Engine Mechanical (Service Information): Other Lexus IS III

PROCEDURE

1. INSPECT V-RIBBED BELT Check the V-ribbed belt for wear, cracks or other signs of damage. If any of the following defects is found, replace the V-ribbed belt. The V-ribbed belt is cracked. The V-ribbed belt is worn out to the extent that the cords are exposed. The V-ribbed belt has chunks missing from the ribs. Check that the V-ribbed belt fits properly in the ribbed grooves. *a Correct *b Incorrect HINT: Check with your hand to confirm that the V-ribbed belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly.

1. REMOVE COOL AIR INTAKE DUCT SEAL Refer to «PROCEDURE - Step 1»(ref-665772-S17684216972014102400000)
2. REMOVE INLET NO. 1 AIR CLEANER See step 20
3. REMOVE V-BANK COVER SUB-ASSEMBLY See step 3
4. REMOVE V-RIBBED BELT Release the V-ribbed belt tension by turning the V-ribbed belt tensioner assembly counterclockwise, remove the V-ribbed belt from the V-ribbed belt tensioner assembly. While turning the V-ribbed belt tensioner assembly counterclockwise, align its holes, and then insert a 5 mm bi-hexagon wrench into the holes to secure the V-ribbed belt tensioner assembly. *a 5 mm Bi-hexagon Wrench

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1. INSTALL V-RIBBED BELT Set the V-ribbed belt onto every pulley. *1 Water Pump Assembly *2 Generator Assembly *3 No. 2 Idler Pulley Sub-assembly *4 V-ribbed Belt Tensioner Assembly *5 Crankshaft Pulley *6 Compressor and Magnetic Clutch Assembly NOTE: Put the backside of the V-ribbed belt on the V-ribbed belt tensioner pulley and No. 2 idler pulley sub-assembly. Check that the V-ribbed belt is properly set to each pulley. While turning the V-ribbed belt tensioner assembly counterclockwise, remove the bar. If it is difficult to install the V-ribbed belt, perform the following procedure. Check that the V-ribbed belt fits properly in the ribbed grooves. HINT: Make sure to check by hand that the V-ribbed belt has not slipped out of the grooves on the bottom of the crankshaft pulley.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See step 104
3. INSTALL INLET NO. 1 AIR CLEANER See step 74
4. INSTALL COOL AIR INTAKE DUCT SEAL Refer to «PROCEDURE - Step 3»(ref-665772-S40987981332014102400000)

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*1 AIR CLEANER CASE SUB-ASSEMBLY *2 IGNITION COIL ASSEMBLY *3 INJECTOR DRIVER *4 NO. 1 ENGINE COVER *5 NO. 2 OIL LEVEL DIPSTICK GUIDE *6 SPARK PLUG *7 ENGINE OIL LEVEL DIPSTICK *8 O-RING N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part

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*1 CYLINDER HEAD COVER SUB-ASSEMBLY *2 CYLINDER HEAD COVER SUB-ASSEMBLY LH *3 NO. 1 OIL PIPE *4 NO. 2 OIL PIPE *5 SPARK PLUG TUBE GASKET *6 CYLINDER HEAD COVER SEAL WASHER *7 GASKET *8 CYLINDER HEAD COVER GASKET *9 OIL CONTROL VALVE FILTER RH *10 CYLINDER HEAD COVER GASKET LH *11 OIL CONTROL VALVE FILTER LH *12 OIL PIPE UNION *13 OIL CHECK VALVE BOLT - - N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part * Precoated part

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*1 CAMSHAFT *2 CAMSHAFT TIMING GEAR ASSEMBLY *3 CHAIN SUB-ASSEMBLY *4 NO. 1 CHAIN TENSIONER ASSEMBLY *5 NO. 2 CAMSHAFT *6 TIMING CHAIN COVER PLATE *7 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH *8 NO. 2 CHAIN SUB-ASSEMBLY *9 GASKET *10 NO. 2 CHAIN TENSIONER ASSEMBLY *11 NO. 1 CAMSHAFT BEARING CAP *12 NO. 2 CAMSHAFT BEARING CAP *13 NO. 5 CAMSHAFT BEARING CAP *14 NO. 6 CAMSHAFT BEARING CAP *15 NO. 7 CAMSHAFT BEARING CAP - - N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part

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*1 CAMSHAFT TIMING GEAR ASSEMBLY *2 CHAIN SUB-ASSEMBLY *3 NO. 3 CAMSHAFT SUB-ASSEMBLY *4 NO. 4 CAMSHAFT SUB-ASSEMBLY *5 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH *6 NO. 3 CHAIN TENSIONER ASSEMBLY *7 NO. 2 CHAIN SUB-ASSEMBLY *8 GASKET *9 NO. 3 CAMSHAFT BEARING CAP *10 NO. 4 CAMSHAFT BEARING CAP *11 NO. 7 CAMSHAFT BEARING CAP *12 NO. 8 CAMSHAFT BEARING CAP N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part

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1. REMOVE BATTERY Refer to «REMOVAL [04/2013 - ]»(ref-665742-S15988043842014102400000)
2. REMOVE FUEL PUMP ASSEMBLY Refer to «REMOVAL [04/2013 - ]»(ref-665752-S11712684222014102400000)
3. REMOVE GENERATOR ASSEMBLY Refer to «REMOVAL [04/2013 - ]»(ref-665778-S20855372512014102400000)
4. REMOVE NO. 1 ENGINE COVER Refer to «PROCEDURE - Step 6»(ref-665752-S37873769332014102400000)
5. REMOVE INJECTOR DRIVER Refer to «PROCEDURE - Step 7»(ref-665752-S37873769332014102400000)
6. REMOVE IGNITION COIL ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665751-S23724193242014102400000)
7. REMOVE SPARK PLUG Refer to «PROCEDURE - Step 3»(ref-665751-S23724193242014102400000)
8. REMOVE AIR CLEANER CASE SUB-ASSEMBLY See step 24
9. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Refer to «PROCEDURE - Step 11»(ref-665769-S23384027332014102400000)
10. REMOVE NO. 1 OIL PIPE See step 21
11. REMOVE NO. 2 OIL PIPE See step 22
12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Detach the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover sub-assembly LH. Remove the 12 bolts, cylinder head cover seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket LH. *a Be careful of baffle plate NOTE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH. HINT: Make sure the removed parts are returned to the same places they were removed from. Remove the 3 gaskets from the No. 3, No. 4 and No. 7 camshaft bearing caps. *1 No. 3 Camshaft Bearing Cap *2 No. 4 Camshaft Bearing Cap *3 No. 7 Camshaft Bearing Cap
13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Detach the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover sub-assembly. Remove the 14 bolts, 2 cylinder head cover seal washers, cylinder head cover sub-assembly and cylinder head cover gasket. HINT: Make sure the removed parts are returned to the same places they were removed from. Remove the 3 gaskets from the No. 1, No. 2 and No. 7 camshaft bearing caps. *1 No. 1 Camshaft Bearing Cap *2 No. 2 Camshaft Bearing Cap *3 No. 7 Camshaft Bearing Cap
14. REMOVE SPARK PLUG TUBE GASKET See step 34
15. REMOVE TIMING CHAIN COVER PLATE Remove the 4 bolts, timing chain cover plate and gasket.
16. SET NO. 1 CYLINDER TO TDC / COMPRESSION Turn the crankshaft pulley and align the notch with the "0" timing mark of the timing chain cover sub-assembly. *1 Notch Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. *1 Timing Mark *2 Paint Mark *a for Bank 2 *b for Bank 1 HINT: If the marks are not aligned, turn the crankshaft again to align the marks. Place paint marks on the chain sub-assembly in alignment with the timing marks on each camshaft timing gear assembly and camshaft bearing cap. HINT: Be sure to place the paint marks on 2 links of the chain sub-assembly and on the sprockets of the camshaft timing gears at the locations of the timing marks of the camshaft timing gears.
17. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain sub-assembly. HINT: This prevents the valves and pistons from interfering with each other. *a 0° *b 30° Align the hole in the stopper plate of the No. 1 chain tensioner assembly with the hole in the No. 1 chain tensioner body as shown in the illustration, and then insert a hexagon wrench into the hole. *1 Hole in the Stopper Plate *2 Hole in the No. 1 Chain Tensioner Assembly *3 Hexagon Wrench Turn the crankshaft clockwise and align the notch with the "0" timing mark of the timing chain or belt cover sub-assembly. *1 Notch Remove the 2 bolts and No. 1 chain tensioner assembly. NOTE: Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain or belt cover sub-assembly.
18. SEPARATE CHAIN SUB-ASSEMBLY (for Bank 1) Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain sub-assembly between the banks. *a 30° WARNING: As the camshafts turn suddenly, do not touch the camshafts or camshaft timing gears. NOTE: When turning the crankshaft, engine oil may spray out of the oil holes. Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be removed easily. *a 5 to 10° NOTE: When turning the crankshaft, engine oil may spray out of the oil holes. Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly. WARNING: As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.
19. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing bearing caps, install service bolts and washers in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) *1 Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly RH) *a Part to be removed *b Install the service bolts and washers to temporarily secure the camshaft housing sub-assembly RH NOTE: Do not install the camshaft bearing caps when installing the service bolts and washers. Be sure to follow the numerical order when performing this procedure. Do not allow the service bolts and washers to contact the camshaft. Do not drop the service bolts and washers into the cylinder head sub-assembly. HINT: Arrange the removed parts so that they can be reinstalled in their original locations. Part number for the service bolts used to temporarily secure the camshaft housing sub-assembly RH: 91551-G0845 (9 bolts) Part number for the service washers used to temporarily secure the camshaft housing sub-assembly RH: 90201-12028 (18 washers)
20. REMOVE NO. 2 CAMSHAFT Remove the bolt of the No. 2 chain tensioner assembly. Remove the No. 2 chain tensioner assembly while lifting up the No. 2 camshaft. While lifting up the No. 2 camshaft, pass it through the No. 2 chain sub-assembly and pull it out towards the front of the vehicle to remove it.
21. REMOVE CAMSHAFT Lift up the rear of the camshaft so that it is at an angle. Remove the chain sub-assembly from the camshaft timing gear assembly and pull out the camshaft and No. 2 chain sub-assembly towards the rear of the vehicle to remove them. NOTE: Do not drop the chain sub-assembly into the gap between the engine and timing chain cover sub-assembly. Suspend the chain sub-assembly with a string or equivalent.
22. SEPARATE CHAIN SUB-ASSEMBLY (for Bank 2) Turn the crankshaft counterclockwise and align the notch with the "0" timing mark of the timing chain or belt cover sub-assembly. *1 Notch Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly. WARNING: As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.
23. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing bearing caps, install service bolts and washers in the order shown in the illustration. *1 Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly LH) *a Part to be removed *b Install the service bolts and washers to temporarily secure the camshaft housing sub-assembly LH Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Do not install the camshaft bearing caps when installing the service bolts and washers. Be sure to follow the numerical order when performing this procedure. Do not allow the service bolts and washers to contact the camshaft. Do not drop the service bolts and washers into the cylinder head LH. HINT: Arrange the removed parts so that they can be reinstalled in their original locations. Part number for the service bolts used to temporarily secure the camshaft housing sub-assembly LH: 91551-G0845 (8 bolts) Part number for the service washers used to temporarily secure the camshaft housing sub-assembly LH: 90201-12028 (16 washers)
24. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY Remove the bolt of the No. 3 chain tensioner assembly. Remove the No. 3 chain tensioner assembly while lifting up the No. 4 camshaft sub-assembly. While lifting up the No. 4 camshaft sub-assembly, pass it through the No. 2 chain sub-assembly and pull it out towards the front of the vehicle to remove it.
25. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY Lift up the rear of the No. 3 camshaft sub-assembly so that it is at an angle. Remove the chain sub-assembly from the camshaft timing gear assembly and pull out the No. 3 camshaft sub-assembly and No. 2 chain sub-assembly towards the rear of the vehicle to remove them. NOTE: Do not drop the chain sub-assembly into the gap between the engine and timing chain cover sub-assembly. Suspend the chain sub-assembly with a string or equivalent.
26. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Check the lock of the camshaft timing gear assembly. Clamp the camshaft in a vise between aluminum plates, and confirm that the camshaft timing gear assembly is locked. NOTE: Be careful not to damage the camshaft. Release the lock pin. *1 Advanced Side Path *2 Retard Side Path *a Open *b Close Rubber Vinyl Tape Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: Plus 2 of the 4 paths with rubber pieces as shown in the illustration. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 opened paths. *1 Advanced Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path. *1 Advance Side Path *2 Retard Side Path *a Hold Pressure *b Decompress HINT: The lock pin is released and the camshaft timing gear assembly turns in the advance direction. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path. NOTE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. Check for smooth rotation. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly. NOTE: Do not use air pressure to perform the smooth operation check. Check the lock in the most retarded position. Confirm that the camshaft timing gear assembly locks at the most retarded position.
27. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Remove the flange bolt and camshaft timing gear assembly. *1 Flange Bolt *2 Straight Pin *a Do not remove 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 assembly.
28. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Check the lock of the camshaft timing exhaust gear assembly. Clamp the camshaft in a vise between aluminum plates, and confirm that the camshaft timing exhaust gear assembly is locked. Release the lock pin. *1 Advanced Side Path *2 Retard Side Path *a Open *b Close Rubber Vinyl Tape Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: plus 2 of the 4 paths with rubber pieces as shown in the illustration Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path). *1 Advanced Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path. *1 Advance Side Path *2 Retard Side Path *a Hold Pressure *b Decompress HINT: The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path. NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts. Check for smooth rotation. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the camshaft timing exhaust gear assembly turns smoothly. NOTE: When the air pressure is released from the advance side path and then from the retard side path, the camshaft timing exhaust gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check. Check the lock at the most advanced position. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.
29. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Remove the flange bolt and camshaft timing exhaust gear assembly. *1 Flange Bolt *2 Straight Pin *a Do Not Remove NOTE: Be sure not to remove the other 4 bolts. If planning to reuse the camshaft timing exhaust gear assembly, be sure to release the straight pin lock before installing the camshaft timing exhaust gear assembly.

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1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Secure the camshaft between aluminum plates 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. *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. Apply a small amount of engine oil to the threads and seat section of the flange bolt. 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.
2. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Clamp the camshaft in a vise between aluminum plates. 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. *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 assembly in the advanced direction. Apply a small amount of engine oil to the threads and seat section of the flange bolt. 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 exhaust 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.
3. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY Check that the notch is aligned with the "0" timing mark of the timing chain or belt cover sub-assembly. *1 Notch Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly. *1 Timing Mark *2 Mark Plate (yellow) *a Align Clean the camshaft housing sub-assembly LH and No. 3 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. *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap Install the chain sub-assembly to the No. 3 camshaft sub-assembly, and then install the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH. *a Place chain sub-assembly on camshaft timing gear assembly HINT: Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly. Install the No. 3 camshaft sub-assembly so that the timing mark is facing upward.
4. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY Clean the camshaft housing sub-assembly LH and No. 4 camshaft journals, and apply engine oil to them. Pass the No. 4 camshaft sub-assembly through the No. 2 chain sub-assembly from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly LH. *1 Mark Plate (yellow) *2 Timing Mark While lifting up the No. 4 camshaft sub-assembly, pass the No. 3 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place. Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH, and then install the No. 3 chain tensioner assembly with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
5. 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. *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *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 camshaft bearing caps, install the camshaft bearing caps with the bolts in the order shown in the illustration. *1 Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly LH) *a Remove the service bolts and washers used to temporarily secure the camshaft housing sub-assembly LH *b Part to be Installed Bolt A Bolt B 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) NOTE: Be sure to follow the numerical order when performing this procedure. Do not drop the service bolts and washers into the cylinder head LH. Check the torque of each bolt again.
6. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2) Align the paint marks on the camshaft timing gear assembly and chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly. *1 Paint Mark HINT: If the paint marks are not aligned, align them by turning the camshaft slightly.
7. INSTALL CAMSHAFT Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be installed easily. *a 5 to 10° NOTE: 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 assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly. *1 Timing Mark *2 Mark Plate (yellow) *a Align Clean the camshaft housing sub-assembly 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. *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap Install the chain sub-assembly to the camshaft, and then install the camshaft to the camshaft housing sub-assembly RH. *a Place chain sub-assembly on camshaft timing gear HINT: Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly. Install the camshaft so that the timing mark is facing upward.
8. INSTALL NO. 2 CAMSHAFT Clean the camshaft housing sub-assembly RH and No. 2 camshaft journals, and apply engine oil to them. Pass the No. 2 camshaft through the No. 2 chain sub-assembly from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly RH. *1 Mark Plate (yellow) *2 Timing Mark While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place. Install the No. 2 camshaft to the camshaft housing sub-assembly RH, and then install the No. 2 chain tensioner assembly with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
9. 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. *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *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. *1 Service Bolt and Washers (used to temporarily secure the camshaft housing sub-assembly RH) *a Remove the service bolts and washers to temporarily secure the camshaft housing sub-assembly RH *b Part to be Installed Bolt A Bolt B 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) NOTE: Be sure to follow the numerical order when performing this procedure. Do not drop the service bolts and washers into the cylinder head sub-assembly. Check the torque of each bolt again.
10. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1) Align the paint marks on the camshaft timing gear assembly and chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly. *1 Paint Mark HINT: If the paint marks are not aligned, align them by turning the camshaft slightly.
11. 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. *a 0° *b 30° Turn the crankshaft slightly to eliminate the slack in the chain sub-assembly. HINT: Make sure there is some slack in the chain around the area where the No. 1 chain tensioner assembly is installed. While turning the stopper plate of the No. 1 chain tensioner assembly clockwise, push in the plunger of the No. 1 chain tensioner assembly as shown in the illustration. *1 Stopper Plate *2 Hexagon Wrench *a Push While turning the stopper plate of the No. 1 chain tensioner assembly counterclockwise, insert a hexagon wrench into the holes in the stopper plate and No. 1 chain tensioner assembly to secure the stopper plate in place. Install the No. 1 chain tensioner assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
12. INSPECT VALVE TIMING Check that each camshaft timing mark is positioned as shown in the illustration. *1 Timing Mark *a Viewpoint 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 assembly. If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned. 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 chain sub-assembly again. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.
13. 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)
14. INSTALL SPARK PLUG TUBE GASKET See step 49
15. POUR ENGINE OIL HINT: Before installing the cylinder head cover sub-assemblies, pour engine oil into the oil holes shown in the illustration until the oil holes are filled with engine oil.
16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain or belt cover sub-assembly or cylinder head cover sub-assembly. Apply seal packing as shown in the illustration. *1 timing chain cover sub-assembly *2 camshaft housing sub-assembly RH *a 2.0 to 3.0 mm (0.0787 to 0.118 in.) *b 5.0 to 10.0 mm (0.197 to 0.394 in.) Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. Install 3 new gaskets to the No. 1, No. 2 and No. 7 camshaft bearing caps. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly. Apply adhesive to the threads of the 11 bolts indicated by the black arrows in the illustration. *a Bolt with cylinder head cover seal washer Apply adhesive to these bolts Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTE: Tighten the bolts within 3 minute after applying adhesive. Install the cylinder head cover sub-assembly with the 14 bolts and 2 new cylinder head cover seal washers. for Bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) except Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Attach the clamps and connect the connectors to the cylinder head cover sub-assembly.
17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head LH, timing chain or belt cover sub-assembly or cylinder head cover sub-assembly LH. Apply seal packing as shown in the illustration. *1 timing chain cover sub-assembly *2 camshaft housing sub-assembly LH *a 2.0 to 3.0 mm (0.0787 to 0.118 in.) *b 5 to 10 mm (0.197 to 0.394 in.) Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. Install 3 new gaskets to the No. 3, No. 4 and No. 7 camshaft bearing caps. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH. Apply adhesive to the threads of the 10 bolts indicated by the black arrows in the illustration. *a Bolt with cylinder head cover seal washer Apply adhesive to these bolts Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTE: Tighten the bolts within 3 minute after applying adhesive. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new cylinder head cover seal washer. for bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) except bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Attach the clamps and connect the connectors to the cylinder head cover sub-assembly LH.
18. INSTALL NO. 2 OIL PIPE See step 63
19. INSTALL NO. 1 OIL PIPE Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe on the cylinder head cover sub-assembly LH side with the oil pipe union. NOTE: Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. Do not touch the mesh when installing the oil control valve filter LH. Install a new gasket and temporarily install the No. 1 oil pipe on the cylinder head LH side with the oil check valve bolt. Using a 17 mm ball joint lock nut wrench, tighten the oil pipe union on the cylinder head cover sub-assembly LH side. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) NOTE: Use the formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench. Refer to «PRECAUTION [04/2013 - ]»(ref-665529-S00420865962014102400000) Tighten the oil check valve bolt on the cylinder head LH side. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
20. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Refer to «PROCEDURE - Step 3»(ref-665769-S16841631392014102400000)
21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY See step 70
22. INSTALL SPARK PLUG Refer to «PROCEDURE - Step 1»(ref-665751-S29802334862014102400000)
23. INSTALL IGNITION COIL ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665751-S29802334862014102400000)
24. INSTALL INJECTOR DRIVER Refer to «PROCEDURE - Step 1»(ref-665752-S17989845222014102400000)
25. INSTALL NO. 1 ENGINE COVER Refer to «PROCEDURE - Step 2»(ref-665752-S17989845222014102400000)
26. INSTALL GENERATOR ASSEMBLY Refer to «INSTALLATION [04/2013 - ]»(ref-665778-S00639553502014102400000)
27. INSTALL FUEL PUMP ASSEMBLY Refer to «INSTALLATION [04/2013 - ]»(ref-665752-S09100021692014102400000)
28. INSTALL BATTERY Refer to «PROCEDURE - Step 3»(ref-665742-S42250252652014102400000)

