Engine Mechanical (Service Information): Diagnosis Lexus RX III

ON-VEHICLE INSPECTION

1. INSPECT ENGINE COOLANT Inspect engine coolant. HINT: Refer to «ON-VEHICLE INSPECTION»(ref-400812-S31336411972011051800000) .)
2. INSPECT ENGINE OIL Inspect engine oil. HINT: Refer to «ON-VEHICLE INSPECTION»(ref-400814-S09418825152011051800000) .)
3. INSPECT BATTERY Inspect battery. HINT: Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-400815-S27063179152011051800000) .)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Remove the engine room side cover LH. Refer to «REMOVAL - Step 2»(ref-400813-S02084383242011051800000) . Remove the air cleaner filter element sub-assembly. Visually check that the air cleaner filter is not excessively damaged or oily. If necessary, replace the air cleaner filter. HINT: If there is any dirt or a blockage in the air cleaner filter element sub-assembly, clean it with compressed air. If any dirt or a blockage remains even after cleaning the air cleaner filter element sub-assembly with compressed air, replace it. Install the air cleaner filter element sub-assembly. Install the engine room side cover LH. Refer to «INSTALLATION - Step 5»(ref-400813-S41344728382011051800000) .
5. INSPECT V-RIBBED BELT Inspect V-ribbed belt. HINT: Refer to «ON-VEHICLE INSPECTION»(ref-400790-S06411355262011051800000) .)
6. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY Remove the V-ribbed belt. Refer to «REMOVAL»(ref-400790-S08717028402011051800000) . Check that nothing is caught in the tensioner by turning it clockwise and counterclockwise. If a malfunction exists, replace the tensioner. Install the V-ribbed belt. Refer to «INSTALLATION»(ref-400790-S02781114482011051800000) .
7. INSPECT SPARK PLUG Remove the spark plugs. Refer to «REMOVAL»(ref-400788-S04564061382011051800000) . Inspect spark plugs. HINT: Refer to «ON-VEHICLE INSPECTION - Step 2»(ref-400789-S24755786662011051800000) .) Install the spark plugs. Refer to «INSTALLATION»(ref-400788-S23885102112011051800000) .
8. INSPECT VALVE LASH ADJUSTER NOISE Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then perform the preceding inspection. HINT: If any defects or problems are found during the preceding inspection, perform lash adjuster inspection See step 2 .
9. INSPECT IGNITION TIMING Warm up and stop the engine. HINT: A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized. When using the Techstream: Check the ignition timing. Connect the Techstream to the DLC3. Start the engine and run it at idle. Turn the Techstream main switch on. Enter the following menus: Powertrain / Engine / Data List / IGN Advance. Standard ignition timing 9.5 to 24.5° BTDC at idle NOTE: Check the ignition timing with the cooling fans off. Turn off all electrical systems and the A/C. When checking the ignition timing, the transaxle should be in neutral or park. HINT: Refer to the Techstream operator's manual for further details. Check that the ignition timing advances immediately when the engine speed is increased. Enter the following menus: Powertrain / Engine / Active Test / Connect the TC and TE1. Monitor IGN Advance. Perform the Active Test. Standard ignition timing 8 to 12° BTDC at idle NOTE: When checking the ignition timing, the transaxle should be in neutral or park. HINT: Refer to the Techstream operator's manual for further details. When not using the Techstream: Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST: 09843-18040 NOTE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine. Check the ignition timing with the cooling fans off. Turn off all the electrical systems and the A/C. When checking the ignition timing, the transaxle should be in neutral or park. Remove the engine room side cover. Refer to «REMOVAL - Step 1»(ref-400813-S02084383242011051800000) . Remove the engine room side cover LH. Refer to «REMOVAL - Step 2»(ref-400813-S02084383242011051800000) . Remove the cool air intake duct seal. Refer to «REMOVAL - Step 3»(ref-400813-S02084383242011051800000) . Remove the V-bank cover sub-assembly See step 34 . Connect the timing light tester probe to the ignition coil wire for No. 1 cylinder. NOTE: Use a timing light that detects primary signals. Check the ignition timing at idle. Standard ignition timing 8 to 12° BTDC at idle NOTE: When checking the ignition timing, the transaxle should be in neutral or park. HINT: Run the engine at 1000 to 1300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. Check the ignition timing at idle. Standard ignition timing 9.5 to 24.5° BTDC at idle Confirm that the ignition timing advances immediately when the engine rpm is increased. Remove the timing light from the engine. Install the V-bank cover sub-assembly See step 113 . Install the cool air intake duct seal. Refer to «INSTALLATION - Step 3»(ref-400813-S41344728382011051800000) . Install the engine room side cover LH. Refer to «INSTALLATION - Step 4»(ref-400813-S41344728382011051800000) . Install the engine room side cover. Refer to «INSTALLATION - Step 5»(ref-400813-S41344728382011051800000) .
