Engine Mechanical: Overhaul Lexus LS IV

REASSEMBLY

1. INSTALL OIL PUMP RELIEF VALVE Coat the oil pump relief valve with engine oil. Install the relief valve and relief valve spring into the oil pump cover hole. Using a 19 mm socket wrench, install the plug. Torque: 53 N*m (540 kgf*cm, 39 ft.*lbf)
2. INSTALL OIL PUMP COVER Install the oil pump cover, drive rotor and driven rotor with the 13 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

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1. INSTALL WATER INLET PIPE Apply soapy water to 2 new O-rings and install them to the inlet pipe. Install the inlet pipe to the No. 1 heat exchanger cover.
2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Install a new oil pump gasket. Install a new O-ring. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Apply seal packing as follows SEAL PACKING APPLY REFERENCE CHART Area Seal packing diameter Application position from inside edge of cover Continuous Line Area 3.0 to 4.0 mm (0.1181 to 0.1575 in.) 2.5 mm (0.098 in.) Dashed Line Area 6.4 mm (0.2520 in.) or more, or within OK area shown in illustration 0.5 mm (0.020 in.) Diagonal Line Area 3.0 to 4.0 mm (0.1181 to 0.1575 in.) 5.5 mm (0.217 in.) NOTE: When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Align the spline of the oil pump's drive rotor and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft. Temporarily install the 30 bolts and nut. Bolt length BOLT LENGTH REFERENCE CHART Item Length Thread diameter Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.) Bolt B 55 mm (2.165 in.) 8 mm (0.315 in.) Bolt C 70 mm (2.756 in.) 8 mm (0.315 in.) Bolt D 35 mm (1.378 in.) 10 mm (0.394 in.) Bolt E 55 mm (2.165 in.) 10 mm (0.394 in.) Bolt F 80 mm (3.150 in.) 10 mm (0.394 in.) NOTE: Make sure that there is no oil on the bolt threads. Tighten the 11 bolts in several steps, in the sequence shown in the illustration. Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf) Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt. Tighten the 21 bolts and nut in several steps, in the sequence shown in the illustration. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) NOTE: After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off. Install 2 new gaskets and 2 plugs. Torque: 46 N*m (469 kgf*cm, 34 ft.*lbf)
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3, No. 7). Install a new gasket to the cylinder head cover. NOTE: Remove any oil from the contact surface. Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after the installation. Install the cylinder head cover with 2 new seal washers and the 15 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 12 N*m (122 kgf*cm, 9 ft.*lbf) for except bolt A
4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps. (No. 1, No. 3, No. 6). Install a new gasket to the cylinder head cover. NOTE: Remove any oil from the contact surface. Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after the installation. Install the cylinder head cover with 2 new seal washers and the 15 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 12 N*m (122 kgf*cm, 9 ft.*lbf) for except bolt A
5. INSTALL IGNITION COIL ASSEMBLY (See «INSTALLATION»(ref-349718-S03332413792009120800000) )
6. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 300 N*m (3059 kgf*cm, 221 ft.*lbf)
7. INSTALL RESONATOR BRACKET SUB-ASSEMBLY (See «REPLACEMENT»(ref-349714-S40961816732009120800000) )
8. INSTALL OIL FILTER BRACKET Install 2 new gaskets and the filter bracket with the 3 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
9. INSTALL OIL FILTER ELEMENT (See «REPLACEMENT»(ref-349715-S17971478042009120800000) )
10. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY (for Bank 1) (See «INSTALLATION»(ref-349724-S33899692292009120800000) )
11. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY (for Bank 2) (See «INSTALLATION»(ref-349724-S33899692292009120800000) )
12. INSTALL FRONT WATER BY-PASS JOINT (See «REASSEMBLY»(ref-349714-S28869732112009120800000) )
13. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
14. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
15. INSTALL WATER PUMP PULLEY (See «INSTALLATION»(ref-349714-S17702822762009120800000) )
16. INSTALL WATER INLET HOUSING Install the inlet housing and a new gasket with the 3 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Using needle-nose pliers, grip the claws of the clips and slide the clips to connect the water by-pass hoses and water inlet hose.
17. INSTALL FUEL PUMP ASSEMBLY (for High Pressure) (See «INSTALLATION»(ref-349727-S39705074622009120800000) )
18. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-349727-S39705074622009120800000) )
19. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-349727-S39705074622009120800000) )
20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See «INSTALLATION»(ref-349727-S10791541542009120800000) )
21. INSTALL ENGINE COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-349727-S39705074622009120800000) )
22. INSTALL NO. 3 ENGINE COVER (See «INSTALLATION»(ref-349727-S10791541542009120800000) )
23. INSTALL INTAKE MANIFOLD (See «INSTALLATION»(ref-349728-S03199878042009120800000) )
24. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-349728-S03199878042009120800000) )
25. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
26. INSTALL INJECTOR DRIVER (See «INSTALLATION»(ref-349728-S03199878042009120800000) )
27. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(ref-349732-S09051375432009120800000) )
28. INSTALL OIL LEVEL DIPSTICK GUIDE (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
29. CONNECT COOLER COMPRESSOR ASSEMBLY (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
30. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1) (See «INSTALLATION»(ref-349729-S11393153782009120800000) )
31. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See «INSTALLATION»(ref-349729-S11393153782009120800000) )
32. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/ VGRS) (See «INSTALLATION»(ref-349720-S01586454122009120800000) )
33. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/o VGRS) (See «INSTALLATION»(ref-349720-S29560656232009120800000) )
34. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS) (See «INSTALLATION»(ref-349720-S01586454122009120800000) )
35. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS) (See «INSTALLATION»(ref-349720-S29560656232009120800000) )
36. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH (See )
37. CONNECT FRONT STABILIZER BAR (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
38. INSTALL FRONT EXHAUST PIPE ASSEMBLY Install the front exhaust pipe (See «INSTALLATION»(ref-349729-S37582603882009120800000) ).
39. CONNECT ENGINE WIRE Connect the engine wire with the 4 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the clamp and install the 2 clamp brackets with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the intake air control valve actuator connector. Connect the purge VSV connector. Connect the 4 injector driver connectors as shown in the illustration. Connect the ground wire with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for Engine Room RH Side: Connect the 2 clamps and Install the 3 clamp brackets with the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the engine oil level sensor connector. Connect the crankshaft position sensor connector. Connect the starter connector and starter wire with the nut. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the generator connector and generator wire with the nut. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Connect the camshaft position sensor connector. Connect the engine wire connector. Connect the 2 camshaft timing control motor connectors (for Bank 2). Connect the fuel pump connector (for high pressure). Connect the 2 VVT sensor connectors. Connect the 4 ignition coil connectors. Connect the camshaft timing control valve connector. Connect the wires with No. 1 engine room junction block with the 2 nuts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Connect the 3 connectors with front controller with the clamp. for Engine Room LH Side: Install the clamp bracket with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the 3 clamps and 3 ground wires with the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Attach the clamp and connect the cooler compressor connector. Connect the 2 camshaft timing control motor connectors (for Bank 1). Connect the engine oil pressure sensor connector. Connect the engine coolant temperature sensor connector. Connect the clamp and install the 2 clamp brackets with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the No. 8 engine wire connector. Connect the fuel pump connector (for high pressure). Connect the 2 VVT sensor connectors. Connect the 4 ignition coil connectors. Connect the camshaft timing control valve connector. Connect the 3 ECT connectors and 4 ECM connectors. Install the ECM box cover (upper).
40. INSTALL ENGINE ROOM ECU OUTLET DUCT (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
41. INSTALL SKID CONTROL ECU BRACKET (See «INSTALLATION»(ref-349740-S10587781232009120800000) )
42. INSTALL SKID CONTROL ECU (See «INSTALLATION»(ref-349740-S10587781232009120800000) )
43. CONNECT NO. 2 RADIATOR HOSE
44. CONNECT NO. 1 RADIATOR HOSE
45. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-349714-S35834705202009120800000) )
46. INSTALL RADIATOR RESERVOIR ASSEMBLY (See «INSTALLATION»(ref-349716-S19796312192009120800000) )
47. INSTALL AIR CLEANER ASSEMBLY LH (See «INSTALLATION»(ref-349728-S03199878042009120800000) )
48. INSTALL AIR CLEANER ASSEMBLY RH (See «INSTALLATION»(ref-349728-S03199878042009120800000) )
49. INSTALL INTAKE AIR CONNECTOR PIPE (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
50. INSTALL NO. 1 AIR CLEANER INLET (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
51. INSTALL ENGINE UNDER COVER REAR LH (See «INSTALLATION»(ref-349722-S20556009772009120800000) )
52. INSTALL ENGINE UNDER COVER REAR RH (See «INSTALLATION»(ref-349722-S20556009772009120800000) )
53. INSTALL BATTERY TRAY Install the battery tray with the 3 bolts. Torque: 5.4 N*m (55 kgf*cm, 71 in.*lbf) Install the battery and battery insulator.
54. INSTALL BATTERY CLAMP SUB-ASSEMBLY Install the battery clamp and 2 clamp bolts with the nut. Torque: 5.4 N*m (55 kgf*cm, 71 in.*lbf)
55. ADD ENGINE OIL (See «REPLACEMENT»(ref-349715-S17971478042009120800000) )
56. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-349716-S35220647352009120800000) )
57. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
58. PERFORM INITIALIZATION Perform initialization (See «INITIALIZATION»(ref-349706-S07943075812009120800000) ). NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
59. INSPECT FOR OIL LEAK Inspect for engine oil leak (See «INSTALLATION»(ref-349715-S08153072402009120800000) ).
60. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(ref-349716-S37981694442009120800000) )
61. INSPECT FOR FUEL LEAK (See «ON-VEHICLE INSPECTION»(ref-349727-S24203775252009120800000) )
62. INSPECT FOR EXHAUST GAS LEAK (See «INSTALLATION»(ref-349729-S37582603882009120800000) )
63. CHECK ENGINE OIL LEVEL (See «LUBRICATION SYSTEM»(ref-349715-S09135725212009120800000) )
64. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
65. INSTALL NO. 2 ENGINE UNDER COVER (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
66. INSTALL NO. 1 ENGINE UNDER COVER (See «REPLACEMENT»(ref-349716-S35220647352009120800000) )
67. INSTALL ENGINE ROOM SIDE COVER RH (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
68. INSTALL ENGINE ROOM SIDE COVER LH (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
69. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
70. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
71. INSTALL COWL TOP VENTILATOR LOUVER RH (See «INSTALLATION»(ref-349735-S39879645972009120800000) )