Scheme 61

*1 CHAIN SUB-ASSEMBLY *2 CHAIN TENSIONER SLIPPER *3 NO. 1 CHAIN TENSIONER ASSEMBLY *4 NO. 1 CHAIN VIBRATION DAMPER *5 NO. 2 CHAIN VIBRATION DAMPER *6 REAR WATER BY-PASS JOINT *7 GASKET *8 O-RING N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part

Scheme 62

*1 CAMSHAFT *2 CAMSHAFT HOUSING SUB-ASSEMBLY RH *3 NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY *4 NO. 2 CAMSHAFT *5 NO. 2 CHAIN TENSIONER ASSEMBLY *6 VALVE LASH ADJUSTER ASSEMBLY *7 VALVE STEM CAP *8 NO. 2 CHAIN SUB-ASSEMBLY *9 CAMSHAFT TIMING GEAR ASSEMBLY *10 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH *11 NO. 1 CAMSHAFT BEARING CAP *12 NO. 2 CAMSHAFT BEARING CAP *13 NO. 5 CAMSHAFT BEARING CAP *14 NO. 6 CAMSHAFT BEARING CAP *15 NO. 7 CAMSHAFT BEARING CAP - - N*m (kgf*cm, ft*lbf) : Specified torque

Scheme 63

*1 CAMSHAFT HOUSING SUB-ASSEMBLY LH *2 NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY *3 NO. 3 CAMSHAFT SUB-ASSEMBLY *4 NO. 3 CHAIN TENSIONER ASSEMBLY *5 NO. 4 CAMSHAFT SUB-ASSEMBLY *6 VALVE LASH ADJUSTER ASSEMBLY *7 VALVE STEM CAP *8 CAMSHAFT TIMING GEAR ASSEMBLY *9 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH *10 NO. 2 CHAIN SUB-ASSEMBLY *11 NO. 3 CAMSHAFT BEARING CAP *12 NO. 4 CAMSHAFT BEARING CAP *13 NO. 7 CAMSHAFT BEARING CAP *14 NO. 8 CAMSHAFT BEARING CAP N*m (kgf*cm, ft*lbf) : Specified torque

Scheme 64

*1 FUEL DELIVERY PIPE SUB-ASSEMBLY *2 FUEL INJECTOR ASSEMBLY *3 FUEL INJECTOR SEAL *4 NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY *5 NO. 3 FUEL PIPE SUB-ASSEMBLY *6 NO. 1 BACK UP RING *7 NO. 2 BACK UP RING *8 O-RING *9 NO. 3 BACK UP RING *10 E-RING *11 NOZZLE HOLDER CLAMP *12 INJECTOR VIBRATION INSULATOR *13 WIRE HARNESS - - N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part

Scheme 65

*1 CYLINDER HEAD GASKET *2 CYLINDER HEAD LH *3 CYLINDER HEAD SUB-ASSEMBLY *4 NO. 2 CYLINDER HEAD GASKET N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part *T1 1st: 36 (367, 27) 2nd: Turn 90° 3rd: Turn 90°

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Refer to «REMOVAL [04/2013 - ]»(ref-665704-S17407914992014102400000)
2. SET NO. 1 CYLINDER TO TDC / COMPRESSION See step 46
3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 47
4. REMOVE CHAIN TENSIONER SLIPPER See step 48
5. REMOVE CHAIN SUB-ASSEMBLY See step 49
6. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner assembly. *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. *a Turn *b Hold SST: 09922-10010 NOTE: Be careful not to damage the cylinder head sub-assembly 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 RH with a new one. Remove the 2 bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly RH together with the No. 2 chain sub-assembly. Remove the No. 2 chain sub-assembly.
7. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 2 chain tensioner assembly.
8. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Check that the camshafts are positioned as shown in the illustration. *1 Knock Pin *a IN *b EX *c 45° Uniformly loosen and remove the 9 bolts in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 14 bolts in several steps and in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshafts level. Remove the 6 camshaft bearing caps. HINT: Arrange the removed parts in the correct order.
9. REMOVE CAMSHAFT Remove the camshaft from the camshaft housing sub-assembly RH.
10. REMOVE NO. 2 CAMSHAFT Remove the No. 2 camshaft from the camshaft housing sub-assembly RH.
11. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Remove the camshaft housing sub-assembly RH by prying between the cylinder head sub-assembly and camshaft housing sub-assembly RH with a screwdriver. *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly RH. HINT: Tape the screwdriver tip before use.
12. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner assembly. *1 Pin *2 Plunger *a Push Using SST to hold the hexagonal portion of each camshaft sub-assembly, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH. *a Turn *b Hold SST: 09922-10010 NOTE: Be careful not to damage the cylinder head LH 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 LH with a new one. Remove the 2 bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly LH together with the No. 2 chain sub-assembly. Remove the No. 2 chain sub-assembly.
13. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 3 chain tensioner assembly.
14. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Check that the camshafts are positioned as shown in the illustration. *1 Knock Pin *a IN *b EX Uniformly loosen and remove the 8 bolts in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 13 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. HINT: Arrange the removed parts in the correct order.
15. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY Remove the No. 3 camshaft sub-assembly from the camshaft housing sub-assembly LH.
16. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY Remove the No. 4 camshaft sub-assembly from the camshaft housing sub-assembly LH.
17. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Remove the camshaft housing sub-assembly LH by prying between the cylinder head LH and camshaft housing sub-assembly LH with a screwdriver. *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head LH and camshaft housing sub-assembly LH. HINT: Tape the screwdriver tip before use.
18. REMOVE NO. 1 CHAIN VIBRATION DAMPER See step 51
19. REMOVE NO. 2 CHAIN VIBRATION DAMPER See step 52
20. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 24 No. 1 valve rocker arm sub-assemblies. HINT: Arrange the removed parts in the correct order.
21. REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 24 valve lash adjuster assemblies. HINT: Arrange the removed parts in the correct order.
22. REMOVE VALVE STEM CAP Remove the 24 valve stem caps. HINT: Arrange the removed parts in the correct order.
23. REMOVE REAR WATER BY-PASS JOINT See step 31
24. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665752-S14929502462014102400000)
25. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 3»(ref-665752-S14929502462014102400000)
26. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 4»(ref-665752-S14929502462014102400000)
27. REMOVE FUEL INJECTOR ASSEMBLY Refer to «PROCEDURE - Step 5»(ref-665752-S14929502462014102400000)
28. REMOVE FUEL INJECTOR SEAL Refer to «PROCEDURE - Step 6»(ref-665752-S14929502462014102400000)
29. REMOVE CYLINDER HEAD SUB-ASSEMBLY Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head set bolts in the sequence shown in the illustration. Remove the 8 cylinder head set bolts and plate washers. NOTE: Be careful not to drop the plate washers into the cylinder head sub-assembly. Cylinder head warpage or cracking could result from removing cylinder head set bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head sub-assembly.
30. REMOVE CYLINDER HEAD GASKET Remove the cylinder head gasket. NOTE: Clean the bolt holes of the cylinder block sub-assembly and check for damaged. If the bolt holes are damaged, repair them with a tap.
31. REMOVE CYLINDER HEAD LH Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head set bolts in the sequence shown in the illustration. Remove the 8 cylinder head set bolts and plate washers. NOTE: Be careful not to drop plate washers into the cylinder head LH. Cylinder head LH warpage or cracking could result from removing cylinder head set bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head LH.
32. REMOVE NO. 2 CYLINDER HEAD GASKET Remove the No. 2 cylinder head gasket. NOTE: Clean the bolt holes of the cylinder block sub-assembly and check for damaged. If the bolt holes are damaged, repair them with a tap.
33. INSPECT CYLINDER HEAD FOR FLATNESS See step 1
34. INSPECT CYLINDER HEAD FOR CRACKS See step 2
35. INSPECT CYLINDER HEAD SET BOLT See step 6

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

1. INSTALL CYLINDER HEAD GASKET Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration. *1 Seal Packing *2 Cylinder Head Gasket Application Area 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.) NOTE: Remove any oil from the contact surface. Install the cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes after applying the seal packing. Do not add engine oil for at least 2 hours after installation. Do not start engine for at least 2 hours after installation. Place the cylinder head gasket on the cylinder block sub-assembly surface with the Lot No. stamp upward. *1 Lot No. Engine Front NOTE: Be careful of the installation direction.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY Place the cylinder head sub-assembly on the cylinder block sub-assembly. NOTE: Gently place the cylinder head sub-assembly in order not to damage the cylinder head gasket with the bottom part of the cylinder head sub-assembly. Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly. Check the cylinder head set bolts and bolt holes, and clean them. Clean and degrease the installation surface. HINT: The cylinder head set bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts. Step 1: Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head set bolts with the plate washers in several steps and in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) NOTE: Be careful not to drop plate washers into the cylinder head sub-assembly. Install the cylinder head set bolts in their original locations. When reusing the cylinder head set bolts, inspect the diameter of the threads. If the diameter is less than the minimum, replace the cylinder head set bolts with new ones. See step 6 Step 2: Mark the front side of each cylinder head set bolt head with paint. Tighten the cylinder head set bolts another 90°. *1 Point Mark *a 90° Engine Front Step 3: Tighten the cylinder head set 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. *1 Cylinder Head Sub-assembly *2 Cylinder Head Gasket *3 Cylinder Block Sub-assembly *a Wipe Clean
3. 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. *1 Seal Packing *2 No. 2 Cylinder Head Gasket Application Area 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.) NOTE: Remove any oil from the contact surface. Install the No. 2 cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes after applying the seal packing. Do not add engine oil for at least 2 hours after installation. Do not start engine for at least 2 hours after installation. Place the No. 2 cylinder head gasket on the cylinder block sub-assembly surface with the Lot No. stamp upward. *1 Lot No. Engine Front NOTE: Be careful of the installation direction.
4. INSTALL CYLINDER HEAD LH Place the cylinder head LH on the cylinder block sub-assembly. NOTE: Gently place the cylinder head LH in order not to damage the No. 2 cylinder head gasket with the bottom part of the cylinder head LH. Be careful not to allow oil to adhere to the bottom part of the cylinder head LH. Check the cylinder head set bolts and bolt holes, and clean them. Clean and degrease the installation surface. HINT: The cylinder head set bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts. Step 1: Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head set bolts with the plate washers in several steps in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) NOTE: Be careful not to drop plate washers into the cylinder head LH. Install the cylinder head set bolts in their original locations. When reusing the cylinder head set bolts, inspect the diameter of the threads. If the diameter is less than the minimum, replace the cylinder head set bolts with new ones. See step 6 Step 2: Mark the front side of each cylinder head set bolt head with paint. Tighten the cylinder head set bolts another 90°. *1 Point Mark *a 90° Engine Front Step 3: Tighten the cylinder head set 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. *1 Cylinder Head LH *2 No. 2 Cylinder Head Gasket *3 Cylinder Block Sub-assembly *a Wipe Clean
5. INSTALL FUEL INJECTOR SEAL Refer to «PROCEDURE - Step 1»(ref-665752-S01941816702014102400000)
6. INSTALL FUEL INJECTOR ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665752-S01941816702014102400000)
7. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 3»(ref-665752-S01941816702014102400000)
8. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 4»(ref-665752-S01941816702014102400000)
9. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 5»(ref-665752-S01941816702014102400000)
10. INSTALL REAR WATER BY-PASS JOINT See step 53
11. INSTALL VALVE STEM CAP Apply a light coat of engine oil to the valve stem caps. Install the 24 valve stem caps to the intake valves and exhaust valves. NOTE: Install the valve stem cap at the same place it was removed from.
12. INSTALL VALVE LASH ADJUSTER ASSEMBLY Inspect the valve lash adjuster assembly. See step 2 Install the 24 valve lash adjuster assemblies to the cylinder head sub-assembly and cylinder head LH. NOTE: Install the valve lash adjuster assembly at the same place it was removed from.
13. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the valve lash adjuster assembly tips and valve stem cap ends. Install the 24 No. 1 valve rocker arm sub-assemblies as shown in the illustration. *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap NOTE: Make sure that the No. 1 valve rocker arm sub-assemblies are installed correctly as shown in the illustration. Install the No. 1 valve rocker arm sub-assembly at the same place it was removed from.
14. INSTALL NO. 1 CHAIN VIBRATION DAMPER See step 30
15. INSTALL NO. 2 CHAIN VIBRATION DAMPER See step 31
16. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH. Set the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH.
17. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH. Set the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH.
18. 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 camshaft bearing cap in the proper position and direction. *1 No. 3 Camshaft Bearing Cap *2 No. 4 Camshaft Bearing Cap *3 No. 8 Camshaft Bearing Cap *4 No. 7 Camshaft Bearing Cap Uniformly and temporarily tighten the 8 bolts in the order shown in the illustration.
19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Make sure that the No. 1 valve rocker arm sub-assemblies are installed correctly as shown in the illustration. *1 Valve Stem Cap *2 No. 1 Valve Rocker Arm Sub-assembly *3 Valve Lash Adjuster Assembly *4 Valve Stem *a CORRECT *b INCORRECT Apply seal packing in a continuous line as shown in the illustration. *1 Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.5 to 4.0 mm (0.138 to 0.157 in.) NOTE: Remove any oil from the contact surface. Check the bolts and bolt holes, and clean them. Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration. *1 Knock Pin *a IN *b EX Bolt A Bolt B Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. BOLT LENGTH: Item Specified Condition Bolt A 68 mm (2.68 in.) Bolt B 48 mm (1.89 in.) Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) Thoroughly wipe clean any seal parking. NOTE: Be careful not to drop seal packing into the cylinder head LH.
20. INSTALL CAMSHAFT Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH. Install the camshaft to the camshaft housing sub-assembly RH.
21. INSTALL NO. 2 CAMSHAFT Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH. Install the No. 2 camshaft to the camshaft housing sub-assembly RH.
22. 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 camshaft bearing cap in the proper position and direction. *1 No. 1 Camshaft Bearing Cap *2 No. 2 Camshaft Bearing Cap *3 No. 5 Camshaft Bearing Cap *4 No. 7 Camshaft Bearing Cap *5 No. 6 Camshaft Bearing Cap Uniformly and temporarily tighten the 9 camshaft bearing cap bolts in the order shown in the illustration.
23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Make sure that the No. 1 valve rocker arm sub-assemblies are installed correctly as shown in the illustration. *1 Valve Stem Cap *2 No. 1 Valve Rocker Arm Sub-assembly *3 Valve Lash Adjuster Assembly *4 Valve Stem *a CORRECT *b INCORRECT Apply seal packing in a continuous line as shown in the illustration. *1 Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.5 to 4.0 mm (0.138 to 0.157 in.) NOTE: Remove any oil from the contact surface. Check the bolts and bolt holes, and clean them. Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. Install the camshaft housing sub-assembly RH and tighten the 14 bolts in the order shown in the illustration. *1 Knock Pin *a EX *b IN *c 45° Bolt A Bolt B Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. BOLT LENGTH: Item Specified Condition Bolt A 68 mm (2.68 in.) Bolt B 48 mm (1.89 in.) Tighten the 9 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) Thoroughly wipe clean any seal packing. NOTE: Be careful not to drop seal packing into the cylinder head sub-assembly.
24. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Install the No. 3 chain tensioner assembly with the bolt. *1 Plunger *2 Pin *a Push Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
25. 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 assembly and camshaft timing exhaust gear assembly LH as shown in the illustration. *1 Timing Mark *2 Mark Plate (yellow) 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 LH with the No. 2 chain sub-assembly installed. NOTE: Do not forcefully press the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly or camshaft timing exhaust gear assembly LH, leading to poor sealing. Using SST to hold the hexagonal portion of each camshaft sub-assembly, tighten the flange bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH. *a Turn *b Hold SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the pin from the No. 3 chain tensioner assembly.
26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Install the No. 2 chain tensioner assembly with the bolt. *1 Plunger *2 Pin *a Push Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
27. 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 assembly and camshaft timing exhaust gear assembly RH as shown in the illustration. *1 Timing Mark *2 Mark Plate (yellow) 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 RH with the No. 2 chain sub-assembly installed. NOTE: Do not forcefully press the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly or camshaft timing exhaust gear assembly RH, leading to poor sealing. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH. *a Turn *b Hold SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the pin from the No. 2 chain tensioner assembly.
28. INSTALL CHAIN SUB-ASSEMBLY See step 35
29. INSTALL CHAIN TENSIONER SLIPPER See step 36
30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 37
31. INSPECT VALVE TIMING See step 38
32. POUR ENGINE OIL See step 50
33. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Refer to «PROCEDURE - Step 1»(ref-665705-S15427817832014102400000)

Scheme 84

*A for 2WD - - *1 CRANKSHAFT PULLEY *2 CRANKSHAFT TIMING GEAR KEY *3 V-RIBBED BELT *4 TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL *5 WIRE HARNESS - - N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part MP Grease

Scheme 85

1. REMOVE FAN SHROUD ASSEMBLY Refer to «REMOVAL [04/2013 - ]»(ref-665707-S04003876012014102400000)
2. REMOVE V-RIBBED BELT See step 4
3. DISCONNECT WIRE HARNESS (for 2WD) Disconnect the engine oil pressure switch assembly connector. Remove the bolt and disconnect the wire harness bracket.
4. REMOVE CRANKSHAFT PULLEY Using SST, hold the crankshaft pulley and loosen the crankshaft pulley bolt until only 2 or 3 threads are screwed into the crankshaft. *a Hold *b Turn SST: 09330-0002109213-70011 09213-70020 Using SST, remove the crankshaft pulley bolt and crankshaft pulley. *a Hold *b Turn SST: 09950-50013 09951-05010 09952-05010 09953-05010 09954-05021 HINT: Apply molybdenum grease to the threads and tip of SST (center bolt) prior to use.
5. REMOVE CRANKSHAFT TIMING GEAR KEY Using a screwdriver, remove the crankshaft timing gear key from the crankshaft groove. *1 Protective Tape HINT: Tape the screwdriver tip before use.
6. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver, pry out the timing gear case or timing chain case oil seal. *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 86

1. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Apply MP grease to the lip of a new timing gear case or timing chain case oil seal. NOTE: Keep the lip free of foreign matter. Using SST and a hammer, tap in the timing gear case or timing chain case oil seal until its surface is flush with the timing chain or belt cover sub-assembly edge. *a Standard depth SST: 09223-2201009506-35010 Standard depth 0 to 1.0 mm (0 to 0.0394 in.) NOTE: Keep the lip free of foreign matter. Do not tap the timing gear case or timing chain case oil seal at an angle. Do not deform the timing gear case or timing chain case oil seal. Make sure that the timing gear case or timing chain case oil seal is not protruded from the timing chain or belt cover sub-assembly. Wipe off MP grease on the crankshaft. Make sure that the lip of the timing gear case or timing chain case oil seal is not turned over.
2. INSTALL CRANKSHAFT TIMING GEAR KEY Install the crankshaft timing gear key to the crankshaft groove.
3. INSTALL CRANKSHAFT PULLEY Align the crankshaft timing gear key with the key groove of the crankshaft pulley, and slide on the crankshaft pulley. Using SST, hold the crankshaft pulley and install the crankshaft pulley bolt. *a Hold *b Turn SST: 09330-0002109213-70011 09213-70020 Torque: 250 N*m (2549 kgf*cm, 184 ft.*lbf)
4. CONNECT WIRE HARNESS (for 2WD) Install the wire harness bracket with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the engine oil pressure switch assembly connector.
5. INSTALL V-RIBBED BELT See step 1
6. INSTALL FAN SHROUD ASSEMBLY Refer to «INSTALLATION [04/2013 - ]»(ref-665707-S11156125652014102400000)
7. INSPECT FOR OIL LEAK

