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Engine Mechanical (Service Information): Overhaul Lexus RX III

Mechanical 41 illustrations ~8450 words

DISASSEMBLY

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY Remove the oil filler cap sub-assembly and oil filler gasket.
  2. REMOVE SPARK PLUG . Refer to «REMOVAL - Step 17»(ref-400788-S02817236512011051800000)
  3. REMOVE OIL PAN DRAIN PLUG Remove the oil pan drain plug and oil pan drain plug gasket.
  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY Remove the ventilation valve sub-assembly.
  5. REMOVE VVT SENSOR . Refer to «REMOVAL - Step 15»(ref-400788-S10756066692011051800000)
  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to «REMOVAL - Step 15»(ref-400788-S34761709472011051800000)
  7. REMOVE CRANK POSITION SENSOR . Refer to «REMOVAL - Step 3»(ref-400788-S09100341872011051800000)
  8. REMOVE NO. 1 OIL PIPE Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe. TEXT IN ILLUSTRATION *1 Oil Pipe Union Remove the oil control valve filter LH and gaskets.
  9. REMOVE OIL PIPE Remove the bolt. TEXT IN ILLUSTRATION *1 Oil Pipe Union *2 Bolt Remove the 2 oil pipe unions and oil pipe. Remove the oil control valve filter RH and gaskets.
  10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Remove the 2 cylinder block water drain cock sub-assemblies from the cylinder block. Remove the 2 cylinder block water drain cock plugs from the 2 water drain cock sub-assemblies.
  11. REMOVE OIL FILTER ELEMENT Remove the drain plug. NOTE: Do not remove the O-ring from the oil filter cap. Connect the hose to the pipe. TEXT IN ILLUSTRATION *1 Pipe *2 Hose *3 O-ring Insert the pipe with the hose into the oil filter cap. Make sure that the oil is completely drained and remove the pipe and O-ring. Using SST, remove the oil filter cap sub-assembly. SST: 09228-06501 Remove the oil filter element and O-ring from the oil filter cap sub-assembly. TEXT IN ILLUSTRATION *1 Oil Filter Element *2 O-ring NOTE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.
  12. REMOVE CRANKSHAFT PULLEY See step 6
  13. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler) Remove the bolt, 2 clamps and 4 clips, and disconnect the 2 water by-pass hoses. TEXT IN ILLUSTRATION *1 Clip *2 Clamp *3 Bolt Remove the union bolt, oil cooler assembly, and O-ring.
  14. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) Remove the 3 bolts, 3 nuts, and oil cooler pipe with the No. 1 oil cooler bracket. Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
  15. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE w/ oil cooler Remove the engine oil level dipstick guide. w/o oil cooler Remove the bolt and engine oil level dipstick guide. Remove the O-ring.
  16. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH Remove the 6 bolts and No. 1 front engine mounting bracket LH. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
  17. REMOVE WATER INLET HOUSING Remove the 2 nuts, water inlet and thermostat. Remove the gasket. Remove the 2 stud bolts. Separate the No. 1 water by-pass hose from the water inlet housing. Remove the drain cock plug. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Remove the drain cock assembly. Remove the 2 bolts, nut, and water inlet housing. Remove the 2 O-rings.
  18. REMOVE WATER OUTLET Remove the 2 bolts, 4 nuts and water outlet. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Remove the 2 gaskets and O-ring.
  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket. Remove the 3 gaskets.
  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket. TEXT IN ILLUSTRATION *1 Baffle Plate NOTE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH. Remove the 3 gaskets.
  21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Remove the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Insert the blade of the oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly. NOTE: Be careful not to damage the contact surfaces of the oil pans. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
  22. REMOVE OIL STRAINER SUB-ASSEMBLY Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket. TEXT IN ILLUSTRATION *1 Bolt *2 Nut Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
  23. REMOVE OIL PAN SUB-ASSEMBLY Remove the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. HINT: Tape the screwdriver tip before use. Remove the 2 O-rings. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
  24. REMOVE NO. 1 OIL PAN BAFFLE PLATE Remove the 7 bolts and No. 1 oil pan baffle plate.
  25. REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 6 bolts. Using a screwdriver, pry out the engine rear oil seal retainer. NOTE: Be careful not to damage the engine rear oil seal retainer. HINT: Tape the screwdriver tip before use.
  26. REMOVE ENGINE REAR OIL SEAL Place the engine rear oil seal retainer on wooden blocks. TEXT IN ILLUSTRATION *1 Wooden Block Using a screwdriver and a hammer, tap out the oil seal. NOTE: Be careful not to damage the engine rear oil seal retainer. HINT: Tape the screwdriver tip before use.
  27. REMOVE WATER PUMP ASSEMBLY Remove the 16 bolts, water pump assembly and water pump gasket.
  28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Remove the 15 bolts and 2 nuts as shown in the illustration. TEXT IN ILLUSTRATION *1 Nut Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover. HINT: Tape the screwdriver tip before use. Remove the 4 bolts, chain cover plate and chain cover plate gasket. Remove the gasket.
  29. REMOVE TIMING CHAIN CASE OIL SEAL Using a screwdriver, pry out the timing chain case oil seal. TEXT IN ILLUSTRATION *1 Protective Tape *1 Wooden Block HINT: Tape the screwdriver tip before use.
  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily tighten the pulley set bolt. Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression). TEXT IN ILLUSTRATION *1 Center Line *2 Timing Mark *3 Sensor Plate Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark If not, turn the crankshaft clockwise 1 revolution (360°) and align the timing marks as above.
  31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. TEXT IN ILLUSTRATION *1 Plunger *2 Stopper Plate *3 Pin Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.0500 in.) into the stopper plate hole. Remove the 2 bolts and No. 1 chain tensioner assembly.
  32. REMOVE CHAIN TENSIONER SLIPPER Remove the chain tensioner slipper.
  33. REMOVE CHAIN SUB-ASSEMBLY Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket. Remove the pulley set bolt. Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks. Remove the chain sub-assembly.
  34. REMOVE IDLE SPROCKET ASSEMBLY Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.
  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER Remove the 2 bolts and No. 1 chain vibration damper.
  36. REMOVE NO. 2 CHAIN VIBRATION DAMPER Remove the 2 No. 2 chain vibration dampers.
  37. REMOVE CRANKSHAFT TIMING SPROCKET Remove the crankshaft timing sprocket from the crankshaft. Remove the 2 keys from the crankshaft.
  38. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 43
  39. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY See step 44
  40. REMOVE CAMSHAFT BEARING CAP (for Bank 1) See step 45
  41. REMOVE CAMSHAFT See step 46
  42. REMOVE NO. 2 CAMSHAFT See step 47
  43. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 48
  44. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 49
  45. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 50
  46. REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 51
  47. REMOVE NO. 3 CAMSHAFT See step 52
  48. REMOVE NO. 4 CAMSHAFT See step 53
  49. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 54
  50. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 10
  51. REMOVE VALVE LASH ADJUSTER ASSEMBLY See step 11
  52. REMOVE VALVE STEM CAP See step 12
  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH See step 14
  54. REMOVE CYLINDER HEAD GASKET RH See step 15
  55. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH See step 16
  56. REMOVE CYLINDER HEAD GASKET LH See step 17
  57. REMOVE WATER INLET PIPE Remove 2 clamps and separate the No. 1 water by-pass hose. Remove the 2 bolts and water inlet pipe.