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «ON-VEHICLE INSPECTION»(ref-349727-S24203775252009120800000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE ENGINE AND TRANSMISSION Remove the engine and transmission (See «REMOVAL»(ref-349714-S10589957032009120800000) ).
4. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.
5. REMOVE FRONT WATER BY-PASS JOINT (See «DISASSEMBLY»(ref-349714-S04657871382009120800000) )
6. REMOVE CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (See «REMOVAL»(ref-349724-S26123351222009120800000) )
7. REMOVE CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (See «REMOVAL»(ref-349724-S26123351222009120800000) )
8. REMOVE OIL FILTER ELEMENT (See «REPLACEMENT»(ref-349715-S09225651702009120800000) )
9. REMOVE OIL FILTER BRACKET Remove the 3 bolts, filter bracket and 2 gaskets.
10. REMOVE CRANKSHAFT PULLEY Using SST, loosen the crankshaft pulley set bolt. SST 09213-54015 (90119-08216), 09330-00021 Using the pulley set bolt and SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05011) REMOVE IGNITION COIL ASSEMBLY (See «REMOVAL»(ref-349718-S15407708742009120800000) )
11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Remove the 15 bolts, 2 seal washers, cylinder head cover and gasket. HINT: Make sure the removed parts are returned to the same places they were removed from. Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 2, No. 3, No. 7).
12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH Remove the 15 bolts, 2 seal washers, cylinder head cover and gasket. HINT: Make sure the removed parts are returned to the same places they were removed from. Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 1, No. 3, No. 6).
13. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Remove the 2 plugs and 2 gaskets. Remove the 30 bolts and nut shown in the illustration. Remove the timing chain cover by prying between the timing chain cover and cylinder head and cylinder block with a screwdriver as shown in the illustration. HINT: Tape the screwdriver tip before use. NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover. Remove the oil pump gasket from the cylinder block. Remove the O-ring from the cylinder block.
14. REMOVE WATER INLET PIPE Remove the water inlet pipe. Remove the 2 O-rings from the water inlet pipe.
15. REMOVE CRANKSHAFT TIMING GEAR KEY (See «REPLACEMENT»(ref-349714-S40961816732009120800000) )
16. REMOVE TIMING CHAIN CASE OIL SEAL (See «REPLACEMENT»(ref-349714-S40961816732009120800000) )

DISASSEMBLY

1. REMOVE OIL PUMP COVER Remove the 13 bolts, drive rotor, driven rotor and oil pump cover.
2. REMOVE OIL PUMP RELIEF VALVE Using a 19 mm socket wrench, remove the relief valve plug. Remove the valve spring and oil pump relief valve.

1. INSTALL OIL PUMP RELIEF VALVE Coat the oil pump relief valve with engine oil. Install the relief valve and relief valve spring into the oil pump cover hole. Using a 19 mm socket wrench, install the plug. Torque: 53 N*m (540 kgf*cm, 39 ft.*lbf)
2. INSTALL OIL PUMP COVER Install the oil pump cover, drive rotor and driven rotor with the 13 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

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1. INSTALL WATER INLET PIPE Apply soapy water to 2 new O-rings and install them to the inlet pipe. Install the inlet pipe to the No. 1 heat exchanger cover.
2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Install a new oil pump gasket. Install a new O-ring. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Apply seal packing as follows SEAL PACKING APPLY REFERENCE CHART Area Seal packing diameter Application position from inside edge of cover Continuous Line Area 3.0 to 4.0 mm (0.118 to 0.157 in.) 2.5 mm (0.0984 in.) Dashed Line Area 6.4 mm (0.252 in.) or more, or within OK area shown in illustration 0.5 mm (0.0197 in.) Diagonal Line Area 3.0 to 4.0 mm (0.118 to 0.157 in.) 5.5 mm (0.217 in.) NOTE: When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Align the spline of the oil pump's drive rotor and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft. Temporarily instal the 30 bolts and nut. Bolt length BOLT LENGTH REFERENCE CHART Item Length Thread diameter Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.) Bolt B 55 mm (2.17 in.) 8 mm (0.315 in.) Bolt C 70 mm (2.76 in.) 8 mm (0.315 in.) Bolt D 35 mm (1.38 in.) 10 mm (0.394 in.) Bolt E 55 mm (2.17 in.) 10 mm (0.394 in.) Bolt F 80 mm (3.15 in.) 10 mm (0.394 in.) NOTE: Make sure that there is no oil on the bolt threads. Tighten the 11 bolts in several steps, in the sequence shown in the illustration. Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf) Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt. Tighten the 21 bolts and nut in several steps, in the sequence shown in the illustration. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) NOTE: After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off. Install 2 new gaskets and 2 plugs. Torque: 46 N*m (469 kgf*cm, 34 ft.*lbf)
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3, No. 7). Install a new gasket to the cylinder head cover. NOTE: Remove any oil from the contact surface. Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after the installation. Install the cylinder head cover with 2 new seal washers and the 15 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 12 N*m (122 kgf*cm, 9 ft.*lbf) for except bolt A
4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps. (No. 1, No. 3, No. 6). Install a new gasket to the cylinder head cover. NOTE: Remove any oil from the contact surface. Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after the installation. Install the cylinder head cover with 2 new seal washers and the 15 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 12 N*m (122 kgf*cm, 9 ft.*lbf) for except bolt A
5. INSTALL IGNITION COIL ASSEMBLY (See «INSTALLATION»(ref-349718-S03332413792009120800000) )
6. INSTALL TIMING CHAIN CASE OIL SEAL (See «REPLACEMENT»(ref-349714-S40961816732009120800000) )
7. INSTALL CRANKSHAFT TIMING GEAR KEY (See «REPLACEMENT»(ref-349714-S40961816732009120800000) )
8. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 300 N*m (3059 kgf*cm, 221 ft.*lbf)
9. INSTALL OIL FILTER BRACKET Install 2 new gaskets and the filter bracket with the 3 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
10. INSTALL OIL FILTER ELEMENT (See «REPLACEMENT»(ref-349715-S09225651702009120800000) )
11. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (See «INSTALLATION»(ref-349724-S33899692292009120800000) )
12. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (See «INSTALLATION»(ref-349724-S33899692292009120800000) )
13. INSTALL FRONT WATER BY-PASS JOINT (See «REASSEMBLY»(ref-349714-S28869732112009120800000) )
14. INSTALL ENGINE AND TRANSMISSION Install the engine and transmission (See «INSTALLATION»(ref-349714-S27537239552009120800000) ).
15. PERFORM INITIALIZATION Perform initialization (See «INITIALIZATION»(ref-349706-S07943075812009120800000) ). NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «PRECAUTION»(ref-349727-S09663469032009120800000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY for 2WD: Remove the timing chain cover (See «REMOVAL»(ref-349714-S01893944022009120800000) ). for AWD: Remove the timing chain cover (See «REMOVAL»(ref-349714-S26196101182009120800000) ).
4. SET NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily tighten the pulley set bolt. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration. HINT: If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.
5. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole. Remove the 2 bolts and chain tensioner.
6. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)
7. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) Remove the 2 bolts and chain vibration damper.
8. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1) While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it in place. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench. NOTE: Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTE: Be careful not to damage the cylinder head with the wrench. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket. Remove the No. 1 and No. 2 chains from the gears.
9. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the 2 bolts and chain tensioner.
10. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole. Remove the 2 bolts and chain tensioner.
11. REMOVE CHAIN TENSIONER SLIPPER (for Bank 2)
12. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2) Remove the 2 bolts and vibration damper.
13. REMOVE CHAIN SUB-ASSEMBLY (for Bank 2) While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it in place. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench. NOTE: Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTE: Be careful not to damage the cylinder head with the wrench. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket. Remove the No. 1 and No. 2 chains from the gears.
14. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the 2 bolts and chain tensioner.