Scheme 87

*1 DRIVE PLATE *2 ENGINE REAR OIL SEAL *3 FRONT DRIVE PLATE SPACER *4 REAR DRIVE PLATE SPACER N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part Non-reusable part * Precoated part

1. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) Refer to «REMOVAL [04/2013 - ]»(ref-665750-S40640497102014102400000)
2. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY (for AWD) Refer to «REMOVAL [04/2013 - ]»(ref-665725-S17633399262014102400000)
3. REMOVE DRIVE PLATE Using SST, hold the crankshaft pulley. SST: 09330-0002109213-70011 09213-70020 Remove the 8 bolts, front drive plate spacer, drive plate and rear drive plate spacer.
4. REMOVE ENGINE REAR OIL SEAL Using a knife, cut through the engine rear oil seal lip. *1 Protective Tape *a Cut Position Using a screwdriver with its tip taped, pry out the engine rear oil seal. HINT: Tape the screwdriver tip before use. NOTE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

Scheme 88

Scheme 89

1. INSTALL ENGINE REAR OIL SEAL Clean the crankshaft and engine rear oil seal retainer. Apply MP grease to the lip of a new engine rear oil seal. NOTE: Keep the lip free of foreign matter. Do not allow MP grease to contact the dust seal section. Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge. *a Standard depth SST: 09223-1503009950-70010 09951-07150 Standard depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) NOTE: Wipe off extra grease on the crankshaft. Keep the lip free of foreign matter. Do not tap in the engine rear oil seal at an angle. Do not tap in the engine rear oil seal more than necessary. Do not deform the engine rear oil seal.
2. INSTALL DRIVE PLATE Using SST, hold the crankshaft pulley. SST: 09330-0002109213-70011 09213-70020 Clean the 8 bolts and 8 bolt holes. Install the front drive plate spacer. *1 Pin Hole *2 Pin HINT: Align the pin of the front drive plate spacer with the pin hole of the crankshaft. Install the drive plate and rear drive plate spacer onto the crankshaft. *1 Drive Plate and Ring Gear Sub-assembly *2 Rear Drive Plate Spacer Transmission Side HINT: Make sure the installation direction of the drive plate and ring gear sub-assembly and rear drive plate spacer. Apply a few drops of adhesive to 2 or 3 threads of the 8 bolt tips. *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTE: Install the bolt within 3 minutes after applying adhesive. In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 83.5 N*m (851 kgf*cm, 62 ft.*lbf) NOTE: Do not start the engine for at least an hour after installing the drive plate.
3. INSPECT DRIVE PLATE (for 2WD) Refer to «PROCEDURE - Step 2»(ref-665750-S30807346022014102400000)
4. INSPECT DRIVE PLATE (for AWD) Refer to «PROCEDURE - Step 2»(ref-665725-S11703008522014102400000)
5. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY (for AWD) Refer to «INSTALLATION [04/2013 - ]»(ref-665725-S27173768842014102400000)
6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) Refer to «INSTALLATION [04/2013 - ]»(ref-665750-S18338736802014102400000)
7. INSPECT FOR OIL LEAK

Scheme 90

*A for 2WD *B for AWD *C w/ INTAKE AIR SOUND CREATOR *D w/o INTAKE AIR SOUND CREATOR *E w/ NO. 2 ENGINE UNDER COVER - - *1 AIR CLEANER CAP WITH AIR CLEANER HOSE *2 AIR CLEANER CASE SUB-ASSEMBLY *3 AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY *4 COOL AIR INTAKE DUCT SEAL *5 ENGINE UNDER COVER *6 FRONT SUSPENSION MEMBER BRACE *7 INLET NO. 1 AIR CLEANER *8 NO. 2 FUEL VAPOR FEED HOSE *9 NO. 2 ENGINE UNDER COVER *10 REAR ENGINE UNDER COVER RH *11 REAR ENGINE UNDER COVER LH *12 V-BANK COVER SUB-ASSEMBLY *13 WIRE HARNESS *14 NO. 2 VENTILATION HOSE *15 AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE - - N*m (kgf*cm, ft.*lbf): Specified torque

Scheme 91

*A for LHD - - *1 ENGINE ROOM ECU COVER *2 FUEL TUBE SUB-ASSEMBLY *3 HEATER INLET WATER HOSE *4 NO. 1 COOLER REFRIGERANT DISCHARGE HOSE *5 NO. 1 RADIATOR HOSE *6 NO. 2 FUEL VAPOR FEED HOSE *7 NO. 3 FUEL HOSE *8 NO. 2 RADIATOR HOSE *9 HEATER OUTLET WATER HOSE *10 RADIATOR RESERVOIR TANK HOSE *11 SUCTION HOSE *12 WATER INLET SUB-ASSEMBLY *13 FUEL PIPE *14 UNION TO CHECK VALVE HOSE *15 FUEL PIPE CLAMP *16 NO. 1 ENGINE ROOM RELAY BLOCK COVER *17 NO. 1 FUEL PIPE SUB-ASSEMBLY *18 O-RING N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part Compressor Oil ND-OIL8

Scheme 92

*A for LHD - - *1 ENGINE WIRE *2 NO. 2 ENGINE WIRE *3 NO. 3 ENGINE WIRE *4 NO. 4 ENGINE WIRE N*m (kgf*cm, ft.*lbf): Specified torque

Scheme 93

*A for 2WD - - *1 ENGINE ASSEMBLY WITH TRANSMISSION *2 ENGINE UNDER BRACE SUB-ASSEMBLY *3 FRONT LOWER BALL JOINT ASSEMBLY LH *4 FRONT LOWER SUSPENSION MEMBER PROTECTOR *5 FRONT SHOCK ABSORBER ASSEMBLY LH *6 FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY *7 FRONT UPPER NO. 2 SUSPENSION MEMBER *8 STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY *9 WIRE HARNESS *10 STRUT BAR BRACKET REINFORCEMENT LH *11 STRUT BAR BRACKET REINFORCEMENT RH *12 FRONT NO. 2 STABILIZER BRACKET LH *13 FRONT NO. 2 STABILIZER BRACKET RH *14 NO. 2 EARTH WIRE *15 FRONT SUSPENSION LOWER ARM ASSEMBLY LH *16 LEVER N*m (kgf*cm, ft.*lbf): Specified torque

Scheme 94

*A for AWD - - *1 ENGINE ASSEMBLY WITH TRANSMISSION *2 FRONT AXLE SHAFT NUT LH *3 FRONT LOWER BALL JOINT ASSEMBLY LH *4 FRONT SHOCK ABSORBER ASSEMBLY LH *5 FRONT SPEED SENSOR LH *6 FRONT SUSPENSION MEMBER BRACE *7 FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY *8 NO. 1 FRAME CROSSMEMBER ASSEMBLY *9 NO. 2 FRAME CROSSMEMBER ASSEMBLY *10 NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY *11 TIE ROD ASSEMBLY LH *12 WIRE HARNESS *13 STRUT BAR BRACKET REINFORCEMENT LH *14 STRUT BAR BRACKET REINFORCEMENT RH *15 NO. 2 EARTH WIRE *16 FRONT LOWER SHOCK ABSORBER BRACKET LH *17 LEVER *18 FRONT DISC *19 FRONT DISC BRAKE CALIPER ASSEMBLY *20 FRONT NO. 1 DISC BRAKE CALIPER PLATE N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part Do not apply lubricants (to the threaded parts)

Scheme 95

Scheme 96

*A for 2WD - - *1 AUTOMATIC TRANSMISSION ASSEMBLY *2 DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT *3 ENGINE OIL LEVEL DIPSTICK GUIDE *4 EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) *5 EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) *6 FLYWHEEL HOUSING SIDE COVER *7 NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY *8 REAR ENGINE MOUNTING INSULATOR *9 NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE *10 REAR ENGINE MOUNTING MEMBER *11 STARTER ASSEMBLY *12 ENGINE OIL LEVEL DIPSTICK *13 O-RING *14 GASKET *15 WIRE HARNESS - - *a Black: x 1 Silver: x 5 - - N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part

Scheme 97

*A for AWD - - *1 DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT *2 ENGINE OIL LEVEL DIPSTICK GUIDE *3 EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) *4 EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) *5 FLYWHEEL HOUSING SIDE COVER *6 FRONT PROPELLER SHAFT ASSEMBLY *7 NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY *8 REAR NO. 1 ENGINE MOUNTING INSULATOR *9 NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE *10 REAR ENGINE MOUNTING MEMBER *11 STARTER ASSEMBLY *12 AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY *13 ENGINE MOUNTING BRACKET *14 ENGINE OIL LEVEL DIPSTICK *15 O-RING *16 GASKET *17 WIRE HARNESS - - *a Black: x 1 Silver: x 5 - - N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part Do not apply lubricants (to the threaded parts)

Scheme 98

*A for 2WD - - *1 DRIVE PLATE AND RING GEAR SUB-ASSEMBLY *2 FRONT ENGINE MOUNTING INSULATOR *3 FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY *4 FRONT DRIVE PLATE SPACER *5 REAR DRIVE PLATE SPACER *6 ENGINE ASSEMBLY N*m (kgf*cm, ft.*lbf): Specified torque * Precoated part

Scheme 99

*A for AWD - - *1 FRONT DIFFERENTIAL CARRIER ASSEMBLY *2 DRIVE PLATE AND RING GEAR SUB-ASSEMBLY *3 FRONT DRIVE SHAFT ASSEMBLY LH *4 FRONT DRIVE SHAFT ASSEMBLY RH *5 FRONT ENGINE MOUNTING INSULATOR *6 FRONT FRAME ASSEMBLY *7 DRIVE SHAFT BEARING BRACKET HOLE SNAP RING *8 NO. 1 DRIVE SHAFT BEARING BRACKET BOLT *9 FRONT DRIVE PLATE SPACER *10 REAR DRIVE PLATE SPACER *11 SNAP RING *12 GASKET *13 ENGINE ASSEMBLY - - N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part * Precoated part MP Grease Do not apply lubricants (to the threaded parts)

CAUTION / NOTICE / HINT

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

1. PRECAUTION NOTE: After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to «PRECAUTION [04/2013 - ]»(ref-665529-S00420865962014102400000)
2. REMOVE COOL AIR INTAKE DUCT SEAL Refer to «PROCEDURE - Step 1»(ref-665772-S07495103672014102400000)
3. REMOVE V-BANK COVER SUB-ASSEMBLY Hold the rear area of the V-bank cover sub-assembly shown in the illustration and detach the rear clip (1). NOTE: If the V-bank cover sub-assembly is lifted rearward or forward and to the right or left at the same time, the V-bank cover sub-assembly may be damaged. Areas to be held when lifting V-bank cover sub-assembly Front Hold both sides of the V-bank cover sub-assembly and lift it to detach the 2 front clips (2) and (3) to remove the V-bank cover sub-assembly.
4. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Refer to «PROCEDURE - Step 1»(ref-665718-S31675478902014102400000)
5. DISCHARGE FUEL SYSTEM PRESSURE Refer to «PROCEDURE - Step 1»(ref-665746-S18024150712014102400000)
6. PLACE FRONT WHEELS FACING STRAIGHT AHEAD Refer to «PROCEDURE - Step 10»(ref-665717-S03084186482014102400000)
7. SECURE STEERING WHEEL Refer to «PROCEDURE - Step 4»(ref-665774-S05830417702014102400000)
8. REMOVE FRONT WHEELS
9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [04/2013 - ]»(ref-665529-S01115916402014102400000)
10. REMOVE ENGINE UNDER COVER for 2WD: *A for 2WD *B for AWD Remove the 13 screws, 3 clips and engine under cover. for AWD: Remove the 10 screws, 3 clips and engine under cover.
11. REMOVE REAR ENGINE UNDER COVER LH (for 2WD) Remove the screw and rear engine under cover LH.
12. REMOVE REAR ENGINE UNDER COVER RH (for 2WD) HINT: Perform the same procedure as for the LH side.
13. REMOVE FRONT SUSPENSION MEMBER BRACE (for 2WD) Remove the 4 bolts, turn the clip to loosen it, and remove the front suspension member brace. HINT: Do not remove the clip from the front suspension member brace.
14. REMOVE NO. 2 ENGINE UNDER COVER (w/ No. 2 Engine Under Cover) Remove the 4 screws, turn the 2 grommets to loosen them, and remove the No. 2 engine under cover. *1 Grommet
15. DRAIN ENGINE OIL Refer to «PROCEDURE - Step 3»(ref-665705-S39055648952014102400000)
16. DRAIN ENGINE COOLANT Refer to «PROCEDURE - Step 4»(ref-665707-S40400098752014102400000)
17. DRAIN DIFFERENTIAL OIL (for AWD) Refer to «PROCEDURE - Step 1»(ref-665775-S00804033692014102400000)
18. DRAIN AUTOMATIC TRANSMISSION FLUID (for 2WD) Refer to «PROCEDURE - Step 3»(ref-665750-S33561635152014102400000)
19. DRAIN AUTOMATIC TRANSMISSION FLUID (for AWD) Refer to «PROCEDURE - Step 1»(ref-665725-S09824746662014102400000)
20. REMOVE INLET NO. 1 AIR CLEANER Remove the bolt and inlet No. 1 air cleaner.
21. DISCONNECT NO. 2 VENTILATION HOSE Refer to «PROCEDURE - Step 5»(ref-665751-S42219066752014102400000)
22. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE HINT: Perform this procedure only when replacement of the air cleaner filter element sub-assembly or air cleaner case sub-assembly is necessary. Refer to «PROCEDURE - Step 6»(ref-665751-S42219066752014102400000)
23. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY HINT: Perform this procedure only when replacement of the air cleaner filter element sub-assembly is necessary. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY HINT: Perform this procedure only when replacement of the air cleaner case sub-assembly is necessary. Disconnect the wire harness clamp from the air cleaner case sub-assembly. *1 Air Cleaner Support Remove the 2 bolts and air cleaner case sub-assembly. NOTE: Make sure the air cleaner support is attached to the vehicle body.
25. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE Disconnect the mass air flow meter sub-assembly connector. Disconnect the 2 wire harness clamps from the air cleaner assembly with air cleaner hose. Disconnect the No. 2 fuel vapor feed hose clamp from the air cleaner cap with air cleaner hose. Remove the 2 bolts. *1 Air Cleaner Support Loosen the hose clamp and remove the air cleaner assembly with air cleaner hose. NOTE: Make sure the air cleaner support is attached to the vehicle body.
26. DISCONNECT UNION TO CHECK VALVE HOSE Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.
27. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE Slide the clip and disconnect the No. 2 fuel vapor feed hose from the purge valve (purge VSV).
28. DISCONNECT RADIATOR RESERVE TANK HOSE Slide the clip and disconnect the radiator reserve tank hose from the water inlet sub-assembly.
29. REMOVE NO. 1 RADIATOR HOSE Refer to «PROCEDURE - Step 6»(ref-665707-S06905327902014102400000)
30. DISCONNECT NO. 2 RADIATOR HOSE Refer to «PROCEDURE - Step 6»(ref-665707-S32163822802014102400000)
31. DISCONNECT HEATER INLET WATER HOSE Slide the clip and disconnect the heater inlet water hose from the No. 3 heater water by-pass pipe.
32. DISCONNECT HEATER OUTLET WATER HOSE Slide the clip and disconnect the heater outlet water hose from the No. 3 heater water by-pass pipe.
33. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Refer to «PROCEDURE - Step 5»(ref-665718-S22785391692014102400000)
34. DISCONNECT SUCTION HOSE Refer to «PROCEDURE - Step 6»(ref-665718-S22785391692014102400000)
35. REMOVE ENGINE ROOM ECU COVER Refer to «PROCEDURE - Step 2»(ref-665751-S21923957332014102400000)
36. DISCONNECT WIRE HARNESS HINT: After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way. Engine room LH side: Disconnect the engine wire clamp. Disconnect the engine wire from the engine room ECU box. Refer to «PROCEDURE - Step 3»(ref-665751-S21923957332014102400000) Engine room RH side: Disconnect the No. 2 engine wire clamp. Remove the nut and disconnect the No. 2 engine wire from the positive (+) battery terminal. Remove the No. 1 engine room relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly. Disconnect the 2 No. 4 engine wire clamps. Remove the nut from the No. 1 engine room relay block and No. 1 junction block assembly. Disengage the 2 claws and disconnect the No. 4 engine wire from the No. 1 engine room relay block and No. 1 junction block assembly. Disconnect the No. 3 engine wire clamp. Remove the bolt and disconnect the No. 3 engine wire from the body.
37. DISCONNECT FUEL TUBE SUB-ASSEMBLY Remove the fuel pipe clamp. Disconnect the fuel tube sub-assembly from the fuel pipe. Refer to «PRECAUTION [04/2013 - ]»(ref-665746-S08513127682014102400000)
38. DISCONNECT NO. 3 FUEL HOSE Slide the clip and disconnect the No. 3 fuel hose from the No. 1 fuel pipe sub-assembly.
39. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Refer to «PROCEDURE - Step 11»(ref-665769-S23384027332014102400000)
40. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING Refer to «REMOVAL [04/2013 - ]»(ref-665533-S23217642362014102400000)
41. REMOVE ENGINE UNDER BRACE SUB-ASSEMBLY (for 2WD) Remove the 4 bolts and engine under brace sub-assembly.
42. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY Refer to «PROCEDURE - Step 9»(ref-665769-S23384027332014102400000)
43. SEPARATE STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD) Refer to «PROCEDURE - Step 13»(ref-665774-S05830417702014102400000)
44. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 14»(ref-665774-S05830417702014102400000)
45. REMOVE FRONT AXLE SHAFT NUT LH (for AWD) Refer to «PROCEDURE - Step 4»(ref-665775-S28252735372014102400000)
46. REMOVE FRONT AXLE SHAFT NUT RH (for AWD) HINT: Perform the same procedure as for the LH side.
47. SEPARATE FRONT SPEED SENSOR LH (for AWD) Refer to «PROCEDURE - Step 2»(ref-665776-S31355378872014102400000)
48. SEPARATE FRONT SPEED SENSOR RH (for AWD) HINT: Perform the same procedure as for the LH side.
49. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 2»(ref-665775-S38530493472014102400000)
50. REMOVE FRONT DISC (for AWD) Refer to «PROCEDURE - Step 12»(ref-665715-S28884365582014102400000)
51. SEPARATE TIE ROD ASSEMBLY LH (for AWD) Refer to «PROCEDURE - Step 17»(ref-665774-S05830417702014102400000)
52. SEPARATE TIE ROD ASSEMBLY RH (for AWD) HINT: Perform the same procedure as for the LH side.
53. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD) Remove the bolt and nut, and disconnect the front shock absorber assembly LH from the front suspension lower arm assembly LH. NOTE: When removing the bolt, keep the nut from rotating.
54. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD) HINT: Perform the same procedure as for the LH side.
55. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH (for AWD) Remove the bolt and disconnect the front shock absorber assembly LH from the front lower shock absorber bracket LH.
56. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH (for AWD) HINT: Perform the same procedure as for the LH side.
57. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD) Refer to «PROCEDURE - Step 10»(ref-665775-S00026463282014102400000)
58. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD) HINT: Perform the same procedure as for the LH side.
59. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH (for AWD) Refer to «PROCEDURE - Step 11»(ref-665775-S00026463282014102400000)
60. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH (for AWD) HINT: Perform the same procedure as for the LH side.
61. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH (for AWD) Refer to «PROCEDURE - Step 8»(ref-665533-S17189168142014102400000)
62. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH (for AWD) HINT: Perform the same procedure as for the LH side.
63. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for AWD) Refer to «PROCEDURE - Step 9»(ref-665533-S17189168142014102400000)
64. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for AWD) Refer to «PROCEDURE - Step 10»(ref-665533-S17189168142014102400000)
65. DISCONNECT WIRE HARNESS for 2WD: Disconnect the 2 wire harness clamps and 3 wire harness connectors from the power steering link assembly. HINT: For the connector with lock lever, pull up the lock lever to disengage the lock. for AWD: Remove the bolt and wire harness bracket from the front frame assembly. Disconnect the 2 wire harness clamps from the front frame assembly. Disconnect the 3 wire harness connectors from the power steering link assembly. HINT: For the connector with lock lever, pull up the lock lever to disengage the lock.
66. REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD) Refer to «PROCEDURE - Step 14»(ref-665750-S16239561672014102400000)
67. REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 10»(ref-665725-S20409826952014102400000)
68. REMOVE FRONT UPPER NO. 2 SUSPENSION MEMBER (for 2WD) Remove the 6 bolts and 2 front upper No. 2 suspension members.
69. REMOVE NO. 1 FRAME CROSSMEMBER ASSEMBLY (for AWD) Remove the 3 bolts and No. 1 frame crossmember assembly.
70. REMOVE NO. 2 FRAME CROSSMEMBER ASSEMBLY (for AWD) Remove the 3 bolts and No. 2 frame crossmember assembly.
71. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD) Remove the 4 bolts and front lower suspension member protector from the front suspension crossmember sub-assembly.
72. REMOVE FRONT SUSPENSION MEMBER BRACE (for AWD) Remove the 4 bolts and 2 front suspension member braces from the front frame assembly.
73. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION (for 2WD) Remove the nut and disconnect the No. 2 earth wire from the body. Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transmission. NOTE: Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transmission. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand. Attachment Installation Position Remove the 4 bolts, and separate the rear engine mounting member from the body. Remove the 4 bolts and disconnect the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH. Bolt Nut Remove the 6 bolts, 2 nuts and strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly. Operate the engine lifter, then remove the engine assembly with transmission from the vehicle. NOTE: Make sure that the engine assembly with transmission is clear of all wiring, hoses and steering sliding with shaft yoke sub-assembly. After removing the engine assembly with transmission, hang the steering sliding with shaft yoke sub-assembly with rope or equivalent.
74. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION (for AWD) Remove the nut and disconnect the No. 2 earth wire from the body. Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transmission. NOTE: Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transmission. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand. Attachment Installation Position Remove the 4 bolts, and separate the rear engine mounting member from the body. Remove the 6 bolts, 2 nuts and strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front frame assembly. Bolt Nut Operate the engine lifter, then remove the engine assembly with transmission from the vehicle. NOTE: Make sure that the engine assembly with transmission is clear of all wiring, hoses and No. 2 steering intermediate shaft assembly. After removing the engine assembly with transmission, hang the No. 2 steering intermediate shaft assembly with rope or equivalent.
75. INSTALL NO. 1 ENGINE HANGER Install the 2 No. 1 engine hangers with the 4 bolts as shown in the illustration. *a RH Side *b LH Side Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) HINT: No. 1 Engine Hanger 12281-31070 Bolt 91671-F0822 Attach an engine sling device and hang the engine assembly with a chain block. NOTE: Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hangers may be damaged or deformed if the angle is incorrect. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
76. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE for 2WD: *A for 2WD *B for AWD Disconnect the wire harness clamp from the 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. for AWD: Remove the bolt and engine oil level dipstick guide. Remove the O-ring from the engine oil level dipstick guide.
77. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) Refer to «PROCEDURE - Step 13»(ref-665769-S23384027332014102400000)
78. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) Refer to «PROCEDURE - Step 12»(ref-665769-S23384027332014102400000)
79. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 3»(ref-665533-S12726328152014102400000)
80. REMOVE STARTER ASSEMBLY Refer to «PROCEDURE - Step 4»(ref-665749-S25655447872014102400000)
81. REMOVE FLYWHEEL HOUSING SIDE COVER Refer to «PROCEDURE - Step 12»(ref-665750-S16239561672014102400000)
82. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT Refer to «PROCEDURE - Step 13»(ref-665750-S16239561672014102400000)
83. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) Refer to «PROCEDURE - Step 20»(ref-665750-S16239561672014102400000)
84. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 16»(ref-665725-S20409826952014102400000)
85. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 3
86. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 2»(ref-665775-S42897936342014102400000)
87. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD) Remove the 2 bolts and front suspension crossmember sub-assembly from the engine assembly. *a LH Side *b RH Side
88. REMOVE FRONT FRAME ASSEMBLY (for AWD) Remove the 2 bolts and front frame assembly from the engine assembly. *a LH Side *b RH Side
89. REMOVE FRONT ENGINE MOUNTING INSULATOR HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary. for 2WD: *a LH Side *b RH Side Remove the 2 nuts and 2 front engine mounting insulators from the front suspension crossmember sub-assembly. for AWD: *a LH Side *b RH Side Remove the 4 nuts and disconnect the 2 front engine mounting insulators from the front frame assembly.
90. REMOVE REAR ENGINE MOUNTING MEMBER (for 2WD) HINT: Perform this procedure only when replacement of the rear engine mounting insulator is necessary. Remove the 4 nuts and rear engine mounting member from the rear engine mounting insulator.
91. REMOVE REAR ENGINE MOUNTING MEMBER (for AWD) HINT: Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary. Remove the 3 nuts and rear engine mounting member from the rear No. 1 engine mounting insulator.
92. REMOVE REAR ENGINE MOUNTING INSULATOR (for 2WD) HINT: Perform this procedure only when replacement of the rear engine mounting insulator is necessary. Remove the 4 bolts and rear engine mounting insulator from the automatic transmission assembly.
93. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for AWD) HINT: Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary. Remove the 3 bolts and engine mounting bracket from the automatic transmission with transfer assembly. Remove the bolt and rear No. 1 engine mounting insulator from the engine mounting bracket.
94. INSTALL ENGINE TO ENGINE STAND Install the engine assembly to an engine stand. NOTE: Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hangers may be damaged or deformed if the angle is incorrect. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand. Remove the 4 bolts and 2 No. 1 engine hangers.
95. 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 (0.02756 in.) If the warpage is more than the maximum, replace the exhaust manifold sub-assembly.