10. INSPECT ENGINE IDLE SPEED Warm up and stop the engine. HINT: A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized. When using the Techstream: Check the idle speed. Connect the Techstream to the DLC3. Start the engine and run it at idle. Turn the Techstream main switch on. Enter the following menus: Powertrain / Engine / Data List / Engine Speed. Read the value displayed on the tester. Standard idle speed 600 to 700 rpm NOTE: Check the idle speed with the cooling fans off. Turn off all the electrical systems and the A/C. When checking the idle speed, the transaxle should be in neutral or park. HINT: Refer to the Techstream operator's manual for further details. If the speed is not as specified, check the air intake system. When not using the Techstream: Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3. SST: 09843-18030 Check the idle speed. Standard idle speed 600 to 700 rpm NOTE: Check the idle speed with the cooling fans off. Turn off all the electrical systems and the A/C. When checking the idle speed, the transaxle should be in neutral or park. HINT: If the speed is not as specified, check the air intake system.
11. INSPECT COMPRESSION Warm up and stop the engine. HINT: A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized. Remove the 6 spark plugs. Refer to «REMOVAL»(ref-400788-S04564061382011051800000) . Check the cylinder compression pressure. Insert a compression gauge into the spark plug hole. While cranking the engine, measure the compression pressure. Standard compression pressure 1.3 MPa (13 kgf/cm 2 , 189 psi) Minimum pressure 0.98 MPa (10 kgf/cm 2 , 142 psi) Difference between each cylinder 0.1 MPa (1.0 kgf/cm 2 , 15 psi) NOTE: Always use a fully charged battery to obtain an engine speed of 250 rpm or more. Check the compression pressure of the other cylinders in the same way. This measurement must be done as quickly as possible. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. HINT: If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. Install the 6 spark plugs. Refer to «INSTALLATION»(ref-400788-S23885102112011051800000) .
12. INSPECT CO/HC HINT: This check determines whether or not the idle CO/HC complies with regulations. Start the engine. Keep the engine speed at 2500 rpm for approximately 180 seconds. Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idle. Immediately check CO/HC concentration during idle and when running at 2500 rpm. HINT: When performing the 2 mode (with the engine idling/running at 2500 rpm) test, follow the measurement order determined by applicable local regulations. If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the order given below. Check the DTCs. Refer to «DTC CHECK / CLEAR»(ref-400784-S02158227972011051800000) . See the table below for possible causes, then inspect and correct the applicable causes if necessary. CO HC Problem Cause Normal High Rough idle Faulty ignitions: Incorrect valve timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance (valve lash adjuster) Leaks in intake or exhaust valves Leaks in cylinders Low High Rough idle (Fluctuating HC reading) Vacuum leaks: PCV hoses Intake manifold Throttle body assembly Brake booster line Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) Restricted air cleaner filter element sub-assembly Plugged PCV valve Faulty SFI system: Faulty fuel pressure regulator Defective engine coolant temperature sensor Defective mass air flow meter Faulty ECM Faulty injector assemblies Faulty throttle position sensor (built in throttle body assembly)

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

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1. PRECAUTION (w/ Air Suspension) NOTE: Be sure to read Precaution thoroughly before servicing. Refer to «PRECAUTION»(ref-400816-S35527999772011051800000) .
2. REMOVE FRONT WHEEL RH
3. REMOVE FRONT FENDER LINER RH
4. REMOVE FRONT FENDER APRON SEAL RH See step 17
5. REMOVE V-RIBBED BELT Release the V-ribbed belt tension by turning the V-ribbed belt tensioner counterclockwise, and remove the V-ribbed belt from the V-ribbed belt tensioner. While turning the V-ribbed belt tensioner counterclockwise, align with its holes, and then insert a 5 mm bi-hexagon wrench into the holes to fix the V-ribbed belt tensioner.