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1. INSPECT CHAIN SUB-ASSEMBLY Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown the illustration. Using a vernier caliper, measure the length of 15 pins. Maximum chain elongation: 136.9 mm (5.389 in.) If the elongation is greater than the maximum, replace the chain. NOTE: Perform the measurement at 3 random places.
2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown the illustration. Using a vernier caliper, measure the length of 15 pins. Maximum chain elongation: 137.6 mm (5.417 in.) If the elongation is greater than the maximum, replace the chain. NOTE: Perform the measurement at 3 random places.
3. INSPECT CRANKSHAFT TIMING GEAR Wrap the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (w/ chain): 61.4 mm (2.417 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
4. INSPECT CRANKSHAFT TIMING SPROCKET LH Wrap the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (w/ chain): 61.4 mm (2.417 in.) NOTE: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
5. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. If necessary, replace the chain tensioner.
6. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner. Maximum depth: 0.9 mm (0.035 in.) If the depth the is greater than the maximum, replace the chain tensioner.
7. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner. Maximum depth: 0.9 mm (0.035 in.) If the depth is greater than the maximum, replace the chain tensioner.
8. INSPECT CHAIN TENSIONER SLIPPER for Bank 1: Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain tensioner slipper. for Bank 2: Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain tensioner slipper.
9. INSPECT NO. 1 CHAIN VIBRATION DAMPER for Bank 1: Measure the worn depth of the chain vibration damper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain vibration damper. for Bank 2: Measure the worn depth of the chain vibration damper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain vibration damper.

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1. SET NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily install the crankshaft pulley bolt. Rotate the crankshaft so that the timing gear key is as shown in the illustration. Then using a wrench, rotate each camshaft so that the timing marks are as shown in the illustration. NOTE: When the crankshaft or a camshaft is rotated excessively, the valves and pistons may interfere with each other. Remove the crankshaft pulley bolt.
2. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Install the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it in place.
3. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration. Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration. Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration. HINT: The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears. Install the crankshaft timing gear to the crankshaft. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly. Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly. Remove the pin from the No. 2 chain tensioner.
4. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2) Install the vibration damper with the 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
5. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2) HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.
6. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the hexagon wrench from the chain tensioner.
7. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Install the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) While pushing down the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it in place.
8. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration. Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration. Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration. HINT: The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears. Install the crankshaft timing gear to the crankshaft. Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly. Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear assembly. NOTE: Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed. Remove the pin from the No. 2 chain tensioner.
9. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1) HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner.
10. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install the chain tensioner and gasket with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
11. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) Install the vibration damper with the 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Remove the hexagon wrench from the No. 1 chain tensioner.
12. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY for Bank 1: Using a wrench, hold the hexagonal portion of the No. 3 camshaft. Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt. Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) for Bank 2: Using a wrench, hold the hexagonal portion of the No. 1 camshaft. Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt. Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
13. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily install the crankshaft pulley bolt. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration. Remove the crankshaft pulley bolt.
14. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY for 2WD: Install the timing chain cover (See «INSTALLATION»(ref-349714-S06151445972009120800000) ). for AWD: Install the riming chain cover (See «INSTALLATION»(ref-349714-S38774077922009120800000) ).
15. PERFORM INITIALIZATION Perform initialization (See «INITIALIZATION»(ref-349706-S07943075812009120800000) ). NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «PRECAUTION»(ref-349727-S09663469032009120800000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Remove the timing chain cover (See «REMOVAL»(ref-349714-S26196101182009120800000) ).
4. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «REMOVAL»(ref-349714-S38860539352009120800000) )
5. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) (See «REMOVAL»(ref-349714-S38860539352009120800000) )
6. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)
7. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) (See «REMOVAL»(ref-349714-S38860539352009120800000) )
8. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1) (See «REMOVAL»(ref-349714-S38860539352009120800000) )
9. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (See «REMOVAL»(ref-349714-S38860539352009120800000) )
10. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Make sure that the knock pin of the camshaft is positioned as shown in the illustration. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 7 bearing caps. HINT: Arrange the removed parts in the correct order. Remove the No. 3 and No. 4 camshafts.
11. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use.

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1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Using vernier calipers, measure the width of the camshaft timing gear assembly's eccentric shaft cutout. Standard width: 5.9 to 6.2 mm (0.232 to 0.244 in.) Maximum width: 6.7 mm (0.264 in.) If the result is greater than the maximum value, replace the camshaft timing gear assembly. Rotate the keyway part of the camshaft timing gear assembly's eccentric shaft by hand. Standard: Rotates smoothly If the result is not as specified, replace the camshaft timing gear assembly. NOTE: Do not drop the camshaft timing gear assembly. If dropped, replace it. Do not disassemble the camshaft timing gear assembly. If disassembled, replace it.
2. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Install the camshaft bearing cap (see «INSTALLATION»(ref-349714-S41501263152009120800000) ). HINT: Only install the exhaust camshaft. Install the camshaft housing (see «INSTALLATION»(ref-349714-S41501263152009120800000) ). Apply a light coat of engine oil on the camshaft and camshaft timing exhaust gear. Using the hexagonal portion of the camshaft, align and attach the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear assembly. NOTE: Do not forcefully push in the camshaft timing exhaust gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing exhaust gear assembly. Be sure not to remove the other 4 bolts. If removed, replace the camshaft timing exhaust gear assembly. Apply a light coat of engine oil on the threads and under the heads of the bolt. Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing exhaust gear assembly with the bolt. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the camshaft bearing cap (see «REMOVAL»(ref-349714-S08684127622009120800000) ). Check the lock of the camshaft timing gear. Make sure that the camshaft timing exhaust gear is locked. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path on the opposite side to that of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 broken paths (the advance side path and the retard side path). CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. Check that the camshaft timing gear revolves in the retard direction when reducing the air pressure applied to the advance side path. HINT: This operation releases the lock pin for the most retarded position. When the camshaft timing gear reaches the most retarded position, release the air pressure from the advance side path and retard side path, in that order. NOTE: Do not release the air pressure from the retard side path first. The gear may abruptly shift in the advance direction and break the lock pin. Check for smooth rotation. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly. NOTE: Do not use air pressure to perform the smooth rotation check. Check the lock in the most advanced position. Confirm that the camshaft timing gear is locked at the most advanced position. Install the camshaft bearing cap (see «INSTALLATION»(ref-349714-S41501263152009120800000) ). HINT: Only install the exhaust camshaft. Install the camshaft housing (see «INSTALLATION»(ref-349714-S41501263152009120800000) ). Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. Remove the camshaft bearing cap (see «REMOVAL»(ref-349714-S08684127622009120800000) ). Remove the flange bolt and camshaft timing exhaust gear. NOTE: Be sure not to remove the other 4 bolts.
3. INSPECT CAMSHAFT SUB-ASSEMBLY Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.0016 in.) If the circle runout is greater than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. Using a micrometer, measure the cam lobe height. Standard cam lobe height STANDARD CAM LOBE HEIGHT REFERENCE CHART Item Specified Condition Intake 44.293 to 44.443 mm (1.7438 to 1.7497 in.) Exhaust 44.316 to 44.466 mm (1.7447 to 1.7506 in.) Minimum cam lobe height MINIMUM CAM LOBE HEIGHT REFERENCE CHART Item Specified Condition Intake 44.243 mm (1.7419 in.) Exhaust 44.266 mm (1.7428 in.) If the cam lobe height is less than the minimum, replace the camshaft. Using a micrometer, measure the journal diameter. Standard journal diameter STANDARD JOURNAL DIAMETER REFERENCE CHART Item Specified Condition No. 1 journal 29.956 to 29.970 mm (1.1794 to 1.1799 in.) Other journal 25.959 to 25.975 mm (1.0220 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance.
4. INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each of the camshaft journals. Install the bearing caps (see «INSTALLATION»(ref-349714-S41501263152009120800000) ). NOTE: Do not turn the camshaft. Install the camshaft housing (see «INSTALLATION»(ref-349714-S41501263152009120800000) ). NOTE: Do not turn the camshaft. Remove the bearing caps (see «REMOVAL»(ref-349714-S08684127622009120800000) ). Measure the Plastigage at its widest point. Standard oil clearance STANDARD OIL CLEARANCE REFERENCE CHART Item Specified Condition No. 1 journal 0.030 to 0.065 mm (0.00118 to 0.00256 in.) Other Journal 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum oil clearance MAXIMUM OIL CLEARANCE REFERENCE CHART Item Specified Condition No. 1 Journal 0.10 mm (0.0039 in.) Other journal 0.09 mm (0.0035 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