HINT

Perform "Inspection After Repair" after replacing an engine assembly, cylinder head sub-assembly, camshaft, No. 2 camshaft, No. 3 camshaft sub-assembly, No. 4 camshaft sub-assembly, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston or piston ring set.

Scheme 121

Scheme 122

Scheme 123

Scheme 124

1. INSTALL NO. 1 ENGINE HANGER See step 75
2. REMOVE ENGINE FROM ENGINE STAND Remove the engine assembly from the engine stand.
3. INSTALL REAR ENGINE MOUNTING INSULATOR (for 2WD) HINT: Perform this procedure only when replacement of the rear engine mounting insulator is necessary. Install the rear engine mounting insulator to the automatic transmission assembly with the 4 bolts. *a Claw Vehicle Front Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf) HINT: Make sure that the claw is facing towards the front of the vehicle.
4. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for AWD) HINT: Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary. Install the rear No. 1 engine mounting insulator to the engine mounting bracket with the bolt. Torque: 68.6 N*m (700 kgf*cm, 51 ft.*lbf) *a Paint Mark HINT: Make sure that the paint mark is facing as shown in the illustration. Install the engine mounting bracket to the automatic transmission with transfer assembly with the 3 bolts. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
5. INSTALL REAR ENGINE MOUNTING MEMBER (for 2WD) HINT: Perform this procedure only when replacement of the rear engine mounting insulator is necessary. Install the rear engine mounting member to the rear engine mounting insulator with the 4 nuts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
6. INSTALL REAR ENGINE MOUNTING MEMBER (for AWD) HINT: Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary. Install the rear engine mounting member to the rear No. 1 engine mounting insulator with the 3 nuts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
7. INSTALL FRONT ENGINE MOUNTING INSULATOR HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary. for 2WD: Install the 2 front engine mounting insulators to the front suspension crossmember sub-assembly with the 2 nuts. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) for AWD: Install the 2 front engine mounting insulators to the front frame assembly with the 4 nuts. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf)
8. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD) Install the front suspension crossmember sub-assembly to the engine assembly with the 2 bolts Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
9. INSTALL FRONT FRAME ASSEMBLY (for AWD) Install the front frame assembly to the engine assembly with the 2 bolts. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
10. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 1»(ref-665775-S31918540372014102400000)
11. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2
12. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665750-S30807346022014102400000)
13. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) Refer to «PROCEDURE - Step 4»(ref-665750-S25958528492014102400000)
14. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 4»(ref-665725-S25885617782014102400000)
15. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT See step 15
16. INSTALL FLYWHEEL HOUSING SIDE COVER Refer to «PROCEDURE - Step 11»(ref-665750-S25958528492014102400000)
17. INSTALL STARTER ASSEMBLY Refer to «PROCEDURE - Step 1»(ref-665749-S30700842862014102400000)
18. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 1»(ref-665533-S39482806552014102400000)
19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) Refer to «PROCEDURE - Step 1»(ref-665769-S16841631392014102400000)
20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) Refer to «PROCEDURE - Step 2»(ref-665769-S16841631392014102400000)
21. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE for 2WD: Install a new O-ring to the engine oil level dipstick guide. HINT: Apply a light coat of engine oil to the O-ring. Install the engine oil level dipstick guide with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the wire harness clamp to the engine oil level dipstick guide. for AWD: Install a new O-ring to the engine oil level dipstick guide. HINT: Apply a light coat of engine oil to the O-ring. Install the engine oil level dipstick guide with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
22. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION (for 2WD) Set the engine assembly with transmission on the engine lifter. NOTE: Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand. To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transmission. Remove the 4 bolts and 2 No. 1 engine hangers. Install the engine assembly with transmission to the vehicle. NOTE: Make sure that the engine assembly with transmission is clear of all wiring, hoses and steering sliding with shaft yoke sub-assembly. Install the strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly with the 6 bolts and 2 nuts. Bolt Nut Bolt A Torque: 194 N*m (1978 kgf*cm, 143 ft.*lbf) Bolt B Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) Nut Torque: 151 N*m (1540 kgf*cm, 111 ft.*lbf) Install the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH with the 4 bolts. Bolt C Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) Install the rear engine mounting member to the body with the 4 bolts. Torque: 34.7 N*m (354 kgf*cm, 26 ft.*lbf) Install the No. 2 earth wire to the body with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
23. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION (for AWD) Set the engine assembly with transmission on the engine lifter. NOTE: Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand. To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transmission. Remove the 4 bolts and 2 No. 1 engine hangers. Install the engine assembly with transmission to the vehicle. NOTE: Make sure that the engine assembly with transmission is clear of all wiring, hoses and No. 2 steering intermediate shaft assembly. Install the strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front frame assembly with the 6 bolts and 2 nuts. Bolt Nut Bolt A, Nut Torque: 151 N*m (1540 kgf*cm, 111 ft.*lbf) Bolt B Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) Install the rear engine mounting member to the body with the 4 bolts. Torque: 34.7 N*m (354 kgf*cm, 26 ft.*lbf) Install the No. 2 earth wire to the body with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
24. INSTALL FRONT SUSPENSION MEMBER BRACE (for AWD) Install the 2 front suspension member braces to the front frame assembly with the 4 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
25. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD) Install the front lower suspension member protector to the front suspension crossmember sub-assembly with the 4 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
26. INSTALL NO. 2 FRAME CROSSMEMBER ASSEMBLY (for AWD) Install the No. 2 frame crossmember assembly with the 3 bolts. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
27. INSTALL NO. 1 FRAME CROSSMEMBER ASSEMBLY (for AWD) Install the No. 1 frame crossmember assembly with the 3 bolts. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
28. INSTALL FRONT UPPER NO. 2 SUSPENSION MEMBER (for 2WD) Install the 2 front upper No. 2 suspension members with the 6 bolts. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
29. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD) Refer to «PROCEDURE - Step 9»(ref-665750-S25958528492014102400000)
30. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 9»(ref-665725-S25885617782014102400000)
31. CONNECT WIRE HARNESS for 2WD: Connect the 2 wire harness clamps to the power steering link assembly. Connect the 3 wire harness connectors to the power steering link assembly. HINT: For the connector with lock lever, fully insert the connector and push down the lock lever to engage the lock. for AWD: Connect the 3 wire harness connectors to the power steering link assembly. HINT: For the connector with lock lever, fully insert the connector and push down the lock lever to engage the lock. Connect the 2 wire harness clamps to the front frame assembly. Install the wire harness bracket to the front frame assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
32. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for AWD) Refer to «PROCEDURE - Step 2»(ref-665533-S05660072442014102400000)
33. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for AWD) Refer to «PROCEDURE - Step 3»(ref-665533-S05660072442014102400000)
34. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD) Refer to «PROCEDURE - Step 4»(ref-665776-S15302938692014102400000)
35. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD) HINT: Perform the same procedure as for the LH side.
36. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH (for AWD) Refer to «PROCEDURE - Step 4»(ref-665776-S09087344222014102400000)
37. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH (for AWD) HINT: Perform the same procedure as for the LH side.
38. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD) Connect the front shock absorber assembly LH to the front suspension lower arm assembly LH with the bolt and nut. Torque: 180 N*m (1835 kgf*cm, 133 ft.*lbf) NOTE: Insert the bolt from the rear of the vehicle. Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.
39. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD) HINT: Perform the same procedure as for the LH side.
40. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH (for AWD) Connect the front shock absorber assembly LH to the front lower shock absorber bracket LH with the bolt. Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf)
41. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH (for AWD) HINT: Perform the same procedure as for the LH side.
42. CONNECT TIE ROD ASSEMBLY LH (for AWD) Refer to «PROCEDURE - Step 6»(ref-665774-S02326905532014102400000)
43. CONNECT TIE ROD ASSEMBLY RH (for AWD) HINT: Perform the same procedure as for the LH side.
44. INSTALL FRONT DISC (for AWD) Refer to «PROCEDURE - Step 1»(ref-665715-S00006262402014102400000)
45. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 7»(ref-665775-S38530493472014102400000)
46. INSTALL FRONT SPEED SENSOR LH (for AWD) Refer to «PROCEDURE - Step 14»(ref-665775-S23565838582014102400000)
47. INSTALL FRONT SPEED SENSOR RH (for AWD) HINT: Perform the same procedure as for the LH side.
48. INSTALL FRONT AXLE SHAFT NUT LH (for AWD) Refer to «PROCEDURE - Step 12»(ref-665775-S23565838582014102400000)
49. INSTALL FRONT AXLE SHAFT NUT RH (for AWD) HINT: Perform the same procedure as for the LH side.
50. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD) Refer to «PROCEDURE - Step 8»(ref-665774-S02326905532014102400000)
51. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 9»(ref-665774-S02326905532014102400000)
52. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY Refer to «PROCEDURE - Step 5»(ref-665769-S16841631392014102400000)
53. INSTALL ENGINE UNDER BRACE SUB-ASSEMBLY (for 2WD) Install the engine under brace sub-assembly to the body with the 4 bolts. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
54. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Refer to «INSTALLATION [04/2013 - ]»(ref-665533-S02063238412014102400000)
55. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Refer to «PROCEDURE - Step 3»(ref-665769-S16841631392014102400000)
56. CONNECT NO. 3 FUEL HOSE Connect the No. 3 fuel hose to the No. 1 fuel pipe sub-assembly and slide the clip to secure it.
57. CONNECT FUEL TUBE SUB-ASSEMBLY Connect the fuel tube sub-assembly to the fuel pipe and slide the clip to secure it. Refer to «PRECAUTION [04/2013 - ]»(ref-665746-S08513127682014102400000) Install the fuel pipe clamp.
58. CONNECT WIRE HARNESS Engine room LH side: Connect the engine wire to the engine room ECU box. Refer to «PROCEDURE - Step 4»(ref-665751-S32699349962014102400000) Connect the engine wire clamp. Engine room RH side: Connect the No. 3 engine wire to the body with the bolt. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) Connect the No. 3 engine wire clamp. Engage the 2 claws and connect the No. 4 engine wire to the No. 1 engine room relay block and No. 1 junction block assembly. Install the nut to the No. 1 engine room relay block and No. 1 junction block assembly. Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf) Connect the 2 No. 4 engine wire clamps. Install the No. 1 engine room relay block cover to the No. 1 engine room relay block and No. 1 junction block assembly. Connect the No. 2 engine wire to the positive (+) battery terminal with the nut. Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf) Connect the No. 2 engine wire clamp.
59. INSTALL ENGINE ROOM ECU COVER Refer to «PROCEDURE - Step 5»(ref-665751-S32699349962014102400000)
60. CONNECT SUCTION HOSE Refer to «PROCEDURE - Step 3»(ref-665718-S00056089582014102400000)
61. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Refer to «PROCEDURE - Step 4»(ref-665718-S00056089582014102400000)
62. CONNECT HEATER OUTLET WATER HOSE Connect the heater outlet water hose to the No. 3 water by-pass pipe and slide the clip to secure it.
63. CONNECT HEATER INLET WATER HOSE Connect the heater inlet water hose to the No. 3 water by-pass pipe and slide the clip to secure it.
64. CONNECT NO. 2 RADIATOR HOSE Refer to «PROCEDURE - Step 3»(ref-665707-S12421404322014102400000)
65. INSTALL NO. 1 RADIATOR HOSE Refer to «PROCEDURE - Step 9»(ref-665707-S37855369302014102400000)
66. CONNECT RADIATOR RESERVE TANK HOSE Connect the radiator reserve tank hose to the water inlet sub-assembly and slide the clip to secure it.
67. CONNECT NO. 2 FUEL VAPOR FEED HOSE Connect the No. 2 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.
68. CONNECT UNION TO CHECK VALVE HOSE Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.
69. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE Connect the air cleaner assembly with air cleaner hose to the throttle body with motor assembly. *1 Air Cleaner Support *a Pin *b Protrusion Fit the pin of the air cleaner assembly with air cleaner hose into the air cleaner support as shown in the illustration. Install the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Tighten the hose clamp. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) NOTE: Fit the protrusion on the air cleaner hose into the hole of the hose clamp on the throttle body with motor assembly side. Connect the No. 2 fuel vapor feed hose clamp to the air cleaner assembly with air cleaner hose. Connect the 2 wire harness clamps to the air cleaner assembly with air cleaner hose. Connect the mass air flow meter sub-assembly connector.
70. INSTALL AIR CLEANER CASE SUB-ASSEMBLY HINT: Perform this procedure only when replacement of the air cleaner case sub-assembly is necessary. Fit the pin of the air cleaner case sub-assembly into the air cleaner support as shown in the illustration. *1 Air Cleaner Support *a Pin Install the air cleaner case sub-assembly with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Install the wire harness clamp to the air cleaner case sub-assembly.
71. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY HINT: Perform this procedure only when replacement of the air cleaner filter element sub-assembly is necessary. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.
72. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE HINT: Perform this procedure only when replacement of the air cleaner filter element sub-assembly or air cleaner case sub-assembly is necessary. Refer to «PROCEDURE - Step 3»(ref-665751-S29633936302014102400000)
73. CONNECT NO. 2 VENTILATION HOSE Refer to «PROCEDURE - Step 4»(ref-665751-S29633936302014102400000)
74. INSTALL INLET NO. 1 AIR CLEANER Install the inlet No. 1 air cleaner with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
75. ADD ENGINE OIL Refer to «PROCEDURE - Step 7»(ref-665705-S34609640792014102400000)
76. ADD DIFFERENTIAL OIL (for AWD) Refer to «PROCEDURE - Step 2»(ref-665775-S00804033692014102400000)
77. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Connect the cable to negative (-) battery to the negative (-) battery terminal with the nut. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [04/2013 - ]»(ref-665529-S01115916402014102400000)
78. ADD ENGINE COOLANT Refer to «PROCEDURE - Step 5»(ref-665707-S40400098752014102400000)
79. ADD AUTOMATIC TRANSMISSION FLUID (for 2WD) Refer to «ADJUSTMENT [04/2013 - ]»(ref-665750-S38854829892014102400000)
80. ADD AUTOMATIC TRANSMISSION FLUID (for AWD) Refer to «ADJUSTMENT [04/2013 - ]»(ref-665725-S33805047462014102400000)
81. INSPECT FOR REFRIGERANT Refer to «REPLACEMENT [04/2013 - ]»(ref-665718-S29281733902014102400000)
82. INSPECT SHIFT LEVER POSITION Refer to «PROCEDURE - Step 1»(ref-665725-S20614278182014102400000)
83. ADJUST SHIFT LEVER POSITION Refer to «PROCEDURE - Step 3»(ref-665725-S28386345552014102400000)
84. INSPECT FOR COOLANT LEAK Refer to «PROCEDURE - Step 1»(ref-665770-S12066795872014102400000)
85. INSPECT FOR ENGINE OIL LEAK Refer to «PROCEDURE - Step 8»(ref-665705-S34609640792014102400000)
86. INSPECT FOR FUEL LEAK Refer to «PRECAUTION [04/2013 - ]»(ref-665746-S08513127682014102400000)
87. INSPECT FOR EXHAUST GAS LEAK Refer to «PROCEDURE - Step 14»(ref-665769-S16841631392014102400000)
88. INSPECT FOR REFRIGERANT LEAK Refer to «PROCEDURE - Step 4»(ref-665718-S31675478902014102400000)
89. INSTALL FRONT WHEELS Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)
90. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
91. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to «ADJUSTMENT [04/2013 - ]»(ref-665717-S01892977822014102400000)
92. PERFORM INITIALIZATION Refer to «INITIALIZATION [04/2013 - ]»(ref-665529-S01115916402014102400000)
93. INSPECT THROTTLE BODY WITH MOTOR ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665751-S29633936302014102400000)
94. INSPECT IGNITION TIMING See step 8
95. INSPECT ENGINE IDLE SPEED See step 9
96. INSPECT CO/HC See step 11
97. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR Refer to «PROCEDURE - Step 2»(ref-665770-S12066795872014102400000)
98. INSPECT ENGINE OIL LEVEL Refer to «PROCEDURE - Step 1»(ref-665777-S22772485902014102400000)
99. INSTALL NO. 2 ENGINE UNDER COVER (w/ No. 2 Engine Under Cover) Install the No. 2 engine under cover with the 4 screws and 2 grommets.
100. INSTALL FRONT SUSPENSION MEMBER BRACE (for 2WD) Install the front suspension member brace with the clip and 4 bolts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
101. INSTALL REAR ENGINE UNDER COVER LH (for 2WD) Install the rear engine under cover LH with the screw.
102. INSTALL REAR ENGINE UNDER COVER RH (for 2WD) HINT: Perform the same procedure as for the LH side.
103. INSTALL ENGINE UNDER COVER for 2WD: Install the engine under cover with the 13 screws and 3 clips. for AWD: Install the engine under cover with the 10 screws and 3 clips.
104. INSTALL V-BANK COVER SUB-ASSEMBLY Attach the 3 clips in the order shown in the illustration to install the V-bank cover sub-assembly. *a 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).
105. INSTALL COOL AIR INTAKE DUCT SEAL Refer to «PROCEDURE - Step 3»(ref-665772-S40987981332014102400000)