INSPECTION

1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Turn the roller by hand to check that it turns smoothly. HINT: If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.
2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the valve lash adjuster assembly free of dirt and foreign objects. Only use clean engine oil. Place the valve lash adjuster assembly into a container filled with engine oil. Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger. SST: 09276-75010 Squeeze SST and valve lash adjuster assembly together to move the plunger up and down 5 to 6 times. Check the movement of the plunger and bleed the air. OK Plunger moves up and down. NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger by hand. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster assembly.
3. INSPECT CAMSHAFT Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum runout 0.04 mm (0.00157 in.) If the runout is greater than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height Item Specification Intake camshaft 44.316 to 44.416 mm (1.7448 to 1.7486 in.) Exhaust camshaft 44.262 to 44.362 mm (1.7426 to 1.7465 in.) Minimum Cam Lobe Height Item Specification Intake camshaft 44.166 mm (1.7388 in.) Exhaust camshaft 44.112 mm (1.7366 in.) If the cam lobe height is less than the minimum, replace the camshaft. Using a micrometer, measure the journal diameter. Standard Journal Diameter Item Specification No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25.975 mm (1.0221 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance.
4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Clamp the camshaft in a vise. NOTE: Be careful not to damage the camshaft in the vise. Put the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin. TEXT IN ILLUSTRATION *1 Key Groove *2 Straight Pin Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the groove. NOTE: Be sure not to turn the camshaft timing gear assembly in the retard direction. Check that there is no clearance between the camshaft timing gear assembly flange and the camshaft. Tighten the flange bolt while holding the camshaft. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Check the lock of the camshaft timing gear assembly. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked. NOTE: Be careful not to damage the camshaft. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 opened paths. TEXT IN ILLUSTRATION *1 Advanced Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path. HINT: This operation releases the lock pin at the most retarded position. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path. NOTE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. Check for smooth rotation. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. NOTE: Do not use air pressure to perform the smooth operation check. Check the lock in the most retarded position. Confirm that the camshaft timing gear assembly locks at the most retarded position. Remove the flange bolt and camshaft timing gear assembly. NOTE: Do not remove the other 3 bolts. If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.
5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Clamp the camshaft in a vise. NOTE: Be careful not to damage the camshaft in the vise. Put the camshaft timing exhaust gear assembly and camshaft together by aligning the key groove and straight pin. TEXT IN ILLUSTRATION *1 Key Groove *2 Straight Pin Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the groove. NOTE: Be sure not to turn the camshaft timing exhaust gear in the retard direction. Check that there is no clearance between the gear flange and the camshaft. Tighten the flange bolt while holding the camshaft. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Check the camshaft timing exhaust gear lock. Make sure that the camshaft timing exhaust gear assembly locks. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path). TEXT IN ILLUSTRATION *1 Advanced Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path. HINT: The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path. NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts. Check for smooth rotation. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly. NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check. Check the lock at the most advanced position. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position. Remove the flange bolt and camshaft timing exhaust gear assembly. NOTE: Be sure not to remove the other 4 bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
6. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard diameter 10.85 to 11.00 mm (0.4272 to 0.4330 in.) Minimum diameter 10.70 mm (0.4212 in.) Measurement point (distance from the seat) 103 mm (4.06 in.) HINT: If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage. If there is any thread deformation, replace the cylinder head bolt with a new one.
7. INSPECT CHAIN SUB-ASSEMBLY Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 links. Maximum chain elongation 136.9 mm (5.389 in.) NOTE: Perform the measurement at 3 random places. Use the average of the measurements. If the average elongation is greater than the maximum, replace the chain sub-assembly.
8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 links. Maximum chain elongation 137.6 mm (5.417 in.) NOTE: Perform the measurement at 3 random places. Use the average of the measurements. If the average elongation is greater than the maximum, replace the chain sub-assembly.