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1. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. Install the No. 3 and No. 4 camshaft to the camshaft housing. Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper positions and directions. Temporarily install the 8 bolts in the order shown in the illustration.
2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1) Make sure that the valve rocker arms are installed as shown in the illustration. Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter: 3.5 to 4.0 mm (0.138 to 0.158 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after the installation. Install the camshaft housing, and install the 12 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 30 N*m (306 kgf*cm, 22 ft.*lbf) for except bolt A NOTE: Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing. Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) NOTE: Thoroughly wipe clean any seal packing.
3. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (See «INSTALLATION»(ref-349714-S17519491772009120800000) )
4. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1) (See «INSTALLATION»(ref-349714-S17519491772009120800000) )
5. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1) (See «INSTALLATION»(ref-349714-S17519491772009120800000) )
6. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) (See «INSTALLATION»(ref-349714-S17519491772009120800000) )
7. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) (See «INSTALLATION»(ref-349714-S17519491772009120800000) )
8. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY (See «INSTALLATION»(ref-349714-S17519491772009120800000) )
9. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION (See «INSTALLATION»(ref-349714-S17519491772009120800000) )
10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Install the timing chain cover (see «INSTALLATION»(ref-349714-S38774077922009120800000) ).

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «PRECAUTION»(ref-349727-S09663469032009120800000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE CHAIN SUB-ASSEMBLY Remove the timing chain (See «REMOVAL»(ref-349714-S38860539352009120800000) ).
4. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Make sure that the knock pin of the camshaft is positioned as shown in the illustration. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 7 bearing caps. NOTE: Arrange the removed parts in the correct order. Remove the No. 1 and No. 2 camshafts.
5. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use.

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1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Using vernier calipers, measure the width of the camshaft timing gear assembly's eccentric shaft cutout. Standard width: 5.9 to 6.2 mm (0.232 to 0.244 in.) Maximum width: 6.7 mm (0.264 in.) If the result is greater than the maximum value, replace the camshaft timing gear assembly. Rotate the keyway part of the camshaft timing gear assembly's eccentric shaft by hand. Standard: Rotates smoothly If the result is not as specified, replace the camshaft timing gear assembly. NOTE: Do not drop the camshaft timing gear assembly. If dropped, replace it. Do not disassemble the camshaft timing gear assembly. If disassembled, replace it.
2. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Install the camshaft bearing cap (see «INSTALLATION»(ref-349714-S02262980772009120800000) ). HINT: Only install the exhaust camshaft. Install the camshaft housing (see «INSTALLATION»(ref-349714-S02262980772009120800000) ). Apply a light coat of engine oil on the camshaft and camshaft timing exhaust gear. Using the hexagonal portion of the camshaft, align and attach the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear assembly. NOTE: Do not forcefully push in the camshaft timing exhaust gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing exhaust gear assembly. Be sure not to remove the other 4 bolts. If removed, replace the camshaft timing exhaust gear assembly. Apply a light coat of engine oil on the threads and under the heads of the bolt. Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing exhaust gear assembly with the bolt. Torque: 100 N*m (102 kgf*cm, 74 ft.*lbf) Remove the camshaft bearing cap (see «REMOVAL»(ref-349714-S04129525422009120800000) ). Check the lock of the camshaft timing gear. Make sure that the camshaft timing exhaust gear is locked. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path on the opposite side to that of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 broken paths (the advance side path and the retard side path). CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. Check that the camshaft timing gear revolves in the retard direction when reducing the air pressure applied to the advance side path. HINT: This operation releases the lock pin for the most retarded position. When the camshaft timing gear reaches the most retarded position, release the air pressure from the advance side path and retard side path, in that order. NOTE: Do not release the air pressure from the retard side path first. The gear may abruptly shift in the advance direction and break the lock pin. Check for smooth rotation. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly. NOTE: Do not use air pressure to perform the smooth rotation check. Check the lock in the most advanced position. Confirm that the camshaft timing gear is locked at the most advanced position. Install the camshaft bearing cap (see «INSTALLATION»(ref-349714-S02262980772009120800000) ). HINT: Only install the exhaust camshaft. Install the camshaft housing (see «INSTALLATION»(ref-349714-S02262980772009120800000) ). Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. Remove the camshaft bearing cap (see «REMOVAL»(ref-349714-S04129525422009120800000) ). Remove the flange bolt and camshaft timing exhaust gear.
3. INSPECT CAMSHAFT Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.0016 in.) If the circle runout is greater than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. Using a micrometer, measure the cam lobe height. Standard cam lobe height STANDARD CAM LOBE HEIGHT REFERENCE CHART Item Specified Condition Intake 44.293 to 44.443 mm (1.7438 to 1.7497 in.) Exhaust 44.316 to 44.466 mm (1.7447 to 1.7506 in.) Minimum cam lobe height MINIMUM CAM LOBE HEIGHT REFERENCE CHART Item Specified Condition Intake 44.243 mm (1.7419 in.) Exhaust 44.266 mm (1.7428 in.) If the cam lobe height is less than the minimum, replace the camshaft. Using a micrometer, measure the journal diameter. Standard journal diameter STANDARD JOURNAL DIAMETER REFERENCE CHART Item Specified Condition No. 1 journal 29.956 to 29.970 mm (1.1794 to 1.1799 in.) Other journal 25.959 to 25.975 mm (1.0220 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance.
4. INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each of the camshaft journals. Install the bearing caps (see «INSTALLATION»(ref-349714-S02262980772009120800000) ). NOTE: Do not turn the camshaft. Install the camshaft housing (see «INSTALLATION»(ref-349714-S02262980772009120800000) ). NOTE: Do not turn the camshaft. Remove the bearing caps (see «REMOVAL»(ref-349714-S04129525422009120800000) ). Measure the Plastigage at its widest point. Standard oil clearance STANDARD OIL CLEARANCE REFERENCE CHART Item Specified Condition No. 1 Journal 0.030 to 0.065 mm (0.00118 to 0.00256 in.) Other Journal 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum oil clearance MAXIMUM OIL CLEARANCE REFERENCE CHART Item Specified Condition No. 1 journal 0.10 mm (0.0039 in.) Other journal 0.09 mm (0.0035 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

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1. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. Install the No. 1 and No. 2 camshaft to the camshaft housing. Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper positions and directions. Temporarily install the 8 bolts in the order shown in the illustration.
2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2) Make sure that the valve rocker arms are installed as shown in the illustration. Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter: 3.5 to 4.0 mm (0.138 to 0.158 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after the installation. Install the camshaft housing, and install the 12 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 30 N*m (306 kgf*cm, 22 ft.*lbf) for except bolt A NOTE: Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing. Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) NOTE: Thoroughly wipe clean any seal packing.
3. INSTALL CHAIN SUB-ASSEMBLY Install the timing chain (See «INSTALLATION»(ref-349714-S17519491772009120800000) ).

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «PRECAUTION»(ref-349727-S09663469032009120800000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE CAMSHAFT SUB-ASSEMBLY (for Bank 1) Remove the camshaft (see «REMOVAL»(ref-349714-S08684127622009120800000) ).
4. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 16 valve rocker arms from the cylinder head. HINT: Arrange the removed parts in the correct order.
5. REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 16 valve lash adjusters from the cylinder head. HINT: Arrange the removed parts in the correct order.
6. REMOVE VALVE STEM CAP Remove the 16 valve stem caps from the cylinder head. HINT: Arrange the removed parts in the correct order.
7. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 1) Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head. Head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to keep the removed parts separate for each installation position. Remove the cylinder head and gasket.