Scheme 125

*A for COLD START FUEL INJECTOR - - *1 INTAKE AIR SURGE TANK ASSEMBLY *2 INTAKE MANIFOLD *3 NO. 3 WATER BY-PASS PIPE *4 THROTTLE BODY WITH MOTOR ASSEMBLY *5 NO. 1 WATER BY-PASS HOSE *6 FUEL TUBE SUB-ASSEMBLY *7 COLD START FUEL INJECTOR ASSEMBLY *8 NO. 2 WATER BY-PASS HOSE *9 NO. 2 SURGE TANK STAY *10 PURGE VALVE (PURGE VSV) *11 NO. 8 WATER BY-PASS HOSE *12 NO. 9 WATER BY-PASS HOSE *13 GASKET - - N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part Do not apply lubricants (to the threaded parts)

Scheme 126

*A for 2WD *B for AWD *1 GENERATOR ASSEMBLY *2 COMPRESSOR AND MAGNETIC CLUTCH *3 ENGINE WIRE *4 FRONT NO. 1 ENGINE MOUNTING BRACKET LH *5 FRONT NO. 1 ENGINE MOUNTING BRACKET RH *6 NO. 2 ENGINE COVER *7 V-RIBBED BELT *8 V-RIBBED BELT TENSIONER ASSEMBLY *9 WIRE HARNESS CLAMP BRACKET *10 OIL FILTER BRACKET N*m (kgf*cm, ft.*lbf): Specified torque

Scheme 127

*1 IGNITION COIL ASSEMBLY *2 INJECTOR DRIVER *3 NO. 1 ENGINE COVER *4 NO. 2 IDLER PULLEY SUB-ASSEMBLY *5 V-BANK COVER BRACKET SUB-ASSEMBLY *6 WATER PUMP PULLEY *7 WASHER PLATE *8 WIRE HARNESS N*m (kgf*cm, ft.*lbf): Specified torque

Scheme 128

*1 FUEL PRESSURE PULSATION DAMPER ASSEMBLY *2 FUEL PUMP ASSEMBLY *3 NO. 1 FUEL PIPE SUB-ASSEMBLY *4 NO. 2 FUEL PIPE SUB-ASSEMBLY *5 NO. 3 FUEL PIPE SUB-ASSEMBLY *6 NO. 1 BACKUP RING *7 NO. 2 BACKUP RING *8 O-RING *9 NO. 3 BACKUP RING *10 E-RING *11 GASKET *12 FUEL PUMP INSULATOR *13 FUEL TUBE SUB-ASSEMBLY *14 WIRE HARNESS N*m (kgf*cm, ft.*lbf): Specified torque • Non-reusable part * For use with SST

Scheme 129

*1 FUEL DELIVERY PIPE SUB-ASSEMBLY *2 FUEL INJECTOR ASSEMBLY *3 FUEL INJECTOR SEAL *4 NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY *5 NO. 3 FUEL INJECTOR BACK-UP RING *6 NO. 2 FUEL INJECTOR BACK-UP RING *7 NO. 1 FUEL INJECTOR BACK-UP RING *8 NOZZLE HOLDER CLAMP *9 E-RING *10 O-RING *11 INJECTOR VIBRATION INSULATOR - - N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part

Scheme 130

*1 CYLINDER HEAD COVER SUB-ASSEMBLY *2 NO. 2 OIL PIPE *3 SPARK PLUG *4 SPARK PLUG TUBE GASKET *5 CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) *6 CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) *7 CYLINDER HEAD COVER SEAL WASHER *8 O-RING *9 STUD BOLT *10 GASKET *11 OIL CONTROL VALVE FILTER RH *12 OIL PIPE UNION *13 OIL CHECK VALVE BOLT *14 CYLINDER HEAD COVER GASKET *15 VVT SENSOR (for Intake Side of Bank 1) *16 VVT SENSOR (for Exhaust Side of Bank 1) N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part * Precoated part

Scheme 131

*1 CYLINDER HEAD COVER SUB-ASSEMBLY LH *2 NO. 1 OIL PIPE *3 OIL FILLER CAP SUB-ASSEMBLY *4 SPARK PLUG *5 SPARK PLUG TUBE GASKET *6 PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) *7 CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) *8 VVT SENSOR (for Intake Side of Bank 2) *9 VVT SENSOR (for Exhaust Side of Bank 2) *10 O-RING *11 GASKET *12 CYLINDER HEAD COVER SEAL WASHER *13 CYLINDER HEAD COVER GASKET LH *14 OIL CONTROL VALVE FILTER LH *15 OIL PIPE UNION *16 OIL CHECK VALVE BOLT *17 CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) - - N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part * Precoated part

Scheme 132

*1 CRANKSHAFT POSITION SENSOR *2 CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY *3 ENGINE COOLANT TEMPERATURE SENSOR *4 WATER INLET SUB-ASSEMBLY *5 WATER INLET SUB-ASSEMBLY WITH THERMOSTAT *6 RADIATOR CAP SUB-ASSEMBLY *7 ENGINE REAR OIL SEAL *8 ENGINE REAR OIL SEAL RETAINER *9 REAR WATER BY-PASS JOINT *10 NO. 4 WATER BY-PASS HOSE *11 WATER OUTLET PIPE O-RING *12 NO. 6 WATER BY-PASS HOSE *13 NO. 1 WATER INLET HOUSING GASKET *14 WATER INLET HOUSING GASKET *15 NO. 3 WATER BY-PASS HOSE *16 WATER DRAIN COCK PLUG *17 WATER OUTLET GASKET *18 GASKET N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part MP Grease * Precoated part

Scheme 133

*A for 2WD - - *1 ENGINE OIL LEVEL SENSOR *2 ENGINE OIL PRESSURE SWITCH ASSEMBLY *3 NO. 2 OIL PAN SUB-ASSEMBLY *4 OIL PAN DRAIN PLUG *5 OIL PAN SUB-ASSEMBLY *6 OIL STRAINER SUB-ASSEMBLY *7 OIL FILTER ELEMENT *8 OIL STRAINER GASKET *9 NO. 1 OIL PAN BUFFLE PLATE *10 OIL FILTER CAP ASSEMBLY *11 O-RING *12 GASKET *13 STUD BOLT - - N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part * Precoated part - - T1 Type A: 14.7 (150, 11) Type B: 15 (153, 11)

Scheme 134

*B for AWD - - *1 ENGINE OIL LEVEL SENSOR *2 ENGINE OIL PRESSURE SWITCH ASSEMBLY *3 NO. 2 OIL PAN SUB-ASSEMBLY *4 OIL FILTER BRACKET SUB-ASSEMBLY *5 OIL PAN DRAIN PLUG *6 OIL PAN SUB-ASSEMBLY *7 OIL STRAINER SUB-ASSEMBLY *8 OIL STRAINER WITH PIPE SUB-ASSEMBLY *9 OIL FILTER ELEMENT *10 OIL STRAINER GASKET *11 NO. 1 OIL PAN BAFFLE PLATE *12 OIL FILTER CAP SUB-ASSEMBLY *13 OIL FILTER DRAIN PLUG *14 GASKET *15 O-RING *16 STUD BOLT N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part * Precoated part - - T1 Type A: 14.7 (150, 11) Type B: 15 (153, 11)

Scheme 135

*1 CRANKSHAFT PULLEY *2 ENGINE WATER PUMP ASSEMBLY *3 TIMING CHAIN OR BELT COVER SUB-ASSEMBLY *4 TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL *5 TIMING CHAIN COVER GASKET *6 TIMING CHAIN COVER PLATE *7 WATER PUMP GASKET - - N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part MP Grease * Precoated part Do not apply lubricants to the threaded parts

Scheme 136

*1 CHAIN SUB-ASSEMBLY *2 CHAIN TENSIONER SLIPPER *3 CRANKSHAFT TIMING GEAR OR SPROCKET *4 IDLE SPROCKET ASSEMBLY *5 NO. 1 CHAIN TENSIONER ASSEMBLY *6 NO. 1 CHAIN VIBRATION DAMPER *7 NO. 2 CHAIN VIBRATION DAMPER *8 NO. 1 IDLE GEAR SHAFT *9 NO. 2 IDLE GEAR SHAFT *10 OIL PUMP GASKET *11 CRANKSHAFT TIMING GEAR KEY - - N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part

Scheme 137

*1 CAMSHAFT *2 CAMSHAFT HOUSING SUB-ASSEMBLY RH *3 NO. 1 STRAIGHT PIN *4 NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY *5 NO. 2 CAMSHAFT *6 NO. 2 CHAIN TENSIONER ASSEMBLY *7 RING WITH HEAD PIN *8 VALVE LASH ADJUSTER ASSEMBLY *9 VALVE STEM CAP *10 NO. 1 CAMSHAFT BEARING CAP *11 CAMSHAFT TIMING GEAR ASSEMBLY *12 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH *13 NO. 6 CAMSHAFT BEARING CAP *14 NO. 5 CAMSHAFT BEARING CAP *15 NO. 2 CAMSHAFT BEARING CAP *16 GASKET *17 NO. 7 CAMSHAFT BEARING CAP *18 NO. 2 CHAIN SUB-ASSEMBLY N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part

Scheme 138

*1 CAMSHAFT HOUSING SUB-ASSEMBLY LH *2 NO. 1 STRAIGHT PIN *3 NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY *4 NO. 3 CAMSHAFT SUB-ASSEMBLY *5 NO. 3 CHAIN TENSIONER ASSEMBLY *6 NO. 4 CAMSHAFT SUB-ASSEMBLY *7 RING WITH HEAD PIN *8 VALVE LASH ADJUSTER ASSEMBLY *9 VALVE STEM CAP *10 NO. 3 CAMSHAFT BEARING CAP *11 CAMSHAFT TIMING GEAR ASSEMBLY *12 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH *13 NO. 8 CAMSHAFT BEARING CAP *14 NO. 4 CAMSHAFT BEARING CAP *15 NO. 7 CAMSHAFT BEARING CAP *16 NO. 2 CHAIN SUB-ASSEMBLY *17 GASKET - - N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part

Scheme 139

*1 CYLINDER BLOCK WATER JACKET SPACER LH *2 CYLINDER BLOCK WATER JACKET SPACER RH *3 CYLINDER HEAD GASKET *4 CYLINDER HEAD LH *5 CYLINDER HEAD SUB-ASSEMBLY *6 KNOCK CONTROL SENSOR *7 NO. 2 CYLINDER HEAD GASKET *8 WATER OUTLET PIPE SUB-ASSEMBLY *9 CYLINDER HEAD SET BOLT *10 NO. 5 ENGINE WIRE N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part *T1 1st: 36 (367, 27) 2nd: Turn 90° 3rd: Turn 90°

Scheme 140

Scheme 141

1. REMOVE V-RIBBED BELT See step 4
2. REMOVE NO. 2 ENGINE COVER Disconnect the clamp from the No. 2 engine cover sub-assembly. Remove the 3 clips and No. 2 engine cover sub-assembly.
3. REMOVE NO. 1 ENGINE COVER Refer to «PROCEDURE - Step 6»(ref-665752-S37873769332014102400000)
4. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Refer to «PROCEDURE - Step 12»(ref-665707-S16046687922014102400000)
5. REMOVE GENERATOR ASSEMBLY Refer to «PROCEDURE - Step 10»(ref-665778-S42616317152014102400000)
6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (for 2WD) Refer to «PROCEDURE - Step 7»(ref-665718-S22785391692014102400000)
7. REMOVE OIL FILTER BRACKET (for AWD) Refer to «PROCEDURE - Step 7»(ref-665718-S18353383832014102400000)
8. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (for AWD) Refer to «PROCEDURE - Step 9»(ref-665718-S18353383832014102400000)
9. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH Disconnect the 2 clamps. *A for 2WD *B for AWD Remove the 4 bolts and front No. 1 engine mounting bracket LH from the cylinder block sub-assembly.
10. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH Remove the 4 bolts and front No. 1 engine mounting bracket RH from the cylinder block sub-assembly. *A for 2WD *B for AWD
11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Refer to «PROCEDURE - Step 9»(ref-665705-S23014168312014102400000)
12. REMOVE WATER PUMP PULLEY Refer to «PROCEDURE - Step 10»(ref-665707-S16046687922014102400000)
13. REMOVE ENGINE WIRE Remove the engine wire from the engine assembly.
14. REMOVE INJECTOR DRIVER Refer to «PROCEDURE - Step 7»(ref-665752-S37873769332014102400000)
15. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY Refer to «PROCEDURE - Step 7»(ref-665751-S42219066752014102400000)
16. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Refer to «PROCEDURE - Step 7»(ref-665769-S41782566002014102400000)
17. REMOVE NO. 2 SURGE TANK STAY Disconnect the 2 clamps from the No. 2 surge tank stay. Remove the bolt and No. 2 surge tank stay from the camshaft housing sub-assembly LH.
18. REMOVE NO. 3 WATER BY-PASS PIPE Remove the bolt and No. 3 water by-pass pipe from the camshaft housing sub-assembly RH. *1 No. 3 Water By-pass Pipe *2 No. 8 Water By-pass Hose *3 No. 9 Water By-pass Hose Slide the clip and disconnect the No. 8 water by-pass hose from the water outlet pipe assembly. Slide the clip and disconnect the No. 9 water by-pass hose from the rear water by-pass joint.
19. REMOVE INTAKE MANIFOLD Refer to «PROCEDURE - Step 8»(ref-665769-S41782566002014102400000)
20. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY Refer to «PROCEDURE - Step 7»(ref-665752-S37330039182014102400000)
21. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 7»(ref-665752-S06946085562014102400000)
22. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 8»(ref-665752-S06946085562014102400000)
23. REMOVE FUEL PUMP ASSEMBLY Refer to «PROCEDURE - Step 9»(ref-665752-S06946085562014102400000)
24. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 10»(ref-665752-S06946085562014102400000)
25. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665752-S14929502462014102400000)
26. REMOVE WIRE HARNESS CLAMP BRACKET Remove the bolt and wire harness clamp bracket from the camshaft housing sub-assembly RH.
27. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY Remove the bolt and V-bank cover bracket sub-assembly from the cylinder head cover sub-assembly RH.
28. REMOVE IGNITION COIL ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665751-S23724193242014102400000)

