Engine Mechanical (Service Information): Removal & Installation Lexus RX III

REMOVAL

1. PRECAUTION (w/ Air Suspension) NOTE: Be sure to read Precaution thoroughly before servicing. Refer to «PRECAUTION»(ref-400816-S40570634362011051800000) .
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.

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1. INSTALL V-RIBBED BELT Install the V-ribbed belt. TEXT IN ILLUSTRATION *1 Water Pump *2 Idler *3 Generator *4 Crankshaft *5 V-ribbed belt Tensioner *6 A/C Compressor Turn the V-ribbed belt tensioner counterclockwise and remove a 5 mm bi-hexagon wrench. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.
2. INSTALL FRONT FENDER APRON SEAL RH See step 115
3. INSTALL FRONT FENDER LINER RH
4. INSTALL FRONT WHEEL RH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)

INSTALLATION

1. INSTALL V-RIBBED BELT Install the V-ribbed belt. TEXT IN ILLUSTRATION *1 Water Pump *2 Idler *3 Generator *4 Crankshaft *5 V-ribbed belt Tensioner *6 A/C Compressor Turn the V-ribbed belt tensioner counterclockwise and remove a 5 mm bi-hexagon wrench. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.
2. INSTALL FRONT FENDER APRON SEAL RH See step 115
3. INSTALL FRONT FENDER LINER RH
4. INSTALL FRONT WHEEL RH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)

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1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) HINT: See the steps from "Remove Engine Assembly with Transaxle" through "Remove Automatic Transaxle Assembly". Refer to «REMOVAL»(ref-400804-S01619592632011051800000) .
2. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) HINT: See the steps from "Remove Engine Assembly with Transaxle" through "Remove Automatic Transaxle Assembly". Refer to «REMOVAL»(ref-400805-S40177105902011051800000) .
3. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 3
4. INSTALL ENGINE ON ENGINE STAND See step 1
5. REMOVE ENGINE HANGER See step 2
6. REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-400802-S06641726382011051800000)
7. REMOVE NO. 1 SURGE TANK STAY See step 4
8. REMOVE THROTTLE BODY BRACKET See step 5
9. REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL - Step 16»(ref-400788-S05408914652011051800000)
10. REMOVE NO. 2 ENGINE MOUNTING STAY RH See step 7
11. REMOVE INTAKE MANIFOLD See step 8
12. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH See step 9
13. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE See step 10
14. REMOVE NO. 2 MANIFOLD STAY . Refer to «REMOVAL - Step 9»(ref-400802-S33534498812011051800000)
15. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «REMOVAL - Step 11»(ref-400802-S33534498812011051800000)
16. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH See step 13
17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY See step 14
18. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler) See step 13
19. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) See step 14
20. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE See step 15
21. REMOVE NO. 2 TIMING GEAR COVER See step 15
22. REMOVE WATER PUMP PULLEY . Refer to «REMOVAL - Step 9»(ref-400800-S17080005892011051800000)
23. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY See step 17
24. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY See step 18
25. REMOVE CRANK POSITION SENSOR . Refer to «REMOVAL - Step 3»(ref-400788-S17322073042011051800000)
26. REMOVE NO. 1 OIL PIPE See step 8
27. REMOVE OIL PIPE See step 9
28. REMOVE CRANKSHAFT PULLEY See step 6
29. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH See step 16
30. REMOVE WATER INLET HOUSING See step 17
31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY See step 19
32. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 20
33. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY See step 21
34. REMOVE OIL STRAINER SUB-ASSEMBLY See step 22
35. REMOVE OIL PAN SUB-ASSEMBLY See step 23
36. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY See step 28
37. REMOVE TIMING CHAIN CASE OIL SEAL See step 29
38. SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 30
39. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 31
40. REMOVE CHAIN TENSIONER SLIPPER See step 32
41. REMOVE CHAIN SUB-ASSEMBLY See step 33
42. REMOVE IDLE SPROCKET ASSEMBLY See step 34
43. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner assembly. Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. SST: 09922-10010 NOTE: Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one. Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain.
44. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 2 chain tensioner assembly.
45. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Check that the camshafts are positioned as shown in the illustration. Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 12 bearing cap bolts in several steps and in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 5 camshaft bearing caps.
46. REMOVE CAMSHAFT Remove the camshaft.
47. REMOVE NO. 2 CAMSHAFT Remove the No. 2 camshaft.
48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly RH. HINT: Tape the screwdriver tip before use.
49. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner assembly. Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. SST: 09922-10010 NOTE: Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one. Remove the 2 bolts and the camshaft timing gear together with the No. 2 chain.
50. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 3 chain tensioner assembly.
51. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Check that the camshafts are positioned as shown in the illustration. Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 5 camshaft bearing caps.
52. REMOVE NO. 3 CAMSHAFT Remove the No. 3 camshaft.
53. REMOVE NO. 4 CAMSHAFT Remove the No. 4 camshaft.
54. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly LH. HINT: Tape the screwdriver tip before use.

1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) HINT: See the steps from "Remove Engine Assembly with Transaxle" through "Remove Automatic Transaxle Assembly". Refer to «REMOVAL»(ref-400804-S41287515962011051800000) .
2. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) HINT: See the steps from "Remove Engine Assembly with Transaxle" through "Remove Automatic Transaxle Assembly". Refer to «REMOVAL»(ref-400805-S15734634222011051800000) .
3. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 3
4. INSTALL ENGINE ON ENGINE STAND See step 1
5. REMOVE ENGINE HANGER See step 2
6. REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-400802-S36931150902011051800000)
7. REMOVE NO. 1 SURGE TANK STAY See step 4
8. REMOVE THROTTLE BODY BRACKET See step 5
9. REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL - Step 16»(ref-400788-S02817236512011051800000)
10. REMOVE NO. 2 ENGINE MOUNTING STAY RH See step 7
11. REMOVE INTAKE MANIFOLD See step 8
12. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH See step 9
13. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE See step 10
14. REMOVE NO. 2 MANIFOLD STAY . Refer to «REMOVAL - Step 9»(ref-400802-S25680554822011051800000)
15. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «REMOVAL - Step 11»(ref-400802-S25680554822011051800000)
16. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH See step 13
17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY See step 14
18. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler) See step 13
19. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) See step 14
20. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE See step 15
21. REMOVE NO. 2 TIMING GEAR COVER See step 15
22. REMOVE WATER PUMP PULLEY . Refer to «REMOVAL - Step 9»(ref-400800-S29684713152011051800000)
23. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY See step 17
24. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY See step 18
25. REMOVE CRANK POSITION SENSOR . Refer to «REMOVAL - Step 3»(ref-400788-S09100341872011051800000)
26. REMOVE NO. 1 OIL PIPE See step 8
27. REMOVE OIL PIPE See step 9
28. REMOVE CRANKSHAFT PULLEY See step 6
29. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH See step 16
30. REMOVE WATER INLET HOUSING See step 17
31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY See step 19
32. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 20
33. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY See step 21
34. REMOVE OIL STRAINER SUB-ASSEMBLY See step 22
35. REMOVE OIL PAN SUB-ASSEMBLY See step 23
36. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY See step 28
37. REMOVE TIMING CHAIN CASE OIL SEAL See step 29
38. SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 30
39. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 31
40. REMOVE CHAIN TENSIONER SLIPPER See step 32
41. REMOVE CHAIN SUB-ASSEMBLY See step 33
42. REMOVE IDLE SPROCKET ASSEMBLY See step 34
43. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner assembly. Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. SST: 09922-10010 NOTE: Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one. Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain.
44. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 2 chain tensioner assembly.
45. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Check that the camshafts are positioned as shown in the illustration. Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 12 bearing cap bolts in several steps and in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 5 camshaft bearing caps.
46. REMOVE CAMSHAFT Remove the camshaft.
47. REMOVE NO. 2 CAMSHAFT Remove the No. 2 camshaft.
48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly RH. HINT: Tape the screwdriver tip before use.
49. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner assembly. Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. SST: 09922-10010 NOTE: Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one. Remove the 2 bolts and the camshaft timing gear together with the No. 2 chain.
50. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 3 chain tensioner assembly.
51. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Check that the camshafts are positioned as shown in the illustration. Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration. Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 5 camshaft bearing caps.
52. REMOVE NO. 3 CAMSHAFT Remove the No. 3 camshaft.
53. REMOVE NO. 4 CAMSHAFT Remove the No. 4 camshaft.
54. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly LH. HINT: Tape the screwdriver tip before use.

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1. INSTALL NO. 3 CAMSHAFT Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH. Install the No. 3 camshaft to the camshaft housing sub-assembly LH.
2. INSTALL NO. 4 CAMSHAFT Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH. Install the No. 4 camshaft to the camshaft housing sub-assembly LH.
3. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Apply engine oil to the camshaft bearing caps. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. Temporarily tighten the 8 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Make sure that the valve rocker arm is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing sub-assembly LH within 3 minutes. Do not start the engine for at least 2 hours after installing. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
5. INSTALL CAMSHAFT Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH. Install the camshaft to the camshaft housing sub-assembly RH.
6. INSTALL NO. 2 CAMSHAFT Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH. Install the No. 2 camshaft to the camshaft housing sub-assembly RH.
7. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Apply engine oil to the camshaft bearing caps. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing sub-assembly RH within 3 minutes. Do not start the engine for at least 2 hours after installing. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Install the No. 3 chain tensioner assembly with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
10. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate Apply a light coat of engine oil to the bolt threads and bolt-seating surface. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the pin from the No. 3 chain tensioner assembly.
11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Install the No. 2 chain tensioner assembly with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate Apply a light coat of engine oil to the bolt threads and bolt-seating surface. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the pin from the No. 2 chain tensioner assembly.
13. INSTALL IDLE SPROCKET ASSEMBLY See step 26
14. INSTALL CHAIN SUB-ASSEMBLY See step 27
15. INSTALL CHAIN TENSIONER SLIPPER See step 28
16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 29
17. INSPECT VALVE TIMING See step 30
18. INSTALL TIMING CHAIN CASE OIL SEAL See step 31
19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY See step 33
20. INSTALL WATER INLET HOUSING See step 34
21. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH See step 35
22. INSTALL OIL PAN SUB-ASSEMBLY See step 37
23. INSTALL OIL STRAINER SUB-ASSEMBLY See step 38
24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY See step 39
25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY See step 41
26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 42
27. INSTALL CRANKSHAFT PULLEY See step 2
28. INSTALL NO. 1 OIL PIPE See step 50
29. INSTALL OIL PIPE See step 51
30. INSTALL CRANK POSITION SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S37548128282011051800000)
31. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY See step 5
32. INSTALL WATER PUMP PULLEY . Refer to «INSTALLATION - Step 2»(ref-400800-S02462106052011051800000)
33. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY See step 7
34. INSTALL NO. 2 TIMING GEAR COVER See step 8
35. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE See step 44
36. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) See step 45
37. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) See step 46
38. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY See step 9
39. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH See step 10
40. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «INSTALLATION - Step 4»(ref-400802-S21729616722011051800000)
41. INSTALL NO. 2 MANIFOLD STAY . Refer to «INSTALLATION - Step 5»(ref-400802-S21729616722011051800000)
42. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE See step 13
43. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH See step 14
44. INSTALL INTAKE MANIFOLD See step 15
45. INSTALL NO. 2 ENGINE MOUNTING STAY RH See step 16
46. INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-400788-S42778826202011051800000)
47. INSTALL THROTTLE BODY BRACKET See step 19
48. INSTALL NO. 1 SURGE TANK STAY See step 18
49. INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to «INSTALLATION - Step 5»(ref-400802-S09938504842011051800000)
50. INSTALL ENGINE HANGERS See step 21
51. REMOVE ENGINE STAND
52. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2
53. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle". Refer to «INSTALLATION - Step 6»(ref-400804-S20866197102011051800000) .
54. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle". Refer to «INSTALLATION - Step 7»(ref-400805-S32594941712011051800000) .

1. INSTALL NO. 3 CAMSHAFT Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH. Install the No. 3 camshaft to the camshaft housing sub-assembly LH.
2. INSTALL NO. 4 CAMSHAFT Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH. Install the No. 4 camshaft to the camshaft housing sub-assembly LH.
3. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Apply engine oil to the camshaft bearing caps. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. Temporarily tighten the 8 bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Make sure that the valve rocker arm is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing sub-assembly LH within 3 minutes. Do not start the engine for at least 2 hours after installing. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
5. INSTALL CAMSHAFT Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH. Install the camshaft to the camshaft housing sub-assembly RH.
6. INSTALL NO. 2 CAMSHAFT Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH. Install the No. 2 camshaft to the camshaft housing sub-assembly RH.
7. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Apply engine oil to the camshaft bearing caps. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 3.5 to 4.5 mm (0.138 to 0.177 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing sub-assembly RH within 3 minutes. Do not start the engine for at least 2 hours after installing. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing. If the camshaft housing sub-assembly RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages. Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Install the No. 3 chain tensioner assembly with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
10. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate Apply a light coat of engine oil to the bolt threads and bolt-seating surface. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the pin from the No. 3 chain tensioner assembly.
11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Install the No. 2 chain tensioner assembly with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.
12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate Apply a light coat of engine oil to the bolt threads and bolt-seating surface. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly. SST: 09922-10010 Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the pin from the No. 2 chain tensioner assembly.
13. INSTALL IDLE SPROCKET ASSEMBLY See step 26
14. INSTALL CHAIN SUB-ASSEMBLY See step 27
15. INSTALL CHAIN TENSIONER SLIPPER See step 28
16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 29
17. INSPECT VALVE TIMING See step 30
18. INSTALL TIMING CHAIN CASE OIL SEAL See step 31
19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY See step 33
20. INSTALL WATER INLET HOUSING See step 34
21. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH See step 35
22. INSTALL OIL PAN SUB-ASSEMBLY See step 37
23. INSTALL OIL STRAINER SUB-ASSEMBLY See step 38
24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY See step 39
25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY See step 41
26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH See step 42
27. INSTALL CRANKSHAFT PULLEY See step 2
28. INSTALL NO. 1 OIL PIPE See step 50
29. INSTALL OIL PIPE See step 51
30. INSTALL CRANK POSITION SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S25488591382011051800000)
31. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY See step 5
32. INSTALL WATER PUMP PULLEY . Refer to «INSTALLATION - Step 2»(ref-400800-S30156054002011051800000)
33. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY See step 7
34. INSTALL NO. 2 TIMING GEAR COVER See step 8
35. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE See step 44
36. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) See step 45
37. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) See step 46
38. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY See step 9
39. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH See step 10
40. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «INSTALLATION - Step 4»(ref-400802-S40288001152011051800000)
41. INSTALL NO. 2 MANIFOLD STAY . Refer to «INSTALLATION - Step 5»(ref-400802-S40288001152011051800000)
42. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE See step 13
43. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH See step 14
44. INSTALL INTAKE MANIFOLD See step 15
45. INSTALL NO. 2 ENGINE MOUNTING STAY RH See step 16
46. INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-400788-S13802717592011051800000)
47. INSTALL THROTTLE BODY BRACKET See step 19
48. INSTALL NO. 1 SURGE TANK STAY See step 18
49. INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to «INSTALLATION - Step 5»(ref-400802-S09705609702011051800000)
50. INSTALL ENGINE HANGERS See step 21
51. REMOVE ENGINE STAND
52. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2
53. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle". Refer to «INSTALLATION - Step 6»(ref-400804-S04798904902011051800000) .
54. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle". Refer to «INSTALLATION - Step 7»(ref-400805-S08289717372011051800000) .