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1. INSPECT CYLINDER HEAD SET BOLT (See «INSPECTION»(ref-349714-S41362976122009120800000) )
2. INSPECT CYLINDER HEAD SUB-ASSEMBLY (See «INSPECTION»(ref-349714-S06940704172009120800000) )
3. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1) Check the piston protrusions for each cylinder. Clean the cylinder block with solvent. Set the piston of the cylinder to be measured to slightly ATDC. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward. NOTE: Be careful of the installation direction. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head. Place the cylinder head on the cylinder block. NOTE: Ensure that no oil is on the mounting surface of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1: Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps, in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2: Mark the cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts another 90° in the sequence shown in step 1 . Step 3: Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1. Check that the painted marks are now facing rearward. Uniformly install the 2 bolts in the sequence shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
4. INSTALL VALVE STEM CAP Apply a light coat of engine oil to the valve stem caps. Install the 16 valve stem caps to the cylinder head.
5. INSTALL VALVE LASH ADJUSTER ASSEMBLY Be sure to inspect the valve lash adjuster before installing it (see «INSPECTION»(ref-349714-S41362976122009120800000) ). Install the 16 lash adjusters to the cylinder head. NOTE: Install the lash adjuster at the same place it was removed from.
6. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the lash adjuster tips and valve stem cap ends. Make sure that the 16 valve rocker arms are installed as shown in the illustration.
7. INSTALL CAMSHAFT SUB-ASSEMBLY (for Bank 1) Install the camshaft (see «INSTALLATION»(ref-349714-S41501263152009120800000) ).

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «PRECAUTION»(ref-349727-S09663469032009120800000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE CAMSHAFT (for Bank 2) Remove the camshaft (see «REMOVAL»(ref-349714-S04129525422009120800000) ).
4. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 16 valve rocker arms from the cylinder head. HINT: Arrange the removed parts in the correct order.
5. REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 16 valve lash adjusters from the cylinder head. HINT: Arrange the removed parts in the correct order.
6. REMOVE VALVE STEM CAP Remove the 16 valve stem caps from the cylinder head. HINT: Arrange the removed parts in the correct order.
7. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 2) Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head. Head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to keep the removed parts separate for each installation position. Remove the cylinder head and gasket.

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1. INSPECT CYLINDER HEAD SET BOLT (See «INSPECTION»(ref-349714-S41362976122009120800000) )
2. INSPECT CYLINDER HEAD SUB-ASSEMBLY (See «INSPECTION»(ref-349714-S06940704172009120800000) )
3. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2) Check the piston protrusions for each cylinder. Clean the cylinder block with solvent. Set the piston of the cylinder to be measured to slightly ATDC. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward. NOTE: Be careful of the installation direction. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head. Place the cylinder head on the cylinder block. NOTE: Ensure that no oil is on the mounting surface of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1: Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps, in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2: Mark the cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts another 90° in the sequence shown in step 1 . Step 3: Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1. Check that the painting marks are now facing rearward. Uniformly install the 2 bolts in the sequence shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
4. INSTALL VALVE STEM CAP Apply a light coat of engine oil to the valve stem caps. Install the 16 valve stem caps to the cylinder head.
5. INSTALL VALVE LASH ADJUSTER ASSEMBLY Be sure to inspect the valve lash adjuster before installing it (see «INSPECTION»(ref-349714-S41362976122009120800000) ). Install the 16 valve lash adjusters to the cylinder head. NOTE: Install the lash adjuster at the same place it was removed from.
6. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the lash adjuster tips and valve stem cap ends. Make sure that the 16 valve rocker arms are installed as shown in the illustration.
7. INSTALL CAMSHAFT (for Bank 2) Install the camshaft (see «INSTALLATION»(ref-349714-S02262980772009120800000) ).

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1. REMOVE INTAKE VALVE Using SST and wooden blocks, compress the compression spring and remove the valve retainer lock. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) Remove the retainer, compression spring and valve. HINT: Arrange the removed parts in the correct order.
2. REMOVE EXHAUST VALVE Using SST and wooden blocks, compress the compression spring and remove the valve retainer lock. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) Remove the retainer, compression spring and valve. HINT: Arrange the removed parts in the correct order.
3. REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the oil seals.
4. REMOVE VALVE SPRING SEAT Using compressed air and a magnetic finger, remove the valve spring seat by blowing air onto it.
5. REMOVE NO. 1 STRAIGHT SCREW PLUG NOTE: If water leaks from the No. 1 screw plug or the plug is corroded, replace it. Using a 10 mm hexagon wrench, remove the 6 screw plugs and 6 gaskets.
6. REMOVE NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, remove the 2 screw plugs and 2 gaskets. NOTE: If water leaks from the No. 2 screw plug or the plug is corroded, replace it.
7. REMOVE STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it.

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1. INSPECT CYLINDER HEAD SUB-ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces of the cylinder block and manifold. Standard warpage STANDARD WARPAGE REFERENCE CHART Item Specified Condition Cylinder head lower side 0.05 mm (0.0020 in.) Intake side 0.08 mm (0.0031 in.) Exhaust side 0.05 mm (0.0020 in.) Maximum warpage: 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace the cylinder head. Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head.
2. INSPECT INTAKE VALVE Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness: 1.25 mm (0.0492 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the intake valve. Using a vernier caliper, measure the valve's overall length. Standard overall length: 105.85 mm (4.1673 in.) Minimum overall length: 105.35 mm (4.1476 in.) If the overall length is less than the minimum, replace the intake valve.
3. INSPECT EXHAUST VALVE Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2157 in.) Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness: 1.4 mm (0.0551 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the exhaust valve. Using a vernier caliper, measure the valve's overall length. Standard overall length: 110.40 mm (4.3465 in.) Minimum overall length: 109.90 mm (4.3268 in.) If the overall length is less than the minimum, replace the exhaust valve.
4. INSPECT INTAKE VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. HINT: Do not rotate the valve while pressing the valve. Check the valve face and valve seat. Check that the contact surfaces of the valve seat and valve face are in the middle area of their respective surfaces, with the width between 1.1 to 1.5 mm (0.0433 to 0.0591 in.). If not, correct the valve seat. Check that the contact surfaces of the valve seat and valve face are even around the entire valve seat. If not, correct the valve seat.
5. INSPECT EXHAUST VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. Check the valve face and valve seat. Check that the contact surfaces of the valve seat and valve face are in the middle area of their respective surfaces, with the width between 1.1 to 1.5 mm (0.0433 to 0.0591 in.). If not, correct the valve seat. Check that the contact surface of the valve seat and valve face are even around the entire valve seat. If not, correct the valve seat.
6. INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the inner compression spring. Standard free length: 51.70 mm (2.0354 in.) If the free length is not as specified, replace the spring. Using a steel square, measure the deviation of the inner compression spring. Maximum deviation: 1.0 mm (0.0394 in.) Maximum angle (reference): 2° If the deviation is greater than the maximum, replace the spring.
7. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the guide bush. Standard bush inside diameter: 5.51 to 5.53 mm (0.2169 to 0.2177 in.) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance STANDARD OIL CLEARANCE REFERENCE CHART Item Specified Condition Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance MAXIMUM OIL CLEARANCE REFERENCE CHART Item Specified Condition Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush.
8. INSPECT CAMSHAFT THRUST CLEARANCE Inspect the bank 1 camshafts. Install the bank 1 camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.08 to 0.14 mm (0.0031 to 0.0055 in.) Maximum thrust clearance: 0.15 mm (0.006 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. Inspect the bank 2 camshafts. Install the bank 2 camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.08 to 0.14 mm (0.0031 to 0.0055 in.) Maximum thrust clearance: 0.15 mm (0.006 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

