Engine Mechanical (Service Information): Overhaul Lexus RX III рестайлинг

DISASSEMBLY [07/2012 - ]

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 [07/2012 - ] - Step 15»(ref-602706-S31654699392014030500000)
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 [07/2012 - ] - Step 13»(ref-602706-S27267249112014030500000)
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to «REMOVAL [07/2012 - ] - Step 13»(ref-602706-S24141348662014030500000)
7. REMOVE CRANK POSITION SENSOR . Refer to «REMOVAL [03/2012 - ] - Step 2»(ref-602706-S38168516592014030500000)
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 5
13. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler) Remove the bolt, 2 clamps, 4 clips, No. 4 water bypass hose and No. 5 water by-pass hose. TEXT IN ILLUSTRATION *A for TMMC Made *B for TMC Made 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 42
39. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY See step 43
40. REMOVE CAMSHAFT BEARING CAP (for Bank 1) See step 44
41. REMOVE CAMSHAFT See step 45
42. REMOVE NO. 2 CAMSHAFT See step 46
43. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 47
44. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 48
45. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY See step 49
46. REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 50
47. REMOVE NO. 3 CAMSHAFT See step 51
48. REMOVE NO. 4 CAMSHAFT See step 52
49. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 53
50. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 10
51. REMOVE VALVE LASH ADJUSTER ASSEMBLY See step 11
52. REMOVE VALVE STEM CAP See step 12
53. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH See step 14
54. REMOVE CYLINDER HEAD GASKET RH See step 15
55. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH See step 16
56. REMOVE CYLINDER HEAD GASKET LH See step 17
57. REMOVE WATER INLET PIPE Remove 2 clamps and separate the No. 1 water by-pass hose. Remove the 2 bolts and water inlet pipe.

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1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Turn the roller by hand to check that it turns smoothly. HINT: If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.
2. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the valve lash adjuster assembly free of dirt and foreign objects. Only use clean engine oil. Place the valve lash adjuster assembly into a container filled with engine oil. Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger. SST: 09276-75010 Squeeze SST and valve lash adjuster assembly together to move the plunger up and down 5 to 6 times. Check the movement of the plunger and bleed the air. OK Plunger moves up and down. NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger by hand. OK Plunger is very difficult to move. If the result is not as specified, replace the valve lash adjuster assembly.
3. INSPECT CAMSHAFT Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum runout 0.04 mm (0.00157 in.) If the runout is greater than the maximum, replace the camshaft. HINT: Check the oil clearance after replacing the camshaft. Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height Item Specification Intake camshaft 44.316 to 44.416 mm (1.7448 to 1.7486 in.) Exhaust camshaft 44.262 to 44.362 mm (1.7426 to 1.7465 in.) Minimum Cam Lobe Height Item Specification Intake camshaft 44.166 mm (1.7388 in.) Exhaust camshaft 44.112 mm (1.7366 in.) If the cam lobe height is less than the minimum, replace the camshaft. Using a micrometer, measure the journal diameter. Standard Journal Diameter Item Specification No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) Other journals 25.959 to 25.975 mm (1.0221 to 1.0226 in.) If the journal diameter is not as specified, check the oil clearance.
4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Clamp the camshaft in a vise. NOTE: Be careful not to damage the camshaft in the vise. Put the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin. TEXT IN ILLUSTRATION *1 Key Groove *2 Straight Pin Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the groove. NOTE: Be sure not to turn the camshaft timing gear assembly in the retard direction. Check that there is no clearance between the camshaft timing gear assembly flange and the camshaft. Tighten the flange bolt while holding the camshaft. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Check the lock of the camshaft timing gear assembly. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked. NOTE: Be careful not to damage the camshaft. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 opened paths. TEXT IN ILLUSTRATION *1 Advanced Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path. HINT: This operation releases the lock pin at the most retarded position. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path. NOTE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. Check for smooth rotation. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. NOTE: Do not use air pressure to perform the smooth operation check. Check the lock in the most retarded position. Confirm that the camshaft timing gear assembly locks at the most retarded position. Remove the flange bolt and camshaft timing gear assembly. NOTE: Do not remove the other 3 bolts. If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.