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

1. REMOVE CAMSHAFT HINT: See the steps from "Remove Automatic Transaxle Assembly" through "Remove Camshaft". Refer to «REMOVAL»(ref-400790-S30220941282011051800000) .
2. REMOVE NO. 2 CAMSHAFT See step 47
3. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 48
4. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 49
5. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 50
6. REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 51
7. REMOVE NO. 3 CAMSHAFT See step 52
8. REMOVE NO. 4 CAMSHAFT See step 53
9. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 54
10. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 24 valve rocker arms. HINT: Arrange the removed parts in the correct order.
11. REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 24 valve lash adjuster assemblies from the cylinder head. HINT: Arrange the removed parts in the correct order.
12. REMOVE VALVE STEM CAP Remove the 24 valve stem caps.
13. REMOVE WATER OUTLET See step 18
14. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head sub-assembly. Cylinder head warpage or cracking could result from removing bolts in an incorrect order. HINT: Arrange the removed parts in the correct order. Remove the cylinder head sub-assembly RH.
15. REMOVE CYLINDER HEAD GASKET RH Remove the cylinder head gasket RH.
16. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Uniformly loosen and remove the 2 cylinder head set bolts in several steps and in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head sub-assembly. Cylinder head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head sub-assembly LH.
17. REMOVE CYLINDER HEAD GASKET LH Remove the cylinder head gasket LH.

1. REMOVE CAMSHAFT HINT: See the steps from "Remove Automatic Transaxle Assembly" through "Remove Camshaft". Refer to «REMOVAL»(ref-400790-S31624718872011051800000) .
2. REMOVE NO. 2 CAMSHAFT See step 47
3. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 48
4. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 49
5. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 50
6. REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 51
7. REMOVE NO. 3 CAMSHAFT See step 52
8. REMOVE NO. 4 CAMSHAFT See step 53
9. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 54
10. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 24 valve rocker arms. HINT: Arrange the removed parts in the correct order.
11. REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 24 valve lash adjuster assemblies from the cylinder head. HINT: Arrange the removed parts in the correct order.
12. REMOVE VALVE STEM CAP Remove the 24 valve stem caps.
13. REMOVE WATER OUTLET See step 18
14. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head sub-assembly. Cylinder head warpage or cracking could result from removing bolts in an incorrect order. HINT: Arrange the removed parts in the correct order. Remove the cylinder head sub-assembly RH.
15. REMOVE CYLINDER HEAD GASKET RH Remove the cylinder head gasket RH.
16. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Uniformly loosen and remove the 2 cylinder head set bolts in several steps and in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head sub-assembly. Cylinder head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to keep separate the removed parts for each installation position. Remove the cylinder head sub-assembly LH.
17. REMOVE CYLINDER HEAD GASKET LH Remove the cylinder head gasket LH.

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

1. INSTALL CYLINDER HEAD GASKET RH Place a new cylinder head gasket RH on the cylinder block surface with the Lot No. stamp upward. NOTE: Be careful of the installation direction. Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH Place the cylinder head on the cylinder block. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1 Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2 Mark the cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts another 90°. Step 3 Tighten the cylinder head bolts an additional 90°. Check that the painted mark is now facing rearward.
3. INSTALL CYLINDER HEAD GASKET LH Place a new cylinder head gasket LH on the cylinder block surface with the Lot No. stamp upward. NOTE: Be careful of the installation direction. Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH Place the cylinder head on the cylinder block. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1 Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2 Mark the cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts another 90°. Step 3 Tighten the cylinder head bolts an additional 90°. Check that the painted mark is now facing rearward. Tighten the 2 bolts in the order shown in the illustration. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
5. INSTALL WATER OUTLET See step 43
6. INSTALL VALVE STEM CAP Install the 24 valve stem caps.
7. INSTALL VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the lash adjuster free of dirt and foreign objects. Only use clean engine oil. Place the lash adjuster into a container filled with engine oil. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger. SST: 09276-75010 Squeeze SST and lash adjuster 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 press the plunger quickly and firmly by hand. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster. Install the valve lash adjusters. NOTE: Install each valve lash adjuster to the same place it was removed from.
8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the lash adjuster tip and valve stem cap end. Install the valve rocker arms as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap
9. INSTALL NO. 3 CAMSHAFT See step 1
10. INSTALL NO. 4 CAMSHAFT See step 2
11. INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 3
12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 4
13. INSTALL CAMSHAFT See step 5
14. INSTALL NO. 2 CAMSHAFT See step 6
15. INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 7
16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH HINT: See the steps from "Install Camshaft Housing Sub-Assembly RH" through "Install Automatic Transaxle Assembly" See step 8 .

1. INSTALL CYLINDER HEAD GASKET RH Place a new cylinder head gasket RH on the cylinder block surface with the Lot No. stamp upward. NOTE: Be careful of the installation direction. Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH Place the cylinder head on the cylinder block. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1 Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2 Mark the cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts another 90°. Step 3 Tighten the cylinder head bolts an additional 90°. Check that the painted mark is now facing rearward.
3. INSTALL CYLINDER HEAD GASKET LH Place a new cylinder head gasket LH on the cylinder block surface with the Lot No. stamp upward. NOTE: Be careful of the installation direction. Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH Place the cylinder head on the cylinder block. NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1 Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2 Mark the cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts another 90°. Step 3 Tighten the cylinder head bolts an additional 90°. Check that the painted mark is now facing rearward. Tighten the 2 bolts in the order shown in the illustration. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
5. INSTALL WATER OUTLET See step 43
6. INSTALL VALVE STEM CAP Install the 24 valve stem caps.
7. INSTALL VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the lash adjuster free of dirt and foreign objects. Only use clean engine oil. Place the lash adjuster into a container filled with engine oil. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger. SST: 09276-75010 Squeeze SST and lash adjuster 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 press the plunger quickly and firmly by hand. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster. Install the valve lash adjusters. NOTE: Install each valve lash adjuster to the same place it was removed from.
8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the lash adjuster tip and valve stem cap end. Install the valve rocker arms as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap
9. INSTALL NO. 3 CAMSHAFT See step 1
10. INSTALL NO. 4 CAMSHAFT See step 2
11. INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 3
12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 4
13. INSTALL CAMSHAFT See step 5
14. INSTALL NO. 2 CAMSHAFT See step 6
15. INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 7
16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH HINT: See the steps from "Install Camshaft Housing Sub-Assembly RH" through "Install Automatic Transaxle Assembly" See step 8 .

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

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 See step 5
6. REMOVE CRANKSHAFT PULLEY Using SST, loosen the crankshaft pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021 Remove the pulley set key from the crankshaft.
7. REMOVE TIMING CHAIN CASE OIL SEAL Using a knife, cut off the timing chain case oil seal lip. TEXT IN ILLUSTRATION *1 Protective Tape *2 Cut Position Using a screwdriver, pry out the timing chain case oil seal. NOTE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. HINT: Tape the screwdriver tip before use.

1. PRECAUTION (w/ Air Suspension) NOTE: Be sure to read Precaution thoroughly before servicing. Refer t «PRECAUTION»(ref-400816-S40570634362011051800000) .
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 See step 5
6. REMOVE CRANKSHAFT PULLEY Using SST, loosen the crankshaft pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021 Remove the pulley set key from the crankshaft.
7. REMOVE TIMING CHAIN CASE OIL SEAL Using a knife, cut off the timing chain case oil seal lip. TEXT IN ILLUSTRATION *1 Protective Tape *2 Cut Position Using a screwdriver, pry out the timing chain case oil seal. NOTE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. HINT: Tape the screwdriver tip before use.

Scheme 141

Scheme 142

1. INSTALL TIMING CHAIN CASE OIL SEAL Apply MP grease to a new timing chain case oil seal lip. Using SST and a hammer, tap in the timing chain case oil seal until its surface is flush with the timing chain cover edge. SST: 09223-22010 SST: 09506-35010 Oil seal tap in depth 0 to 1.0 mm (0 to 0.0393 in.) NOTE: Keep the lip free of foreign matter. Do not tap the timing chain case oil seal at an angle.
2. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 Torque: 250 N*m (2550 kgf*cm, 184 ft.*lbf)
3. INSTALL V-RIBBED BELT See step 1
4. INSTALL FRONT FENDER APRON SEAL RH See step 115
5. INSTALL FRONT FENDER LINER RH
6. INSTALL FRONT WHEEL RH See step 4

1. INSTALL TIMING CHAIN CASE OIL SEAL Apply MP grease to a new timing chain case oil seal lip. Using SST and a hammer, tap in the timing chain case oil seal until its surface is flush with the timing chain cover edge. SST: 09223-22010 SST: 09506-35010 Oil seal tap in depth 0 to 1.0 mm (0 to 0.0393 in.) NOTE: Keep the lip free of foreign matter. Do not tap the timing chain case oil seal at an angle.
2. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST: 09213-70011 09213-70020 SST: 09330-00021 Torque: 250 N*m (2550 kgf*cm, 184 ft.*lbf)
3. INSTALL V-RIBBED BELT See step 1
4. INSTALL FRONT FENDER APRON SEAL RH See step 115
5. INSTALL FRONT FENDER LINER RH
6. INSTALL FRONT WHEEL RH See step 4

Scheme 143

Scheme 144

Scheme 145

Scheme 146

1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) HINT: See the steps from "Remove Engine Assembly with Transaxle" through "Remove Automatic Transaxle Assembly". Refer to «REMOVAL»(ref-400804-S01619592632011051800000) .
2. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) HINT: See the steps from "Remove Engine Assembly with Transaxle" through "Remove Automatic Transaxle Assembly". Refer to «REMOVAL»(ref-400805-S40177105902011051800000) .
3. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly and rear drive plate spacer.
4. REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the engine rear oil seal lip. TEXT IN ILLUSTRATION *1 Protective Tape *2 Cut Position Using a screwdriver, pry out the engine rear oil seal. NOTE: Be careful not to damage the crankshaft. HINT: Tape the screwdriver tip before use.

1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) HINT: See the steps from "Remove Engine Assembly with Transaxle" through "Remove Automatic Transaxle Assembly". Refer to «REMOVAL»(ref-400804-S41287515962011051800000) .
2. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) HINT: See the steps from "Remove Engine Assembly with Transaxle" through "Remove Automatic Transaxle Assembly". Refer to «REMOVAL»(ref-400805-S15734634222011051800000) .
3. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly and rear drive plate spacer.
4. REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the engine rear oil seal lip. TEXT IN ILLUSTRATION *1 Protective Tape *2 Cut Position Using a screwdriver, pry out the engine rear oil seal. NOTE: Be careful not to damage the crankshaft. HINT: Tape the screwdriver tip before use.

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1. INSTALL ENGINE REAR OIL SEAL Apply MP grease to a new engine rear oil seal lip. Using SST and a hammer, tap in the engine rear oil seal. SST: 09223-15030 SST: 09950-70010 09951-07150 Oil seal tap in depth -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Clean the 8 bolts and 8 bolt holes. Install the front drive plate spacer. HINT: Align the pin of the front drive plate spacer with the pin hole of the crankshaft. Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft. Apply adhesive to 2 or 3 threads of the 8 bolts. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf)
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle". Refer to «INSTALLATION - Step 6»(ref-400804-S20866197102011051800000) .
4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle". Refer to «INSTALLATION - Step 7»(ref-400805-S32594941712011051800000) .

1. INSTALL ENGINE REAR OIL SEAL Apply MP grease to a new engine rear oil seal lip. Using SST and a hammer, tap in the engine rear oil seal. SST: 09223-15030 SST: 09950-70010 09951-07150 Oil seal tap in depth -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Clean the 8 bolts and 8 bolt holes. Install the front drive plate spacer. HINT: Align the pin of the front drive plate spacer with the pin hole of the crankshaft. Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft. Apply adhesive to 2 or 3 threads of the 8 bolts. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf)
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle". Refer to «INSTALLATION - Step 6»(ref-400804-S04798904902011051800000) .
4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) HINT: See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle". Refer to «INSTALLATION - Step 7»(ref-400805-S08289717372011051800000) .

