the oil clearance. Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.5 mm (0.0197 in.) TEXT IN ILLUSTRATION *1 Margin Thickness If the margin thickness is less than the minimum, replace the intake valve. Using a vernier caliper, measure the valve overall length. Standard overall length 105.85 mm (4.17 in.) Minimum overall length 105.35 mm (4.15 in.) If the overall length is less than the minimum, replace the intake valve.
INSPECT EXHAUST VALVE Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter 5.465 to 5.480 mm (0.215 to 0.216 in.) If the valve stem is not as specified, check the oil clearance. Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.5 mm (0.0197 in.) TEXT IN ILLUSTRATION *1 Margin Thickness If the margin thickness is less than the minimum, replace the exhaust valve. Using a vernier caliper, measure the valve overall length. Standard overall length 110.40 mm (4.35 in.) Minimum overall length 109.90 mm (4.33 in.) If the overall length is less than the minimum, replace the exhaust valve.
INSPECT INTAKE VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. Check the valve face and valve spring seat by using the following procedure: TEXT IN ILLUSTRATION *1 Width If Prussian blue appears around the entire valve face, the valve face is circular. If not, replace the valve. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve spring seat. Check that the valve spring seat contacts the middle of the valve face with the width between 1.1 to 1.5 mm (0.0433 to 0.0591 in.).
INSPECT EXHAUST VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve spring seat. Check the valve face and valve spring seat by using the following procedure: TEXT IN ILLUSTRATION *1 Width If Prussian blue appears around the entire valve face, the valve face is circular. If not, replace the valve. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve spring seat. Check that the valve spring seat contacts the middle of the valve face with the width between 1.3 to 1.7 mm (0.0512 to 0.0669 in.).
INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the inner compression spring. Standard free length 48.05 mm (1.89 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. Maximum deviation 1.0 mm (0.0394 in.) Maximum angle (reference) 2° TEXT IN ILLUSTRATION *1 Deviation If the deviation is more than the maximum, replace the inner compression spring.
INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. Standard bush inside diameter 5.510 to 5.530 mm (0.217 to 0.218 in.) Subtract the valve stem diameter measurement from the valve guide bush inside diameter measurement. Standard Oil Clearance Item Specified Condition Intake 0.030 to 0.060 mm (0.00118 to 0.00236 in.) Exhaust 0.025 to 0.065 mm (0.000984 to 0.00256 in.) Maximum Oil Clearance Item Specified Condition Intake 0.08 mm (0.00315 in.) Exhaust 0.01 mm (0.000394 in.) If the clearance is more than the maximum, replace the valve and valve guide bush.
INSPECT CAMSHAFT THRUST CLEARANCE Inspect the bank 1 camshaft thrust clearance. Install the bank 1 camshafts See step 20 . 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 more than the maximum, replace the camshaft housing sub-assembly. If the thrust surface is damaged, replace the camshaft. Inspect the bank 2 camshaft thrust clearance. Install the bank 2 camshafts See step 16 . 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 more than the maximum, replace the camshaft housing sub-assembly. If the thrust surface is damaged, replace the camshaft.

Scheme 347

Scheme 347: REPLACEMENT [03/2012 - ]

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REPLACE INTAKE VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the intake valve guide bushes. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head. Standard 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 Specified Condition STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) If the bush bore diameter of the cylinder head is more than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is more than 10.356 mm (0.4077 in.), replace the cylinder head. Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST, tap in new intake valve guide bushes to the specified protrusion height. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Standard protrusion height 9.10 to 9.90 mm (0.358 to 0.390 in.) TEXT IN ILLUSTRATION *1 Protrusion Height Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance. Standard oil clearance 0.030 to 0.060 mm (0.00118 to 0.00236 in.)
REPLACE EXHAUST VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the exhaust valve guide bushes. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head. Standard 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 Specified Condition STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) If the bush bore diameter of the cylinder head is more than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is more than 10.356 mm (0.4077 in.), replace the cylinder head. Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST, tap in new exhaust valve guide bushes to the specified protrusion height. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Standard protrusion height 9.10 to 9.90 mm (0.358 to 0.390 in.) TEXT IN ILLUSTRATION *1 Protrusion Height Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance. Standard oil clearance 0.025 to 0.065 mm (0.000984 to 0.00256 in.)
REPLACE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Using a plastic-faced hammer, tap in new ring pins to the specified protrusion height. Standard protrusion height 2.5 to 3.8 mm (0.0984 to 0.150 in.) TEXT IN ILLUSTRATION *A Bank 1 *B Bank 2 *1 Protrusion Height
REPLACE STRAIGHT PIN NOTE: It is not necessary to remove the straight pin unless it is being replaced. Using a plastic-faced hammer, tap in new straight pins as shown in the illustration. TEXT IN ILLUSTRATION *A Bank 1 *B Bank 2 *1 Protrusion Height - - Standard protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.)