5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Clamp the camshaft in a vise. NOTE: Be careful not to damage the camshaft in the vise. Put the camshaft timing exhaust gear assembly and camshaft together by aligning the key groove and straight pin. TEXT IN ILLUSTRATION *1 Key Groove *2 Straight Pin Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the groove. NOTE: Be sure not to turn the camshaft timing exhaust gear in the retard direction. Check that there is no clearance between the gear flange and the camshaft. Tighten the flange bolt while holding the camshaft. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Check the camshaft timing exhaust gear lock. Make sure that the camshaft timing exhaust gear assembly locks. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path). TEXT IN ILLUSTRATION *1 Advanced Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path. HINT: The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path. NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts. Check for smooth rotation. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly. NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check. Check the lock at the most advanced position. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position. Remove the flange bolt and camshaft timing exhaust gear assembly. NOTE: Be sure not to remove the other 4 bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
6. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard diameter 10.85 to 11.00 mm (0.4272 to 0.4330 in.) Minimum diameter 10.70 mm (0.4212 in.) Measurement point (distance from the seat) 103 mm (4.06 in.) HINT: If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage. If there is any thread deformation, replace the cylinder head bolt with a new one.
7. INSPECT CHAIN SUB-ASSEMBLY Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 links. Maximum chain elongation 136.9 mm (5.389 in.) NOTE: Perform the measurement at 3 random places. Use the average of the measurements. If the average elongation is greater than the maximum, replace the chain sub-assembly.
8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 links. Maximum chain elongation 137.6 mm (5.417 in.) NOTE: Perform the measurement at 3 random places. Use the average of the measurements. If the average elongation is greater than the maximum, replace the chain sub-assembly.
9. INSPECT CRANKSHAFT TIMING SPROCKET Place the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly. Minimum sprocket diameter (with chain) 61.4 mm (2.418 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
10. INSPECT IDLE SPROCKET ASSEMBLY Place the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain) 61.4 mm (2.418 in.) HINT: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.
11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE Using a micrometer, measure the idle gear shaft diameter. Standard idle gear shaft diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.) Using a caliper gauge, measure the inside diameter of the idle sprocket assembly. Standard idle gear inside diameter 23.020 to 23.030 mm (0.9063 to 0.9067 in.) Subtract the idle gear shaft diameter measurement from the idle sprocket inside diameter measurement. Standard oil clearance 0.020 to 0.043 mm (0.000787 to 0.00169 in.) Maximum oil clearance 0.093 mm (0.00366 in.) If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle sprocket assembly.
12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. TEXT IN ILLUSTRATION *1 Plunger *2 Stopper Plate If necessary, replace the No. 1 chain tensioner assembly.
13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. TEXT IN ILLUSTRATION *1 Depth Measure the worn depth of the No. 2 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is greater than the maximum, replace the No. 2 chain tensioner assembly.
14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. TEXT IN ILLUSTRATION *1 Depth Measure the worn depth of the No. 3 chain tensioner assembly. Maximum depth 0.9 mm (0.0354 in.) If the depth is greater than the maximum, replace the No. 3 chain tensioner assembly.
15. INSPECT CHAIN TENSIONER SLIPPER Measure the worn depth of the chain tensioner slipper. TEXT IN ILLUSTRATION *1 Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the chain tensioner slipper.
16. INSPECT NO. 1 CHAIN VIBRATION DAMPER Measure the worn depth of the No. 1 chain vibration damper. TEXT IN ILLUSTRATION *1 Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the No. 1 chain vibration damper.
17. INSPECT NO. 2 CHAIN VIBRATION DAMPER Measure the worn depth of the No. 2 chain vibration damper. TEXT IN ILLUSTRATION *1 Depth Maximum depth 1.0 mm (0.0394 in.) If the depth is greater than the maximum, replace the No. 2 chain vibration damper.
18. INSPECT CAMSHAFT THRUST CLEARANCE Inspect the bank 1 camshaft thrust clearance. Install the bank 1 camshaft. Refer to «INSTALLATION [03/2012 - 07/2012]»(ref-602689-S03858742082014030500000) . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.08 to 0.13 mm (0.00315 to 0.00512 in.) Maximum thrust clearance 0.15 mm (0.00591 in.) If the thrust clearance is greater than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft. Inspect the bank 2 camshaft thrust clearance. Install the bank 2 camshaft. Refer to «INSTALLATION [03/2012 - 07/2012]»(ref-602689-S03858742082014030500000) . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.08 to 0.13 mm (0.00315 to 0.00512 in.) Maximum thrust clearance 0.15 mm (0.00591 in.) If the thrust clearance is greater than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.