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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. PRECAUTION (w/ Navigation System for HDD) NOTE: After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal. Refer to «PRECAUTION»(ref-400817-S35803230232011051800000) .
3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE ENGINE ROOM SIDE COVER . Refer to «REMOVAL - Step 1»(ref-400813-S02084383242011051800000)
5. REMOVE ENGINE ROOM SIDE COVER LH . Refer to «REMOVAL - Step 2»(ref-400813-S02084383242011051800000)
6. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 3»(ref-400813-S02084383242011051800000)
7. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM . Refer to «REPLACEMENT - Step 1»(ref-400783-S08693988022011051800000)
8. DISCHARGE FUEL SYSTEM PRESSURE HINT: Refer to «PRECAUTION»(ref-400801-S10472917662011051800000) .)
9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-400649-S12881576452011051800000) .
10. REMOVE FRONT WHEEL
11. REMOVE NO. 1 ENGINE UNDER COVER
12. REMOVE NO. 2 ENGINE UNDER COVER
13. REMOVE FRONT FLOOR COVER LH . Refer to «REMOVAL - Step 2»(ref-400802-S33534498812011051800000)
14. REMOVE FRONT FENDER LINER LH
15. REMOVE FRONT FENDER LINER RH
16. REMOVE FRONT FENDER APRON SEAL LH Remove the 2 bolts, clip and front fender apron seal LH.
17. REMOVE FRONT FENDER APRON SEAL RH Remove the 2 bolts, clip and front fender apron seal RH.
18. DRAIN ENGINE OIL . Refer to «REPLACEMENT - Step 2»(ref-400818-S09227417132011051800000)
19. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 7»(ref-400800-S21803137222011051800000)
20. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD) . Refer to «REPLACEMENT - Step 4»(ref-400804-S23662034482011051800000)
21. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD) . Refer to «REPLACEMENT - Step 4»(ref-400805-S00039668842011051800000)
22. DRAIN TRANSFER OIL (for AWD) . Refer to «REPLACEMENT - Step 2»(ref-400819-S24943384442011051800000)
23. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH . Refer to «REMOVAL - Step 4»(ref-400809-S15454837202011051800000)
24. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH . Refer to «REMOVAL - Step 5»(ref-400809-S15454837202011051800000)
25. REMOVE FRONT FENDER TO COWL SIDE SEAL LH . Refer to «REMOVAL - Step 6»(ref-400809-S15454837202011051800000)
26. REMOVE FRONT FENDER TO COWL SIDE SEAL RH . Refer to «REMOVAL - Step 7»(ref-400809-S15454837202011051800000)
27. REMOVE FRONT WIPER ARM HEAD CAP . Refer to «REMOVAL - Step 8»(ref-400809-S15454837202011051800000)
28. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to «REMOVAL - Step 9»(ref-400809-S15454837202011051800000)
29. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to «REMOVAL - Step 10»(ref-400809-S15454837202011051800000)
30. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 11»(ref-400809-S15454837202011051800000)
31. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to «REMOVAL - Step 12»(ref-400809-S15454837202011051800000)
32. REMOVE FRONT SHOCK ABSORBER CAP (w/ Air Suspension) . Refer to «REMOVAL - Step 3»(ref-400810-S01269755922011051800000)
33. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «REMOVAL - Step 11»(ref-400778-S07130150422011051800000)
34. REMOVE V-BANK COVER SUB-ASSEMBLY Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the 2 retainers on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly. NOTE: Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.
35. REMOVE NO. 2 AIR CLEANER INLET Disconnect the 2 vacuum hose clamps from the No. 2 air cleaner inlet. Remove the 2 bolts and No. 2 air cleaner inlet.
36. REMOVE NO. 1 AIR CLEANER INLET Disconnect the vacuum hose clamp from the No. 1 air cleaner inlet. Remove the bolt and No. 1 air cleaner inlet.
37. REMOVE BATTERY Disconnect the positive (+) cable from the positive (+) battery terminal. Loosen the nut, and remove the bolt from the battery clamp. Remove the battery and battery tray.
38. REMOVE AIR CLEANER ASSEMBLY . Refer to «REMOVAL - Step 13»(ref-400788-S24793579022011051800000)
39. REMOVE AIR CLEANER BRACKET Disconnect the engine wire clamp. Remove the 2 bolts and air cleaner bracket.
40. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Disconnect the connector from the brake master cylinder reservoir sub-assembly. Remove the bolt and separate the radiator reservoir tank assembly from the reservoir bracket.
41. REMOVE RESERVOIR BRACKET Remove the 2 bolts and reservoir bracket.
42. REMOVE NO. 1 RELAY BLOCK COVER Remove the No. 1 relay block cover.
43. DISCONNECT ENGINE WIRE Remove the 2 bolts and separate the 2 earth wires. Disconnect the 2 wire clamps. Disconnect the 3 connectors. Remove the nut. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block. Pull up the lever to disconnect the ECM connector. Disconnect the 2 wire clamps.
44. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Remove the nut from the control shaft lever. Using a screwdriver, disengage the 4 claws and disconnect the control cable with clip from the control cable bracket. Remove the clip.
45. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE Disconnect the No. 1 fuel vapor feed hose.
46. DISCONNECT NO. 1 RADIATOR HOSE Disconnect the No. 1 radiator hose. Separate the No. 1 radiator hose from the radiator pipe clamp.
47. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the No. 2 radiator hose.
48. DISCONNECT INLET HEATER WATER HOSE Disconnect the inlet heater water hose.
49. DISCONNECT OUTLET HEATER WATER HOSE Disconnect the outlet heater water hose.
50. DISCONNECT FUEL MAIN TUBE Remove the No. 1 fuel pipe clamp. Disconnect the connector from the pipe by hand. When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully. NOTE: Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector. Do not use any tools to separate the pipe and connector. Do not forcefully bend or twist the nylon tube. Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary. Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination. If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.
51. DISCONNECT NO. 1 INLET OIL COOLER HOSE Disconnect the No. 1 inlet oil cooler hose.
52. DISCONNECT NO. 1 OUTLET OIL COOLER HOSE Disconnect the No. 1 outlet oil cooler hose.
53. DISCONNECT UNION TO CHECK VALVE HOSE Disconnect the union to check valve hose.
54. SEPARATE NO. 2 EARTH WIRE Remove the 2 bolts and separate the No. 2 earth wire clamps.
55. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
56. REMOVE ENGINE MOVING CONTROL ROD BRACKET Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.
57. REMOVE ENGINE MOVING CONTROL ROD Remove the bolt and engine moving control rod from the engine moving control rod bracket. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary.
58. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY Remove the nut and disconnect the discharge hose sub-assembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
59. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Remove the nut and disconnect the suction hose sub-assembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
60. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-400802-S33534498812011051800000)
61. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to «REMOVAL - Step 8»(ref-400802-S39560348452011051800000)
62. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET Remove the 2 nuts and No. 1 exhaust pipe support bracket.
63. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) . Refer to «REMOVAL - Step 2»(ref-400654-S01313503552011051800000)
64. SECURE STEERING WHEEL . Refer to «REMOVAL - Step 4»(ref-400820-S31533963532011051800000)
65. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to «REMOVAL - Step 5»(ref-400820-S31533963532011051800000)
66. SEPARATE HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (w/ Air Suspension) Remove the nut and separate the height control sensor link sub-assembly from the lower suspension arm.
67. REMOVE FRONT AXLE SHAFT NUT LH . Refer to «REMOVAL - Step 6»(ref-400654-S42053042262011051800000)
68. REMOVE FRONT AXLE SHAFT NUT RH HINT: Perform the same procedure as for the LH side.
69. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH . Refer to «REMOVAL - Step 5»(ref-400810-S42816404982011051800000)
70. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
71. SEPARATE FRONT SPEED SENSOR LH . Refer to «REMOVAL - Step 5»(ref-400821-S29969856842011051800000)
72. SEPARATE FRONT SPEED SENSOR RH HINT: Perform the same procedure as for the LH side.
73. SEPARATE TIE ROD ASSEMBLY LH . Refer to «REMOVAL - Step 6»(ref-400820-S31533963532011051800000)
74. SEPARATE TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
75. SEPARATE FRONT LOWER SUSPENSION ARM LH . Refer to «REMOVAL - Step 9»(ref-400810-S30935807342011051800000)
76. SEPARATE FRONT LOWER SUSPENSION ARM RH HINT: Perform the same procedure as for the LH side.
77. SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to «REMOVAL - Step 5»(ref-400810-S30935807342011051800000)
78. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to «REMOVAL - Step 12»(ref-400654-S42053042262011051800000)
79. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING . Refer to «DISASSEMBLY - Step 1»(ref-400654-S04210961262011051800000)
80. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to «REMOVAL - Step 13»(ref-400654-S42053042262011051800000)
81. REMOVE FLYWHEEL HOUSING UNDER COVER Remove the 2 bolts and flywheel housing under cover.
82. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Remove the 6 drive plate and torque converter clutch setting bolts. HINT: There will be one black colored bolt.
83. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Set the engine lifter. NOTE: Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand. Remove the 6 bolts, 2 nuts and frame side rail plates RH and LH. TEXT IN ILLUSTRATION *1 Nut Remove the 6 bolts, 2 nuts and front suspension member rear braces RH and LH. TEXT IN ILLUSTRATION *1 Nut Operate the engine lifter, then remove the engine assembly from the vehicle. NOTE: Make sure that the engine is clear of all wiring and hoses. While lowering the engine from the vehicle, do not allow it to contact the vehicle. Install the No. 1 and No. 2 engine hangers with the 4 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) PART NO. Item Part No. No. 1 engine hanger 12281-31120 No. 2 engine hanger 12282-31100 Bolt 91671-10825 Attach the sling device to the engine hangers and chain block.
84. REMOVE NO. 2 EARTH WIRE Remove the bolt and No. 2 earth wire from the engine assembly.
85. REMOVE V-RIBBED BELT See step 5
86. REMOVE GENERATOR ASSEMBLY . Refer to «REMOVAL - Step 8»(ref-400822-S05630348172011051800000)
87. REMOVE COMPRESSOR AND MAGNETIC CLUTCH . Refer to «REMOVAL - Step 38»(ref-400783-S34973673832011051800000)
88. REMOVE STARTER ASSEMBLY . Refer to «REMOVAL - Step 12»(ref-400787-S20238134782011051800000)
89. REMOVE RADIATOR PIPE CLAMP Separate the breather plug hose and sensor wire from the radiator pipe clamp. Remove the bolt and radiator pipe clamp.
90. REMOVE ENGINE WIRE Remove the engine wire from the engine with transaxle.
91. REMOVE NO. 1 FRONT STABILIZER BRACKET LH (for AWD) . Refer to «REMOVAL - Step 4»(ref-400810-S27164968442011051800000)
92. REMOVE NO. 1 FRONT STABILIZER BRACKET RH (for AWD) HINT: Perform the same procedure as for the LH side.
93. REMOVE FRONT STABILIZER BAR (for AWD)
94. REMOVE STEERING LINK ASSEMBLY (for AWD) . Refer to «REMOVAL - Step 12»(ref-400820-S31533963532011051800000)
95. REMOVE FRONT FRAME ASSEMBLY Remove the nut and separate the engine mounting insulator LH. Disconnect the wire clamp and connector. Remove the bolt and separate the front engine mounting insulator. Remove the nut and separate the engine mounting insulator RH. Remove the 2 bolts and separate the rear engine mounting insulator assembly. NOTE: Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly. Remove the front frame assembly.
96. REMOVE FRONT ENGINE MOUNTING INSULATOR Remove the 2 hole plugs. Remove the 3 nuts and front engine mounting insulator. HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary.
97. REMOVE ENGINE MOUNTING INSULATOR LH Remove the 2 hole plugs. Remove the 3 nuts and engine mounting insulator LH. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
98. REMOVE ENGINE MOUNTING INSULATOR RH Remove the 2 hole plugs. Remove the 3 nuts and engine mounting insulator RH. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
99. REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY Remove the 2 hole plugs. Remove the 2 nuts and rear engine mounting insulator assembly. NOTE: Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly. HINT: Perform this procedure only when replacement of the engine mounting insulator assembly is necessary.
100. REMOVE MANIFOLD STAY Remove the bolt, nut and manifold stay.
101. REMOVE TRANSFER STIFFENER PLATE RH (for AWD) Remove the 4 bolts and transfer stiffener plate RH.
102. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) . Refer to «REMOVAL - Step 8»(ref-400804-S04429949922011051800000)
103. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) . Refer to «REMOVAL - Step 13»(ref-400805-S14148239652011051800000)
104. REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and engine mounting bracket RH.
105. REMOVE REAR ENGINE MOUNTING BRACKET (for 2WD) Remove the 3 bolts and rear engine mounting bracket.
106. REMOVE REAR ENGINE MOUNTING BRACKET (for AWD) Remove the 3 bolts and rear engine mounting bracket.
107. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 3