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1. REPLACE INTAKE VALVE GUIDE BUSH Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the valve guide bush. SST 09201-10000, 09201-01055, 09950-70010 (09951-07100) Using a caliper gauge, measure the bush bore diameter of the cylinder head side. Standard cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) If the bush bore diameter of the cylinder head is between 10.285 to 10.306 mm (0.4049 to 0.4057 in.), proceed to the next step. If the bush bore diameter of the cylinder head is 10.356 mm (0.4077 in.) or more, replace the cylinder head. Select a new guide bush (STD or O/S 0.05), and measure its diameter. Machine the bush bore diameter of the cylinder head side to the diameter of the selected guide bush. Bush bore diameter BUSH BORE DIAMETER REFERENCE CHART Bush Size Specified Condition STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). Using SST and a hammer, tap in a new guide bush to the specified protrusion height. Standard protrusion height: 14.3 to 14.7 mm (0.563 to 0.579 in.) SST 09201-10000, 09201-01055, 09950-70010 (09951-07100) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.
2. REPLACE EXHAUST VALVE GUIDE BUSH Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the valve guide bush. SST 09201-10000, 09201-01055, 09950-70010 (09951-07100) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) If the bush diameter of the cylinder head is between 10.285 to 10.306 mm (0.4049 to 0.4057 in.), proceed to the next step. If the bush bore diameter of the cylinder head is 10.356 mm (0.4077 in.) or more, replace the cylinder head. Select a new guide bush (STD or O/S 0.05), and measure its diameter. Machine the bush bore diameter of the cylinder head side to the diameter of the selected guide bush. Bush bore diameter BUSH BORE DIAMETER REFERENCE CHART Bush Size Specified Condition STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201-10000, 09201-01055, 09950-70010 (09951-07100) Standard protrusion height: 14.3 to 14.7 mm (0.563 to 0.579 in.) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the specified clearance between the guide bush and valve stem.
3. REPLACE SPARK PLUG TUBE HINT: When using a new cylinder head, the spark plug tubes must be replaced. Remove the spark plug tube. Apply adhesive to the end of a new spark plug tube. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Standard seal diameter: 15 mm (0.591 in.) NOTE: Install the spark plug tube within 3 minutes after applying adhesive. Be careful not to deform the spark plug tube. Be careful not to expose the seal to coolant for at least 1 hour after installing it. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height. Standard protrusion height: 66.6 to 67.6 mm (2.62 to 2.66 in.) NOTE: To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.
4. REPLACE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Remove the ring pins. Using a plastic-faced hammer, tap in new ring pins until the pin stops. Standard protrusion STANDARD PROTRUSION REFERENCE CHART Item Specified Condition Ring pin A 5.5 to 6.5 mm (0.217 to 0.256 in.) Ring pin B 3.5 to 6.5 mm (0.138 to 0.256 in.)

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1. INSTALL STUD BOLT NOTE: If a stud bolt are deformed or threads are damaged, replace it. Using E6 and E8 "TORX" socket wrenches, install the stud bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) for stud bolts A, B, C and D
2. INSTALL NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
3. INSTALL NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, install 6 new gaskets and the 6 straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
4. INSTALL VALVE SPRING SEAT Install the valve spring seats to the cylinder head.
5. INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to new oil seals. NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later. HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. Using SST, push in the oil seals. SST 09201-41020 NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
6. INSTALL INTAKE VALVE Apply plenty of engine oil to the tip area of the intake valve shown in the illustration. Install the valve, compression spring and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to original locations. Using SST and wooden blocks, compress the spring and install the retainer lock. 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.
7. INSTALL EXHAUST VALVE Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration. Install the valve, compression spring and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to their original locations. Using SST and wooden blocks, compress the spring and install the retainer lock. 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.

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1. REPAIR INTAKE VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Standard width: 1.1 to 1.5 mm (0.043 to 0.059 in.) Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position.
2. REPAIR EXHAUST VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Standard width: 1.3 to 1.7 mm (0.051 to 0.067 in.) Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position.

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1. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 to 0.55 mm (0.0059 to 0.0217 in.) Maximum thrust clearance: 0.70 mm (0.0276 in.) If the thrust clearance is greater than the maximum, replace one or more connecting rods as necessary. If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE Check that the front mark on the connecting rod and cap are aligned to ensure the correct reassembly. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. Clean the crank pin and bearing. NOTE: Check the crank pin and bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. Check that the front mark of the connecting rod cap is facing forward. Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE: Do not turn the crankshaft. Mark the front side of each connecting cap bolt with paint. Retighten the cap bolts by 90° as shown. Check that the painted marks are now at a 90° angle to the front. NOTE: Do not turn the crankshaft. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. Measure the Plastigage at its widest point. Standard oil clearance: 0.025 to 0.050 mm (0.0010 to 0.0020 in.) Maximum oil clearance: 0.070 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface. Select the correct bearing by adding together the number marks imprinted on the connecting rod big end and crank pin. Example: Connecting rod "1" + Crank pin "2" = 3 (Use bearing "3") Reference: Standard sized bearing center wall thickness STANDARD SIZED BEARING CENTER WALL THICKNESS REFERENCE CHART Mark Thickness 2 1.489 to 1.492 mm (0.0586 to 0.0587 in.) 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.) 4 1.495 to 1.498 mm (0.0589 to 0.0590 in.) 5 1.498 to 1.501 mm (0.0590 to 0.0591 in.) 6 1.501 to 1.504 mm (0.0591 to 0.0592 in.) 7 1.504 to 1.507 mm (0.0592 to 0.0593 in.) Connecting rod big end inside diameter CONNECTING ROD BIG END INSIDE DIAMETER REFERENCE CHART Mark Thickness 1 56.000 to 56.006 mm (2.2047 to 2.2050 in.) 2 56.007 to 56.012 mm (2.2050 to 2.2052 in.) 3 56.013 to 56.018 mm (2.2052 to 2.2054 in.) 4 56.019 to 56.024 mm (2.2055 to 2.2057 in.) Crankshaft pin diameter CRANKSHAFT PIN DIAMETER REFERENCE CHART Mark Thickness 1 52.995 to 53.000 mm (2.0864 to 2.0866 in.) 2 52.989 to 52.994 mm (2.0862 to 2.0864 in.) 3 52.982 to 52.998 mm (2.0859 to 2.0865 in.) Completely remove the Plastigage. Perform the inspection above for each cylinder.
3. REMOVE PISTON AND CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Remove the 16 cap bolts and 8 connecting rod caps. Push the 8 pistons, 8 connecting rods and 8 upper bearings through the top of the cylinder block. HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod in the correct order.
4. REMOVE CONNECTING ROD BEARING Remove the connecting rod bearings from the connecting rods and connecting rod caps. HINT: Arrange the removed parts in the correct order.
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: 0.020 to 0.220 mm (0.0008 to 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Standard thrust washer thickness: 2.44 to 2.49 mm (0.0961 to 0.0980 in.)
6. REMOVE CRANKSHAFT Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown the illustration. Uniformly loosen the 20 bearing cap bolts in several steps, in the sequence shown in the illustration. Using a screwdriver, pry out the main bearing caps. Remove the 5 main bearing caps and lower bearings. HINT: Tape the screwdriver tip before use. NOTE: Pry up the main cap little by little to the right and left in turns. Be careful not to damage the joint surface of the cylinder block and main bearing caps. Remove the crankshaft.
7. REMOVE CRANKSHAFT BEARING Remove the crankshaft bearings from the bearing caps and cylinder block. HINT: Arrange the removed parts in the correct order.
8. REMOVE CRANKSHAFT THRUST WASHER SET Remove the thrust washer set from the cylinder block and No. 3 bearing cap.
9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.
10. REMOVE PISTON RING SET HINT: Arrange the piston rings in the correct order. Using a piston ring expander, remove the 2 compression rings. Using a piston ring expander, remove the oil ring. Remove the oil ring expander by hand.
11. REMOVE PISTON WITH PIN SUB-ASSEMBLY Disconnect the connecting rod from the piston. Using a screwdriver, pry off the snap rings from the piston. Gradually heat the piston to approximately 80°C (176°F). Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. Clean piston 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.
12. REMOVE STUD BOLT NOTE: If the stud bolt is deformed or its threads are damaged, replace it.