19. INSPECT CAMSHAFT OIL CLEARANCE Clean the camshaft bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each camshaft journal. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps. Refer to «INSTALLATION [03/2012 - 07/2012]»(ref-602689-S03858742082014030500000) . NOTE: Do not turn the camshaft. Remove the camshaft bearing caps See step 45 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 Other Journals Standard Oil Clearance Item Oil Clearance No. 1 journal 0.032 to 0.071 mm (0.00126 to 0.00280 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance Item Oil Clearance No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing. Clean the camshaft bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each camshaft journal. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps. Refer to «INSTALLATION [03/2012 - 07/2012]»(ref-602689-S03858742082014030500000) . NOTE: Do not turn the camshaft. Remove the camshaft bearing caps See step 45 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 Other Journals Standard Oil Clearance Item Oil Clearance No. 1 journal 0.040 to 0.079 mm (0.00157 to 0.00311 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance Item Oil Clearance No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly.
20. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Maximum warpage 0.7 mm (0.0276 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.). If the warpage is greater than the maximum, replace the manifold.
21. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Maximum warpage 0.7 mm (0.0276 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.). If the warpage is greater than the maximum, replace the manifold.
22. INSPECT INTAKE MANIFOLD Cylinder head side: Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage 0.1 mm (0.00394 in.) If the warpage is greater than the maximum, replace the intake manifold. Surge tank side: Using a precision straightedge and feeler gauge, measure the surface contacting the surge tank for warpage. Maximum warpage 0.1 mm (0.00394 in.) If the warpage is greater than the maximum, replace the intake manifold.

REASSEMBLY [07/2012 - ]

1. INSTALL ENGINE REAR OIL SEAL Place the oil seal retainer on wooden blocks. Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge. SST: 09223-15030 SST: 09950-70010 09951-07100 NOTE: Keep the lip free of foreign matter. Do not tap on the engine rear oil seal at an angle.
2. INSTALL ENGINE REAR OIL SEAL RETAINER Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.) NOTE: Remove any oil from the contact surfaces. Install the oil seal retainer within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. Install the engine rear oil seal retainer with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
3. INSTALL WATER INLET PIPE Install the water inlet pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the No. 1 water by-pass hose.
4. INSTALL CYLINDER HEAD GASKET RH See step 1
5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH See step 2
6. INSTALL CYLINDER HEAD GASKET LH See step 3
7. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH See step 4
8. INSTALL VALVE STEM CAP See step 6
9. INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 7
10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY See step 8
11. INSTALL NO. 3 CAMSHAFT See step 1
12. INSTALL NO. 4 CAMSHAFT See step 2
13. INSTALL CAMSHAFT BEARING CAP (for Bank 2) See step 3
14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH See step 4
15. INSTALL CAMSHAFT See step 5
16. INSTALL NO. 2 CAMSHAFT See step 6
17. INSTALL CAMSHAFT BEARING CAP (for Bank 1) See step 7
18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH See step 8
19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY See step 9
20. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) See step 10
21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY See step 11
22. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) See step 12
23. INSTALL NO. 1 CHAIN VIBRATION DAMPER Install the No. 1 chain vibration damper with the 2 bolts. Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
24. INSTALL NO. 2 CHAIN VIBRATION DAMPER Install the 2 No. 2 chain vibration dampers.
25. INSTALL CRANKSHAFT TIMING SPROCKET Install the 2 keys and crankshaft timing sprocket as shown in the illustration.
26. INSTALL IDLE SPROCKET ASSEMBLY Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. TEXT IN ILLUSTRATION *1 Knock Pin Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block. NOTE: Be careful of the idle gear installation position. HINT: Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) HINT: After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
27. INSTALL CHAIN SUB-ASSEMBLY Align the mark plates and timing marks as shown in the illustration and install the chain. TEXT IN ILLUSTRATION *1 Mark Plate *2 Timing Mark HINT: The camshaft mark plates are orange. Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks. NOTE: When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks. Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket. TEXT IN ILLUSTRATION *1 Mark Plate *2 Timing Plate HINT: The crankshaft mark plate is yellow. Temporarily tighten the pulley set bolt. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression). TEXT IN ILLUSTRATION *1 Center Line *2 Timing Mark *3 Sensor Plate
28. INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper.
29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. TEXT IN ILLUSTRATION *1 Stopper Plate *2 Plunger Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install the No. 1 chain tensioner assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
30. INSPECT VALVE TIMING Check the camshaft timing marks. NOTE: Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear. If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned. Check that each camshaft timing mark is positioned as shown in the illustration. HINT: For the intake camshaft: Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly. If the valve timing is misaligned, reinstall the timing chain. Remove the pulley set bolt.