Scheme 355

Scheme 355: REASSEMBLY [03/2012 - ]

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INSTALL SPARK PLUG TUBE NOTE: When using a new cylinder head, the spark plug tubes must be replaced. Apply adhesive onto the shaded area of a new spark plug tube. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Standard application width 1.0 to 3.0 mm (0.0394 to 0.118 in.) TEXT IN ILLUSTRATION *1 Standard Application Width *a 9.0 to 15.0 mm (0.354 to 0.591 in.) NOTE: Install the spark plug tube within 3 minutes after applying adhesive. Be careful not to deform the spark plug tube. Be careful not to expose the seal to coolant for at least 1 hour after installing it. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height. Standard protrusion height 72.9 mm (2.87 in.) TEXT IN ILLUSTRATION *1 Standard Protrusion Height *2 Cylinder Head Casting Surface NOTE: To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.
INSTALL NO. 1 STRAIGHT PLUG Apply adhesive to the No. 1 straight plug of the cylinder head. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the 2 No. 1 straight plugs to the cylinder head. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
INSTALL NO. 1 STRAIGHT SCREW PLUG Apply adhesive to the No. 1 straight screw plug of the cylinder head. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
INSTALL NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
INSTALL UNION Apply adhesive to the union of the cylinder head. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Using a union nut wrench (12 mm), install the union to the cylinder head as shown in the illustration. TEXT IN ILLUSTRATION *A Bank 1 *B Bank 2 Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf)
INSTALL STUD BOLT NOTE: If the stud bolt is deformed or the threads are damaged, replace it. Using E6 and E8 "TORX" socket wrenches, install the stud bolts. TEXT IN ILLUSTRATION *a Rear Side LH *b Intake Side RH *c Rear Side RH *d Exhaust Side RH *e Exhaust Side LH *f Intake Side LH for stud bolt A, B Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for stud bolt C Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
INSTALL VALVE SPRING SEAT Install the valve spring seats to the cylinder head.
INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to new valve stem oil seals. TEXT IN ILLUSTRATION *1 Gray *2 Black *a Intake Side *b Exhaust Side NOTE: Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal to the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later. HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. Using SST, push in the oil seals. SST: 09201-41020 TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
INSTALL EXHAUST VALVE Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration. TEXT IN ILLUSTRATION *a 40 mm (1.57 in.) or more Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to their original locations. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
INSTALL INTAKE VALVE Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. TEXT IN ILLUSTRATION *a 40 mm (1.57 in.) or more Install the intake valve, inner compression spring and valve spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to their original locations. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.

Scheme 363

Scheme 363: REPAIR [03/2012 - ]

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REPAIR INTAKE VALVE SEATS NOTE: Repair the intake valve seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 60° cutters, correct the valve seat so that the intake valve contacts the entire circumference of the seat. The contact should be in the center of the intake valve seat, and the intake valve seat width should be maintained within the specified range around the entire circumference of the intake valve seat. Standard width 1.1 to 1.5 mm (0.0433 to 0.0591 in.) TEXT IN ILLUSTRATION *1 Standard Width Hand-lap the intake valve and intake valve seat with an abrasive compound. Check the intake valve seating position.
REPAIR EXHAUST VALVE SEATS NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 75° cutters, correct the exhaust valve seat so that the exhaust valve contacts the entire circumference of the seat. The contact should be in the center of the exhaust valve seat, and the exhaust valve seat width should be maintained within the specified range around the entire circumference of the exhaust valve seat. Standard width 1.3 to 1.7 mm (0.0512 to 0.0669 in.) TEXT IN ILLUSTRATION *1 Standard Width Hand-lap the exhaust valve and exhaust valve seat with an abrasive compound. Check the exhaust valve seating position.