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1. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY Push the check valve with a pin to check if it is stuck. If stuck, replace the oil nozzle. While covering A, apply air into B. Then check the oil nozzle for damage or clogging. If there is an air leak, clean or replace the oil nozzle. HINT: Cover B and apply air into A. Perform the check again. Push the check valve while covering A, and apply air into B. Check that air passes through the oil nozzle. If air cannot pass through, clean or replace the oil nozzle. HINT: Cover B and, while pushing the check valve, apply air into A. Perform the check again.
2. INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket. Maximum warpage: 0.07 mm (0.0028 in.) If the warpage is greater than the maximum, replace the cylinder block. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 8 cylinders. If necessary, replace the cylinder block.
3. INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.77013 in.) Maximum diameter: 94.200 mm (3.7087 in.) If the diameter is greater than the maximum, replace the cylinder block.
4. INSPECT PISTON SUB-ASSEMBLY WITH PIN Using a micrometer, measure the piston diameter at a position that is 10.7 mm (0.421 in.) downward from the center of the piston pin hole (refer to the illustration below). Standard diameter: 93.955 to 93.965 mm (3.6990 to 3.6994 in.) Maximum diameter: 93.830 mm (3.6941 in.)
5. INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust direction. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.035 to 0.057 mm (0.0014 to 0.0022 in.) Maximum oil clearance: 0.370 mm (0.0146 in.) If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.
6. 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 STANDARD RING GROOVE CLEARANCE REFERENCE CHART Item Specified Condition No. 1 0.020 to 0.070 mm (0.0008 to 0.0028 in.) No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.) Oil 0.020 to 0.070 mm (0.0008 to 0.0028 in.) If the clearance is not as specified, replace the piston.
7. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 60 mm (2.362 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard end gap STANDARD END GAP REFERENCE CHART Item Specified Condition No. 1 0.23 to 0.33 mm (0.0091 to 0.0130 in.) No. 2 0.35 to 0.45 mm (0.0138 to 0.0177 in.) Oil 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum end gap MAXIMUM END GAP REFERENCE CHART Item Specified Condition No. 1 0.40 mm (0.0157 in.) No. 2 0.50 mm (0.0197 in.) Oil 0.45 mm (0.0177 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block.
8. INSPECT PISTON PIN OIL CLEARANCE Check each mark on the piston, piston pin and connecting rod. Using a caliper gauge, measure the inside diameter of the piston pin hole. Standard piston pin hole inside diameter STANDARD PISTON PIN HOLE INSIDE DIAMETER REFERENCE CHART Mark Specified Condition A 21.998 to 22.001 mm (0.8661 to 0.8662 in.) B 22.002 to 22.004 mm (0.8662 to 0.8663 in.) C 22.005 to 22.007 mm (0.8663 to 0.8664 in.) Using a micrometer, measure the piston pin diameter. Standard piston pin diameter STANDARD PISTON PIN DIAMETER REFERENCE CHART Mark Specified Condition A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.001 to 22.003 mm (0.8662 to 0.8663 in.) C 22.004 to 22.006 mm (0.8663 to 0.8664 in.) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance: -0.002 to 0.004 mm (-0.0001 to 0.0002 in.) Maximum oil clearance: 0.015 mm (0.0006 in.) If the oil clearance is greater than the maximum, replace the piston and piston pin as a set. Using a caliper gauge, measure the inside diameter of the connecting rod bush. Standard bush inside diameter STANDARD BUSH INSIDE DIAMETER REFERENCE CHART Mark Specified Condition A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) B 22.009 to 22.011 mm (0.8665 to 0.8666 in.) C 22.012 to 22.014 mm (0.8666 to 0.8667 in.) Subtract the piston pin diameter measurement from the bush inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.03 mm (0.0012 in.) If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the connecting rod and piston pin as a set.
9. INSPECT CONNECTING ROD SUB-ASSEMBLY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.937 in.) If the bend is greater than the maximum, replace the connecting rod. Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.937 in.) If the twist is greater than the maximum, replace the connecting rod.
10. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 8.5 to 8.6 mm (0.335 to 0.339 in.) Minimum diameter: 8.3 mm (0.327 in.) If the diameter is less than the minimum, replace the bolt.
11. INSPECT CRANKSHAFT Inspect for circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than the maximum, replace the crankshaft. Inspect the main journals. Using a micrometer, measure the diameter of each main journal. Standard journal diameter: 66.988 to 67.000 mm (2.6373 to 2.6378 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. Inspect the crank pin. Using a micrometer, measure the diameter of each crank pin. Standard crank pin diameter: 52.982 to 53.000 mm (2.0859 to 2.0866 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft.
12. INSPECT CRANKSHAFT OIL CLEARANCE Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown the illustration. Uniformly loosen the 20 bearing cap bolts in several steps, in the sequence shown in the illustration. Using a screwdriver, pry out the main bearing caps. Remove the 5 main bearing caps and lower bearings. HINT: Tape the screwdriver tip before use. NOTE: Pry up the main cap little by little to the right and left in turns. Be careful not to damage the joint surface of the cylinder block and main bearing caps. Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. HINT: If the journal or bearing is damaged, replace the bearing. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. Examine the front marks and numbers, and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Place the crankshaft bearing cap on the cylinder block. Temporarily install the 10 main bearing cap bolts to the inside positions. Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide. Bolt length: 91 mm (3.583 in.) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts. Temporarily install the 10 main bearing cap bolts to the outside positions. Bolt length: 79.5 mm (3.130 in.) HINT: The main bearing cap bolts are tightened in 2 progressive steps. Step 1: Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) for inside position 27 N*m (275 kgf*cm, 20 ft.*lbf) for outside position If any of the main bearing cap bolts does not meet the specified torque, replace it. NOTE: Do not turn the crankshaft. Step 2: Mark the front of the bearing cap bolts with paint. Tighten the bearing cap bolts another 90° in the order shown in step 1 . Check that the painted marks are now at a 90° angle to the front. Install and uniformly tighten the 10 main bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) Remove the 30 bolts and bearing caps. Measure the plastigage at its widest point. Standard oil clearance STANDARD OIL CLEARANCE REFERENCE CHART Number Mark Specified Condition No. 1 and No. 5 Journal 0.017 to 0.030 mm (0.0007 to 0.0012 in.) Other journal 0.024 to 0.037 mm (0.0009 to 0.0015 in.) Maximum oil clearance MAXIMUM OIL CLEARANCE REFERENCE CHART Number Mark Specified Condition No. 1 and No. 5 journal 0.050 mm (0.0020 in.) Other journal 0.060 mm (0.0024 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: 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. Refer to the table below for the appropriate bearing number. There are 6 sizes of standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 4, 5, 6, 7, 8 and 9. For other position bearings, use bearing marked 3, 4, 5, 6, 7 and 8. Example: Cylinder block "07" + Crankshaft "06" = Total number 13 (Use upper bearing "6" and lower bearing "7") Standard crankshaft main journal diameter STANDARD CRANKSHAFT MAIN JOURNAL DIAMETER REFERENCE CHART Number Mark Specified Condition 00 66.999 to 67.000 mm (2.63776 to 2.63780 in.) 01 66.998 to 66.999 mm (2.63772 to 2.63776 in.) 02 66.997 to 66.998 mm (2.63768 to 2.63772 in.) 03 66.996 to 66.997 mm (2.63764 to 2.63768 in.) 04 66.995 to 66.996 mm (2.63760 to 2.63764 in.) 05 66.994 to 66.995 mm (2.63756 to 2.63760 in.) 06 66.993 to 66.994 mm (2.63752 to 2.63756 in.) 07 66.992 to 66.993 mm (2.63748 to 2.63752 in.) 08 66.991 to 66.992 mm (2.63744 to 2.63748 in.) 09 66.990 to 66.991 mm (2.63740 to 2.63744 in.) 10 66.989 to 66.990 mm (2.63736 to 2.63740 in.) 11 66.988 to 66.989 mm (2.63736 to 2.63736 in.) Standard bearing center wall thickness No. 1 and No. 5 journal STANDARD BEARING CENTER WALL THICKNESS NO. 1 AND NO. 5 JOURNAL REFERENCE CHART + (B) Upper bearing Lower bearing Number Mark Specified condition Number Mark Specified condition 00 to 02 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 03 to 05 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 5 2.488 to 2.491 (0.0988 to 0.0981 in.) 06 to 08 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 09 to 11 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 12 to 14 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 15 to 17 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 18 to 20 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 21 to 23 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 24 to 26 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 9 2.500 to 2.503 (0.0984 to 0.0985 in.) 27 to 28 9 2.516 to 2.519 (0.0991 to 0.0992 in.) 9 2.500 to 2.503 (0.0984 to 0.0985 in.) Standard bearing center wall thickness other journal STANDARD BEARING CENTER WALL THICKNESS OTHER JOURNAL REFERENCE CHART (A) + (B) Upper bearing Lower bearing Number Mark Specified condition Number Mark Specified condition 00 to 02 3 2.482 to 2.485 (0.0977 to 0.0978 in.) 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 03 to 05 4 2.485 to 2.488 (0.0978 to 0.0980 in.) 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 06 to 08 4 2.485 to 2.488 (0.0978 to 0.0980 in.) 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 09 to 11 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 12 to 14 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 15 to 17 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 18 to 20 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 21 to 23 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 24 to 26 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 27 to 28 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 8 2.513 to 2.516 (0.0989 to 0.0991 in.) Completely remove the Plastigage.
13. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point. Standard diameter: 10.8 to 11.0 mm (0.425 to 0.433 in.) for bolt A 9.8 to 10.0 mm (0.386 to 0.394 in.) for bolt B Minimum diameter: 10.7 mm (0.421 in.) for bolt A 9.7 mm (0.382 in.) for bolt B Measuring point: 47 mm (1.850 in.) If the diameter is less than the minimum, replace the bolt.