1. PRECAUTION (w/ Air Suspension) NOTE: Be sure to read Precaution thoroughly before servicing. Refer to «PRECAUTION»(ref-400816-S40570634362011051800000) .
2. PRECAUTION (w/ Navigation System for HDD) NOTE: After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal. Refer to «PRECAUTION»(ref-400817-S06395767762011051800000) .
3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE ENGINE ROOM SIDE COVER . Refer to «REMOVAL - Step 1»(ref-400813-S02084383242011051800000)
5. REMOVE ENGINE ROOM SIDE COVER LH . Refer to «REMOVAL - Step 2»(ref-400813-S02084383242011051800000)
6. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 3»(ref-400813-S02084383242011051800000)
7. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM . Refer to «REPLACEMENT - Step 1»(ref-400783-S08693988022011051800000)
8. DISCHARGE FUEL SYSTEM PRESSURE HINT: Refer to «PRECAUTION»(ref-400801-S22910762732011051800000) .)
9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-400649-S34584305262011051800000) .
10. REMOVE FRONT WHEEL
11. REMOVE NO. 1 ENGINE UNDER COVER
12. REMOVE NO. 2 ENGINE UNDER COVER
13. REMOVE FRONT FLOOR COVER LH . Refer to «REMOVAL - Step 2»(ref-400802-S25680554822011051800000)
14. REMOVE FRONT FENDER LINER LH
15. REMOVE FRONT FENDER LINER RH
16. REMOVE FRONT FENDER APRON SEAL LH Remove the 2 bolts, clip and front fender apron seal LH.
17. REMOVE FRONT FENDER APRON SEAL RH Remove the 2 bolts, clip and front fender apron seal RH.
18. DRAIN ENGINE OIL . Refer to «REPLACEMENT - Step 2»(ref-400818-S26419162612011051800000)
19. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 7»(ref-400800-S05976021912011051800000)
20. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD) . Refer to «REPLACEMENT - Step 4»(ref-400804-S27162233242011051800000)
21. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD) . Refer to «REPLACEMENT - Step 4»(ref-400805-S19891084712011051800000)
22. DRAIN TRANSFER OIL (for AWD) . Refer to «REPLACEMENT - Step 2»(ref-400819-S42618065672011051800000)
23. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH . Refer to «REMOVAL - Step 4»(ref-400809-S15454837202011051800000)
24. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH . Refer to «REMOVAL - Step 5»(ref-400809-S15454837202011051800000)
25. REMOVE FRONT FENDER TO COWL SIDE SEAL LH . Refer to «REMOVAL - Step 6»(ref-400809-S15454837202011051800000)
26. REMOVE FRONT FENDER TO COWL SIDE SEAL RH . Refer to «REMOVAL - Step 7»(ref-400809-S15454837202011051800000)
27. REMOVE FRONT WIPER ARM HEAD CAP . Refer to «REMOVAL - Step 8»(ref-400809-S15454837202011051800000)
28. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to «REMOVAL - Step 9»(ref-400809-S15454837202011051800000)
29. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to «REMOVAL - Step 10»(ref-400809-S15454837202011051800000)
30. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 11»(ref-400809-S15454837202011051800000)
31. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to «REMOVAL - Step 12»(ref-400809-S15454837202011051800000)
32. REMOVE FRONT SHOCK ABSORBER CAP (w/ Air Suspension) . Refer to «REMOVAL - Step 3»(ref-400810-S20661286162011051800000)
33. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «REMOVAL - Step 11»(ref-400778-S19229320722011051800000)
34. REMOVE V-BANK COVER SUB-ASSEMBLY Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the 2 retainers on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly. NOTE: Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.
35. REMOVE NO. 2 AIR CLEANER INLET Disconnect the 2 vacuum hose clamps from the No. 2 air cleaner inlet. Remove the 2 bolts and No. 2 air cleaner inlet.
36. REMOVE NO. 1 AIR CLEANER INLET Disconnect the vacuum hose clamp from the No. 1 air cleaner inlet. Remove the bolt and No. 1 air cleaner inlet.
37. REMOVE BATTERY Disconnect the positive (+) cable from the positive (+) battery terminal. Loosen the nut, and remove the bolt from the battery clamp. Remove the battery and battery tray.
38. REMOVE AIR CLEANER ASSEMBLY . Refer to «REMOVAL - Step 13»(ref-400788-S33098149072011051800000)
39. REMOVE AIR CLEANER BRACKET Disconnect the engine wire clamp. Remove the 2 bolts and air cleaner bracket.
40. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Disconnect the connector from the brake master cylinder reservoir sub-assembly. Remove the bolt and separate the radiator reservoir tank assembly from the reservoir bracket.
41. REMOVE RESERVOIR BRACKET Remove the 2 bolts and reservoir bracket.
42. REMOVE NO. 1 RELAY BLOCK COVER Remove the No. 1 relay block cover.
43. DISCONNECT ENGINE WIRE Remove the 2 bolts and separate the 2 earth wires. Disconnect the 2 wire clamps. Disconnect the 3 connectors. Remove the nut. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block. Pull up the lever to disconnect the ECM connector. Disconnect the 2 wire clamps.
44. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Remove the nut from the control shaft lever. Using a screwdriver, disengage the 4 claws and disconnect the control cable with clip from the control cable bracket. Remove the clip.
45. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE Disconnect the No. 1 fuel vapor feed hose.
46. DISCONNECT NO. 1 RADIATOR HOSE Disconnect the No. 1 radiator hose. Separate the No. 1 radiator hose from the radiator pipe clamp.
47. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the No. 2 radiator hose.
48. DISCONNECT INLET HEATER WATER HOSE Disconnect the inlet heater water hose.
49. DISCONNECT OUTLET HEATER WATER HOSE Disconnect the outlet heater water hose.
50. DISCONNECT FUEL MAIN TUBE Remove the No. 1 fuel pipe clamp. Disconnect the connector from the pipe by hand. When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully. NOTE: Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector. Do not use any tools to separate the pipe and connector. Do not forcefully bend or twist the nylon tube. Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary. Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination. If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.
51. DISCONNECT NO. 1 INLET OIL COOLER HOSE Disconnect the No. 1 inlet oil cooler hose.
52. DISCONNECT NO. 1 OUTLET OIL COOLER HOSE Disconnect the No. 1 outlet oil cooler hose.
53. DISCONNECT UNION TO CHECK VALVE HOSE Disconnect the union to check valve hose.
54. SEPARATE NO. 2 EARTH WIRE Remove the 2 bolts and separate the No. 2 earth wire clamps.
55. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
56. REMOVE ENGINE MOVING CONTROL ROD BRACKET Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.
57. REMOVE ENGINE MOVING CONTROL ROD Remove the bolt and engine moving control rod from the engine moving control rod bracket. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary.
58. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY Remove the nut and disconnect the discharge hose sub-assembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
59. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Remove the nut and disconnect the suction hose sub-assembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
60. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-400802-S25680554822011051800000)
61. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to «REMOVAL - Step 8»(ref-400802-S07854733242011051800000)
62. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET Remove the 2 nuts and No. 1 exhaust pipe support bracket.
63. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) . Refer to «REMOVAL - Step 2»(ref-400654-S31372310192011051800000)
64. SECURE STEERING WHEEL . Refer to «REMOVAL - Step 4»(ref-400820-S23363140602011051800000)
65. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to «REMOVAL - Step 5»(ref-400820-S23363140602011051800000)
66. SEPARATE HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (w/ Air Suspension) Remove the nut and separate the height control sensor link sub-assembly from the lower suspension arm.
67. REMOVE FRONT AXLE SHAFT NUT LH . Refer to «REMOVAL - Step 6»(ref-400654-S09904296332011051800000)
68. REMOVE FRONT AXLE SHAFT NUT RH HINT: Perform the same procedure as for the LH side.
69. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH . Refer to «REMOVAL - Step 5»(ref-400810-S42816404982011051800000)
70. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
71. SEPARATE FRONT SPEED SENSOR LH . Refer to «REMOVAL - Step 5»(ref-400821-S02291095292011051800000)
72. SEPARATE FRONT SPEED SENSOR RH HINT: Perform the same procedure as for the LH side.
73. SEPARATE TIE ROD ASSEMBLY LH . Refer to «REMOVAL - Step 6»(ref-400820-S23363140602011051800000)
74. SEPARATE TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
75. SEPARATE FRONT LOWER SUSPENSION ARM LH . Refer to «REMOVAL - Step 9»(ref-400810-S10866355442011051800000)
76. SEPARATE FRONT LOWER SUSPENSION ARM RH HINT: Perform the same procedure as for the LH side.
77. SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to «REMOVAL - Step 5»(ref-400810-S10866355442011051800000)
78. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to «REMOVAL - Step 12»(ref-400654-S09904296332011051800000)
79. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING . Refer to «DISASSEMBLY - Step 1»(ref-400654-S04210961262011051800000)
80. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to «REMOVAL - Step 13»(ref-400654-S09904296332011051800000)
81. REMOVE FLYWHEEL HOUSING UNDER COVER Remove the 2 bolts and flywheel housing under cover.
82. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Remove the 6 drive plate and torque converter clutch setting bolts. HINT: There will be one black colored bolt.
83. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Set the engine lifter. NOTE: Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand. Remove the 6 bolts, 2 nuts and frame side rail plates RH and LH. TEXT IN ILLUSTRATION *1 Nut Remove the 6 bolts, 2 nuts and front suspension member rear braces RH and LH. TEXT IN ILLUSTRATION *1 Nut Operate the engine lifter, then remove the engine assembly from the vehicle. NOTE: Make sure that the engine is clear of all wiring and hoses. While lowering the engine from the vehicle, do not allow it to contact the vehicle. Install the No. 1 and No. 2 engine hangers with the 4 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) PART NO. Item Part No. No. 1 engine hanger 12281-31120 No. 2 engine hanger 12282-31100 Bolt 91671-10825 Attach the sling device to the engine hangers and chain block.
84. REMOVE NO. 2 EARTH WIRE Remove the bolt and No. 2 earth wire from the engine assembly.
85. REMOVE V-RIBBED BELT See step 5
86. REMOVE GENERATOR ASSEMBLY . Refer to «REMOVAL - Step 8»(ref-400822-S25225099532011051800000)
87. REMOVE COMPRESSOR AND MAGNETIC CLUTCH . Refer to «REMOVAL - Step 38»(ref-400783-S29074551352011051800000)
88. REMOVE STARTER ASSEMBLY . Refer to «REMOVAL - Step 12»(ref-400787-S41199964642011051800000)
89. REMOVE RADIATOR PIPE CLAMP Separate the breather plug hose and sensor wire from the radiator pipe clamp. Remove the bolt and radiator pipe clamp.
90. REMOVE ENGINE WIRE Remove the engine wire from the engine with transaxle.
91. REMOVE NO. 1 FRONT STABILIZER BRACKET LH (for AWD) . Refer to «REMOVAL - Step 4»(ref-400810-S19129063232011051800000)
92. REMOVE NO. 1 FRONT STABILIZER BRACKET RH (for AWD) HINT: Perform the same procedure as for the LH side.
93. REMOVE FRONT STABILIZER BAR (for AWD)
94. REMOVE STEERING LINK ASSEMBLY (for AWD) . Refer to «REMOVAL - Step 12»(ref-400820-S23363140602011051800000)
95. REMOVE FRONT FRAME ASSEMBLY Remove the nut and separate the engine mounting insulator LH. Disconnect the wire clamp and connector. Remove the bolt and separate the front engine mounting insulator. Remove the nut and separate the engine mounting insulator RH. Remove the 2 bolts and separate the rear engine mounting insulator assembly. NOTE: Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly. Remove the front frame assembly.
96. REMOVE FRONT ENGINE MOUNTING INSULATOR Remove the 2 hole plugs. Remove the 3 nuts and front engine mounting insulator. HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary.
97. REMOVE ENGINE MOUNTING INSULATOR LH Remove the 2 hole plugs. Remove the 3 nuts and engine mounting insulator LH. HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
98. REMOVE ENGINE MOUNTING INSULATOR RH Remove the 2 hole plugs. Remove the 3 nuts and engine mounting insulator RH. HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
99. REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY Remove the 2 hole plugs. Remove the 2 nuts and rear engine mounting insulator assembly. NOTE: Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly. HINT: Perform this procedure only when replacement of the engine mounting insulator assembly is necessary.
100. REMOVE MANIFOLD STAY Remove the bolt, nut and manifold stay.
101. REMOVE TRANSFER STIFFENER PLATE RH (for AWD) Remove the 4 bolts and transfer stiffener plate RH.
102. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) . Refer to «REMOVAL - Step 8»(ref-400804-S26338619232011051800000)
103. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) . Refer to «REMOVAL - Step 13»(ref-400805-S23584351632011051800000)
104. REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and engine mounting bracket RH.
105. REMOVE REAR ENGINE MOUNTING BRACKET (for 2WD) Remove the 3 bolts and rear engine mounting bracket.
106. REMOVE REAR ENGINE MOUNTING BRACKET (for AWD) Remove the 3 bolts and rear engine mounting bracket.
107. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 3