Scheme 367

Scheme 367: ILLUSTRATION

Scheme 368

Scheme 368: DISASSEMBLY [03/2012 - ]

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INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance 0.15 to 0.40 mm (0.00591 to 0.0157 in.) Maximum thrust clearance 0.50 mm (0.0197 in.) If the thrust clearance is more than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.
INSPECT CONNECTING ROD OIL CLEARANCE Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned. HINT: The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for correct reassembly. Remove the 2 connecting rod cap bolts. TEXT IN ILLUSTRATION Engine Front Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. TEXT IN ILLUSTRATION *1 Plastigage Check that the front mark of the connecting rod cap is facing forward. TEXT IN ILLUSTRATION *1 Front Mark Engine Front Install the connecting rod cap See step 9 . NOTE: Do not turn the crankshaft. Remove the 2 bolts and connecting rod cap. NOTE: Completely remove the Plastigage after the measurement. Measure the Plastigage at its widest point. Standard oil clearance 0.032 to 0.052 mm (0.00126 to 0.00205 in.) Maximum oil clearance 0.070 mm (0.00276 in.) TEXT IN ILLUSTRATION *1 Plastigage *2 1, 2, 3 or 4 Mark If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing standard thickness is indicated by a number (1, 2, 3 or 4) marked on its surface. Standard Connecting Rod Diameter Mark Specified Condition 1 56.000 to 56.006 mm (2.20472 to 2.20496 in.) 2 56.006 to 56.012 mm (2.20496 to 2.20519 in.) 3 56.012 to 56.018 mm (2.20519 to 2.20543 in.) 4 56.018 to 56.024 mm (2.20543 to 2.20566 in.) Standard Connecting Rod Bearing Center Wall Thickness Mark Specified Condition 1 1.481 to 1.484 mm (0.05831 to 0.05843 in.) 2 1.484 to 1.487 mm (0.05843 to 0.05854 in.) 3 1.487 to 1.490 mm (0.05854 to 0.05866 in.) 4 1.490 to 1.493 mm (0.05866 to 0.05878 in.) Standard crankshaft pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. TEXT IN ILLUSTRATION *1 Ridge Reamer Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
REMOVE CONNECTING ROD BEARING Remove the connecting rod bearings from the connecting rods and connecting rod caps. HINT: Arrange the removed parts in the correct order.
REMOVE CRANKSHAFT Uniformly loosen and remove the 8 crankshaft bearing cap bolts and 8 seal washers in several steps and in the sequence shown in the illustration. Uniformly loosen the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration. Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings. TEXT IN ILLUSTRATION *1 Protective Tape *2 Cylinder Block *3 Bearing Cap *4 Joint Surface NOTE: Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed. Be careful not to damage the joint surfaces of the cylinder block and the crankshaft bearing cap. Remove the crankshaft.
REMOVE CRANKSHAFT BEARING Remove the upper crankshaft bearings and lower crankshaft bearings. HINT: Arrange the removed parts in the correct order.
REMOVE CRANKSHAFT THRUST WASHER SET Remove the upper crankshaft thrust washers from the cylinder block sub-assembly.
REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. TEXT IN ILLUSTRATION *1 Piston Ring Expander Remove the oil ring expander and 2 side rails by hand. HINT: Arrange the removed parts in the correct order.
REMOVE PISTON SUB-ASSEMBLY WITH PIN Disconnect the connecting rod from the piston. Using a screwdriver, pry off the piston pin hole snap rings from the piston. Gradually heat the piston to approximately 80°C (176°F). Using a brass bar and a plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly. HINT: The piston and piston pin are a matched set. Arrange the pistons, piston pins, connecting rods and connecting rod bearings in the correct order. Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush.
REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 3 bolts and No. 1 oil nozzle sub-assemblies. Check the 3 No. 1 oil nozzles for damage or clogging. If necessary, replace the No. 1 oil nozzle sub-assembly.
REMOVE CONNECTING ROD SMALL END BUSH Using SST and a press, press out the bush. SST: 09222-30010

Scheme 384

Scheme 384: INSPECTION [03/2012 - ]