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  1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Turn the roller by hand to check that it turns smoothly. HINT: If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.
  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the valve lash adjuster assembly free of dirt and foreign 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-S30637500912011051800000) . 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-S30637500912011051800000) . 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-S30637500912011051800000) . 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-S30637500912011051800000) . 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.

REASSEMBLY

  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-S25488591382011051800000)
  53. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-400788-S01885408182011051800000)
  54. INSTALL VVT SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S09568391722011051800000)
  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-S13802717592011051800000)
  57. INSTALL OIL FILLER CAP SUB-ASSEMBLY Install a new oil filler gasket. Install the oil filler cap sub-assembly.

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  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S15475217842011051800000)
  2. INSTALL KNOCK CONTROL SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S15349842572011051800000)
  3. INSTALL KNOCK CONTROL SENSOR WIRE Connect the 2 clamps, 2 knock control sensor connectors and knock control sensor wire connector.
  4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch assembly. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE: Do not start the engine within 1 hour after installation to prevent oil leaks.
  5. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Install the No. 1 vacuum switching valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  6. INSTALL WATER PUMP PULLEY . Refer to «INSTALLATION - Step 2»(ref-400800-S02462106052011051800000)
  7. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt. Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf)
  8. INSTALL NO. 2 TIMING GEAR COVER Install the No. 2 timing gear cover with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts. HINT: Each bolt length is as follows: A: 70 mm (2.76 in.) B: 33 mm (1.30 in.) Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Tighten the other bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
  10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Install a new gasket as shown in the illustration. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «INSTALLATION - Step 4»(ref-400802-S21729616722011051800000)
  12. INSTALL NO. 2 MANIFOLD STAY . Refer to «INSTALLATION - Step 5»(ref-400802-S21729616722011051800000)
  13. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Install a new O-ring to the No. 2 engine oil level dipstick guide. Apply a light coat of engine oil to the O-ring. Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide. Install the No. 2 engine oil level dipstick guide with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Install the engine oil level dipstick.
  14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Install a new gasket as shown in the illustration. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  15. INSTALL INTAKE MANIFOLD NOTE: DO NOT apply oil to the bolts listed below: Tightening Part Intake Manifold and Cylinder Head Sub-assembly RH Intake Manifold and Cylinder Head Sub-assembly LH Set a new gasket on each cylinder head. NOTE: Align the port holes of the gasket and cylinder head. Make sure that the gasket is installed in the correct direction. Set the intake manifold on the cylinder heads. Install and tighten the 6 bolts and 4 nuts uniformly in several steps. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  16. INSTALL NO. 2 ENGINE MOUNTING STAY RH Install the No. 2 engine mounting stay RH with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  17. INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-400788-S42778826202011051800000)
  18. INSTALL NO. 1 SURGE TANK STAY Install the No. 1 surge tank stay with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  19. INSTALL THROTTLE BODY BRACKET Install the throttle body bracket with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to «INSTALLATION - Step 5»(ref-400802-S09938504842011051800000)
  21. INSTALL ENGINE HANGERS Install the 2 engine hangers with the 4 bolts as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger Part No. No. 1 engine hanger 12281-31120 No. 2 engine hanger 12282-31100 Bolts 91671-10825 Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) Attach the engine sling device and hang the engine with the chain block.
  22. REMOVE ENGINE STAND

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