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2
2. INSTALL REAR ENGINE MOUNTING BRACKET (for 2WD) Install the rear engine mounting bracket with the 3 bolts. Torque: 64 N*m (649 kgf*cm, 47 ft.*lbf)
3. INSTALL REAR ENGINE MOUNTING BRACKET (for AWD) Install the rear engine mounting bracket with the 3 bolts. Torque: 64 N*m (649 kgf*cm, 47 ft.*lbf)
4. INSTALL ENGINE MOUNTING BRACKET RH Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) . Refer to «INSTALLATION - Step 6»(ref-400804-S20866197102011051800000)
6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) . Refer to «INSTALLATION - Step 7»(ref-400805-S32594941712011051800000)
7. INSTALL TRANSFER STIFFENER PLATE RH (for AWD) Install the transfer stiffener plate RH with the 4 bolts. Bolt A Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) Bolt B Torque: 78 N*m (796 kgf*cm, 58 ft.*lbf)
8. INSTALL MANIFOLD STAY Install the manifold stay with the bolt and nut. Bolt Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) Nut Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
9. INSTALL RADIATOR PIPE CLAMP Install the radiator pipe clamp with the bolt. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) Install the sensor wire and the breather plug hose to the radiator pipe clamp.
10. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY Install the rear engine mounting insulator assembly with the 2 bolts. Torque: 52 N*m (531 kgf*cm, 39 ft.*lbf) HINT: Perform this procedure only when replacement of the rear engine mounting insulator assembly is necessary. Install the 2 hole plugs.
11. INSTALL ENGINE MOUNTING INSULATOR RH Install the engine mounting insulator RH with the 3 bolts. Torque: 87 N*m (888 kgf*cm, 65 ft.*lbf) HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary. Install the 2 hole plugs.
12. INSTALL ENGINE MOUNTING INSULATOR LH Install the engine mounting insulator LH with the 3 bolts. Torque: 87 N*m (888 kgf*cm, 65 ft.*lbf) HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. Install the 2 hole plugs.
13. INSTALL FRONT ENGINE MOUNTING INSULATOR Install the front engine mounting insulator with the 3 bolts. Torque: 52 N*m (531 kgf*cm, 39 ft.*lbf) HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary. Install the 2 hole plugs.
14. INSTALL ENGINE WIRE Install the engine wire to the engine with transaxle.
15. INSTALL STARTER ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-400787-S06355397292011051800000)
16. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH . Refer to «INSTALLATION - Step 1»(ref-400783-S36642141972011051800000)
17. INSTALL COMPRESSOR AND MAGNETIC CLUTCH . Refer to «INSTALLATION - Step 2»(ref-400783-S36642141972011051800000)
18. INSTALL GENERATOR ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-400822-S15646943862011051800000)
19. INSTALL V-RIBBED BELT See step 1
20. INSTALL NO. 2 EARTH WIRE Install the No. 2 earth wire with the bolt. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
21. INSTALL FRONT FRAME ASSEMBLY Install the engine mounting insulator RH with the nut. Torque: 95 N*m (969 kgf*cm, 71 ft.*lbf) Install the engine mounting insulator LH with the nut. Torque: 95 N*m (969 kgf*cm, 71 ft.*lbf) Install the front engine mounting insulator with the bolt. Torque: 87 N*m (888 kgf*cm, 65 ft.*lbf) Connect the wire clamp and connector. Install the rear engine mounting insulator assembly with the 2 bolts. Torque: 78 N*m (795 kgf*cm, 57 ft.*lbf)
22. INSTALL STEERING LINK ASSEMBLY (for AWD) . Refer to «INSTALLATION - Step 3»(ref-400820-S30494330852011051800000)
23. INSTALL FRONT STABILIZER BAR (for AWD)
24. INSTALL NO. 1 FRONT STABILIZER BRACKET LH (for AWD) . Refer to «INSTALLATION - Step 5»(ref-400810-S18047890532011051800000)
25. INSTALL NO. 1 FRONT STABILIZER BRACKET RH (for AWD) HINT: Perform the same procedure as for the LH side.
26. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Set the engine assembly with transaxle on the engine lifter. NOTE: Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly. HINT: Place the engine on wooden blocks or equivalents so that the engine is level. Remove the 4 bolts and 2 engine hangers. Install the engine assembly with transaxle to the vehicle. NOTE: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up. HINT: Make sure that the engine is clear of all wiring and hoses. While raising the engine into the vehicle, do not allow it to contact the vehicle. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut *2 Bolt A *3 Bolt B Nut Torque: 32 N*m (327 kgf*cm, 24 ft.*lbf) Bolt A Torque: 32 N*m (327 kgf*cm, 24 ft.*lbf) Bolt B Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut *2 Bolt C *3 Bolt D Nut Torque: 32 N*m (327 kgf*cm, 24 ft.*lbf) Bolt C Torque: 32 N*m (327 kgf*cm, 24 ft.*lbf) Bolt D Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
27. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Apply a few drops of adhesive to 2 or 3 threads of the 6 drive plate and torque converter clutch setting bolt tips. TEXT IN ILLUSTRATION *1 Adhesive 1324 Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Tighten the 6 drive plate and torque converter clutch setting bolts. Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) NOTE: Install the black colored bolt first, and then the silver colored 5 bolts.
28. INSTALL FLYWHEEL HOUSING UNDER COVER Install the flywheel housing under cover with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
29. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING . Refer to «REASSEMBLY - Step 13»(ref-400654-S17745459902011051800000)
30. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to «INSTALLATION - Step 1»(ref-400654-S07792665342011051800000)
31. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to «INSTALLATION - Step 2»(ref-400654-S07792665342011051800000)
32. INSTALL FRONT LOWER SUSPENSION ARM LH . Refer to «INSTALLATION - Step 4»(ref-400810-S20411910822011051800000)
33. INSTALL FRONT LOWER SUSPENSION ARM RH HINT: Perform the same procedure as for the LH side.
34. CONNECT TIE ROD ASSEMBLY LH . Refer to «INSTALLATION - Step 8»(ref-400820-S30494330852011051800000)
35. CONNECT TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
36. CONNECT FRONT SPEED SENSOR LH . Refer to «INSTALLATION - Step 8»(ref-400810-S20411910822011051800000)
37. CONNECT FRONT SPEED SENSOR RH HINT: Perform the same procedure as for the LH side.
38. CONNECT FRONT STABILIZER LINK ASSEMBLY LH . Refer to «INSTALLATION - Step 10»(ref-400810-S06310431522011051800000)
39. CONNECT FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
40. INSTALL FRONT AXLE SHAFT NUT LH . Refer to «INSTALLATION - Step 7»(ref-400654-S07792665342011051800000)
41. INSTALL FRONT AXLE SHAFT NUT RH HINT: Perform the same procedure as for the LH side.
42. INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (w/ Air Suspension) Install the height control sensor link sub-assembly with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
43. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to «INSTALLATION - Step 10»(ref-400820-S30494330852011051800000)
44. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) . Refer to «INSTALLATION - Step 1»(ref-400654-S32813719322011051800000)
45. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) . Refer to «INSTALLATION - Step 2»(ref-400654-S32813719322011051800000)
46. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Install the No. 1 exhaust pipe support bracket with the 2 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
47. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-400802-S39933712072011051800000)
48. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 12»(ref-400802-S21729616722011051800000)
49. CONNECT SUCTION HOSE SUB-ASSEMBLY Remove the attached vinyl tape from the hose. Apply sufficient compressor oil to a new O-ring. Compressor oil ND-OIL 8 or equivalent Install the O-ring onto the suction hose sub-assembly. Connect the suction hose sub-assembly with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE: Be sure to hold the suction hose while tightening the nut so that the suction hose is not deformed.
50. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Remove the attached vinyl tape from the hose. Apply sufficient compressor oil to a new O-ring. Compressor oil ND-OIL 8 or equivalent Install the O-ring onto the discharge hose sub-assembly. Connect the discharge hose sub-assembly with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE: Be sure to hold the discharge hose while tightening the nut so that the discharge hose is not deformed.
51. INSTALL ENGINE MOVING CONTROL ROD Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary.
52. INSTALL ENGINE MOVING CONTROL ROD BRACKET When replaced the engine moving control rod. Temporarily install the engine moving control rod and engine moving control rod bracket with the 4 bolts. Install the engine moving control rod bracket with the bolts except A. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) Tighten the bolt A. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) When not replaced the engine moving control rod. Install the engine moving control rod bracket with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
53. INSTALL NO. 2 ENGINE MOUNTING STAY RH Install the No. 2 engine mounting stay RH with the bolt and 2 nuts. Bolt Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) Nut Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf)
54. CONNECT NO. 2 EARTH WIRE Install the No. 2 earth wire with the 2 bolts and connect the 2 wire clamps. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
55. CONNECT UNION TO CHECK VALVE HOSE Connect the union to check valve hose.
56. CONNECT NO. 1 OUTLET OIL COOLER HOSE Connect the No. 1 outlet oil cooler hose.
57. CONNECT NO. 1 INLET OIL COOLER HOSE Connect the No. 1 inlet oil cooler hose.
58. CONNECT FUEL MAIN TUBE Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound. NOTE: Check that there is no damage or foreign objects on the fuel tube connector. After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them. Install the No. 1 EFI fuel pipe clamp. HINT: The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.
59. CONNECT OUTLET HEATER WATER HOSE Connect the outlet heater water hose.
60. CONNECT INLET HEATER WATER HOSE Connect the inlet heater water hose.
61. CONNECT NO. 1 RADIATOR HOSE Install the No. 1 radiator hose to the radiator pipe clamp. Connect the No. 1 radiator hose.
62. CONNECT NO. 2 RADIATOR HOSE Connect the No. 2 radiator hose.
63. CONNECT NO. 1 FUEL VAPOR FEED HOSE Connect the No. 1 fuel vapor feed hose.
64. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Install a new clip to the control cable bracket. Install the control cable to the control cable bracket. TEXT IN ILLUSTRATION *1 Claw (A) *2 Claw (B) *3 Control Cable NOTE: Make sure that the claws (A) on the clip are securely fit into the bracket holes. Make sure that the cable is securely installed inside of the claws (B) of the clip. Connect the transmission control cable to the control shaft lever with the nut. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) NOTE: Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.
65. CONNECT ENGINE WIRE Connect the 2 wire clamps. Connect the connector to the ECU with the lock lever. Connect the engine wire to the engine room junction block. Install the engine wire with the nut and 3 connectors. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) Connect the 2 wire clamps. Install the earth wire with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
66. INSTALL NO. 1 RELAY BLOCK COVER Install the No. 1 relay block cover.
67. INSTALL RESERVOIR BRACKET Install the reservoir bracket with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
68. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Install the brake master cylinder reservoir sub-assembly with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Connect the connector to the brake master cylinder reservoir sub-assembly.
69. INSTALL AIR CLEANER BRACKET Install the air cleaner bracket with the 2 bolts. Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf) Connect the engine wire clamp.
70. INSTALL AIR CLEANER ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-400788-S16135119482011051800000)
71. INSTALL BATTERY Install the battery and battery tray. Install the battery clamp with the bolt and nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the positive (+) cable to the positive (+) battery terminal. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
72. INSTALL NO. 1 AIR CLEANER INLET Install the No. 1 air cleaner inlet with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the vacuum hose clamp to the No. 1 air cleaner inlet.
73. INSTALL NO. 2 AIR CLEANER INLET Install the No. 2 air cleaner inlet with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the 2 vacuum hose clamps to the No. 2 air cleaner inlet.
74. INSPECT VACUUM HOSES Inspect the vacuum hoses.
75. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «INSTALLATION - Step 17»(ref-400778-S06004016952011051800000)
76. INSTALL FRONT SHOCK ABSORBER CAP (w/ Air Suspension) . Refer to «INSTALLATION - Step 10»(ref-400810-S37673499492011051800000)
77. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to «INSTALLATION - Step 3»(ref-400809-S08188241832011051800000)
78. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 4»(ref-400809-S08188241832011051800000)
79. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to «INSTALLATION - Step 5»(ref-400809-S08188241832011051800000)
80. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to «INSTALLATION - Step 6»(ref-400809-S08188241832011051800000)
81. INSTALL FRONT WIPER ARM HEAD CAP . Refer to «INSTALLATION - Step 7»(ref-400809-S08188241832011051800000)
82. INSTALL FRONT FENDER TO COWL SIDE SEAL LH . Refer to «INSTALLATION - Step 8»(ref-400809-S08188241832011051800000)
83. INSTALL FRONT FENDER TO COWL SIDE SEAL RH . Refer to «INSTALLATION - Step 9»(ref-400809-S08188241832011051800000)
84. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH . Refer to «INSTALLATION - Step 10»(ref-400809-S08188241832011051800000)
85. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH . Refer to «INSTALLATION - Step 11»(ref-400809-S08188241832011051800000)
86. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-400649-S12881576452011051800000) .
87. INSTALL FRONT WHEEL Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)
88. ADD ENGINE OIL . Refer to «REPLACEMENT - Step 5»(ref-400818-S09227417132011051800000)
89. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 8»(ref-400800-S21803137222011051800000)
90. ADD TRANSFER OIL (for AWD)
91. INSPECT TRANSFER OIL (for AWD) . Refer to «ON-VEHICLE INSPECTION - Step 2»(ref-400819-S31319356522011051800000)
92. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD) HINT: Refer to «ADJUSTMENT»(ref-400804-S35806271502011051800000) .)
93. ADD AUTOMATIC TRANSAXLE FLUID (for AWD) HINT: Refer to «ON-VEHICLE INSPECTION»(ref-400805-S27262670412011051800000) .)
94. WARM UP ENGINE
95. INSPECT ENGINE OIL LEVEL . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-400814-S06625273702011051800000)
96. INSPECT FOR ENGINE COOLANT LEVEL . Refer to «ON-VEHICLE INSPECTION - Step 2»(ref-400812-S34139223332011051800000)
97. CHARGE WITH REFRIGERANT . Refer to «REPLACEMENT - Step 2»(ref-400783-S08693988022011051800000)
98. INSPECT FOR FUEL LEAK . Refer to «INSTALLATION - Step 6»(ref-400791-S08210593102011051800000)
99. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-400812-S34139223332011051800000)
100. INSPECT FOR OIL LEAK
101. INSPECT FOR EXHAUST GAS LEAK
102. INSPECT IGNITION TIMING See step 9
103. INSPECT ENGINE IDLE SPEED See step 10
104. INSPECT CO/HC See step 12
105. CHECK FOR SPEED SENSOR SIGNAL HINT: Refer to «TEST MODE PROCEDURE»(ref-400653-S03755609162011051800000) .)
106. INSPECT SHIFT LEVER POSITION (for 2WD) . Refer to «ADJUSTMENT - Step 1»(ref-400804-S03289891882011051800000)
107. INSPECT SHIFT LEVER POSITION (for AWD) . Refer to «ADJUSTMENT - Step 1»(ref-400805-S28635072252011051800000)
108. CHECK VEHICLE HEIGHT (w/ Air Suspension) NOTE: If the height control sensor link is removed, check the vehicle height. Change the height control switch from the "NORM" position to the "HIGH" position and back to the "NORM" position. Measure the vehicle height (. Refer to «ADJUSTMENT - Step 3»(ref-400782-S33435189622011051800000) ).
109. ADJUST VEHICLE HEIGHT (w/ Air Suspension) NOTE: If the height control sensor has been replaced, be sure to adjust the vehicle height. Adjust the vehicle height (. Refer to «ON-VEHICLE INSPECTION»(ref-400808-S21597805222011051800000) ).
110. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: Refer to «ADJUSTMENT»(ref-400782-S34673386002011051800000) .)
111. INSPECT AUTOMATIC TRANSAXLE SYSTEM (for 2WD) NOTE: If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary (. Refer to «PRECAUTION»(ref-400823-S02290043642011051800000) ).
112. INSPECT AUTOMATIC TRANSAXLE SYSTEM (for AWD) NOTE: If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary (. Refer to «PRECAUTION»(ref-400824-S28970228382011051800000) ).
113. INSTALL V-BANK COVER SUB-ASSEMBLY Fit the 4 retainers and install the V-bank cover sub-assembly.
114. INSTALL FRONT FENDER APRON SEAL LH Install the front fender apron seal LH with the 2 bolts and clip.
115. INSTALL FRONT FENDER APRON SEAL RH Install the front fender apron seal RH with the 2 bolts and clip.
116. INSTALL FRONT FENDER LINER LH
117. INSTALL FRONT FENDER LINER RH
118. INSTALL NO. 2 ENGINE UNDER COVER
119. INSTALL NO. 1 ENGINE UNDER COVER
120. INSTALL FRONT FLOOR COVER LH . Refer to «INSTALLATION - Step 13»(ref-400802-S21729616722011051800000)
121. PERFORM INITIALIZATION Perform initialization (. Refer to «INITIALIZATION»(ref-400649-S12881576452011051800000) ). NOTE: Some systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
122. ADJUST HEADLIGHT ASSEMBLY (w/ Air Suspension) Adjust the headlight (. Refer to «ADJUSTMENT»(ref-400664-S34379441992011051800000) ).
123. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION - Step 3»(ref-400813-S41344728382011051800000)
124. INSTALL ENGINE ROOM SIDE COVER . Refer to «INSTALLATION - Step 4»(ref-400813-S41344728382011051800000)
125. INSTALL ENGINE ROOM SIDE COVER LH . Refer to «INSTALLATION - Step 5»(ref-400813-S41344728382011051800000)