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INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket. Standard warpage 0 to 0.05 mm (0 to 0.00197 in.) Maximum warpage 0.07 mm (0.00276 in.) If the warpage is more than the maximum, replace the cylinder block sub-assembly.
INSPECT CYLINDER BORE Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 6 cylinders. If necessary, replace the cylinder block sub-assembly. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard Diameter 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum Diameter 94.200 mm (3.7087 in.) TEXT IN ILLUSTRATION *1 Thrust Direction *2 Axial Direction *3 Center Engine Front If the average diameter of 4 positions is more than the maximum, replace the cylinder block sub-assembly.
INSPECT PISTON SUB-ASSEMBLY WITH PIN Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified. Distance 8.7 mm (0.3425 in.) Standard diameter 93.956 to 93.986 mm (3.6990 to 3.7002 in.) Minimum diameter 93.826 mm (3.6939 in.) If the piston diameter is less than the minimum, replace the piston sub-assembly with pin.
INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust directions. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance 0.014 to 0.056 mm (0.00055 to 0.00220 in.) Maximum oil clearance 0.090 mm (0.00354 in.) If the oil clearance is more than the maximum, replace all the pistons. If necessary, replace the cylinder block sub-assembly.
INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Standard Ring Groove Clearance Item Specified Condition No. 1 0.020 to 0.070 mm (0.000787 to 0.00276 in.) No. 2 0.020 to 0.060 mm (0.000787 to 0.00236 in.) Oil 0.020 to 0.070 mm (0.000787 to 0.00276 in.) If the clearance is not as specified, replace the piston sub-assembly with pin.
INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston pin hole. Standard Piston Pin Hole Inside Diameter Mark Specified Condition A 21.998 to 22.001 mm (0.8661 to 0.8662 in.) B 22.001 to 22.004 mm (0.8662 to 0.8663 in.) C 22.004 to 22.007 mm (0.8663 to 0.8664 in.) Using a micrometer, measure the piston pin diameter. Standard Piston Pin Diameter Mark Specified Condition A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.000 to 22.003 mm (0.8661 to 0.8663 in.) C 22.003 to 22.006 mm (0.8663 to 0.8664 in.) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance -0.002 to 0.004 mm (-0.0000787 to 0.000158 in.) Maximum oil clearance 0.015 mm (0.000591 in.) If the oil clearance is more than the maximum, replace the piston sub-assembly with pin. Using a caliper gauge, measure the inside diameter of the connecting rod small end bush. Standard Bushing Inside Diameter Mark Specified Condition A 22.005 to 22.008 mm (0.86634 to 0.86645 in.) B 22.008 to 22.011 mm (0.86645 to 0.86657 in.) C 22.011 to 22.014 mm (0.86657 to 0.86669 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance 0.030 mm (0.00118 in.) TEXT IN ILLUSTRATION *1 Front Mark *2 Piston Pin Hole Inside Diameter Mark *3 Connecting Rod Bushing Inside Diameter Mark *a Piston RH *b Piston LH If the oil clearance is more than the maximum, replace the connecting rod small end bush. If necessary, replace the connecting rod sub-assembly and piston sub-assembly with pin.