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

1. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 3»(ref-665752-S14929502462014102400000)
2. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 4»(ref-665752-S14929502462014102400000)
3. REMOVE FUEL INJECTOR ASSEMBLY Refer to «PROCEDURE - Step 5»(ref-665752-S14929502462014102400000)
4. REMOVE FUEL INJECTOR SEAL Refer to «PROCEDURE - Step 6»(ref-665752-S14929502462014102400000)
5. REMOVE OIL FILLER CAP SUB-ASSEMBLY Remove the oil filler cap sub-assembly and gasket.
6. REMOVE RADIATOR CAP SUB-ASSEMBLY Remove the radiator cap sub-assembly.
7. REMOVE SPARK PLUG Refer to «PROCEDURE - Step 3»(ref-665751-S23724193242014102400000)
8. REMOVE OIL PAN DRAIN PLUG Remove the oil pan drain plug and gasket.
9. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) Refer to «PROCEDURE - Step 2»(ref-665713-S06937069652014102400000)
10. REMOVE VVT SENSOR (for Intake Side of Bank 1) Refer to «PROCEDURE - Step 2»(ref-665751-S33053073132014102400000)
11. REMOVE VVT SENSOR (for Exhaust Side of Bank 1) Refer to «PROCEDURE - Step 3»(ref-665751-S33053073132014102400000)
12. REMOVE VVT SENSOR (for Intake Side of Bank 2) Refer to «PROCEDURE - Step 4»(ref-665751-S33053073132014102400000)
13. REMOVE VVT SENSOR (for Exhaust Side of Bank 2) Refer to «PROCEDURE - Step 5»(ref-665751-S33053073132014102400000)
14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) Refer to «PROCEDURE - Step 2»(ref-665751-S13826647552014102400000)
15. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) Refer to «PROCEDURE - Step 3»(ref-665751-S13826647552014102400000)
16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) Refer to «PROCEDURE - Step 5»(ref-665751-S13826647552014102400000)
17. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) Refer to «PROCEDURE - Step 4»(ref-665751-S13826647552014102400000)
18. REMOVE ENGINE OIL LEVEL SENSOR Refer to «PROCEDURE - Step 4»(ref-665705-S24872312842014102400000)
19. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Refer to «PROCEDURE - Step 3»(ref-665751-S33606799842014102400000)
20. REMOVE CRANKSHAFT POSITION SENSOR Refer to «PROCEDURE - Step 2»(ref-665751-S18786789222014102400000)
21. REMOVE NO. 1 OIL PIPE Remove the oil check valve bolt, oil pipe union, 3 gaskets and No. 1 oil pipe. *1 Oil Pipe Union *2 Oil Check Valve Bolt Remove the oil control valve filter LH. NOTE: Do not touch the mesh when removing the oil control valve filter LH.
22. REMOVE NO. 2 OIL PIPE Remove the oil check valve bolt, oil pipe union, 3 gaskets and No. 2 oil pipe. *1 Oil Pipe Union *2 Oil Check Valve Bolt Remove the oil control valve filter RH. NOTE: Do not touch the mesh when removing the oil control valve filter RH.
23. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Remove the 2 water drain cock plugs from the 2 cylinder block water drain cock sub-assemblies. Remove the 2 cylinder block water drain cock sub-assemblies from the cylinder block sub-assembly. *a for Bank 1 *b for Bank 2
24. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY Refer to «PROCEDURE - Step 4»(ref-665705-S39055648952014102400000)
25. REMOVE OIL FILTER CAP ASSEMBLY (for 2WD) Refer to «PROCEDURE - Step 3»(ref-665705-S34609640792014102400000)
26. REMOVE OIL FILTER CAP ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 4»(ref-665705-S34609640792014102400000)
27. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY (for AWD) Remove the bolt, 2 nuts and oil filter bracket sub-assembly. Remove the gasket.
28. REMOVE CRANKSHAFT PULLEY See step 4
29. REMOVE WATER INLET SUB-ASSEMBLY Disconnect the No. 3, No. 4 and No. 6 water by-pass hoses. *1 No. 4 Water By-pass Hose *2 No. 6 Water By-pass Hose *3 No. 3 Water By-pass Hose Remove the 4 bolts, nut and water inlet sub-assembly. Remove the No. 1 water inlet housing gasket and water outlet pipe O-ring. *1 No. 1 Water Inlet Housing Gasket *2 Water Outlet Pipe O-ring Remove the No. 3, No. 4 and No. 6 water by-pass hoses. *1 No. 4 Water By-pass Hose *2 No. 6 Water By-pass Hose *3 No. 3 Water By-pass Hose
30. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT Remove the 3 nuts and water inlet with thermostat sub-assembly. Remove the water inlet housing gasket from the water inlet sub-assembly.
31. REMOVE REAR WATER BY-PASS JOINT Remove the 2 bolts, 4 nuts and rear water by-pass joint. Remove the 2 water outlet gaskets and water outlet pipe O-ring.
32. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Remove the 14 bolts, 2 cylinder head cover seal washers, cylinder head cover sub-assembly and cylinder head cover gasket. Remove the 3 gaskets.
33. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Remove the 12 bolts, cylinder head cover seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket LH. *a Be careful of baffle plate NOTE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH. Remove the 3 gaskets.
34. REMOVE SPARK PLUG TUBE GASKET Pry up the claws of the ventilation baffle plate. *1 Claw NOTE: Do not deform the claws of the ventilation baffle plate more than necessary. Remove the 6 spark plug tube gaskets from the cylinder head cover sub-assemblies. NOTE: As much as possible prevent the spark plug tube gaskets from being deformed. The removed spark plug tube gaskets will be used when reinstalling new spark plug tube gaskets. Do not damage the cylinder head cover sub-assemblies.
35. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY for 2WD: Remove the 15 bolts and 2 nuts. for AWD: Remove the 14 bolts and 2 nuts. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly. *1 Oil Pan Seal Cutter NOTE: Be careful not to damage the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.
36. REMOVE OIL STRAINER WITH PIPE SUB-ASSEMBLY (for AWD) Remove the 3 nuts and oil strainer with pipe sub-assembly. Remove the oil strainer gasket from the oil strainer with pipe sub-assembly.
37. REMOVE OIL PAN SUB-ASSEMBLY for 2WD: Remove the 16 bolts and 2 nuts. HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. Arrange the removed parts in the correct order. for AWD: Remove the 16 bolts and 2 nuts. HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. Arrange the removed parts in the correct order. Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver. *A for 2WD *B for AWD *a LH Side *b RH Side NOTE: Be careful not to damage the contact surfaces of the cylinder block sub-assembly and oil pan sub-assembly. HINT: Tape the screwdriver tip before use. Remove the 2 O-rings.
38. REMOVE OIL STRAINER SUB-ASSEMBLY for 2WD: Remove the 3 nuts, oil strainer sub-assembly and oil strainer gasket. for AWD: Remove the bolt, 2 nuts, oil strainer sub-assembly and oil strainer gasket.
39. REMOVE NO. 1 OIL PAN BAFFLE PLATE for 2WD: Remove the 8 bolts and No. 1 oil pan baffle plate. for AWD: Remove the 7 bolts and No. 1 oil pan baffle plate.
40. REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 6 bolts. Using a screwdriver, pry out the engine rear oil seal retainer. *1 Protective tape NOTE: Be careful not to damage the engine rear oil seal retainer and cylinder block sub-assembly. HINT: Tape the screwdriver tip before use.
41. REMOVE ENGINE REAR OIL SEAL Place the engine rear oil seal retainer on wooden blocks. *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 engine rear oil seal. HINT: Tape the screwdriver tip before use.
42. REMOVE TIMING CHAIN COVER PLATE See step 15
43. REMOVE ENGINE WATER PUMP ASSEMBLY Refer to «PROCEDURE - Step 13»(ref-665707-S16046687922014102400000)
44. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Refer to «PROCEDURE - Step 27»(ref-665705-S23014168312014102400000)
45. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Refer to «PROCEDURE - Step 28»(ref-665705-S23014168312014102400000)
46. SET NO. 1 CYLINDER TO TDC / COMPRESSION Temporarily tighten the crankshaft pulley set bolt. Set the timing mark on the crank angle sensor plate to the bank 1 cylinder block bore center line (TDC/compression). *1 Timing Mark *2 Bank 1 Cylinder Block Center Line Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the camshaft bearing caps as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above. *1 Timing Mark
47. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly. *1 Plunger *2 Stopper Plate *3 Hexagon Wrench *a Move Stopper Plate Upward *b Move Stopper Plate Downward Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Remove the 2 bolts and No. 1 chain tensioner assembly.
48. REMOVE CHAIN TENSIONER SLIPPER Remove the chain tensioner slipper.
49. REMOVE CHAIN SUB-ASSEMBLY Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly around the crankshaft timing gear or sprocket. *1 Timing Mark *2 Bank 1 Cylinder Block Center Line *a 10° Remove the crankshaft pulley set bolt. Remove the chain sub-assembly from the crankshaft timing gear or sprocket and place it on the crankshaft. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks. *1 Chain Sub-assembly between Banks *a for Bank 1 WARNING: As the camshafts turn suddenly, do not touch the camshafts or camshaft timing gears. Remove the chain sub-assembly.
50. REMOVE IDLE SPROCKET ASSEMBLY Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.
51. REMOVE NO. 1 CHAIN VIBRATION DAMPER Remove the 2 bolts and No. 1 chain vibration damper.
52. REMOVE NO. 2 CHAIN VIBRATION DAMPER Remove the 2 No. 2 chain vibration dampers.
53. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET Remove the crankshaft timeng gear or sprocket from the crankshaft. *1 Crankshaft Timing Gear Key NOTE: Be careful not to drop the crankshaft timing gear keys.
54. REMOVE CRANKSHAFT TIMING GEAR KEY Remove the 2 crankshaft timing gear keys from the crankshaft. *1 Protective Tape HINT: Tape the screwdriver tip before use.
55. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 6
56. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY See step 7
57. REMOVE CAMSHAFT BEARING CAP (for Bank 1) See step 8
58. REMOVE CAMSHAFT See step 9
59. REMOVE NO. 2 CAMSHAFT See step 10
60. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 11
61. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 12
62. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 13
63. REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 14
64. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY See step 15
65. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY See step 16
66. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 17
67. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 20
68. REMOVE VALVE LASH ADJUSTER ASSEMBLY See step 21
69. REMOVE VALVE STEM CAP See step 22
70. REMOVE CYLINDER HEAD SUB-ASSEMBLY See step 29
71. REMOVE CYLINDER HEAD GASKET See step 30
72. REMOVE CYLINDER HEAD LH See step 31
73. REMOVE NO. 2 CYLINDER HEAD GASKET See step 32
74. REMOVE NO. 5 ENGINE WIRE Detach the clamp and remove the No. 5 engine wire.
75. REMOVE KNOCK CONTROL SENSOR Refer to «PROCEDURE - Step 2»(ref-665751-S28466910722014102400000)
76. REMOVE CYLINDER BLOCK WATER JACKET SPACER RH Using needle-nose pliers, remove the cylinder block water jacket spacer RH. NOTE: Be sure to remove the cylinder block water jacket spacer RH if turning the cylinder block sub-assembly.
77. REMOVE CYLINDER BLOCK WATER JACKET SPACER LH Using needle-nose pliers, remove the cylinder block water jacket spacer LH. NOTE: Be sure to remove the cylinder block water jacket spacer LH if turning the cylinder block sub-assembly.
78. REMOVE WATER OUTLET PIPE SUB-ASSEMBLY Remove the 2 bolts and water outlet pipe sub-assembly.
79. REMOVE NO. 1 STRAIGHT PIN NOTE: It is not necessary to remove a straight pin unless it is being replaced.
80. REMOVE RING WITH HEAD PIN NOTE: It is not necessary to remove a ring with head pin unless it is being replaced.
81. REMOVE STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it.

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1. 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.
2. 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 *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 is very difficult to move. If the plunger can still be compressed after bleeding air 3 times, replace the valve lash adjuster with a new one.
3. 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 0.08 mm (0.00315 in.) If the runout is more than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. See step 18 Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height Item Specified Condition Intake 43.940 to 44.040 mm (1.7299 to 1.7339 in.) Exhaust 44.090 to 44.190 mm (1.7358 to 1.7398 in.) Exhaust (for Fuel Pump) 56.450 to 56.550 mm (2.2224 to 2.2264 in.) Minimum Cam Lobe Height Item Specified Condition Intake 43.790 mm (1.7240 in.) Exhaust 43.940 mm (1.7299 in.) Exhaust (for Fuel Pump) 56.300 mm (2.2165 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. See step 18
4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Install the camshaft timing gear assembly. See step 1 Inspect the camshaft timing gear assembly. See step 26 Remove the flange bolt and camshaft timing gear assembly. *a Do Not Remove NOTE: Do not remove the other 3 bolts. If planning to reuse the camshaft timing gear assembly, be sure to release the straight pin lock before installing the camshaft timing gear assembly.
5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Install the camshaft timing exhaust gear assembly. See step 2 Inspect the camshaft timing exhaust gear assembly. See step 28 Remove the flange bolt and camshaft timing exhaust gear assembly. *a Do Not Remove NOTE: Be sure not to remove the other 4 bolts. If planning to reuse the camshaft timing exhaust gear assembly, be sure to release the straight pin lock before installing the camshaft timing exhaust gear assembly.
6. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end. *1 Measurement Length Standard length 141.3 to 142.7 mm (5.56 to 5.62 in.) Maximum length 143.7 mm (5.66 in.) 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. *1 Measurement Point *a Approximately 100 mm (3.94 in.) Standard diameter 10.80 to 11.00 mm (0.425 to 0.433 in.) Minimum diameter 10.70 mm (0.421 in.) NOTE: If the diameter is less than the minimum, replace the cylinder head set bolt. Failure to do so may lead to engine damage. If there is any thread deformation, replace the cylinder head set bolt with a new one.
7. INSPECT CHAIN SUB-ASSEMBLY Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain sub-assembly using a vernier caliper. *1 Measurement Area Maximum chain elongation 136.9 mm (5.39 in.) HINT: Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the chain sub-assembly.
8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY *1 Measurement Area Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain sub-assembly 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 sub-assembly.
9. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET Place the chain sub-assembly around the crankshaft timing gear or sprocket. Using a vernier caliper, measure the crankshaft timing gear or sprocket diameter with the chain sub-assembly. Minimum sprocket diameter (with chain sub-assembly) 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 sub-assembly and crankshaft timing gear or sprocket.
10. INSPECT IDLE SPROCKET ASSEMBLY Place the chain sub-assembly around the idle sprocket assembly. Using a vernier caliper, measure the idle sprocket assembly diameter with the chain sub-assembly. Minimum sprocket diameter (with chain sub-assembly) 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 sub-assembly and idle sprocket assembly.
11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE Using a micrometer, measure the No. 1 idle gear shaft diameter. Standard diameter 22.987 to 23.000 mm (0.905 to 0.906 in.) Using a caliper gauge, measure the inside diameter of the idle sprocket assembly. Standard diameter 23.020 to 23.030 mm (0.906 to 0.907 in.) Subtract the No. 1 idle gear shaft diameter measurement from the idle sprocket assembly inside diameter measurement. Standard oil clearance 0.020 to 0.043 mm (0.00079 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 No. 1 idle gear shaft and idle sprocket assembly.
12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. If necessary, replace the No. 1 chain tensioner assembly. *1 Plunger *2 Stopper Plate
13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY *a Depth *b Moves Smoothly Check that the plunger moves smoothly. Measure the depth of wear of the No. 2 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is more than the maximum, replace the No. 2 chain tensioner assembly.
14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY *a Depth *b Moves Smoothly Check that the plunger moves smoothly. Measure the depth of wear of the No. 3 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is more than the maximum, replace the No. 3 chain tensioner assembly.
15. INSPECT CHAIN TENSIONER SLIPPER Measure the depth of wear of the chain tensioner slipper. *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the chain tensioner slipper.
16. INSPECT NO. 1 CHAIN VIBRATION DAMPER Measure the depth of wear of the No. 1 chain vibration damper. *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 1 chain vibration damper.
17. INSPECT NO. 2 CHAIN VIBRATION DAMPER Measure the depth of wear of the No. 2 chain vibration damper. *a Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 2 chain vibration damper.
18. INSPECT CAMSHAFT OIL CLEARANCE for Bank 1: Clean the camshaft bearing caps, camshaft housing sub-assembly RH and camshaft journals. Place the camshafts on the camshaft housing sub-assembly RH. Lay a strip of Plastigage across each camshaft journal. *1 Plastigage Install the camshaft bearing caps. NOTE: Do not turn the camshafts. See step 22 Remove the camshaft bearing caps. See step 8 Measure the Plastigage at its widest point. *1 Plastigage *2 No. 1 Journal *3 Other Journals *a Intake Side *b Exhaust Side Standard Oil Clearance Item Specified Condition Exhaust side No. 1 journal 0.031 to 0.078 mm (0.00122 to 0.00307 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.) Maximum Oil Clearance Item Specified Condition Exhaust side No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is more than the maximum, replace the camshaft. If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing sub-assembly RH. for Bank 2: Clean the camshaft bearing caps, camshaft housing sub-assembly LH and camshaft journals. Place the camshafts on the camshaft housing sub-assembly LH. Lay a strip of Plastigage across each camshaft journal. *1 Plastigage Install the camshaft bearing caps. NOTE: Do not turn the camshafts. See step 18 Remove the camshaft bearing caps. See step 14 Measure the Plastigage at its widest point. *1 Plastigage *2 No. 1 Journal *3 Other Journals *a Intake Side *b Exhaust Side Standard Oil Clearance Item Specified Condition Exhaust side No. 1 journal 0.031 to 0.078 mm (0.00122 to 0.00307 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.) Maximum Oil Clearance Item Specified Condition Exhaust side No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is more than the maximum, replace the camshaft. If the oil clearance is still more than the maximum after replacing the camshafts, replace the camshaft housing sub-assembly LH.
19. INSPECT EXHAUST MANIFOLD Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head. Maximum warpage 0.70 mm (0.02756 in.) If the warpage is more than the maximum, replace the exhaust manifold sub-assembly.
20. 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. *a Intake Air Surge Tank Side *b Cylinder Head Side Maximum warpage 0.10 mm (0.00394 in.) If the warpage is more than the maximum, replace the intake manifold.