9. INSPECT CRANKSHAFT TIMING SPROCKET Place the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly. Minimum sprocket diameter (with chain) 61.4 mm (2.418 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
10. INSPECT IDLE SPROCKET ASSEMBLY Place the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain) 61.4 mm (2.418 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE Using a micrometer, measure the idle gear shaft diameter. Standard idle gear shaft diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.) Using a caliper gauge, measure the inside diameter of the idle sprocket assembly. Standard idle gear inside diameter 23.020 to 23.030 mm (0.9063 to 0.9067 in.) Subtract the idle gear shaft diameter measurement from the idle sprocket inside diameter measurement. Standard oil clearance 0.020 to 0.043 mm (0.000787 to 0.00169 in.) Maximum oil clearance 0.093 mm (0.00366 in.) If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle sprocket assembly.
12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. TEXT IN ILLUSTRATION *1 Plunger *2 Stopper Plate If necessary, replace the No. 1 chain tensioner assembly.
13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. TEXT IN ILLUSTRATION *1 Depth Measure the worn depth of the No. 2 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is greater than the maximum, replace the No. 2 chain tensioner assembly.
14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. TEXT IN ILLUSTRATION *1 Depth Measure the worn depth of the No. 3 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is greater than the maximum, replace the No. 3 chain tensioner assembly.
15. INSPECT CHAIN TENSIONER SLIPPER Measure the worn depth of the chain tensioner slipper. TEXT IN ILLUSTRATION *1 Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the chain tensioner slipper.
16. INSPECT NO. 1 CHAIN VIBRATION DAMPER Measure the worn depth of the No. 1 chain vibration damper. TEXT IN ILLUSTRATION *1 Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the No. 1 chain vibration damper.
17. INSPECT NO. 2 CHAIN VIBRATION DAMPER Measure the worn depth of the No. 2 chain vibration damper. TEXT IN ILLUSTRATION *1 Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the No. 2 chain vibration damper.
18. INSPECT CAMSHAFT THRUST CLEARANCE Inspect the bank 1 camshaft thrust clearance. Install the bank 1 camshaft. Refer to «INSTALLATION»(ref-400790-S40024089562011051800000) . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.08 to 0.13 mm (0.00315 to 0.00512 in.) Maximum thrust clearance 0.15 mm (0.00591 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. Inspect the bank 2 camshaft thrust clearance. Install the bank 2 camshaft. Refer to «INSTALLATION»(ref-400790-S40024089562011051800000) . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.08 to 0.13 mm (0.00315 to 0.00512 in.) Maximum thrust clearance 0.15 mm (0.00591 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
19. INSPECT CAMSHAFT OIL CLEARANCE Clean the camshaft bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each camshaft journal. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps. Refer to «INSTALLATION»(ref-400790-S40024089562011051800000) . NOTE: Do not turn the camshaft. Remove the camshaft bearing caps See step 45 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 Other Journals Standard Oil Clearance Item Oil Clearance No. 1 journal 0.032 to 0.071 mm (0.00126 to 0.00280 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance Item Oil Clearance No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing. Clean the camshaft bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each camshaft journal. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps. Refer to «INSTALLATION»(ref-400790-S40024089562011051800000) . NOTE: Do not turn the camshaft. Remove the camshaft bearing caps See step 45 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 Other Journals Standard Oil Clearance Item Oil Clearance No. 1 journal 0.040 to 0.079 mm (0.00157 to 0.00311 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance Item Oil Clearance No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly.
20. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Maximum warpage 0.7 mm (0.0276 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.). If the warpage is greater than the maximum, replace the manifold.
21. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Maximum warpage 0.7 mm (0.0276 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.). If the warpage is greater than the maximum, replace the manifold.
22. INSPECT INTAKE MANIFOLD Cylinder head side: Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage 0.1 mm (0.00394 in.) If the warpage is greater than the maximum, replace the intake manifold. Surge tank side: Using a precision straightedge and feeler gauge, measure the surface contacting the surge tank for warpage. Maximum warpage 0.1 mm (0.00394 in.) If the warpage is greater than the maximum, replace the intake manifold.

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1. INSTALL ENGINE REAR OIL SEAL Place the oil seal retainer on wooden blocks. Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge. SST: 09223-15030 SST: 09950-70010 09951-07100 NOTE: Keep the lip free of foreign matter. Do not tap on the engine rear oil seal at an angle.
2. INSTALL ENGINE REAR OIL SEAL RETAINER Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.) NOTE: Remove any oil from the contact surfaces. Install the oil seal retainer within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install the engine rear oil seal retainer with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
3. INSTALL WATER INLET PIPE Install the water inlet pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the No. 1 water by-pass hose.