1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 2
2. INSTALL REAR ENGINE MOUNTING BRACKET (for 2WD) Install the rear engine mounting bracket with the 3 bolts. Torque: 64 N*m (649 kgf*cm, 47 ft.*lbf)
3. INSTALL REAR ENGINE MOUNTING BRACKET (for AWD) Install the rear engine mounting bracket with the 3 bolts. Torque: 64 N*m (649 kgf*cm, 47 ft.*lbf)
4. INSTALL ENGINE MOUNTING BRACKET RH Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) . Refer to «INSTALLATION - Step 6»(ref-400804-S04798904902011051800000)
6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) . Refer to «INSTALLATION - Step 7»(ref-400805-S08289717372011051800000)
7. INSTALL TRANSFER STIFFENER PLATE RH (for AWD) Install the transfer stiffener plate RH with the 4 bolts. Bolt A Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) Bolt B Torque: 78 N*m (796 kgf*cm, 58 ft.*lbf)
8. INSTALL MANIFOLD STAY Install the manifold stay with the bolt and nut. Bolt Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) Nut Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
9. INSTALL RADIATOR PIPE CLAMP Install the radiator pipe clamp with the bolt. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) Install the sensor wire and the breather plug hose to the radiator pipe clamp.
10. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY Install the rear engine mounting insulator assembly with the 2 bolts. Torque: 52 N*m (531 kgf*cm, 39 ft.*lbf) HINT: Perform this procedure only when replacement of the rear engine mounting insulator assembly is necessary. Install the 2 hole plugs.
11. INSTALL ENGINE MOUNTING INSULATOR RH Install the engine mounting insulator RH with the 3 bolts. Torque: 87 N*m (888 kgf*cm, 65 ft.*lbf) HINT: Perform this procedure only when replacement of the engine mounting insulator RH is necessary. Install the 2 hole plugs.
12. INSTALL ENGINE MOUNTING INSULATOR LH Install the engine mounting insulator LH with the 3 bolts. Torque: 87 N*m (888 kgf*cm, 65 ft.*lbf) HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. Install the 2 hole plugs.
13. INSTALL FRONT ENGINE MOUNTING INSULATOR Install the front engine mounting insulator with the 3 bolts. Torque: 52 N*m (531 kgf*cm, 39 ft.*lbf) HINT: Perform this procedure only when replacement of the front engine mounting insulator is necessary. Install the 2 hole plugs.
14. INSTALL ENGINE WIRE Install the engine wire to the engine with transaxle.
15. INSTALL STARTER ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-400787-S41274500222011051800000)
16. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH . Refer to «INSTALLATION - Step 1»(ref-400783-S00865158772011051800000)
17. INSTALL COMPRESSOR AND MAGNETIC CLUTCH . Refer to «INSTALLATION - Step 2»(ref-400783-S00865158772011051800000)
18. INSTALL GENERATOR ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-400822-S14966166352011051800000)
19. INSTALL V-RIBBED BELT See step 1
20. INSTALL NO. 2 EARTH WIRE Install the No. 2 earth wire with the bolt. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
21. INSTALL FRONT FRAME ASSEMBLY Install the engine mounting insulator RH with the nut. Torque: 95 N*m (969 kgf*cm, 71 ft.*lbf) Install the engine mounting insulator LH with the nut. Torque: 95 N*m (969 kgf*cm, 71 ft.*lbf) Install the front engine mounting insulator with the bolt. Torque: 87 N*m (888 kgf*cm, 65 ft.*lbf) Connect the wire clamp and connector. Install the rear engine mounting insulator assembly with the 2 bolts. Torque: 78 N*m (795 kgf*cm, 57 ft.*lbf)
22. INSTALL STEERING LINK ASSEMBLY (for AWD) . Refer to «INSTALLATION - Step 3»(ref-400820-S09125766512011051800000)
23. INSTALL FRONT STABILIZER BAR (for AWD)
24. INSTALL NO. 1 FRONT STABILIZER BRACKET LH (for AWD) . Refer to «INSTALLATION - Step 5»(ref-400810-S06542876812011051800000)
25. INSTALL NO. 1 FRONT STABILIZER BRACKET RH (for AWD) HINT: Perform the same procedure as for the LH side.
26. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Set the engine assembly with transaxle on the engine lifter. NOTE: Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly. HINT: Place the engine on wooden blocks or equivalents so that the engine is level. Remove the 4 bolts and 2 engine hangers. Install the engine assembly with transaxle to the vehicle. NOTE: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up. HINT: Make sure that the engine is clear of all wiring and hoses. While raising the engine into the vehicle, do not allow it to contact the vehicle. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut *2 Bolt A *3 Bolt B Nut Torque: 32 N*m (327 kgf*cm, 24 ft.*lbf) Bolt A Torque: 32 N*m (327 kgf*cm, 24 ft.*lbf) Bolt B Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut *2 Bolt C *3 Bolt D Nut Torque: 32 N*m (327 kgf*cm, 24 ft.*lbf) Bolt C Torque: 32 N*m (327 kgf*cm, 24 ft.*lbf) Bolt D Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
27. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Using SST, hold the crankshaft pulley. SST: 09213-70011 09213-70020 SST: 09330-00021 Apply a few drops of adhesive to 2 or 3 threads of the 6 drive plate and torque converter clutch setting bolt tips. TEXT IN ILLUSTRATION *1 Adhesive 1324 Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Tighten the 6 drive plate and torque converter clutch setting bolts. Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) NOTE: Install the black colored bolt first, and then the silver colored 5 bolts.
28. INSTALL FLYWHEEL HOUSING UNDER COVER Install the flywheel housing under cover with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
29. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING . Refer to «REASSEMBLY - Step 13»(ref-400654-S17745459902011051800000)
30. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to «INSTALLATION - Step 1»(ref-400654-S38126515482011051800000)
31. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to «INSTALLATION - Step 2»(ref-400654-S38126515482011051800000)
32. INSTALL FRONT LOWER SUSPENSION ARM LH . Refer to «INSTALLATION - Step 4»(ref-400810-S12674617392011051800000)
33. INSTALL FRONT LOWER SUSPENSION ARM RH HINT: Perform the same procedure as for the LH side.
34. CONNECT TIE ROD ASSEMBLY LH . Refer to «INSTALLATION - Step 8»(ref-400820-S09125766512011051800000)
35. CONNECT TIE ROD ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
36. CONNECT FRONT SPEED SENSOR LH . Refer to «INSTALLATION - Step 8»(ref-400810-S12674617392011051800000)
37. CONNECT FRONT SPEED SENSOR RH HINT: Perform the same procedure as for the LH side.
38. CONNECT FRONT STABILIZER LINK ASSEMBLY LH . Refer to «INSTALLATION - Step 10»(ref-400810-S35188808942011051800000)
39. CONNECT FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side.
40. INSTALL FRONT AXLE SHAFT NUT LH . Refer to «INSTALLATION - Step 7»(ref-400654-S38126515482011051800000)
41. INSTALL FRONT AXLE SHAFT NUT RH HINT: Perform the same procedure as for the LH side.
42. INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (w/ Air Suspension) Install the height control sensor link sub-assembly with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
43. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to «INSTALLATION - Step 10»(ref-400820-S09125766512011051800000)
44. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) . Refer to «INSTALLATION - Step 1»(ref-400654-S12782318732011051800000)
45. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) . Refer to «INSTALLATION - Step 2»(ref-400654-S12782318732011051800000)
46. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Install the No. 1 exhaust pipe support bracket with the 2 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
47. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-400802-S07946296732011051800000)
48. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 12»(ref-400802-S40288001152011051800000)
49. CONNECT SUCTION HOSE SUB-ASSEMBLY Remove the attached vinyl tape from the hose. Apply sufficient compressor oil to a new O-ring. Compressor oil ND-OIL 8 or equivalent Install the O-ring onto the suction hose sub-assembly. Connect the suction hose sub-assembly with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE: Be sure to hold the suction hose while tightening the nut so that the suction hose is not deformed.
50. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Remove the attached vinyl tape from the hose. Apply sufficient compressor oil to a new O-ring. Compressor oil ND-OIL 8 or equivalent Install the O-ring onto the discharge hose sub-assembly. Connect the discharge hose sub-assembly with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE: Be sure to hold the discharge hose while tightening the nut so that the discharge hose is not deformed.
51. INSTALL ENGINE MOVING CONTROL ROD Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt. HINT: Perform this procedure only when replacement of the engine moving control rod is necessary.
52. INSTALL ENGINE MOVING CONTROL ROD BRACKET When replaced the engine moving control rod. Temporarily install the engine moving control rod and engine moving control rod bracket with the 4 bolts. Install the engine moving control rod bracket with the bolts except A. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) Tighten the bolt A. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) When not replaced the engine moving control rod. Install the engine moving control rod bracket with the 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
53. INSTALL NO. 2 ENGINE MOUNTING STAY RH Install the No. 2 engine mounting stay RH with the bolt and 2 nuts. Bolt Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) Nut Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf)
54. CONNECT NO. 2 EARTH WIRE Install the No. 2 earth wire with the 2 bolts and connect the 2 wire clamps. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
55. CONNECT UNION TO CHECK VALVE HOSE Connect the union to check valve hose.
56. CONNECT NO. 1 OUTLET OIL COOLER HOSE Connect the No. 1 outlet oil cooler hose.
57. CONNECT NO. 1 INLET OIL COOLER HOSE Connect the No. 1 inlet oil cooler hose.
58. CONNECT FUEL MAIN TUBE Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound. NOTE: Check that there is no damage or foreign objects on the fuel tube connector. After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them. Install the No. 1 EFI fuel pipe clamp. HINT: The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.
59. CONNECT OUTLET HEATER WATER HOSE Connect the outlet heater water hose.
60. CONNECT INLET HEATER WATER HOSE Connect the inlet heater water hose.
61. CONNECT NO. 1 RADIATOR HOSE Install the No. 1 radiator hose to the radiator pipe clamp. Connect the No. 1 radiator hose.
62. CONNECT NO. 2 RADIATOR HOSE Connect the No. 2 radiator hose.
63. CONNECT NO. 1 FUEL VAPOR FEED HOSE Connect the No. 1 fuel vapor feed hose.
64. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Install a new clip to the control cable bracket. Install the control cable to the control cable bracket. TEXT IN ILLUSTRATION *1 Claw (A) *2 Claw (B) *3 Control Cable NOTE: Make sure that the claws (A) on the clip are securely fit into the bracket holes. Make sure that the cable is securely installed inside of the claws (B) of the clip. Connect the transmission control cable to the control shaft lever with the nut. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) NOTE: Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.
65. CONNECT ENGINE WIRE Connect the 2 wire clamps. Connect the connector to the ECU with the lock lever. Connect the engine wire to the engine room junction block. Install the engine wire with the nut and 3 connectors. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) Connect the 2 wire clamps. Install the earth wire with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
66. INSTALL NO. 1 RELAY BLOCK COVER Install the No. 1 relay block cover.
67. INSTALL RESERVOIR BRACKET Install the reservoir bracket with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
68. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Install the brake master cylinder reservoir sub-assembly with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Connect the connector to the brake master cylinder reservoir sub-assembly.
69. INSTALL AIR CLEANER BRACKET Install the air cleaner bracket with the 2 bolts. Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf) Connect the engine wire clamp.
70. INSTALL AIR CLEANER ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-400788-S38450411322011051800000)
71. INSTALL BATTERY Install the battery and battery tray. Install the battery clamp with the bolt and nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the positive (+) cable to the positive (+) battery terminal. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
72. INSTALL NO. 1 AIR CLEANER INLET Install the No. 1 air cleaner inlet with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the vacuum hose clamp to the No. 1 air cleaner inlet.
73. INSTALL NO. 2 AIR CLEANER INLET Install the No. 2 air cleaner inlet with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the 2 vacuum hose clamps to the No. 2 air cleaner inlet.
74. INSPECT VACUUM HOSES Inspect the vacuum hoses.
75. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «INSTALLATION - Step 17»(ref-400778-S22039083752011051800000)
76. INSTALL FRONT SHOCK ABSORBER CAP (w/ Air Suspension) . Refer to «INSTALLATION - Step 10»(ref-400810-S15685281082011051800000)
77. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to «INSTALLATION - Step 3»(ref-400809-S08188241832011051800000)
78. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 4»(ref-400809-S08188241832011051800000)
79. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to «INSTALLATION - Step 5»(ref-400809-S08188241832011051800000)
80. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to «INSTALLATION - Step 6»(ref-400809-S08188241832011051800000)
81. INSTALL FRONT WIPER ARM HEAD CAP . Refer to «INSTALLATION - Step 7»(ref-400809-S08188241832011051800000)
82. INSTALL FRONT FENDER TO COWL SIDE SEAL LH . Refer to «INSTALLATION - Step 8»(ref-400809-S08188241832011051800000)
83. INSTALL FRONT FENDER TO COWL SIDE SEAL RH . Refer to «INSTALLATION - Step 9»(ref-400809-S08188241832011051800000)
84. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH . Refer to «INSTALLATION - Step 10»(ref-400809-S08188241832011051800000)
85. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH . Refer to «INSTALLATION - Step 11»(ref-400809-S08188241832011051800000)
86. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-400649-S34584305262011051800000) .
87. INSTALL FRONT WHEEL Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)
88. ADD ENGINE OIL . Refer to «REPLACEMENT - Step 5»(ref-400818-S26419162612011051800000)
89. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 8»(ref-400800-S05976021912011051800000)
90. ADD TRANSFER OIL (for AWD)
91. INSPECT TRANSFER OIL (for AWD) . Refer to «ON-VEHICLE INSPECTION - Step 2»(ref-400819-S01783378392011051800000)
92. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD) HINT: Refer to «ADJUSTMENT»(ref-400804-S41001820762011051800000) .)
93. ADD AUTOMATIC TRANSAXLE FLUID (for AWD) HINT: Refer to «ON-VEHICLE INSPECTION»(ref-400805-S39951429812011051800000) .)
94. WARM UP ENGINE
95. INSPECT ENGINE OIL LEVEL . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-400814-S27456129652011051800000)
96. INSPECT FOR ENGINE COOLANT LEVEL . Refer to «ON-VEHICLE INSPECTION - Step 2»(ref-400812-S34139223332011051800000)
97. CHARGE WITH REFRIGERANT . Refer to «REPLACEMENT - Step 2»(ref-400783-S08693988022011051800000)
98. INSPECT FOR FUEL LEAK . Refer to «INSTALLATION - Step 6»(ref-400791-S10677839382011051800000)
99. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-400812-S34139223332011051800000)
100. INSPECT FOR OIL LEAK
101. INSPECT FOR EXHAUST GAS LEAK
102. INSPECT IGNITION TIMING See step 9
103. INSPECT ENGINE IDLE SPEED See step 10
104. INSPECT CO/HC See step 12
105. CHECK FOR SPEED SENSOR SIGNAL HINT: Refer to «TEST MODE PROCEDURE»(ref-400653-S19810423992011051800000) .)
106. INSPECT SHIFT LEVER POSITION (for 2WD) . Refer to «ADJUSTMENT - Step 1»(ref-400804-S09737868332011051800000)
107. INSPECT SHIFT LEVER POSITION (for AWD) . Refer to «ADJUSTMENT - Step 1»(ref-400805-S10924001962011051800000)
108. CHECK VEHICLE HEIGHT (w/ Air Suspension) NOTE: If the height control sensor link is removed, check the vehicle height. Change the height control switch from the "NORM" position to the "HIGH" position and back to the "NORM" position. Measure the vehicle height (. Refer to «ADJUSTMENT - Step 3»(ref-400782-S41339985692011051800000) ).
109. ADJUST VEHICLE HEIGHT (w/ Air Suspension) NOTE: If the height control sensor has been replaced, be sure to adjust the vehicle height. Adjust the vehicle height (. Refer to «ON-VEHICLE INSPECTION»(ref-400808-S19452096872011051800000) ).
110. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: Refer to «ADJUSTMENT»(ref-400782-S39216068852011051800000) .)
111. INSPECT AUTOMATIC TRANSAXLE SYSTEM (for 2WD) NOTE: If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary (. Refer to «PRECAUTION»(ref-400823-S31557915692011051800000) ).
112. INSPECT AUTOMATIC TRANSAXLE SYSTEM (for AWD) NOTE: If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary (. Refer to «PRECAUTION»(ref-400824-S18386277832011051800000) ).
113. INSTALL V-BANK COVER SUB-ASSEMBLY Fit the 4 retainers and install the V-bank cover sub-assembly.
114. INSTALL FRONT FENDER APRON SEAL LH Install the front fender apron seal LH with the 2 bolts and clip.
115. INSTALL FRONT FENDER APRON SEAL RH Install the front fender apron seal RH with the 2 bolts and clip.
116. INSTALL FRONT FENDER LINER LH
117. INSTALL FRONT FENDER LINER RH
118. INSTALL NO. 2 ENGINE UNDER COVER
119. INSTALL NO. 1 ENGINE UNDER COVER
120. INSTALL FRONT FLOOR COVER LH . Refer to «INSTALLATION - Step 13»(ref-400802-S40288001152011051800000)
121. PERFORM INITIALIZATION Perform initialization (. Refer to «INITIALIZATION»(ref-400649-S34584305262011051800000) ). NOTE: Some systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
122. ADJUST HEADLIGHT ASSEMBLY (w/ Air Suspension) Adjust the headlight (. Refer to «ADJUSTMENT»(ref-400664-S34379441992011051800000) ).
123. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION - Step 3»(ref-400813-S41344728382011051800000)
124. INSTALL ENGINE ROOM SIDE COVER . Refer to «INSTALLATION - Step 4»(ref-400813-S41344728382011051800000)
125. INSTALL ENGINE ROOM SIDE COVER LH . Refer to «INSTALLATION - Step 5»(ref-400813-S41344728382011051800000)