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1. INSTALL STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. for 2WD: Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration. for stud bolt A Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) for stud bolt B Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) *a Timing Chain Or Belt Cover Sub-assembly Lower *b Cylinder Block Sub-assembly Lower *c 9.0 mm (0.354 in.) *d 19 mm (0.748 in.) *e 16 mm (0.630 in.) *f 27 mm (1.06 in.) for AWD: Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration. for stud bolt A Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) for stud bolt B Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) *a Timing Chain Or Belt Cover Sub-assembly Lower *b Oil Pan Sub-assembly Lower *c 9.0 mm (0.354 in.) *d 19 mm (0.748 in.) *e 16 mm (0.630 in.) *f 27 mm (1.06 in.) Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) *A for 2WD *B for AWD *a 9.0 mm (0.354 in.) *b 19 mm (0.748 in.) Using an E8 "TORX" socket wrench, install the stud bolts as shown in the illustration. * 1 Cylinder Head Cover Sub-assembly *a 19 mm (0.748 in.) *b 16 mm (0.630 in.) *c 44 mm (1.73 in.) Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. INSTALL RING WITH HEAD PIN NOTE: It is not necessary to remove a ring with head pin unless it is being replaced. Using a plastic-faced hammer, tap in new ring with head pins to the camshaft housing sub-assembly. Standard protrusion height 2.7 to 3.3 mm (0.106 to 0.130 in.) *a for Bank 2 *b for Bank 1 *c Protrusion Height
3. 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 sub-assemblies. 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.) *a for Bank 2 *b for Bank 1 *c Protrusion Height
4. INSTALL ENGINE REAR OIL SEAL Place the engine rear oil seal retainer on wooden blocks. Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge. *a Standard depth SST: 09223-1503009950-70010 09951-07100 Standard depth -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) NOTE: Keep the lip free of foreign matter. Do not tap in the engine rear oil seal at an angle. Do not tap in the engine rear oil seal more than necessary. Do not deform the engine rear oil seal.
5. INSTALL ENGINE REAR OIL SEAL RETAINER Apply MP grease to the lip of the engine rear oil seal. Apply seal packing in a continuous line as shown in the illustration. *1 Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.) NOTE: Remove any oil from the contact surface. Install the engine rear oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Apply adhesive 1324 to the 2 bolts A. NOTE: Tighten the bolts within 3 minute after applying adhesive. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the engine rear oil seal retainer with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Thoroughly wipe clean any seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation.
6. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY Install the water outlet pipe sub-assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
7. INSTALL CYLINDER BLOCK WATER JACKET SPACER RH Install the cylinder block water jacket spacer RH as shown in the illustration.
8. INSTALL CYLINDER BLOCK WATER JACKET SPACER LH Install the cylinder block water jacket spacer LH as shown in the illustration.
9. INSTALL KNOCK CONTROL SENSOR Refer to «PROCEDURE - Step 1»(ref-665751-S34781474142014102400000)
10. INSTALL NO. 5 ENGINE WIRE Install the No. 5 engine wire with the clamp.
11. INSTALL CYLINDER HEAD GASKET See step 1
12. INSTALL CYLINDER HEAD SUB-ASSEMBLY See step 2
13. INSTALL NO. 2 CYLINDER HEAD GASKET See step 3
14. INSTALL CYLINDER HEAD LH See step 4
15. INSTALL VALVE STEM CAP See step 11
16. INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 12
17. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 13
18. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY See step 16
19. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY See step 17
20. INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 18
21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 19
22. INSTALL CAMSHAFT See step 20
23. INSTALL NO. 2 CAMSHAFT See step 21
24. INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 22
25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 23
26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY See step 26
27. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 27
28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY See step 24
29. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 25
30. INSTALL NO. 1 CHAIN VIBRATION DAMPER Install the No. 1 chain vibration damper with the 2 bolts. Torque: 22.5 N*m (229 kgf*cm, 17 ft.*lbf)
31. INSTALL NO. 2 CHAIN VIBRATION DAMPER Install the 2 No. 2 chain vibration dampers.
32. INSTALL CRANKSHAFT TIMING GEAR KEY Install the 2 crankshaft timing gear keys to the crankshaft.
33. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET Install the crankshaft timeng gear or sprocket to the crankshaft.
34. INSTALL IDLE SPROCKET ASSEMBLY Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. *1 No. 1 Idle Gear Shaft *2 No. 2 Idle Gear Shaft *3 Idle Sprocket Assembly *4 Knock Pin Apply Engine Oil Temporarily install the No. 1 idle gear shaft and idle sprocket assembly with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block sub-assembly. NOTE: Make sure that the idle sprocket assembly is facing the correct direction. HINT: Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) HINT: After installing the idle sprocket assembly, check that the idle sprocket assembly turns smoothly.
35. INSTALL CHAIN SUB-ASSEMBLY Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly. *1 Mark Plate (Orange) *2 Timing Mark HINT: The camshaft mark plates are orange. Rest the chain sub-assembly on top of the crankshaft. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain sub-assembly between the banks. *1 Inner Chain Plate *2 Outer Chain Plate *a Chain sub-assembly between banks *b When idle sprocket assembly is reused *c Mark Turn NOTE: When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain sub-assembly between the banks. Align the mark plate and timing mark as shown in the illustration and install the chain sub-assembly onto the crankshaft timing gear or sprocket. *1 Mark Plate (Yellow) *2 Timing Mark HINT: The crankshaft mark plate is yellow. Temporarily tighten the crankshaft pulley set bolt. Turn the crankshaft clockwise to set the timing mark to the bank 1 cylinder block bore center line (TDC/compression). *1 Timing Mark *a Bank 1 Cylinder block Bore Center Line (TDC/compression) Turn
36. INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper.
37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner assembly. *1 Stopper Plate *2 Plunger *3 Hexagon Wrench *a Move Stopper Plate upward *b Move Stopper Plate downward Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install the No. 1 chain tensioner assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
38. 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. *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 chain sub-assembly. Remove the crankshaft pulley set bolt.
39. INSTALL ENGINE WATER PUMP ASSEMBLY Install a new water pump gasket and the engine water pump assembly with the 7 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE: Be sure to replace the 2 bolts (A) with new ones or reuse them after applying adhesive. Tighten the bolts within 3 minute after applying adhesive. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
40. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665705-S15427817832014102400000)
41. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL See step 1
42. INSTALL TIMING CHAIN COVER PLATE See step 13
43. INSTALL NO. 1 OIL PAN BAFFLE PLATE for 2WD: Temporarily install the No. 1 oil pan baffle plate with the 8 bolts. Tighten the 2 bolts A shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Tighten the other 6 bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for AWD: Temporarily install the No. 1 oil pan baffle plate with the 7 bolts. Tighten the 2 bolts A shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Tighten the other 5 bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
44. INSTALL OIL STRAINER SUB-ASSEMBLY for 2WD: Install a new oil strainer gasket and the oil strainer sub-assembly with the 3 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for AWD: Install a new oil strainer gasket and the oil strainer sub-assembly with the bolt and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
45. INSTALL OIL PAN SUB-ASSEMBLY Install 2 new O-rings. Apply seal packing in a continuous line as shown in the illustration. *A for 2WD *B for AWD *a Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.156 in.) NOTE: Check the bolts and bolt holes and clean them. Remove any oil from the contact surface. Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. for 2WD: Install the oil pan sub-assembly and temporarily tighten the 16 bolts and 2 nuts in several steps. Bolt Nut 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.) Tighten the 16 bolts and 2 nuts in the order shown in the illustration. for bolt A, B and nut Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt C Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt Nut for AWD: Install the oil pan sub-assembly and temporarily tighten the 16 bolts and 2 nuts in several steps. HINT: STANDARD BOLT: Item Length Bolt A 25 mm (0.984 in.) Bolt B 45 mm (1.77 in.) Bolt C 93 mm (3.66 in.) Bolt D 16 mm (0.630 in.) Bolt Nut Tighten the 16 bolts and 2 nuts in the order shown in the illustration. for bolt A, B, C and nut Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt D Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt Nut
46. INSTALL OIL STRAINER WITH PIPE SUB-ASSEMBLY (for AWD) Install a new oil strainer gasket and the oil strainer with pipe sub-assembly with the 3 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
47. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Apply seal packing in a continuous line as shown in the illustration. *A for 2WD *B for AWD *a Seal Packing 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.) NOTE: Check the bolts and bolt holes and clean them. Remove any oil from the contact surface. Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. for 2WD: Install the No. 2 oil pan sub-assembly and tighten the 15 bolts and 2 nuts in several steps in the order shown in the illustration. Bolt Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for AWD: Install the No. 2 oil pan sub-assembly and tighten the 14 bolts and 2 nuts in several steps in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt Nut
48. 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)
49. INSTALL SPARK PLUG TUBE GASKET Using a cutter, cut off the sealing part of the removed spark plug tube gasket. *a Before cutting off *b After cutting off Area to be cut off Using a spark plug tube gasket which has had the sealing part cut off, uniformly press in a new spark plug tube gasket all the way. *1 Spark Plug Tube Gasket without Sealing Part *2 New Spark Plug Tube Gasket *3 Claw NOTE: Keep the lip free of foreign matter. Do not tap in the spark plug tube gasket at an angle. HINT: If a spark plug tube gasket that will be used to install a new spark plug tube gasket is deformed, and cannot be positioned on a new spark plug tube gasket, correct the deformation using pliers. Return the claws of the ventilation baffle plate to their original positions.
50. POUR ENGINE OIL HINT: Before installing the cylinder head cover sub-assemblies, pour engine oil into the locations shown in the illustration.
51. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Apply seal packing as shown in the illustration. *1 timing chain cover sub-assembly *2 camshaft housing sub-assembly RH *a 2.0 to 3.0 mm (0.0787 to 0.118 in.) *b 5.0 to 10.0 mm (0.197 to 0.394 in.) Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. Install 3 new gaskets to the No. 1, No. 2 and No. 7 camshaft bearing caps. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly. Apply adhesive 1324 to the threads of the 11 bolts indicated by the black arrows in the illustration. *a Bolt with cylinder head cover seal washer Apply adhesive 1324 to these bolts Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTE: Tighten the bolts within 3 minute after applying adhesive. Install the cylinder head cover sub-assembly and 2 new seal washers with the 14 bolts. for bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) except bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
52. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Apply seal packing as shown in the illustration. *1 timing chain cover sub-assembly *2 camshaft housing sub-assembly LH *a 2.0 to 3.0 mm (0.0787 to 0.118 in.) *b 5.0 to 10.0 mm (0.197 to 0.394 in.) Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation. Install 3 new gaskets to the No. 3, No. 4 and No. 7 camshaft bearing caps. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH. Apply adhesive 1324 to the threads of the 10 bolts indicated by the black arrows in the illustration. *a Bolt with cylinder head cover seal washer Apply adhesive 1324 to these bolts Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTE: Tighten the bolts within 3 minute after applying adhesive. Install the cylinder head cover sub-assembly LH and a new seal washer with the 12 bolts. for bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) except bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
53. INSTALL REAR WATER BY-PASS JOINT Install 2 new water outlet gaskets and a new water outlet pipe O-ring. HINT: Apply water to the water outlet pipe O-ring. Install the rear 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 water outlet pipe O-ring does not get caught between the parts.
54. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT Install a new No. 1 water inlet housing gasket and water inlet sub-assembly with thermostat with the 3 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
55. INSTALL WATER INLET SUB-ASSEMBLY Connect the No. 3, No. 4 and No. 6 water by-pass hoses on engine side. *1 No. 4 Water By-pass Hose *2 No. 6 Water By-pass Hose *3 No. 3 Water By-pass Hose *a RH Side HINT: Install the water by-pass hoses so that the paint marks are positioned on the cylinder head side. Attach the No. 4 water by-pass hose clamp as shown in the illustration. Install a new No. 1 water inlet housing gasket and water outlet pipe O-ring. Install the water inlet sub-assembly with the 4 bolts and nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful not to allow the No. 1 water inlet housing gasket and water outlet pipe O-ring to get caught between the parts. Connect the No. 3, No. 4 and No. 6 water by-pass hoses to the water inlet sub-assembly.
56. INSTALL CRANKSHAFT PULLEY See step 3
57. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for AWD) Install a new gasket. Install the oil filter bracket sub-assembly with the bolt and 2 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
58. INSTALL OIL FILTER CAP ASSEMBLY (for AWD) Refer to «PROCEDURE - Step 6»(ref-665705-S34609640792014102400000)
59. INSTALL OIL FILTER CAP ASSEMBLY (for 2WD) Refer to «PROCEDURE - Step 5»(ref-665705-S34609640792014102400000)
60. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Refer to «PROCEDURE - Step 1»(ref-665705-S18874013422014102400000)
61. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Apply adhesive to 2 or 3 threads at the end of the cylinder block water drain cock sub-assembly. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent *1 Adhesive NOTE: Install the cylinder block water drain cock sub-assembly within 3 minutes after applying adhesive. Install the cylinder block water drain cock sub-assemblies as shown in the illustration. *a for Bank 1 *b for Bank 2 Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) NOTE: Do not rotate the cylinder block water drain cock sub-assembly by more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assembly to the specified torque. Do not loosen the cylinder block water drain cock sub-assembly after setting it correctly. Install the 2 water drain cock plugs to the 2 cylinder block water drain cock sub-assemblies. Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf)
62. INSTALL NO. 1 OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. NOTE: Do not touch the mesh when installing the oil control valve filter LH. Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe on the cylinder head cover sub-assembly LH side. *1 Oil Pipe Union *2 Oil Check Valve Bolt Install a new gasket and temporarily install the No. 1 oil pipe on the cylinder head LH side with the oil check valve bolt. Tighten the oil pipe union on the cylinder head cover sub-assembly LH side. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) Tighten the oil check valve bolt on the cylinder head LH side. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
63. INSTALL NO. 2 OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter RH. NOTE: Do not touch the mesh when installing the oil control valve filter RH. Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 2 oil pipe on the cylinder head cover sub-assembly side. *1 Oil Pipe Union *2 Oil Check Valve Bolt Install a new gasket and temporarily install the No. 2 oil pipe on the cylinder head sub-assembly side with the oil check valve bolt. Tighten the oil pipe union on the cylinder head cover sub-assembly side. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) Tighten the oil check valve bolt on the cylinder head sub-assembly side. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
64. INSTALL CRANKSHAFT POSITION SENSOR Refer to «PROCEDURE - Step 1»(ref-665751-S15751632012014102400000)
65. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Refer to «PROCEDURE - Step 1»(ref-665751-S07434144472014102400000)
66. INSTALL ENGINE OIL LEVEL SENSOR Refer to «PROCEDURE - Step 1»(ref-665705-S32925685222014102400000)
67. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) Refer to «PROCEDURE - Step 2»(ref-665751-S37185619902014102400000)
68. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) Refer to «PROCEDURE - Step 1»(ref-665751-S37185619902014102400000)
69. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) Refer to «PROCEDURE - Step 3»(ref-665751-S37185619902014102400000)
70. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) Refer to «PROCEDURE - Step 4»(ref-665751-S37185619902014102400000)
71. INSTALL VVT SENSOR (for Exhaust Side of Bank 2) Refer to «PROCEDURE - Step 1»(ref-665751-S11378281922014102400000)
72. INSTALL VVT SENSOR (for Intake Side of Bank 2) Refer to «PROCEDURE - Step 2»(ref-665751-S11378281922014102400000)
73. INSTALL VVT SENSOR (for Exhaust Side of Bank 1) Refer to «PROCEDURE - Step 3»(ref-665751-S11378281922014102400000)
74. INSTALL VVT SENSOR (for Intake Side of Bank 1) Refer to «PROCEDURE - Step 4»(ref-665751-S11378281922014102400000)
75. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) Refer to «PROCEDURE - Step 1»(ref-665713-S27142318352014102400000)
76. INSTALL SPARK PLUG Refer to «PROCEDURE - Step 1»(ref-665751-S29802334862014102400000)
77. INSTALL RADIATOR CAP SUB-ASSEMBLY Install the radiator cap sub-assembly.
78. INSTALL OIL FILLER CAP SUB-ASSEMBLY Install a new gasket. Install the oil filler cap sub-assembly.
79. INSTALL FUEL INJECTOR SEAL Refer to «PROCEDURE - Step 1»(ref-665752-S01941816702014102400000)
80. INSTALL FUEL INJECTOR ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665752-S01941816702014102400000)
81. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 3»(ref-665752-S01941816702014102400000)
82. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 4»(ref-665752-S01941816702014102400000)

1. INSTALL IGNITION COIL ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665751-S29802334862014102400000)
2. INSTALL V-BANK COVER BRACKET SUB-ASSEMBLY Install the V-bank cover bracket sub-assembly to the cylinder head cover sub-assembly RH with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. INSTALL WIRE HARNESS CLAMP BRACKET Install the wire harness clamp bracket to the camshaft housing sub-assembly RH with the bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
4. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 5»(ref-665752-S01941816702014102400000)
5. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 1»(ref-665752-S29805489822014102400000)
6. INSTALL FUEL PUMP ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665752-S29805489822014102400000)
7. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 3»(ref-665752-S29805489822014102400000)
8. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY Refer to «PROCEDURE - Step 4»(ref-665752-S29805489822014102400000)
9. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY Refer to «PROCEDURE - Step 1»(ref-665752-S23710317962014102400000)
10. INSTALL INTAKE MANIFOLD Refer to «PROCEDURE - Step 2»(ref-665769-S08378769372014102400000)
11. INSTALL NO. 3 WATER BY-PASS PIPE Connect the No. 9 water by-pass hose to the rear water by-pass joint and slide the clip to secure it. Connect the No. 8 water by-pass hose to the water outlet pipe assembly and slide the clip to secure it. Install the No. 3 water by-pass pipe to the camshaft housing sub-assembly RH with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
12. INSTALL NO. 2 SURGE TANK STAY Install the No. 2 surge tank stay to the camshaft housing sub-assembly LH with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Connect the 2 clamps to the No. 2 surge tank stay.
13. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Refer to «PROCEDURE - Step 3»(ref-665769-S08378769372014102400000)
14. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665751-S29633936302014102400000)
15. INSTALL INJECTOR DRIVER Refer to «PROCEDURE - Step 1»(ref-665752-S17989845222014102400000)
16. INSTALL ENGINE WIRE Install the engine wire to the engine assembly.
17. INSTALL WATER PUMP PULLEY Refer to «PROCEDURE - Step 4»(ref-665707-S21459071752014102400000)
18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Refer to «PROCEDURE - Step 20»(ref-665705-S15427817832014102400000)
19. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH Install the front No. 1 engine mounting bracket LH to the cylinder block sub-assembly with the 4 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Connect the 2 clamps.
20. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH Install the front No. 1 engine mounting bracket RH to the cylinder block sub-assembly with the 4 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
21. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 2WD) Refer to «PROCEDURE - Step 2»(ref-665718-S00056089582014102400000)
22. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH (for AWD) Refer to «PROCEDURE - Step 2»(ref-665718-S38910663502014102400000)
23. INSTALL OIL FILTER BRACKET (for AWD) Refer to «PROCEDURE - Step 4»(ref-665718-S38910663502014102400000)
24. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for AWD) Refer to «PROCEDURE - Step 5»(ref-665718-S38910663502014102400000)
25. INSTALL GENERATOR ASSEMBLY Refer to «PROCEDURE - Step 1»(ref-665778-S38680183932014102400000)
26. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Refer to «PROCEDURE - Step 2»(ref-665707-S21459071752014102400000)
27. INSTALL NO. 1 ENGINE COVER Refer to «PROCEDURE - Step 2»(ref-665752-S17989845222014102400000)
28. INSTALL NO. 2 ENGINE COVER Install the No. 2 engine cover with the 3 clips. Connect the clamp to the No. 2 engine cover.
29. INSTALL V-RIBBED BELT See step 1

Scheme 177

*1 EXHAUST VALVE *2 EXHAUST VALVE GUIDE BUSH *3 INTAKE VALVE *4 INTAKE VALVE GUIDE BUSH *5 NO. 1 STRAIGHT SCREW PLUG *6 NO. 2 STRAIGHT SCREW PLUG *7 RING PIN *8 SPARK PLUG TUBE *9 STRAIGHT PIN *10 STUD BOLT *11 UNION *12 VALVE SPRING SEAT *13 INTAKE VALVE STEM OIL SEAL *14 EXHAUST VALVE STEM OIL SEAL *15 VALVE SPRING RETAINER *16 VALVE SPRING RETAINER LOCK *17 INNER COMPRESSION SPRING *18 WATER HOLE GASKET *19 CYLINDER HEAD SCREW PLUG GASKET *20 CYLINDER HEAD N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part Adhesive 1324 * Precoated part

Scheme 178

Scheme 179

Scheme 180

1. REMOVE INTAKE VALVE Using SST, compress the inner compression spring and remove the 2 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.
2. REMOVE EXHAUST VALVE Using SST, compress the inner compression spring and remove the 2 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.
3. REMOVE INTAKE VALVE STEM OIL SEAL Using needle-nose pliers, remove the intake valve stem oil seals.
4. REMOVE EXHAUST VALVE STEM OIL SEAL Using needle-nose pliers, remove the exhaust valve stem oil seals.
5. REMOVE VALVE SPRING SEAT Using compressed air and a magnet hand, remove the valve spring seats by blowing air onto them.
6. REMOVE NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, remove the 4 No. 1 straight screw plugs and 4 water hole gaskets. *a for Bank 1 *b for Bank 2 NOTE: If water leaks from a No. 1 straight screw plug or the No. 1 straight screw plug is corroded, replace it.
7. REMOVE NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, remove the 2 No. 2 straight screw plugs and 2 cylinder head screw plug gaskets. *a for Bank 1 *b for Bank 2 NOTE: If water leaks from a No. 2 straight screw plug or the No. 2 straight screw plug is corroded, replace it.
8. REMOVE UNION HINT: It is not necessary to remove the union unless it is being replaced.
9. REMOVE STUD BOLT HINT: If the stud bolt is deformed or the threads are damaged, replace it.

Scheme 181

Scheme 182

Scheme 183

1. INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block sub-assembly, intake manifold and exhaust manifold. *a Cylinder Block Sub-assembly Side *b Intake Side *c Exhaust Side - - Standard Warpage Item Specified Condition Cylinder block sub-assembly side 0 to 0.05 mm (0 to 0.00197 in.) Intake side 0 to 0.08 mm (0 to 0.00315 in.) Exhaust 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.
2. INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head.
3. 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 valve guide bush oil clearance. See step 8 Using a vernier caliper, measure the valve head margin thickness. *a Margin Thickness Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the intake valve. Using a vernier caliper, measure the valve overall length. Standard overall length 106.15 mm (4.18 in.) Minimum overall length 105.65 mm (4.16 in.) If the overall length is less than the minimum, replace the intake valve. *a Overall Length
4. 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 valve guide bush oil clearance. See step 8 Using a vernier caliper, measure the valve head margin thickness. *a Margin Thickness Standard margin thickness 0.81 mm (0.0319 in.) Minimum margin thickness 0.31 mm (0.0122 in.) 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 111.70 mm (4.40 in.) Minimum overall length 111.20 mm (4.38 in.) If the overall length is less than the minimum, replace the exhaust valve. *a Overall Length
5. INSPECT INTAKE VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the intake valve seat. NOTE: Do not rotate the intake valve. Check the valve face and intake valve seat by using the following procedure: *a Width If Prussian blue appears around the entire valve face, the valve face is circular. If not, replace the intake valve. If Prussian blue appears around the entire intake valve seat, the valve guide bush and valve face are concentric. If not, resurface the intake valve seat. Check that the intake valve seat contacts the middle of the valve face with the width between 1.0 to 1.4 mm (0.0394 to 0.0551 in.).
6. INSPECT EXHAUST VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the exhaust valve seat. NOTE: Do not rotate the exhaust valve. Check the valve face and exhaust valve seat by using the following procedure: *a Width If Prussian blue appears around the entire valve face, the valve face is circular. If not, replace the exhaust valve. If Prussian blue appears around the entire exhaust valve seat, the valve guide bush and valve face are concentric. If not, resurface the exhaust valve seat. Check that the exhaust valve seat contacts the middle of the valve face with the width between 1.2 to 1.6 mm (0.0472 to 0.0630 in.).
7. INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the inner compression spring. Standard free length 57.46 mm (2.26 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. *a Deviation Maximum deviation 1.0 mm (0.0394 in.) Maximum angle (reference) 2° If the deviation is more than the maximum, replace the inner compression spring.
8. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. 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 (0.00098 to 0.00256 in.) Maximum Oil Clearance Item Specified Condition Intake 0.08 mm (0.00315 in.) Exhaust 0.01 mm (0.00039 in.) If the oil clearance is more than the maximum, replace the intake or exhaust valve and valve guide bush.
9. INSPECT CAMSHAFT THRUST CLEARANCE Inspect the bank 1 camshaft thrust clearance. Install the camshaft. See step 20 Install the No. 2 camshaft. See step 21 Using a dial indicator, measure the camshaft thrust clearance while moving the camshaft and No. 2 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 RH. If the thrust surface is damaged, replace the camshaft or No. 2 camshaft. Inspect the bank 2 camshaft thrust clearance. Install the No. 3 camshaft sub-assembly. See step 16 Install the No. 4 camshaft sub-assembly. See step 17 Using a dial indicator, measure the thrust clearance while moving the No. 3 camshaft and No. 4 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 LH. If the thrust surface is damaged, replace the No. 3 camshaft sub-assembly or No. 4 camshaft sub-assembly.

Scheme 184

Scheme 185

1. 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. WARNING: Be sure to wear protective gloves. 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 valve guide bush 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 intake valve guide 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 intake valve guide bush. If the intake valve guide 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. WARNING: Be sure to wear protective gloves. Using SST, tap in new intake valve guide bushes to the specified protrusion height. *a Protrusion Height SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Standard protrusion height 10.2 to 10.6 mm (0.402 to 0.417 in.) Using a sharp 5.5 mm reamer, ream the intake valve guide bushes to obtain the specified valve guide bush oil clearance. Standard oil clearance 0.030 to 0.060 mm (0.00118 to 0.00236 in.)
2. 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. WARNING: Be sure to wear protective gloves. 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 valve guide bush 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 exhaust valve guide 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 exhaust valve guide bush. If the exhaust valve guide 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. WARNING: Be sure to wear protective gloves. Using SST, tap in new exhaust valve guide bushes to the specified protrusion height. *1 Protrusion Height SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Standard protrusion height 9.30 to 9.70 mm (0.366 to 0.382 in.) Using a sharp 5.5 mm reamer, ream the exhaust valve guide bushes to obtain the specified valve guide bush oil clearance. Standard oil clearance 0.025 to 0.065 mm (0.000984 to 0.00256 in.)
3. REPLACE RING PIN HINT: 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. *a for Bank 1 *b for Bank 2 *c Protrusion Height Standard protrusion height 2.5 to 3.8 mm (0.0984 to 0.150 in.)
4. 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. *1 Protrusion Height - - *a for Bank 1 *b for Bank 2 *c 34.0 mm (1.34 in) - - Standard protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.)