4. INSTALL CYLINDER HEAD GASKET RH See step 1
5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH See step 2
6. INSTALL CYLINDER HEAD GASKET LH See step 3
7. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH See step 4
8. INSTALL VALVE STEM CAP See step 6
9. INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 7
10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 8
11. INSTALL NO. 3 CAMSHAFT See step 1
12. INSTALL NO. 4 CAMSHAFT See step 2
13. INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 3
14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 4
15. INSTALL CAMSHAFT See step 5
16. INSTALL NO. 2 CAMSHAFT See step 6
17. INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 7
18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 8
19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY See step 9
20. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 10
21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY See step 11
22. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 12
23. INSTALL NO. 1 CHAIN VIBRATION DAMPER Install the No. 1 chain vibration damper with the 2 bolts. Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
24. INSTALL NO. 2 CHAIN VIBRATION DAMPER Install the 2 No. 2 chain vibration dampers.
25. INSTALL CRANKSHAFT TIMING SPROCKET Install the 2 keys and crankshaft timing sprocket as shown in the illustration.
26. INSTALL IDLE SPROCKET ASSEMBLY Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. TEXT IN ILLUSTRATION *1 Knock Pin Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block. NOTE: Be careful of the idle gear installation position. HINT: Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) HINT: After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
27. INSTALL CHAIN SUB-ASSEMBLY Align the mark plates and timing marks as shown in the illustration and install the chain. TEXT IN ILLUSTRATION *1 Mark Plate *2 Timing Mark HINT: The camshaft mark plates are orange. Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks. NOTE: When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks. Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket. TEXT IN ILLUSTRATION *1 Mark Plate *2 Timing Plate HINT: The crankshaft mark plate is yellow. Temporarily tighten the pulley set bolt. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression). TEXT IN ILLUSTRATION *1 Center Line *2 Timing Mark *3 Sensor Plate
28. INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper.
29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. TEXT IN ILLUSTRATION *1 Stopper Plate *2 Plunger Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install the No. 1 chain tensioner assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
30. INSPECT VALVE TIMING Check the camshaft timing marks. NOTE: Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear. If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned. Check that each camshaft timing mark is positioned as shown in the illustration. HINT: For the intake camshaft: Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly. If the valve timing is misaligned, reinstall the timing chain. Remove the pulley set bolt.
31. INSTALL TIMING CHAIN CASE OIL SEAL Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge. SST: 09223-22010 SST: 09506-35010 Oil seal tap in depth 0 to 1.0 mm (0 to 0.0393) NOTE: Keep the lip free of foreign matter. Do not tap on the oil seal at an angle. Make sure that the oil seal edge does not stick out of the timing chain case.
32. INSTALL WATER PUMP ASSEMBLY Install a new water pump gasket and the water pump assembly with the 8 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Apply seal packing in a continuous line to the engine unit as shown in the following illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 mm (0.118 in.) NOTE: Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration. If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes. Do not start the engine for at least 2 hours after installing. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent NOTE: If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. SEAL PACKING APPLICATION CHART Area Seal Packing Diameter Application Position from Inside Seal Line Continuous Line Area 4.5 mm or more (0.177 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Alternate Long and Short Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.) Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.) Install a new gasket. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft. TEXT IN ILLUSTRATION *1 Drive Rotor Spline *2 Crankshaft Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts. BOLT LENGTH Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 25 mm (0.98 in.) NOTE: Make sure that there is no oil on the bolt and nut threads. Fully tighten the bolts in this order: Area 1 and Area 2. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Fully tighten the bolts in Area 3. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: First tighten the upper bolts and nuts followed by lower bolts and nuts as shown in the illustration. Fully tighten the bolts in Area 4. Bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Except bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts in the order of lower to upper as shown in the illustration. Install a new chain cover plate gasket and the chain cover plate with the 4 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
34. INSTALL WATER INLET HOUSING Install 2 new O-rings. HINT: Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation. Install the 2 stud bolts. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Install the water inlet housing with the 2 bolts and nut. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful that the O-ring does not get caught between the parts. Connect the No. 1 water by-pass hose. Apply adhesive around the drain cock. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the drain cock assembly to the water inlet housing. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) Install the drain cock plug to the drain cock assembly. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Install a new gasket to the thermostat. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 10° of either side of the prescribed position. Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH Using an E8 "TORX" socket wrench, install the 2 stud bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the No. 1 front engine mounting bracket LH with the 6 bolts. Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf) NOTE: Install the water inlet and mounting bracket within 15 minutes after installing the chain cover. Do not start the engine for at least 2 hours after installation.