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1. INSTALL ENGINE ON ENGINE STAND Install the engine onto an engine stand with the bolts.
2. REMOVE ENGINE HANGER Remove the 4 bolts and 2 engine hangers. TEXT IN ILLUSTRATION *1 No. 1 engine hanger *2 No. 2 engine hanger
3. REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-400802-S06641726382011051800000)
4. REMOVE NO. 1 SURGE TANK STAY Remove the bolt and No. 1 surge tank stay.
5. REMOVE THROTTLE BODY BRACKET Remove the bolt and throttle body bracket.
6. REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL - Step 16»(ref-400788-S05408914652011051800000)
7. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt and No. 2 engine mounting stay RH.
8. REMOVE INTAKE MANIFOLD Uniformly loosen and remove the 6 bolts and 4 nuts. Remove the intake manifold and 2 gaskets.
9. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Uniformly loosen and remove the 6 nuts. Remove the exhaust manifold sub-assembly RH and gasket.
10. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Remove the oil level dipstick. Remove the bolt and No. 2 engine oil level dipstick guide. Remove the O-ring from the No. 2 engine oil level dipstick guide.
11. REMOVE NO. 2 MANIFOLD STAY . Refer to «REMOVAL - Step 9»(ref-400802-S33534498812011051800000)
12. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «REMOVAL - Step 11»(ref-400802-S33534498812011051800000)
13. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Uniformly loosen and remove the 6 nuts. Remove the exhaust manifold assembly LH and gasket.
14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the 5 bolts and V-ribbed belt tensioner assembly.
15. REMOVE NO. 2 TIMING GEAR COVER Remove the 2 bolts and No. 2 timing gear cover.
16. REMOVE WATER PUMP PULLEY . Refer to «REMOVAL - Step 9»(ref-400800-S17080005892011051800000)
17. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the bolt, No. 2 idler pulley cover plate, No. 2 idler pulley sub-assembly and idler pulley cover plate.
18. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Remove the bolt and No. 1 vacuum switching valve.
19. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
20. REMOVE KNOCK CONTROL SENSOR WIRE Disconnect the 2 knock control sensor connectors and knock control sensor wire connector. Disconnect the 2 clamps and remove the knock control sensor wire from the engine assembly.
21. REMOVE KNOCK CONTROL SENSOR . Refer to «REMOVAL - Step 3»(ref-400788-S35539252832011051800000)
22. REMOVE ENGINE COOLANT TEMPERATURE SENSOR . Refer to «REMOVAL - Step 14»(ref-400788-S35077933392011051800000)

1. INSTALL ENGINE ON ENGINE STAND Install the engine onto an engine stand with the bolts.
2. REMOVE ENGINE HANGER Remove the 4 bolts and 2 engine hangers. TEXT IN ILLUSTRATION *1 No. 1 engine hanger *2 No. 2 engine hanger
3. REMOVE INTAKE AIR SURGE TANK ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-400802-S36931150902011051800000)
4. REMOVE NO. 1 SURGE TANK STAY Remove the bolt and No. 1 surge tank stay.
5. REMOVE THROTTLE BODY BRACKET Remove the bolt and throttle body bracket.
6. REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL - Step 16»(ref-400788-S02817236512011051800000)
7. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt and No. 2 engine mounting stay RH.
8. REMOVE INTAKE MANIFOLD Uniformly loosen and remove the 6 bolts and 4 nuts. Remove the intake manifold and 2 gaskets.
9. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Uniformly loosen and remove the 6 nuts. Remove the exhaust manifold sub-assembly RH and gasket.
10. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Remove the oil level dipstick. Remove the bolt and No. 2 engine oil level dipstick guide. Remove the O-ring from the No. 2 engine oil level dipstick guide.
11. REMOVE NO. 2 MANIFOLD STAY . Refer to «REMOVAL - Step 9»(ref-400802-S25680554822011051800000)
12. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «REMOVAL - Step 11»(ref-400802-S25680554822011051800000)
13. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Uniformly loosen and remove the 6 nuts. Remove the exhaust manifold assembly LH and gasket.
14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the 5 bolts and V-ribbed belt tensioner assembly.
15. REMOVE NO. 2 TIMING GEAR COVER Remove the 2 bolts and No. 2 timing gear cover.
16. REMOVE WATER PUMP PULLEY . Refer to «REMOVAL - Step 9»(ref-400800-S29684713152011051800000)
17. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the bolt, No. 2 idler pulley cover plate, No. 2 idler pulley sub-assembly and idler pulley cover plate.
18. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Remove the bolt and No. 1 vacuum switching valve.
19. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
20. REMOVE KNOCK CONTROL SENSOR WIRE Disconnect the 2 knock control sensor connectors and knock control sensor wire connector. Disconnect the 2 clamps and remove the knock control sensor wire from the engine assembly.
21. REMOVE KNOCK CONTROL SENSOR . Refer to «REMOVAL - Step 3»(ref-400788-S06535189112011051800000)
22. REMOVE ENGINE COOLANT TEMPERATURE SENSOR . Refer to «REMOVAL - Step 14»(ref-400788-S01219467482011051800000)

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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-S05408914652011051800000)
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-S13006801502011051800000)
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to «REMOVAL - Step 15»(ref-400788-S22797363162011051800000)
7. REMOVE CRANK POSITION SENSOR . Refer to «REMOVAL - Step 3»(ref-400788-S17322073042011051800000)
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.

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S37778429892011051800000)
2. INSTALL KNOCK CONTROL SENSOR . Refer to «INSTALLATION - Step 1»(ref-400788-S03341403492011051800000)
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-S30156054002011051800000)
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-S40288001152011051800000)
12. INSTALL NO. 2 MANIFOLD STAY . Refer to «INSTALLATION - Step 5»(ref-400802-S40288001152011051800000)
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-S13802717592011051800000)
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-S09705609702011051800000)
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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1. REMOVE VALVE STEM CAP Remove the valve stem caps from the cylinder heads. HINT: Arrange the removed parts in the correct order.
2. REMOVE INTAKE VALVE Using SST, compress the inner compression spring and remove the valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Remove the valve spring retainer, inner compression spring and intake valve. HINT: Arrange the removed parts in the correct order.
3. REMOVE EXHAUST VALVE Using SST, compress the inner compression spring and remove the valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Remove the valve spring retainer, inner compression spring and exhaust valve. HINT: Arrange the removed parts in the correct order.
4. REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the valve stem oil seals.
5. REMOVE VALVE SPRING SEAT Using compressed air and a Magnet Hand, remove the valve spring seats by blowing air onto them.
6. REMOVE NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, remove the 4 No. 1 straight screw plugs and 4 gaskets. NOTE: If water leaks from a straight screw plug or the plug is corroded, replace it.
7. REMOVE NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, remove the 2 No. 2 straight screw plugs and 2 gaskets. NOTE: If water leaks from a straight screw plug or the plug is corroded, replace it.

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1. INSPECT CYLINDER HEAD SUB-ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder block sub-assembly and manifolds. Standard Warpage Item Warpage Cylinder head lower 0.05 mm (0.00197 in.) Intake 0.08 mm (0.00315 in.) Exhaust 0.08 mm (0.00315 in.) Maximum Warpage Item Warpage Cylinder head lower 0.10 mm (0.00394 in.) Intake 0.10 mm (0.00394 in.) Exhaust 0.10 mm (0.00394 in.) If the warpage is greater than the maximum, replace the cylinder head sub-assembly.
2. INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head sub-assembly.
3. INSPECT INTAKE VALVE Using a micrometer, measure the diameter of the valve stem. Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.) If the valve stem is not as specified, check the oil clearance. Using a vernier caliper, measure the valve head margin thickness. TEXT IN ILLUSTRATION *1 Margin thickness Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the intake valve. Using a vernier caliper, measure the valve overall length. TEXT IN ILLUSTRATION *1 Overall Length Standard overall length 105.85 mm (4.1673 in.) Minimum overall length 105.35 mm (4.1476 in.) If the overall length is less than the minimum, replace the intake valve.
4. INSPECT EXHAUST VALVE Using a micrometer, measure the diameter of the valve stem. Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2157 in.) If the valve stem is not as specified, check the oil clearance. Using a vernier caliper, measure the valve head margin thickness. TEXT IN ILLUSTRATION *1 Margin thickness Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the exhaust valve. Using a vernier caliper, measure the valve overall length. TEXT IN ILLUSTRATION *1 Overall Length Standard overall length 110.40 mm (4.3464 in.) Minimum overall length 109.90 mm (4.3268 in.) If the overall length is less than the minimum, replace the exhaust valve.
5. INSPECT INTAKE VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. Check the valve face and valve spring seat by using the following procedure: TEXT IN ILLUSTRATION *1 Width If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve spring seat. Check that the valve spring seat contacts in the middle of the valve face with the width between 1.1 and 1.6 mm (0.0433 and 0.0630 in.).
6. INSPECT EXHAUST VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve spring seat. Check the valve face and valve spring seat by using the following procedure: TEXT IN ILLUSTRATION *1 Width If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve spring seat. Check that the valve spring seat contacts in the middle of the valve face with the width between 1.1 and 1.6 mm (0.0433 and 0.0630 in.).
7. INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the inner compression spring. Free length 45.91 mm (1.8075 in.) If the free length is not as specified, replace the inner compression spring. Using a steel square, measure the deviation of the inner compression spring. TEXT IN ILLUSTRATION *1 Deviation Maximum deviation 1.0 mm (0.0394 in.) Maximum angle (reference) 2° If the deviation is greater than the maximum, replace the inner compression spring.
8. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. Bush inside diameter 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Subtract the valve stem diameter measurement from the valve guide bush inside diameter measurement. Standard Oil Clearance Item Clearance Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.) Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.) Maximum Oil Clearance Item Clearance Intake 0.08 mm (0.00315 in.) Exhaust 0.10 mm (0.00394 in.) If the clearance is greater than the maximum, replace the valve and valve guide bush.

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1. REPLACE INTAKE VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the intake valve guide bushes. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head. Cylinder bore diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05) Bush Size Bush Bore Diameter STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST, tap in new intake valve guide bushes to the specified protrusion height. TEXT IN ILLUSTRATION *1 Protrusion Height SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Protrusion height 9.30 to 9.70 mm (0.3661 to 0.3819 in.) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance. Standard oil clearance 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
2. REPLACE EXHAUST VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the exhaust valve guide bushes. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head. Cylinder bore diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Select a new guide bush (STD or O/S 0.05) Bush Size Bush Bore Diameter STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. Heat the cylinder head to 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST, tap in new exhaust valve guide bushes to the specified protrusion height. TEXT IN ILLUSTRATION *1 Protrusion Height SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Protrusion height 9.30 to 9.70 mm (0.3661 to 0.3819 in.) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance. Standard oil clearance 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
3. REPLACE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Using a plastic hammer, tap in new ring pins to the specified protrusion height. Specified protrusion height 2.5 to 3.5 mm (0.0984 to 0.138 in.)
4. REPLACE STUD BOLT NOTE: If a stud bolt is deformed or the threads are damaged, replace it. Using an E6 and E8 "TORX" sockets, install the stud bolts. Bolts A and B Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt C Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
5. REPLACE STRAIGHT PIN NOTE: If a straight pin is deformed, replace it. Using a plastic hammer, tap in new straight pins as shown in the illustration. Protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.)

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1. INSTALL NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
2. INSTALL NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
3. INSTALL VALVE SPRING SEAT Install the valve spring seats to the cylinder head.
4. INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to new valve stem oil seals. NOTE: Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later. HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black. Using SST, push in the oil seals. SST: 09201-41020 NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
5. INSTALL EXHAUST VALVE Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to the original locations. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
6. INSTALL INTAKE VALVE Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to their original locations. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
7. INSTALL VALVE STEM CAP Apply a light coat of engine oil to the valve stem caps. Install the valve stem caps on the valves.

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1. REPAIR INTAKE VALVE SEAT NOTE: Repair the intake valve seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is greater than the specification. Using 30° and 60° cutters, correct the valve seat so that the intake valve contacts the entire circumference of the seat. The contact should be in the center of the intake valve seat, and the intake valve seat width should be maintained within the specified range around the entire circumference of the intake valve seat. Width 1.1 to 1.6 mm (0.0433 to 0.0630 in.) Handrub the intake valve and intake valve seat with an abrasive compound. Check the intake valve seating position.
2. REPAIR EXHAUST VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is greater than the specification. Using 30° and 75° cutters, correct the exhaust valve seat so that the exhaust valve contacts the entire circumference of the seat. The contact should be in the center of the exhaust valve seat, and the exhaust valve seat width should be maintained within the specified range around the entire circumference of the exhaust valve seat. Width 1.1 to 1.6 mm (0.0433 to 0.0630 in.) Handrub the exhaust valve and exhaust valve seat with an abrasive compound. Check the exhaust valve seating position.