31. INSTALL TIMING CHAIN CASE OIL SEAL Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge. SST: 09223-22010 SST: 09506-35010 Oil seal tap in depth 0 to 1.0 mm (0 to 0.0393) NOTE: Keep the lip free of foreign matter. Do not tap on the oil seal at an angle. Make sure that the oil seal edge does not stick out of the timing chain case.
32. INSTALL WATER PUMP ASSEMBLY Install a new water pump gasket and the water pump assembly with the 8 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Apply seal packing in a continuous line to the engine unit as shown in the following illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 mm (0.118 in.) NOTE: Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration. If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes. Do not start the engine for at least 2 hours after installing. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent NOTE: If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. SEAL PACKING APPLICATION CHART Area Seal Packing Diameter Application Position from Inside Seal Line Continuous Line Area 4.5 mm or more (0.177 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Alternate Long and Short Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.) Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.) Install a new gasket. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft. TEXT IN ILLUSTRATION *1 Drive Rotor Spline *2 Crankshaft Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts. BOLT LENGTH Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 25 mm (0.98 in.) NOTE: Make sure that there is no oil on the bolt and nut threads. Fully tighten the bolts in this order: Area 1 and Area 2. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Fully tighten the bolts in Area 3. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: First tighten the upper bolts and nuts followed by lower bolts and nuts as shown in the illustration. Fully tighten the bolts in Area 4. Bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Except bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Tighten the bolts in the order of lower to upper as shown in the illustration. Install a new chain cover plate gasket and the chain cover plate with the 4 bolts. Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
34. INSTALL WATER INLET HOUSING Install 2 new O-rings. HINT: Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation. Install the 2 stud bolts. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Install the water inlet housing with the 2 bolts and nut. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful that the O-ring does not get caught between the parts. Connect the No. 1 water by-pass hose. Apply adhesive around the drain cock. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the drain cock assembly to the water inlet housing. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) Install the drain cock plug to the drain cock assembly. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Install a new gasket to the thermostat. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 10° of either side of the prescribed position. Install the water inlet with the 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH Using an E8 "TORX" socket wrench, install the 2 stud bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the No. 1 front engine mounting bracket LH with the 6 bolts. Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf) NOTE: Install the water inlet and mounting bracket within 15 minutes after installing the chain cover. Do not start the engine for at least 2 hours after installation.
36. INSTALL NO. 1 OIL PAN BAFFLE PLATE Install the No. 1 oil pan baffle plate with the 7 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Temporarily tighten the 7 bolts. Fully tighten 2 bolts (A) shown in the illustration before tightening the other bolts.
37. INSTALL OIL PAN SUB-ASSEMBLY Using an E8 "TORX" socket wrench, install the 2 stud bolts. Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt B Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Install 2 new O-rings. Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install the oil pan with the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Except bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
38. INSTALL OIL STRAINER SUB-ASSEMBLY Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts. TEXT IN ILLUSTRATION *1 Nut Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
40. INSTALL OIL PAN DRAIN PLUG Install a new oil pan drain plug gasket and the oil pan drain plug. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Apply seal packing as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the head cover within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install 3 new gaskets as shown in the illustration. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly. Install the head cover with the 12 bolts and a new seal washer. Bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Except bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Apply seal packing as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surfaces. Install the cylinder head cover sub-assembly LH within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing. Install 3 new gaskets as shown in the illustration. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer. Bolts A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Except bolts A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
43. INSTALL WATER OUTLET Install 2 new gaskets and a new O-ring. HINT: Apply soapy water to the O-ring. Install the water outlet with the 2 bolts and 4 nuts. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful that the O-ring does not get caught between the parts.