36. INSTALL NO. 1 OIL PAN BAFFLE PLATE Install the No. 1 oil pan baffle plate with the 7 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Temporarily tighten the 7 bolts. Fully tighten 2 bolts (A) shown in the illustration before tightening the other bolts.
37. INSTALL OIL PAN SUB-ASSEMBLY Using an E8 "TORX" socket wrench, install the 2 stud bolts. Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt B Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Install 2 new O-rings. Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install the oil pan with the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Except bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
38. INSTALL OIL STRAINER SUB-ASSEMBLY Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
40. INSTALL OIL PAN DRAIN PLUG Install a new oil pan drain plug gasket and the oil pan drain plug. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Apply seal packing as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the head cover within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install 3 new gaskets as shown in the illustration. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly. Install the head cover with the 12 bolts and a new seal washer. Bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Except bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Apply seal packing as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surfaces. Install the cylinder head cover sub-assembly LH within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install 3 new gaskets as shown in the illustration. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer. Bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Except bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
43. INSTALL WATER OUTLET Install 2 new gaskets and a new O-ring. HINT: Apply soapy water to the O-ring. Install the water outlet with the 2 bolts and 4 nuts. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful that the O-ring does not get caught between the parts.
44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide. w/ oil cooler Install the engine oil level dipstick guide. w/o oil cooler Install the engine oil level dipstick guide with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
45. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install a new gasket to the No. 1 oil cooler bracket. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Install the oil cooler pipe with the bolt and 2 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) Install a new gasket to the No. 1 oil pan. Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
46. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) Install a new O-ring. Install the oil cooler assembly with the union bolt. Torque: 68 N*m (693 kgf*cm, 50 ft.*lbf) Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
47. INSTALL CRANKSHAFT PULLEY See step 2
48. INSTALL OIL FILTER ELEMENT Clean the inside of the oil filter cap sub-assembly, the threads and O-ring groove. TEXT IN ILLUSTRATION *1 Oil Filter Element *2 O-ring Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap sub-assembly. Set a new oil filter element to the oil filter cap sub-assembly. Remove dirt and foreign matter from the installation surface of the engine. Apply a light coat of engine oil to the O-ring again and install the oil filter cap sub-assembly. NOTE: Be careful that the O-ring does not get caught between any parts. The O-ring must not be twisted on the groove. Using SST, tighten the oil filter cap sub-assembly. SST: 09228-06501 Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Make sure that the oil filter is installed securely as shown in the illustration. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap. TEXT IN ILLUSTRATION *1 O-ring NOTE: Remove all dirt and foreign matter from the installation surfaces. Install the oil filter drain plug to the oil filter cap sub-assembly. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) NOTE: Make sure that the O-ring does not get caught between the parts.
49. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Apply adhesive around the drain cock sub-assembly. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the water drain cocks as shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque. Install the water drain cock plugs to the water drain cocks. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
50. INSTALL NO. 1 OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. NOTE: Do not touch the mesh when installing the oil control valve filter. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union. TEXT IN ILLUSTRATION *1 Oil Pipe Union Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union. Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
51. INSTALL OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter RH. NOTE: Do not touch the mesh when installing the oil control valve filter. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union. TEXT IN ILLUSTRATION *1 Oil Pipe Union Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union. Install the bolt (A) to the cylinder head. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
52. INSTALL CRANK POSITION SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S37548128282011051800000)
53. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-400788-S13454337612011051800000)
54. INSTALL VVT SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S04538685282011051800000)
55. INSTALL VENTILATION VALVE SUB-ASSEMBLY Apply adhesive around the ventilation valve sub-assembly. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the ventilation valve sub-assembly. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
56. INSTALL SPARK PLUG . Refer to «INSTALLATION - Step 1»(ref-400788-S42778826202011051800000)
57. INSTALL OIL FILLER CAP SUB-ASSEMBLY Install a new oil filler gasket. Install the oil filler cap sub-assembly.