INSPECT CRANKSHAFT THRUST CLEARANCE Install the main bearing cap. Refer to «REASSEMBLY [03/2012 - ]»(ref-600560-S10573144382014022400000) . Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance 0.04 to 0.24 mm (0.00157 to 0.00945 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring slightly beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block sub-assembly. Using a feeler gauge, measure the end gap. Standard End Gap Item Specified Condition No. 1 0.23 to 0.33 mm (0.00906 to 0.0130 in.) No. 2 0.35 to 0.45 mm (0.0138 to 0.0177 in.) Oil 0.10 to 0.40 mm (0.00394 to 0.0157 in.) Maximum End Gap Item Specified Condition No. 1 0.40 mm (0.0157 in.) No. 2 0.50 mm (0.0197 in.) Oil 0.45 mm (0.0177 in.) If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum even with a new piston ring, replace the cylinder block sub-assembly.
INSPECT CONNECTING ROD SUB-ASSEMBLY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for out-of-alignment. Maximum out-of-alignment 0.05 mm (0.00197 in.) per 100 mm (3.94 in.) If the out-of-alignment is more than the maximum, replace the connecting rod sub-assembly. Check for twist. Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is more than the maximum, replace the connecting rod sub-assembly.
INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the diameter of the bolt at several points within the area shown in the illustration. Standard diameter 8.5 to 8.6 mm (0.335 to 0.339 in.) Minimum diameter 8.3 mm (0.327 in.) TEXT IN ILLUSTRATION *1 Measurement Area If the diameter is less than the minimum, replace the bolt. HINT: Diameter measurements should be done at several points. If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage. If there is any thread deformation, replace the connecting rod bolt with a new one.
INSPECT CRANKSHAFT Inspect runout. Clean the crank journal. Place the crankshaft on V-blocks. Using a dial indicator, measure the runout at the center journal. Maximum runout 0.06 mm (0.00236 in.) If the runout is more than the maximum, replace the crankshaft. Inspect the main journals. Using a micrometer, measure the diameter of each main journal. Standard journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.02 mm (0.000787 in.) If the taper and out-of-round is more than the maximum, replace the crankshaft. Inspect the crank pins. Using a micrometer, measure the diameter of each crank pin. Standard crank pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.02 mm (0.000787 in.) If the taper and out-of-round is more than the maximum, replace the crankshaft.
INSPECT CRANKSHAFT OIL CLEARANCE Check the crank journal and crankshaft bearing for pitting and scratches. Install the crankshaft bearing See step 5 . Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. TEXT IN ILLUSTRATION *1 Plastigage Examine the front marks and numbers to install the crankshaft bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Install the main bearing caps See step 7 . NOTE: Do not turn the crankshaft. Remove the main bearing caps See step 5 . Measure the Plastigage at its widest point. Standard Oil Clearance Item Specified Condition No. 1, No. 4 Journal 0.026 to 0.047 mm (0.00102 to 0.00185 in.) No. 2, No. 3 Journal 0.032 to 0.053 mm (0.00126 to 0.00209 in.) Maximum Oil Clearance Item Specified Condition No. 1, No. 4 Journal 0.050 mm (0.00197 in.) No. 2, No. 3 Journal 0.060 mm (0.00236 in.) TEXT IN ILLUSTRATION *1 Plastigage If the oil clearance is more than the maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: Completely remove the Plastigage after the measurement. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly. JOURNAL BEARINGS Cylinder block + Crankshaft 0 - 5 6 - 11 12 - 17 18 - 23 24 - 28 Bearing to be used "1" "2" "3" "4" "5" TEXT IN ILLUSTRATION *1 No. 1 *2 No. 2 *3 No. 3 *4 No. 4 *5 Number Mark *6 No. 1 and No. 4 Journal Bearing *7 No. 2 and No. 3 Journal Bearing HINT: EXAMPLE: Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3") Standard Crankshaft Main Journal Diameter Mark Specified Condition "00" 60.999 to 61.000 mm (2.40153 to 2.40157 in.) "01" 60.998 to 60.999 mm (2.40149 to 2.40153 in.) "02" 60.997 to 60.998 mm (2.40145 to 2.40149 in.) "03" 60.996 to 60.997 mm (2.40141 to 2.40145 in.) "04" 60.995 to 60.996 mm (2.40137 to 2.40141 in.) "05" 60.994 to 60.995 mm (2.40133 to 2.40137 in.) "06" 60.993 to 60.994 mm (2.40129 to 2.40133 in.) "07" 60.992 to 60.993 mm (2.40126 to 2.40129 in.) "08" 60.991 to 60.992 mm (2.40122 to 2.40126 in.) "09" 60.990 to 60.991 mm (2.40118 to 2.40122 in.) "10" 60.989 to 60.990 mm (2.40114 to 2.40118 in.) "11" 60.988 to 60.989 mm (2.40110 to 2.40114 in.) Standard Upper Bearing Center Wall Thickness (No. 1 and No. 4 journal) Mark Specified Condition "1" 2.500 to 2.503 mm (0.09843 to 0.09854 in.) "2" 2.503 to 2.506 mm (0.09854 to 0.09866 in.) "3" 2.506 to 2.509 mm (0.09866 to 0.09878 in.) "4" 2.509 to 2.512 mm (0.09878 to 0.09890 in.) "5" 2.512 to 2.515 mm (0.09890 to 0.09902 in.) Standard Lower Bearing Center Wall Thickness (No. 1 and No. 4 journal) Mark Specified Condition "1" 2.478 to 2.481 mm (0.09756 to 0.09768 in.) "2" 2.481 to 2.484 mm (0.09768 to 0.09780 in.) "3" 2.484 to 2.487 mm (0.09780 to 0.09791 in.) "4" 2.487 to 2.490 mm (0.09791 to 0.09803 in.) "5" 2.490 to 2.493 mm (0.09803 to 0.09815 in.) Standard Upper Bearing Center Wall Thickness (No. 2 and No. 3 journal) Mark Specified Condition "1" 2.475 to 2.478 mm (0.09744 to 0.09756 in.) "2" 2.478 to 2.481 mm (0.09756 to 0.09768 in.) "3" 2.481 to 2.484 mm (0.09768 to 0.09780 in.) "4" 2.484 to 2.487 mm (0.09780 to 0.09791 in.) "5" 2.487 to 2.490 mm (0.09791 to 0.09803 in.) Standard Lower Bearing Center Wall Thickness (No. 2 and No. 3 journal) Mark Specified Condition "1" 2.497 to 2.500 mm (0.09831 to 0.09843 in.) "2" 2.500 to 2.503 mm (0.09843 to 0.09854 in.) "3" 2.503 to 2.506 mm (0.09854 to 0.09866 in.) "4" 2.506 to 2.509 mm (0.09866 to 0.09878 in.) "5" 2.509 to 2.512 mm (0.09878 to 0.09890 in.)
INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard diameter 10.8 to 11.0 mm (0.4252 to 0.4331 in.) Minimum diameter 10.7 mm (0.4213 in.) Measurement point (distance from the seat) 47 mm (1.85 in.) TEXT IN ILLUSTRATION *1 Measurement Point HINT: If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. Failure to do so may lead to engine damage. If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.
INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY Push the check valve with a pin to check if it is stuck. HINT: If the check valve is stuck, replace the No. 1 oil nozzle. Push the check valve with a pin to check if it moves smoothly. If the check valve does not move smoothly, clean or replace the No. 1 oil nozzle. While covering A, blow air into B. Check that air does not leak through C. Perform the check again while covering B and blowing air into A. If air leaks, clean or replace the No. 1 oil nozzle. Push the check valve while covering A, and blow air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and blowing air into A. If air does not pass through C, clean or replace the No. 1 oil nozzle.