44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide. w/ oil cooler Install the engine oil level dipstick guide. w/o oil cooler Install the engine oil level dipstick guide with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
45. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install a new gasket to the No. 1 oil cooler bracket. TEXT IN ILLUSTRATION *1 Nut *2 Bolt Install the oil cooler pipe with the bolt and 2 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) Install a new gasket to the No. 1 oil pan. Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
46. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) Install a new O-ring. Install the oil cooler assembly with the union bolt. Torque: 68 N*m (693 kgf*cm, 50 ft.*lbf) Install the No. 4 water by-pass hose and No. 5 water by-pass hose with the bolt, 2 clamps and 4 clips. TEXT IN ILLUSTRATION *A for TMMC Made *B for TMC Made Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
47. INSTALL CRANKSHAFT PULLEY See step 2
48. INSTALL OIL FILTER ELEMENT Clean the inside of the oil filter cap sub-assembly, the threads and O-ring groove. TEXT IN ILLUSTRATION *1 Oil Filter Element *2 O-ring Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap sub-assembly. Set a new oil filter element to the oil filter cap sub-assembly. Remove dirt and foreign matter from the installation surface of the engine. Apply a light coat of engine oil to the O-ring again and install the oil filter cap sub-assembly. NOTE: Be careful that the O-ring does not get caught between any parts. The O-ring must not be twisted on the groove. Using SST, tighten the oil filter cap sub-assembly. SST: 09228-06501 Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Make sure that the oil filter is installed securely as shown in the illustration. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap. TEXT IN ILLUSTRATION *1 O-ring NOTE: Remove all dirt and foreign matter from the installation surfaces. Install the oil filter drain plug to the oil filter cap sub-assembly. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) NOTE: Make sure that the O-ring does not get caught between the parts.
49. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Apply adhesive around the drain cock sub-assembly. TEXT IN ILLUSTRATION *1 Adhesive Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the water drain cocks as shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque. Install the water drain cock plugs to the water drain cocks. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
50. INSTALL NO. 1 OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. NOTE: Do not touch the mesh when installing the oil control valve filter. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union. TEXT IN ILLUSTRATION *1 Oil Pipe Union Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union. Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
51. INSTALL OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter RH. NOTE: Do not touch the mesh when installing the oil control valve filter. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union. TEXT IN ILLUSTRATION *1 Oil Pipe Union Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union. Install the bolt (A) to the cylinder head. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Tighten the oil pipe union (on the head cover side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) Tighten the oil pipe union (on the cylinder head side). Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) NOTE: If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
52. INSTALL CRANK POSITION SENSOR . Refer to «INSTALLATION [07/2012 - ] - Step 1»(ref-602706-S26906820812014030500000)
53. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY . Refer to «INSTALLATION [07/2012 - ] - Step 1»(ref-602706-S20360715602014030500000)
54. INSTALL VVT SENSOR . Refer to «INSTALLATION [07/2012 - ] - Step 1»(ref-602706-S30644201852014030500000)
55. INSTALL VENTILATION VALVE SUB-ASSEMBLY Apply adhesive around the ventilation valve sub-assembly. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the ventilation valve sub-assembly. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
56. INSTALL SPARK PLUG . Refer to «INSTALLATION [07/2012 - ] - Step 1»(ref-602706-S19756557322014030500000)
57. INSTALL OIL FILLER CAP SUB-ASSEMBLY Install a new oil filler gasket. Install the oil filler cap sub-assembly.

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1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR . Refer to «INSTALLATION [03/2012 - 07/2012] - Step 1»(ref-602706-S04326888772014030500000)
2. INSTALL KNOCK CONTROL SENSOR . Refer to «INSTALLATION [03/2012 - ] - Step 1»(ref-602706-S18764978422014030500000)
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 [03/2012 - 07/2012] - Step 2»(ref-602691-S04051481922014030500000)
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 [03/2012 - 07/2012] - Step 4»(ref-602713-S18174393842014030500000)
12. INSTALL NO. 2 MANIFOLD STAY . Refer to «INSTALLATION [03/2012 - 07/2012] - Step 5»(ref-602713-S18174393842014030500000)
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 Set the new No. 1 and No. 2 intake manifold to head gaskets 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) Install the fuel hose protector with the 2 bolts and nut. Bolt Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Nut Torque: 10 N*m (102 kgf*cm, 7 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 [03/2012 - 07/2012] - Step 2»(ref-602706-S23678727752014030500000)
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 [03/2012 - 07/2012] - Step 6»(ref-602713-S07245508312014030500000)
21. INSTALL ENGINE HANGERS Install the No. 1 and No. 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 penetrant, 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 E6 and E8 "TORX" socket wrenches, install the stud bolts. Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt B 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 .