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1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned. HINT: The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for the correct reassembly. Remove the 2 connecting rod cap bolts. TEXT IN ILLUSTRATION *1 Engine Front Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. Using a ridge reamer, remove all the carbon from the top of the cylinder. TEXT IN ILLUSTRATION *1 Ridge Reamer Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
2. REMOVE CONNECTING ROD BEARING HINT: Arrange the removed parts in the correct order.
3. REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. TEXT IN ILLUSTRATION *1 Piston Ring Expander Remove the oil ring expander and 2 side rails by hand. HINT: Arrange the removed parts in the correct order.
4. REMOVE PISTON Check the fitting condition between the piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. Disconnect the connecting rod from the piston. Using a screwdriver, pry off the piston pin hole snap rings from the piston. Gradually heat the piston to approximately 80°C (176°F). Using a brass bar and a plastic hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly. HINT: The piston and piston pin are a matched set. Arrange the pistons, piston pins, piston pin hole snap rings, connecting rods and connecting rod bearings in the correct order. Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush.
5. REMOVE CRANKSHAFT Uniformly loosen and remove the 8 crankshaft bearing cap bolts and the 8 seal washers in several steps and in the sequence shown in the illustration. Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration. Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings. TEXT IN ILLUSTRATION *1 Protective Tape *2 Cylinder Block *3 Bearing Cap *4 Joint Surface NOTE: Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed. Be careful not to damage the joint surface of the cylinder block and the crankshaft bearing cap. Remove the crankshaft.
6. REMOVE CRANKSHAFT BEARING Remove the upper crankshaft bearings and lower crankshaft bearings. HINT: Arrange the removed parts in the correct order.
7. REMOVE CRANKSHAFT THRUST WASHER SET Remove the upper crankshaft thrust washers from the cylinder block sub-assembly.
8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 3 bolts and No. 1 oil nozzle sub-assemblies. Check the 3 oil nozzles for damage or clogging. If necessary, replace the No. 1 oil nozzle sub-assembly.
9. CLEAN CYLINDER BLOCK

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1. INSPECT CONNECTING ROD THRUST CLEARANCE Install the connecting rod cap See step 8 . Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance 0.15 to 0.40 mm (0.00591 to 0.0157 in.) Maximum thrust clearance 0.50 mm (0.0197 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. Lay a strip of Plastigage on the crank pin. TEXT IN ILLUSTRATION *1 Plastigage Ensure that the front mark of the connecting rod cap is facing forward. TEXT IN ILLUSTRATION *1 Engine Front *2 Front Mark Install the connecting rod cap See step 8 . NOTE: Do not turn the crankshaft. Remove the 2 bolts and connecting rod cap See step 1 . Measure the Plastigage at its widest point. Standard oil clearance 0.045 to 0.067 mm (0.00177 to 0.00264 in.) Maximum oil clearance 0.070 mm (0.00276 in.) If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing standard thickness is indicated by a number (1, 2, 3 or 4) marked on its surface. Connecting Rod Diameter Mark Diameter 1 56.000 to 56.006 mm (2.20472 to 2.20496 in.) 2 56.007 to 56.012 mm (2.20500 to 2.20519 in.) 3 56.013 to 56.018 mm (2.20523 to 2.20543 in.) 4 56.019 to 56.024 mm (2.20547 to 2.20566 in.) Connecting Rod Bearing Center Wall Thickness Mark Thickness 1 1.481 to 1.484 mm (0.05831 to 0.05843 in.) 2 1.484 to 1.487 mm (0.05843 to 0.05854 in.) 3 1.487 to 1.490 mm (0.05854 to 0.05866 in.) 4 1.490 to 1.493 mm (0.05866 to 0.05878 in.) Standard crankshaft pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.) NOTE: Completely remove the Plastigage after the measurement.
3. INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket. Maximum warpage 0.07 mm (0.00276 in.) If the warpage is greater than the maximum, replace the cylinder block sub-assembly.
4. INSPECT CYLINDER BORE Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter 94.13 mm (3.7059 in.) If the average diameter of 4 positions is greater than the maximum, replace the cylinder block sub-assembly.
5. INSPECT PISTON Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified. Distance 8.9 mm (0.3504 in.) Standard diameter 93.960 to 93.980 mm (3.6992 to 3.7000 in.) Minimum diameter 93.830 mm (3.6941 in.) If the piston diameter is less than the minimum, replace the piston and piston pin as a set.
6. INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust directions. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance 0.020 to 0.052 mm (0.000787 to 0.00205 in.) Maximum oil clearance 0.060 mm (0.00236 in.) If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block sub-assembly.
7. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring Groove Clearance Item Clearance No. 1 0.020 to 0.070 mm (0.000787 to 0.00276 in.) No. 2 0.020 to 0.060 mm (0.000787 to 0.00236 in.) Oil 0.070 to 0.150 mm (0.00276 to 0.00591 in.) If the clearance is not as specified, replace the piston.
8. INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston pin hole. Piston Pin Hole Inside Diameter Mark Diameter A 22.001 to 22.004 mm (0.8662 to 0.8663 in.) B 22.004 to 22.007 mm (0.8663 to 0.8664 in.) C 22.007 to 22.010 mm (0.8664 to 0.8665 in.) Using a micrometer, measure the piston pin diameter. Piston Pin Diameter Mark Diameter A 21.997 to 22.000 mm (0.8660 to 0.8661 in.) B 22.000 to 22.003 mm (0.8661 to 0.8663 in.) C 22.003 to 22.006 mm (0.8663 to 0.8664 in.) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance 0.001 to 0.007 mm (0.0000394 to 0.000276 in.) Maximum oil clearance 0.015 mm (0.000591 in.) If the oil clearance is greater than the maximum, replace the piston and piston pin as a set. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing Inside Diameter Mark Diameter A 22.005 to 22.008 mm (0.86634 to 0.86645 in.) B 22.009 to 22.011 mm (0.86649 to 0.86657 in.) C 22.012 to 22.014 mm (0.86661 to 0.86669 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. TEXT IN ILLUSTRATION *1 Front Mark *2 Piston Pin Hole Inside Diameter Mark *3 Connecting Rod Bushing Inside Diameter Mark Standard oil clearance 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance 0.030 mm (0.00118 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.
9. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring slightly beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block sub-assembly. Using a feeler gauge, measure the end gap. Standard End Gap Item End Gap No. 1 0.22 to 0.32 mm (0.00866 to 0.0126 in.) No. 2 0.35 to 0.45 mm (0.0138 to 0.0177 in.) Oil 0.10 to 0.40 mm (0.00394 to 0.0157 in.) Maximum End Gap Item End Gap No. 1 0.50 mm (0.0197 in.) No. 2 0.85 mm (0.0335 in.) Oil 0.60 mm (0.0236 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, rebore all the 6 cylinders or replace the cylinder block sub-assembly.
10. INSPECT CRANKSHAFT THRUST CLEARANCE Install the crankshaft bearing cap See step 8 . Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance 0.04 to 0.24 mm (0.00157 to 0.00945 in.) Maximum thrust clearance 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Thrust washer thickness 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
11. INSPECT CONNECTING ROD SUB-ASSEMBLY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for out-of-alignment. Maximum out-of-alignment 0.05 mm (0.00197 in.) per 100 mm (3.94 in.) If the out-of-alignment is greater than the maximum, replace the connecting rod sub-assembly. Check for twist. Maximum twist 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod sub-assembly.
12. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the diameter of the bolt in the area shown in the illustration. Standard diameter 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt. HINT: Diameter measurements should be done at several points. If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage. If there is any thread deformation, replace the connecting rod bolt with a new one.
13. INSPECT CRANKSHAFT Inspect for runout. Clean the crank journal. Place the crankshaft on V-blocks. Using a dial indicator, measure the runout at the center journal. Maximum runout 0.06 mm (0.00236 in.) If the runout is greater than the maximum, replace the crankshaft. Inspect the main journals. Using a micrometer, measure the diameter of each main journal. Standard journal diameter 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.02 mm (0.000787 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. Inspect the crank pin. Using a micrometer, measure the diameter of each crank pin. Crank pin diameter 52.992 to 53.000 mm (2.0863 to 2.0866 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round 0.02 mm (0.000787 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft.
14. INSPECT CRANKSHAFT OIL CLEARANCE Check the crank journal and crankshaft bearing for pitting and scratches. Install the crankshaft bearing See step 8 . Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. TEXT IN ILLUSTRATION *1 Plastigage Examine the front marks and numbers to install the crankshaft bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Install the main bearing cap See step 8 . NOTE: Do not turn the crankshaft. Remove the main bearing caps See step 1 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage Standard oil clearance 0.026 to 0.047 mm (0.00102 to 0.00185 in.) Maximum oil clearance 0.050 mm (0.00197 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: Completely remove the Plastigage after the measurement. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly. JOURNAL BEARINGS Cylinder block + Crankshaft 0 - 5 6 - 11 12 - 17 18 - 23 24 - 28 Bearing to be used "1" "2" "3" "4" "5" HINT: EXAMPLE: Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3") Crankshaft Main Journal Diameter Mark Diameter "00" 60.999 to 61.000 mm (2.40153 to 2.40157 in.) "01" 60.998 to 60.999 mm (2.40149 to 2.40153 in.) "02" 60.997 to 60.998 mm (2.40145 to 2.40149 in.) "03" 60.996 to 60.997 mm (2.40141 to 2.40145 in.) "04" 60.995 to 60.996 mm (2.40137 to 2.40141 in.) "05" 60.994 to 60.995 mm (2.40133 to 2.40137 in.) "06" 60.993 to 60.994 mm (2.40129 to 2.40133 in.) "07" 60.992 to 60.993 mm (2.40126 to 2.40129 in.) "08" 60.991 to 60.992 mm (2.40122 to 2.40126 in.) "09" 60.990 to 60.991 mm (2.40118 to 2.40122 in.) "10" 60.989 to 60.990 mm (2.40114 to 2.40118 in.) "11" 60.988 to 60.989 mm (2.40110 to 2.40114 in.) Standard Upper Bearing Center Wall Thickness (No. 1 and No. 4 journal) Mark Thickness "1" 2.500 to 2.503 mm (0.09843 to 0.09854 in.) "2" 2.503 to 2.506 mm (0.09854 to 0.09866 in.) "3" 2.506 to 2.509 mm (0.09866 to 0.09878 in.) "4" 2.509 to 2.512 mm (0.09878 to 0.09890 in.) "5" 2.512 to 2.515 mm (0.09890 to 0.09902 in.) Standard Lower Bearing Center Wall Thickness (No. 1 and No. 4 journal) Mark Thickness "1" 2.478 to 2.481 mm (0.09756 to 0.09768 in.) "2" 2.481 to 2.484 mm (0.09768 to 0.09780 in.) "3" 2.484 to 2.487 mm (0.09780 to 0.09791 in.) "4" 2.487 to 2.490 mm (0.09791 to 0.09803 in.) "5" 2.490 to 2.493 mm (0.09803 to 0.09815 in.) Standard Upper Bearing Center Wall Thickness (No. 2 and No. 3 journal) Mark Thickness "1" 2.478 to 2.481 mm (0.09756 to 0.09768 in.) "2" 2.481 to 2.484 mm (0.09768 to 0.09780 in.) "3" 2.484 to 2.487 mm (0.09780 to 0.09791 in.) "4" 2.487 to 2.490 mm (0.09791 to 0.09803 in.) "5" 2.490 to 2.493 mm (0.09803 to 0.09815 in.) Standard Lower Bearing Center Wall Thickness (No. 2 and No. 3 journal) Mark Thickness "1" 2.500 to 2.503 mm (0.09843 to 0.09854 in.) "2" 2.503 to 2.506 mm (0.09854 to 0.09866 in.) "3" 2.506 to 2.509 mm (0.09866 to 0.09878 in.) "4" 2.509 to 2.512 mm (0.09878 to 0.09890 in.) "5" 2.512 to 2.515 mm (0.09890 to 0.09902 in.)
15. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard diameter 10.8 to 11.0 mm (0.4252 to 0.4331 in.) Minimum diameter 10.7 mm (0.4213 in.) Measurement Point 40 mm (1.57 in.) HINT: If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. Failure to do so may lead to engine damage. If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.
16. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY Check the oil nozzles for damage or clogs. HINT: If there is damage or clogs, replace the oil nozzle.

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1. REPLACE STRAIGHT PIN Using a plastic hammer, tap in new straight pins to the cylinder block. Standard Protrusion Item Protrusion Pin A 23 mm (0.906 in.) Pin B 6 mm (0.236 in.) Pin C 11 mm (0.433 in.) Pin D 9 mm (0.354 in.)
2. REPLACE STUD BOLT Using an E8 and E10 "TORX" sockets, install the stud bolts. Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt B Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)

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1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assemblies with the 3 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. INSTALL PISTON Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole. TEXT IN ILLUSTRATION *1 Service Hole HINT: Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Gradually heat the piston to approximately 80°C (176°F). Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. TEXT IN ILLUSTRATION *1 Front Mark HINT: The piston and pin are a matched set. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole. TEXT IN ILLUSTRATION *1 Service Hole HINT: Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
3. INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the compression ring as shown in the illustration. Position the piston rings so that the ring ends are as shown in the illustration. NOTE: Do not align the ring ends.
4. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the bearings. TEXT IN ILLUSTRATION *1 No. 1 and No. 4 Journal Bearing *2 No. 2 and No. 3 Journal Bearing NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions. Install the upper crankshaft bearing. Install the upper crankshaft bearings to the cylinder block as shown in the illustration. NOTE: Do not apply engine oil to the bearings and the contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Install the lower crankshaft bearing. TEXT IN ILLUSTRATION *1 Vernier Caliper *2 Mark 1, 2, 3, 4 or 5 Install the lower crankshaft bearings to the crankshaft bearing caps. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower crankshaft bearing edge. Dimension (A - B) 0.7 mm (0.0276 in.) or less NOTE: Do not apply engine oil to the crankshaft bearings and the contact surfaces.
5. INSTALL CRANKSHAFT THRUST WASHER SET Apply engine oil to the crankshaft thrust washer. Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward. TEXT IN ILLUSTRATION *1 Oil Grooves
6. INSTALL CRANKSHAFT Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block. Confirm the projections and numbers on the main bearing caps and install the crankshaft bearing caps on the cylinder block. TEXT IN ILLUSTRATION *1 Projection *2 Number Mark HINT: A number is marked on each main bearing cap to indicate the installation position. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts. Temporarily install the 8 crankshaft bearing cap bolts to the inside positions. Insert the crankshaft bearing cap with your hand until the clearance between the crankshaft bearing cap and the cylinder block is less than 6 mm (0.236 in.) by marking the 2 internal crankshaft bearing cap bolts as a guide. TEXT IN ILLUSTRATION *1 Less than 6 mm *2 Bolt Length 100 to 102 mm Bolt length 100 to 102 mm (3.94 to 4.02 in.) Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 8 crankshaft bearing cap bolts. Install the 8 crankshaft bearing cap bolts to the outside positions. TEXT IN ILLUSTRATION *1 Bolt Length 105.5 to 107.5 mm Bolt length 105.5 to 107.5 mm (4.15 to 4.23 in.) Install the crankshaft bearing cap bolts. HINT: The crankshaft bearing cap bolts are tightened in 2 progressive steps. Step 1 Install and uniformly tighten the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) If any of the crankshaft bearing cap bolts does not meet the torque specified, replace it. Step 2 Mark the front of the bearing cap bolts with paint. Retighten the bearing cap bolts 90° in the sequence shown in the illustration. Check that the painted mark is now at a 90° angle to the front of the engine. Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration. Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf) Bolt Length Item Length Bolt A 45 mm (1.77 in.) Except bolt A 30 mm (1.18 in.) Check that the crankshaft turns smoothly. Check the crankshaft thrust clearance See step 10 .
7. INSTALL CONNECTING ROD BEARING Install the connecting rod bearing to the connecting rod and connecting rod cap. Using a vernier caliper, measure the distance between the connecting rod and bearing cap edges and the connecting rod bearing edge. TEXT IN ILLUSTRATION *1 Vernier Caliper Dimension (A - B) 0.7 mm (0.0276 in.) or less NOTE: Do not apply engine oil to the bearings and the contact surfaces.
8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. Position the piston rings so that the ring ends are as shown in the illustration. NOTE: Do not align the ring ends. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward. TEXT IN ILLUSTRATION *1 Engine Front *2 Front Mark NOTE: Match the numbered connecting rod cap with the connecting rod. Check that the front mark of the connecting rod cap is facing forward. TEXT IN ILLUSTRATION *1 Engine Front *2 Front Mark Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. Install the connecting rod cap bolts. HINT: The connecting rod cap bolts are tightened in 2 progressive steps. Step 1 Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) Step 2 Mark the front side of each connecting rod cap bolt with paint. Retighten the cap bolts 90° as shown in the illustration. Check the painted mark is now at a 90° angle to the front. Confirm that the crankshaft turns smoothly. Check the connecting rod thrust clearance See step 1 .