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1. REPLACE STRAIGHT PIN NOTE: It is not necessary to remove the straight pin unless it is being replaced. Remove the straight pins. Using a plastic-faced hammer, tap in new straight pins to the cylinder block. Standard protrusion STANDARD PROTRUSION REFERENCE CHART Item Specified Condition Pin A 23 mm (0.9055 in.) Pin B 11 mm (0.4331 in.) Pin C 9 mm (0.3543 in.) Pin D 6 mm (0.2362 in.)

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1. INSTALL STUD BOLT NOTE: If a stud bolt is deformed or the threads are damaged, replace it. Using an E8 "TORX" socket wrench, install the stud bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for stud bolt A 9.0 N*m (92 kgf*cm, 80 in.*lbf) for stud bolt B
2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. INSTALL PISTON WITH PIN SUB-ASSEMBLY Using a screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the service hole of the piston. Gradually heat the piston to approximately 80°C (176°F). Coat the piston pin and connecting rod with engine oil. Align the front marks of the piston and connecting rod as shown in the illustration. Then push in the piston pin with your thumb until the piston pin contacts the snap ring. Front mark FRONT MARK REFERENCE CHART Item Front Mark Bank 1 Piston 1 Bank 2 Piston 2 NOTE: For bank 1, perform the assembly so that the front marks of the piston and connecting rod are on the same side. For bank 2, perform the assembly so that the front marks of the piston and connecting rod are on opposite sides. HINT: The piston and pin are a matched set. Move the connecting rod back and forth on the piston pin. Check the fitting condition. Rotate the piston back and forth on the piston pin. Check the fitting condition. Using a screwdriver, install a new snap ring at the other end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
4. INSTALL PISTON RING SET Install the oil ring expander by hand. Using a piston ring expander, install the oil ring as shown the illustration. Using a piston ring expander, install the 2 compression rings so that the code marks are positioned as shown in the illustration. HINT: Install the No. 1 compression ring with the code mark (1N) facing upward. Install the No. 2 compression ring with the code mark (2N) facing upward.
5. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the bearing. Install the upper bearing. NOTE: Main bearings come in widths of 21 mm (0.8268 in.) and 22.5 mm (0.8858 in.). Install the 22.5 mm (0.8858 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.8268 in.) bearings in the No. 2, No. 3 and No. 4 positions. Install the upper bearing to the cylinder block as shown in the illustration. NOTE: Do not apply engine oil to the bearings and the contact surface. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one. Install the lower bearing. NOTE: Be sure to install the selected bearing. Main bearings come in widths of 21 mm (0.8268 in.) and 22.5 mm (0.8858 in.). Install the 22.5 mm (0.8858 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.8268 in.) bearings in the No. 2, No. 3 and No. 4 positions. Install the lower bearings to the bearing caps. Using a vernier caliper, measure the distance between the bearing cap's edge and the lower bearing's edge. Dimension A - B or B - A: 0 to 0.7 mm (0 to 0.028 in.) NOTE: Do not apply engine oil to the bearings and the contact surface. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
6. INSTALL CRANKSHAFT THRUST WASHER SET Apply engine oil to the thrust washer set. Install the 4 thrust washers to the No. 3 journal position of the cylinder block and bearing cap with the oil grooves facing outward.
7. INSTALL CRANKSHAFT Apply engine oil to the upper bearing and lower bearing, then place the crankshaft on the cylinder block. Confirm the front marks and numbers of the main bearing caps, and install the bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Temporarily install the 10 main bearing cap bolts to the inside positions. Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide. Bolt length: 91 mm (3.583 in.) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 10 main bearing cap bolts. Temporarily install the 10 main bearing cap bolts to the outside positions. Bolt length: 79.5 mm (3.130 in.) HINT: The main bearing cap bolts are tightened in 2 progressive steps. Step 1: Install and uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) for inside position 27 N*m (275 kgf*cm, 20 ft.*lbf) for outside position If any of the main bearing cap bolts does not meet the specified torque, replace it. Step 2: Mark the front of the bearing cap bolts with paint. Tighten the bearing cap bolts another 90° in the order shown in step 1 . Check that the painted marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly. Install and uniformly tighten the 10 main bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) Check that the crankshaft turns smoothly.
8. INSTALL CONNECTING ROD BEARING Install the connecting rod bearing to the connecting rod and bearing cap. Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges, and each connecting rod bearing's edge. Dimension A - B or B - A: 0 to 0.7 mm (0 to 0.028 in.) NOTE: Do not apply engine oil to the bearings and the contact surface. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
9. INSTALL PISTON AND CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. Position the piston rings so that the ring ends are as shown in the illustration. NOTE: Do not align the ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward. NOTE: Match the numbered connecting rod cap with the connecting rod. Front mark FRONT MARK REFERENCE CHART Item Front Mark Bank 1 1 Bank 2 2 Check that the front mark of the connecting rod cap is facing forward. Front mark FRONT MARK REFERENCE CHART Item Front Mark Bank 1 Front Side Bank 2 Rear Side Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. Temporarily install the connecting cap bolts. HINT: The connecting cap bolts are tightened in 2 progressive steps. Step 1: Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) Step 2: Mark the front side of each connecting cap bolt with paint. Tighten the cap bolts another 90° as shown in the illustration in the order in step 1 . Check that the painted marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly.

Scheme 607

Scheme 608

Scheme 609

Scheme 610

Scheme 611

1. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-349724-S31319866602009120800000) )
2. REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY (See «REMOVAL»(ref-349724-S31319866602009120800000) )
3. REMOVE NO. 1 AIR CLEANER INLET (See «REMOVAL»(ref-349724-S31319866602009120800000) )
4. REMOVE INTAKE AIR CONNECTOR PIPE (See «REMOVAL»(ref-349724-S31319866602009120800000) )
5. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-349714-S30226729992009120800000) )
6. REMOVE RESONATOR BRACKET SUB-ASSEMBLY Remove the bolt and resonator bracket.
7. REMOVE CRANKSHAFT PULLEY (See «REMOVAL»(ref-349714-S26196101182009120800000) )
8. REMOVE CRANKSHAFT TIMING GEAR KEY Remove the crankshaft timing gear key from the crankshaft.
9. REMOVE TIMING CHAIN CASE OIL SEAL Remove the oil seal with a screwdriver. HINT: Tape the screwdriver tip before use. NOTE: Do not damage the surface of the oil seal press fit hole and crankshaft.
10. INSTALL TIMING CHAIN CASE OIL SEAL Using SST, tap in a new oil seal until its surface is flush with the timing chain case edge. SST 09223-22010, 09506-35010 NOTE: Keep the lip free from foreign matter. Do not tap oil seal at an angle.
11. INSTALL CRANKSHAFT TIMING GEAR KEY Install the crankshaft timing gear key.
12. INSTALL CRANKSHAFT PULLEY (See «INSTALLATION»(ref-349714-S38774077922009120800000) )
13. INSTALL RESONATOR BRACKET SUB-ASSEMBLY Install the resonator bracket with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
14. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-349714-S35834705202009120800000) )
15. INSTALL INTAKE AIR CONNECTOR PIPE (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
16. INSTALL NO. 1 AIR CLEANER INLET (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
17. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-349724-S09859827162009120800000) )
18. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-349724-S09859827162009120800000) )

Scheme 612

Scheme 613

Scheme 614

1. DISCHARGE FUEL SYSTEM PRESSURE (See «PRECAUTION»(ref-349727-S09663469032009120800000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
3. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY Remove the automatic transmission (See «REMOVAL»(ref-349712-S35304403202009120800000) ).
4. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See «REMOVAL»(ref-349714-S31912998822009120800000) )
5. REMOVE ENGINE REAR OIL SEAL Remove the oil seal with a screwdriver. HINT: Tape the screwdriver tip before use. NOTE: Do not damage the surface of the oil seal press fit hole and crankshaft.
6. INSTALL ENGINE REAR OIL SEAL Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07150) NOTE: Keep the lip free from foreign matter. Do not tap on the oil seal at an angle.
7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See «INSTALLATION»(ref-349714-S23488176532009120800000) )
8. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY Install the automatic transmission (See «INSTALLATION»(ref-349712-S11836634372009120800000) ).
9. PERFORM INITIALIZATION Preform initialization (See «INITIALIZATION»(ref-349706-S07943075812009120800000) ). NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

Scheme 615