Scheme 186

Scheme 187

Scheme 188

1. INSTALL SPARK PLUG TUBE NOTE: When using a new cylinder head, the spark plug tubes must be replaced with new ones. Apply adhesive onto the shaded area of a new spark plug tube. *a Standard Application Width *b 9.0 to 15.0 mm (0.354 to 0.591 in.) 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.) NOTE: Install the spark plug tube within 3 minutes after applying adhesive. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height. *a Standard Protrusion Height *b Cylinder Head Casting Surface Standard protrusion height 72.9 mm (2.87 in.) NOTE: Be careful not to deform the spark plug tube. Be careful not to expose the seal to engine oil for at least 1 hour after installing it. To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.
2. 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 NOTE: Install the No. 1 straight screw plug within 3 minutes after applying adhesive. Using a 10 mm hexagon wrench, install 4 new water hole gaskets and the 4 No. 1 straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) NOTE: Do not add engine oil at least 1 hour after installation.
3. INSTALL NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, install 2 new cylinder head screw plug gaskets and the 2 No. 2 straight screw plugs. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
4. INSTALL UNION HINT: It is not necessary to remove the union unless it is being replaced. Apply adhesive to the union of the cylinder head. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTE: Install the union within 3 minutes after applying adhesive. *1 Adhesive 1324 Using a 12 mm union nut wrench, install 2 unions to the cylinder head as shown in the illustration. *a for Bank 1 *b for Bank 2 *c 67 mm (2.64 in.) *d 30 mm (1.18 in.) Torque: 14.7 N*m (150 kgf*cm, 11 ft.*lbf) NOTE: Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench. Refer to «PRECAUTION [04/2013 - ]»(ref-665529-S00420865962014102400000) Do not add engine oil at least 2 hours after installation.
5. 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. *a for Bank 1 Rear Side *b for Bank 1 Intake Side *c for Bank 2 Intake Side *d for Bank 1 Exhaust Side *e for Bank 2 Exhaust Side *f for Bank 2 Rear Side *g 52 mm (2.05 in.) *h 35 mm (1.38 in.) *i 27 mm (1.06 in.) - - Bolt A, B Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt C Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
6. INSTALL VALVE SPRING SEAT Install the valve spring seats to the cylinder head.
7. INSTALL INTAKE VALVE STEM OIL SEAL Apply a light coat of engine oil to new intake valve stem oil seals. *a Intake Side *b Exhaust Side *c Gray *d Black NOTE: Pay attention when installing the intake valve stem oil seal and exhaust valve stem oil seal. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later. HINT: The intake valve stem oil seals are gray and the exhaust valve stem oil seals are black. Using SST, push in the intake valve stem oil seals. *1 Valve Stem Oil Seal *a CORRECT *b INCORRECT SST: 09201-41020 NOTE: Failure to use SST will cause the intake valve stem oil seal to be damaged or improperly seated. Do not push in the intake valve stem oil seal at an angle.
8. INSTALL EXHAUST VALVE STEM OIL SEAL HINT: Use the same procedure as for the intake side. SST: 09201-41020
9. INSTALL EXHAUST VALVE Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the 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.
10. INSTALL INTAKE VALVE Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the 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 189

1. REPAIR INTAKE VALVE SEATS NOTE: Repair the intake valve seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the intake valve seat smooth. Using a 45° cutter, resurface the intake valve seat so that the intake valve seat width is more than the specification. *1 45° Cutter Using 30° and 75° cutters, correct the intake valve seat so that the intake valve contacts the entire circumference of the intake valve 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. *a Standard Width Standard width 1.0 to 1.4 mm (0.0394 to 0.0551 in.) Hand-lap the intake valve and intake valve seat with an abrasive compound. Check the intake valve seating position.
2. REPAIR EXHAUST VALVE SEATS NOTE: Repair the exhaust valve seat while checking the seating position. Keep the lip free of foreign matter. Take off the cutter gradually to make the exhaust valve seat smooth. Using a 45° cutter, resurface the exhaust valve seat so that the exhaust valve seat width is more than the specification. *1 45° Cutter Using 30° and 60° cutters, correct the exhaust valve seat so that the exhaust valve contacts the entire circumference of the exhaust valve 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. *a Standard Width Standard width 1.2 to 1.6 mm (0.0472 to 0.0630 in.) Hand-lap the exhaust valve and exhaust valve seat with an abrasive compound. Check the exhaust valve seating position.

Scheme 190

*1 CONNECTING ROD BEARING *2 CONNECTING ROD SMALL END BUSH *3 CRANKSHAFT *4 CRANKSHAFT BEARING *5 CRANKSHAFT THRUST WASHER SET *6 NO. 1 OIL NOZZLE SUB-ASSEMBLY *7 PISTON RING SET *8 STRAIGHT PIN *9 STUD BOLT *10 NO. 1 COMPRESSION RING *11 NO. 2 COMPRESSION RING *12 OIL RING *13 OIL RING EXPANDER *14 PISTON *15 PISTON PIN *16 PISTON PIN HOLE SNAP RING *17 CONNECTING ROD *18 CONNECTING ROD CAP *19 CONNECTING ROD BOLT *20 SEAL WASHER *21 CRANKSHAFT BEARING CAP *22 CRANKSHAFT BEARING CAP SET BOLT N*m (kgf*cm, ft*lbf) : Specified torque • Non-reusable part *T1 1st: 24.5 (250, 18) 2nd: Turn 90° *T2 1st: 61 (622, 45) 2nd: Turn 90°

Scheme 191

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Scheme 196

1. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the connecting rod thrust clearance while moving the connecting rod sub-assembly back and forth. Standard thrust clearance 0.25 to 0.40 mm (0.00984 to 0.0158 in.) Maximum thrust clearance 0.50 mm (0.0197 in.) If the thrust clearance is more than the maximum, replace the connecting rod sub-assemblies as necessary. If necessary, replace the crankshaft.
2. 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 bolts. Using the 2 removed connecting rod 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 connecting rod bearing. Check the crank pin and connecting rod bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. *1 Plastigage Check that the front mark of the connecting rod cap is facing forward. *1 Front Mark Engine Front Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts. Install the connecting rod cap. NOTE: Do not turn the crankshaft. HINT: The connecting rod bolts are tightened in 2 progressive steps. Step 1 Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps. Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) Step 2 Mark the front side of each connecting rod bolt with paint. Tighten the connecting rod bolts 90°. *1 Front Mark *a 90° Engine Front Check that the paint marks are now at a 90° angle to the front. Remove the 2 connecting rod bolts and connecting rod cap. Measure the Plastigage at its widest point. Standard oil clearance 0.026 to 0.046 mm (0.00102 to 0.00181 in.) Maximum oil clearance 0.070 mm (0.00276 in.) *1 Plastigage *a 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 connecting rod 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 51.000 to 51.006 mm (2.00787 to 2.00811 in.) 2 51.007 to 51.012 mm (2.00815 to 2.00834 in.) 3 51.013 to 51.018 mm (2.00838 to 2.00858 in.) 4 51.019 to 51.024 mm (2.00862 to 2.00881 in.) Standard Connecting Rod Bearing Center Wall Thickness Mark Specified Condition 1 1.484 to 1.487 mm (0.05843 to 0.05854 in.) 2 1.487 to 1.490 mm (0.05854 to 0.05866 in.) 3 1.490 to 1.493 mm (0.05866 to 0.05878 in.) 4 1.493 to 1.496 mm (0.05878 to 0.05890 in.) Standard crankshaft pin diameter 47.992 to 48.000 mm (1.8894 to 1.8898 in.) NOTE: Completely remove the Plastigage after the measurement.
3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. *1 Ridge Reamer Push the piston, connecting rod sub-assembly and upper connecting rod bearing through the top of the cylinder block sub-assembly. HINT: Keep the connecting rod bearing, connecting rod sub-assembly and connecting rod cap together. Arrange the piston and connecting rod assemblies in the correct order.
4. REMOVE CONNECTING ROD BEARING Remove the connecting rod bearings from the connecting rod sub-assemblies and connecting rod caps. HINT: Arrange the removed parts in the correct order.
5. INSPECT CRANKSHAFT THRUST CLEARANCE 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.)
6. REMOVE CRANKSHAFT Uniformly loosen and remove the 8 bolts and 8 seal washers in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 16 crankshaft bearing cap set 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. *1 Protective Tape *2 Cylinder Block *3 Crankshaft Bearing Cap *a Joint Surface NOTE: Push up on the crankshaft bearing cap slowly and evenly, alternating from the right and left side so that the crankshaft bearing cap can be removed. Be careful not to damage the joint surfaces of the cylinder block and the crankshaft bearing cap. HINT: Tape the screwdriver tip before use. Arrange the removed parts in the correct order. Remove the crankshaft.
7. REMOVE CRANKSHAFT BEARING Remove the upper crankshaft bearings and lower crankshaft bearings. HINT: Arrange the removed parts in the correct order.
8. REMOVE CRANKSHAFT THRUST WASHER SET Remove the crankshaft thrust washer set from the cylinder block.
9. REMOVE PISTON RING SET Using a piston ring expander, remove the No. 1 compression ring, No. 2 compression ring and oil ring. *1 Piston Ring Expander Remove the oil ring expander by hand. HINT: Arrange the removed parts in the correct order.
10. 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). WARNING: Be sure to wear protective gloves. 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 rod sub-assemblies 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.
11. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging. If necessary, replace the No. 1 oil nozzle sub-assembly.
12. REMOVE CONNECTING ROD SMALL END BUSH Using SST and press, press out the connecting rod small end bush. SST: 09222-30010

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Scheme 208

1. INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, measure the warpage of the surface witch contact the cylinder head gaskets. *1 Feeler Gauge *2 Precision Straightedge 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.
2. 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. Reference value (New parts) 83.000 to 83.012 mm (3.2677 to 3.2682 in.) Maximum diameter 83.13 mm (3.27 in.) *a Thrust Direction *b Axial Direction *c 10 mm (0.394 in.) *d Center Engine Front If the average diameter of 4 positions is more than the maximum, replace the cylinder block sub-assembly.
3. 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. *a for Bank 1 *b for Bank 2 *c Distance Distance 14.3 mm (0.563 in.) Reference value (New Parts) 82.960 to 82.970 mm (3.2661 to 3.2665 in.) Minimum diameter 82.846 mm (3.2616 in.) If the piston diameter is less than the minimum, replace the piston sub-assembly with pin.
4. INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust directions. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Reference value (New Parts) 0.030 to 0.052 mm (0.00118 to 0.00205 in.) Maximum oil clearance 0.072 mm (0.00284 in.) If the oil clearance is more than the maximum, replace the piston sub-assembly with pin or cylinder block sub-assembly according to their measurement values.
5. 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 Compression Ring 0.020 to 0.070 mm (0.00079 to 0.00276 in.) No. 2 Compression Ring 0.030 to 0.070 mm (0.00118 to 0.00276 in.) Oil Ring 0.020 to 0.070 mm (0.00079 to 0.00276 in.) If the clearance is not as specified, replace the piston sub-assembly with pin. *1 Feeler Gauge
6. INSPECT PISTON PIN OIL CLEARANCE Check each mark on the piston and connecting rod. *1 Front Mark *2 Piston Pin Hole Inside Diameter Mark *3 Connecting Rod Bushing Inside Diameter Mark *a for Bank 1 *b for Bank 2 HINT: Do not change the combination of the piston and piston pin. 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 (0.86606 to 0.86618 in.) B 22.002 to 22.004 mm (0.86622 to 0.86630 in.) C 22.005 to 22.007 mm (0.86634 to 0.86642 in.) *1 Caliper Gauge Using a micrometer, measure the piston pin diameter. Standard Piston Pin Diameter Mark Specified Condition A 21.997 to 22.000 mm (0.86602 to 0.86614 in.) B 22.001 to 22.003 mm (0.86618 to 0.86626 in.) C 22.004 to 22.006 mm (0.86630 to 0.86638 in.) *a 5 mm (0.197 in.) *b 28 mm (1.10 in.) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance -0.002 to 0.004 mm (-0.00008 to 0.00016 in.) Maximum oil clearance 0.015 mm (0.00059 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 22.009 to 22.011 mm (0.86649 to 0.86657 in.) C 22.012 to 22.014 mm (0.86661 to 0.86669 in.) *1 Caliper Gauge Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance 0.005 to 0.011 mm (0.00020 to 0.00043 in.) Maximum oil clearance 0.030 mm (0.00118 in.) 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.
7. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. *1 Piston Ring *a Approximately 110 mm (4.33 in.) 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 Compression Ring 0.20 to 0.25 mm (0.00787 to 0.00984 in.) No. 2 Compression Ring 0.35 to 0.40 mm (0.01378 to 0.01575 in.) Oil Ring 0.10 to 0.20 mm (0.00394 to 0.0787 in.) Maximum End Gap Item Specified Condition No. 1 Compression Ring 0.50 mm (0.0197 in.) No. 2 Compression Ring 0.80 mm (0.0315 in.) Oil Ring 0.65 mm (0.0256 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.
8. INSPECT CONNECTING ROD SUB-ASSEMBLY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for out-of-alignment. *1 Feeler Gauge 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. *1 Feeler Gauge 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.
9. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the diameter of the connecting rod bolt at several points within the area shown in the illustration. Standard diameter 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter 7.0 mm (0.276 in.) *a Measurement Area If the diameter is less than the minimum, replace the connecting rod 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.
10. 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 (0.00079 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 47.992 to 48.000 mm (1.889 to 1.890 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 (0.00079 in.) If the taper and out-of-round is more than the maximum, replace the crankshaft.
11. 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 sub-assembly. Lay a strip of Plastigage across each journal. *1 Plastigage Confirm the front marks and numbers to install the crankshaft bearing caps on the cylinder block sub-assembly. HINT: A number is marked on each crankshaft bearing cap to indicate the installation position. Install the crankshaft bearing caps. See step 7 NOTE: Do not apply engine oil to the crankshaft bearings or crankshaft journals. Do not turn the crankshaft. Remove the crankshaft bearing caps. See step 6 Measure the Plastigage at its widest point. Standard Oil Clearance 0.026 to 0.047 mm (0.00102 to 0.00185 in.) Maximum Oil Clearance 0.05 mm (0.00197 in.) *1 Plastigage If the oil clearance is more than the maximum, replace the crankshaft 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" *1 Cylinder Block Main Journal Diameter Number Mark *2 Crankshaft Main Journal Diameter Number Mark *3 Bearing Number *4 No. 1 and No. 4 Journal Bearing *5 No. 2 and No. 3 Journal Bearing *6 No. 1 *7 No. 2 *8 No. 3 *9 No. 4 *a 21 mm (0.827 in.) *b 18 mm (0.709 in.) - - HINT: EXAMPLE: Cylinder block "11" (A) + Crankshaft "06" (B) = Total number 17 (Use bearing "3") Standard Cylinder Block Main Journal Bore Diameter (A) Mark Specified Condition "00" 66.000 mm (2.59842 in.) "01" 66.001 mm (2.59846 in.) "02" 66.002 mm (2.59850 in.) "03" 66.003 mm (2.59854 in.) "04" 66.004 mm (2.59858 in.) "05" 66.005 mm (2.59862 in.) "06" 66.006 mm (2.59866 in.) "07" 66.007 mm (2.59870 in.) "08" 66.008 mm (2.59874 in.) "09" 66.009 mm (2.59877 in.) "10" 66.010 mm (2.59881 in.) "11" 66.011 mm (2.59885 in.) "12" 66.012 mm (2.59889 in.) "13" 66.013 mm (2.59893 in.) "14" 66.014 mm (2.59897 in.) "15" 66.015 mm (2.59901 in.) "16" 66.016 mm (2.59905 in.) Standard Crankshaft Main Journal Diameter (B) 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" 2.478 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 Lower Bearing Center Wall Thickness (No. 2 and No. 3 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.)
12. 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.) *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. Diameter measurements should be done at several points.
13. 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 sub-assembly. 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 sub-assembly. 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 sub-assembly. 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 sub-assembly.

Scheme 209

1. 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. *a Front Side *b Rear Side *c Upper Side *d Lower Side *e Protrusion Height - - 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.)
2. 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. *a Front Side *b Lower Side *c 52 mm (2.05 in.) *d 35 mm (1.38 in.) Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Scheme 210

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Scheme 218

1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the 3 No. 1 oil nozzle sub-assemblies with the 3 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. INSTALL CONNECTING ROD SMALL END BUSH Align the oil holes of a new connecting rod small end bush and the connecting rod sub-assembly. *1 Oil Hole Using SST and a press, press in the connecting rod small end bush. SST: 09222-30010 HINT: Make sure that the oil holes are aligned. Using a pin hole grinder, hone the bush to obtain the specified clearance between the connecting rod small end bush and piston pin. Standard oil clearance -0.002 to 0.004 mm (-0.00008 to 0.00016 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.
3. 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. *1 Cutout Portion HINT: Confirm that the end gap of the piston pin hole snap ring is not aligned with the pin hole cutout portion of the piston. Gradually heat the piston to approximately 80°C (176°F). WARNING: Be sure to wear protective gloves. 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. *1 Front Mark *a for Bank 1 *b for Bank 2 HINT: The piston and piston 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. *1 Cutout Portion HINT: Confirm that the end gap of the piston pin hole snap ring is not aligned with the pin hole cutout portion of the piston. Check that the piston moves smoothly.
4. INSTALL PISTON RING SET Install the oil ring expander by hand. Using a piston ring expander, install the No. 1 compression ring, No. 2 compression ring and oil ring as shown in the illustration. *1 Piston Ring Expander *2 No. 1 Compression Ring *3 No. 2 Compression Ring *4 Oil Ring *5 Oil Ring Expander *6 Cutout NOTE: The No. 1 compression ring can be installed with either side facing upward. Install the No. 2 compression ring with the cutout facing downward. Position the piston rings so that the ring ends are as shown in the illustration. *1 Oil Ring End *2 No. 1 Compression Ring End *3 No. 2 Compression Ring End *4 Oil Ring Expander End *5 Front Mark *a for Bank 1 *b for Bank 2 Engine Front NOTE: Do not align the ring ends.
5. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the bearings. *1 No. 1 and No. 4 Journal Bearing *2 No. 2 and No. 3 Journal Bearing *a 21.0 mm (0.827 in.) *b 18.0 mm (0.709 in.) NOTE: Crankshaft 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 crankshaft bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions. Install the upper crankshaft bearing. *1 Oil Groove *2 Oil Feed Hole *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 crankshaft 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 crankshaft bearing inner surface, replace the crankshaft bearing with a new one. Install the lower crankshaft bearing. *1 Journal Number *2 Vernier Caliper 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 to 0.7 mm (0 to 0.0276 in.) NOTE: Do not apply engine oil to the crankshaft bearings and the contact surfaces. Do not allow coolant to come into contact with the crankshaft bearing inner surface. If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.
6. INSTALL CRANKSHAFT THRUST WASHER SET Apply engine oil to the crankshaft thrust washer set. Install the crankshaft thrust washer set under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward. *1 Oil Groove NOTE: Be sure not to install the crankshaft thrust washer set the wrong way around.
7. INSTALL CRANKSHAFT Apply engine oil to the upper crankshaft bearing, and then place the crankshaft on the cylinder block sub-assembly. Apply engine oil to the lower crankshaft bearing. Confirm the projections and numbers on the crankshaft bearing caps and install the crankshaft bearing caps on the cylinder block sub-assembly. *1 Projection *2 Number Mark HINT: A number is marked on each crankshaft 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 set bolts. Temporarily install the 8 crankshaft bearing cap set bolts to the inside positions. NOTE: Confirm the crankshaft bearing cap set bolt length before installing. Bolt Length 100 to 102 mm (3.94 to 4.02 in.) 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 set bolts as a guide. *a Less than 6 mm (0.236 in.) *b Bolt Length 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 set bolts. Install the 8 crankshaft bearing cap set bolts to the outside positions. *a Bolt Length NOTE: Confirm the crankshaft bearing cap set bolt length before installing. 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.) Tighten the crankshaft bearing cap set bolts. HINT: The crankshaft bearing cap set bolts are tightened in 2 progressive steps. Step 1 Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps and in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) NOTE: Check that the crankshaft turns smoothly during the procedure. If any of the crankshaft bearing cap set bolts does not meet the torque specified, replace it. Step 2 Mark the front of the crankshaft bearing cap set bolts with paint. *1 Paint Mark *a 90° Engine Front Tighten the crankshaft bearing cap set 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 bolts in several steps and in the sequence shown in the illustration. Torque: 25.7 N*m (262 kgf*cm, 19 ft.*lbf) NOTE: Check that the crankshaft turns smoothly during the procedure. Confirm the crankshaft bearing cap set bolt length before installing. 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 5
8. INSTALL CONNECTING ROD BEARING Clean the connecting rod, connecting rod cap and 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 to 0.7 mm (0 to 0.0276 in.) *1 Vernier Caliper NOTE: Do not apply engine oil to the connecting rod bearings and the contact surfaces. Do not allow coolant to come into contact with the connecting rod bearing inner surface. If any coolant comes into contact with the connecting rod bearing inner surface, replace the connecting rod bearing with a new one.
9. 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. *1 Oil Ring End *2 No. 1 Compression Ring End *3 No. 2 Compression Ring End *4 Oil Ring Expander End *5 Front Mark *a for Bank 1 *b for Bank 2 Engine Front NOTE: Do not align the ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod sub-assembly into the cylinder with the front mark of the piston facing forward. *1 Front Mark *a for Bank 1 *b for Bank 2 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. *1 Front Mark Engine Front Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts. Install the connecting rod bolts. HINT: The connecting rod bolts are tightened in 2 progressive steps. Step 1 Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps. Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) NOTE: Check that the crankshaft turns smoothly during the procedure. Mark the front side of each connecting rod bolt with paint. *1 Paint Mark *a 90° Engine Front Step 2 Tighten the connecting rod bolts 90°. Check that the paint marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly.
10. INSPECT CONNECTING ROD THRUST CLEARANCE See step 1