Scheme 402

Scheme 402: REPLACEMENT [03/2012 - ]

Scheme 403

REPLACE STRAIGHT PIN NOTE: It is not necessary to remove the straight pin unless it is being replaced. Using a plastic-faced hammer, tap in new straight pins to the cylinder block. TEXT IN ILLUSTRATION *1 Protrusion Height - - *a Front Cylinder Block *b Rear Cylinder Block *c Upper Cylinder Block *d Lower Cylinder Block Standard Protrusion Item Specified Condition Pin A 22.5 to 23.5 mm (0.886 to 0.925 in.) Pin B 5.5 to 6.5 mm (0.217 to 0.256 in.) Pin C 10.5 to 11.5 mm (0.413 to 0.453 in.) Pin D 8.5 to 9.5 mm (0.335 to 0.374 in.)
REPLACE STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. Using an E8 "TORX" socket wrench, install the stud bolts. TEXT IN ILLUSTRATION *a Front Side *b Lower Side Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

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Scheme 404: REASSEMBLY [03/2012 - ]

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INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assemblies with the 3 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL CONNECTING ROD SMALL END BUSH Align the oil holes of a new bush and the connecting rod. TEXT IN ILLUSTRATION *1 Oil Hole Using SST and a press, press in the bush. SST: 09222-30010 Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin. Standard oil clearance -0.002 to 0.004 mm (-0.0000787 to 0.000156 in.) Check that the piston pin fits at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
INSTALL PISTON SUB-ASSEMBLY WITH PIN Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole. TEXT IN ILLUSTRATION *1 Cutout Portion HINT: Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Gradually heat the piston to approximately 80°C (176°F). Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. TEXT IN ILLUSTRATION *1 Front Mark *a Piston RH *b Piston LH HINT: The piston and pin are a matched set. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole. TEXT IN ILLUSTRATION *1 Cutout Portion HINT: Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the oil ring rail as shown in the illustration. TEXT IN ILLUSTRATION *1 Oil Ring *2 Oil Ring Expander *3 Front Mark - - *a Piston RH *b Piston LH Engine Front - - Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Ring *2 No. 2 Ring *3 Code Mark HINT: Install the compression ring No. 1 with the code mark (1N) facing upward. Install the compression ring No. 2 with the code mark (2N) facing upward. Position the piston rings so that the ring ends are as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Ring *2 No. 2 Ring *3 Front Mark *a Piston RH *b Piston LH Engine Front NOTE: Do not align the ring ends.
INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the bearings. TEXT IN ILLUSTRATION *1 No. 1 and No. 4 Journal Bearing *2 No. 2 and No. 3 Journal Bearing NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions. Install the upper crankshaft bearing. TEXT IN ILLUSTRATION *1 Upper Bearing *a CORRECT *b INCORRECT Install the upper crankshaft bearings to the cylinder block as shown in the illustration. NOTE: Do not apply engine oil to the bearings and the contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one. Install the lower crankshaft bearing. TEXT IN ILLUSTRATION *1 Vernier Caliper *2 Mark 1, 2, 3, 4 or 5 Install the lower crankshaft bearings to the crankshaft bearing caps. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft bearing edge. Standard Dimension (A - B or B - A) 0.7 mm (0.0276 in.) or less NOTE: Do not apply engine oil to the crankshaft bearings and the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
INSTALL CRANKSHAFT THRUST WASHER SET Apply engine oil to the crankshaft thrust washer. Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward. TEXT IN ILLUSTRATION *1 Oil Grooves
INSTALL CRANKSHAFT Apply engine oil to the upper bearing, and then place the crankshaft on the cylinder block. Confirm the projections and numbers on the main bearing caps and install the crankshaft bearing caps on the cylinder block. TEXT IN ILLUSTRATION *1 Projection *2 Number Mark HINT: A number is marked on each main bearing cap to indicate the installation position. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts. Temporarily install the 8 crankshaft bearing cap bolts to the inside positions. Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal crankshaft bearing cap bolts as a guide. Bolt Length 100 to 102 mm (3.937 to 4.0157 in.) TEXT IN ILLUSTRATION *1 Bolt Length *a Less than 6 mm (0.236 in.) Using a plastic-faced hammer, lightly tap the crankshaft bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts. Install the 8 crankshaft bearing cap bolts to the outside positions. Bolt Length Item Specified Condition Bolt A 100 to 102 mm (3.94 to 4.02 in.) Except bolt A 105.5 to 107.5 mm (4.15 to 4.23 in.) TEXT IN ILLUSTRATION *1 Bolt Length Install the crankshaft bearing cap bolts. HINT: The crankshaft bearing cap bolts are tightened in 2 progressive steps. Step 1 Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it. Step 2 Mark the front of the bearing cap bolts with paint. Tighten the cap bolts another 90°. Check that the painted marks are now at a 90° angle to the front of the engine. Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration. Torque: 26 N*m (262 kgf*cm, 19 ft.*lbf) Bolt Length Item Specified Condition Bolt A 45 mm (1.77 in.) Except bolt A 30 mm (1.18 in.) Check that the crankshaft turns smoothly. Check the crankshaft thrust clearance See step 7 .
INSTALL CONNECTING ROD BEARING Install the connecting rod bearings to the connecting rod and connecting rod cap. Using a vernier caliper, measure the distance between each connecting rod bearing edge and the connecting rod edges, and the connecting rod cap edges respectively. Standard Dimension (A - B or B - A) 0.7 mm (0.0276 in.) or less TEXT IN ILLUSTRATION *1 Vernier Caliper NOTE: Do not apply engine oil to the bearings and the contact surfaces.
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. Position the piston rings so that the ring ends are as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Ring *2 No. 2 Ring *3 Oil Ring *4 Oil Ring Expander *5 Front Mark *a Piston RH *b Piston LH Engine Front NOTE: Do not align the ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward. TEXT IN ILLUSTRATION *1 Front Mark *a Piston RH *b Piston LH Engine Front NOTE: Match the numbered connecting rod cap with the connecting rod. Check that the front mark of the connecting rod cap is facing forward. TEXT IN ILLUSTRATION *1 Front Mark Engine Front Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. Install the connecting rod cap bolts. HINT: The cap bolts are tightened in 2 progressive steps. Step 1 Install and alternately tighten the bolts of each connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) Mark the front side of each connecting rod cap bolt with paint. Step 2 Tighten the cap bolts 90°. Check that the paint marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly.
INSPECT CONNECTING ROD THRUST CLEARANCE See step 1

Engine Mechanical (Service Information): Removal & Installation Lexus GS IV