REPLACEMENT — Part 3 — Scion tC I (2004-2007)

Scheme 187

REMOVE SPARK PLUG
REMOVE OIL FILLER CAP SUB-ASSY
REMOVE OIL FILLER CAP GASKET
REMOVE VENTILATION VALVE SUB-ASSY
REMOVE CYLINDER HEAD COVER SUB-ASSY Remove the 8 bolts and 2 nuts, then remove the cylinder head cover.
REMOVE CYLINDER HEAD COVER GASKET
REMOVE OIL FILTER SUB-ASSY Using SST, remove the oil filter. SST 09228-06501
REMOVE OIL FILTER UNION Using a socket hexagon wrench 12, remove the oil filter union.
REMOVE CAMSHAFT POSITION SENSOR
REMOVE CRANKSHAFT POSITION SENSOR
REMOVE WATER PUMP PULLEY Using SST, remove the 4 bolts and water pump pulley. SST 09960-10010 (09962-01000, 09963-00700)
REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts, bracket and water pump.
REMOVE OIL PAN DRAIN PLUG Remove the oil pan drain plug and gasket.
REMOVE OIL PAN SUB-ASSY Remove the 12 bolts and 2 nuts. Insert the blade of SST between the crankcase, chain cover and oil pan, then cut off the applied sealer and remove the oil pan. SST 09032-00100 NOTE: Be careful not to damage the contact surface of the crank case, chain cover and oil pan.
REMOVE CRANKSHAFT PULLEY Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) and align the timing marks as above. Using SST, fix the pulley and loosen the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Using SST and pulley bolt, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
REMOVE CHAIN TENSIONER ASSY NO. 1 Remove the 2 nuts, chain tensioner and gasket. NOTE: Do not turn the crankshaft without the chain tensioner.
REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY Remove the 14 bolts and 2 nuts. Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver and hammer, tap out the oil seal.
REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
REMOVE TIMING CHAIN GUIDE Remove the bolt and timing chain guide.
REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and chain tensioner slipper.
REMOVE CHAIN SUB-ASSY
REMOVE CHAIN VIBRATION DAMPER NO. 1 Remove the 2 bolts and chain vibration damper.
REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
REMOVE NO. 2 CHAIN SUB-ASSY Turn the crankshaft counterclockwise by 90° to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then remove the nut. Remove the bolt, then remove the chain tensioner plate and spring. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.
REMOVE OIL PUMP ASSY Remove the 3 bolts, then remove the oil pump and gasket.
REMOVE CAMSHAFTS Using several steps, uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration. Remove the 10 bearing caps, then remove the camshaft and No. 2 camshaft.
REMOVE CAMSHAFT BEARING NO. 1 Remove the camshaft bearing No. 1 from the camshaft bearing cap No. 1.
REMOVE CAMSHAFT BEARING NO. 2 Remove the camshaft bearing No. 2 from the cylinder head.
REMOVE CAMSHAFT TIMING GEAR OR SPROCKET Clamp the camshaft in a vise, then remove the bolt and camshaft timing gear. NOTE: Be careful not to damage the camshaft.
REMOVE CAMSHAFT TIMING GEAR ASSY Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate. Cover all the oil ports with vinyl tape except the advance side port shown in the illustration. Apply air pressure to the oil port of 100 kPa (1.0 kgf/cm 2 14 psi), then turn the camshaft timing gear to the advance direction (counterclockwise) by hand. CAUTION: Cover the paths with a shop rag to avoid oil splashes. HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released. Remove the fringe bolt of the camshaft timing gear. NOTE: Be sure not to remove the other 4 bolts. When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY Remove the bolt, then remove the camshaft timing oil control valve. Remove the O-ring from the camshaft timing oil control valve.
REMOVE CYLINDER HEAD SUB-ASSY Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers. NOTE: Be careful not to drop the plate washers into the cylinder head. Head warpage or cracking could result from removing the bolts in the wrong order.
REMOVE CYLINDER HEAD GASKET
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
REMOVE OIL CONTROL VALVE FILTER Using a socket hexagon wrench 6, remove the plug and gasket. Remove the oil control valve filter.
REMOVE W/HEAD TAPER SCREW PLUG NO. 1 Remove the plug from the cylinder block.
INSPECT BALANCESHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth. Standard thrust clearance: 0.05 to 0.09 mm (0.0020 to 0.0035 in.) Maximum thrust clearance: 0.09 mm (0.0035 in.) If the thrust clearance is greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balanceshaft.
CHECK BALANCESHAFT OIL CLEARANCE Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. Remove the balanceshaft housing from the crankcase. HINT: Keep the lower bearing and balanceshaft housing together. Lift out the No. 1 and No. 2 balances hafts. HINT: Keep the upper bearing with the crankcase. Clean each bearing and journal. Check each bearing and journal for pitting and scratches. If a bearing or journal is damaged, replace the bearings. If necessary, replace the balanceshaft. Place the No. 1 and No. 2 balanceshafts onto the crankcase. Lay a strip of Plastigage across each journal. Install the balanceshaft housing. Apply a light coat of engine oil on the threads and under the heads of the bolts. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 21.6 N.m (220 kgf.cm, 16 ft.lbf) Mark the front of the bolts with paint. Retighten the bolts 90° as shown in the illustration. Check that the painted mark is now at a 90° angle to the front. Remove the balanceshaft housing from the crankcase. Measure the Plastigage at its widest point. Standard oil clearance: 0.004 to 0.049 mm (0.0002 to 0.0019 in.) Maximum oil clearance: 0.049 mm (0.0019 in.) NOTE: Remove the Plastigage completely after the measurement. If the oil clearance is greater than maximum, replace the bearing. If necessary, replace the balanceshaft. HINT: If replacing a bearing, select a new one with the same number. BALANCESHAFT HOUSING JOURNAL BORE DIAMETER: BALANCESHAFT HOUSING JOURNAL BORE DIAMETER Mark 1 26.000 to 26.006 mm (1.0236 to 1.0239 in.) Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.) Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.) Balanceshaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 in.) STANDARD BEARING CENTER WALL THICKNESS: STANDARD BEARING CENTER WALL THICKNESS Mark 1 1.486 to 1.489 mm (0.0585 to 0.0586 in.) Mark 2 1.490 to 1.492 mm (0.0587 to 0.0587 in.) Mark 3 1.493 to 1.495 mm (0.0588 to 0.0589 in.)
REMOVE BALANCESHAFT
REMOVE BALANCESHAFT BEARING NO. 1
REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver with its tip wrapped with tape, pry out the oil seal. NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
REMOVE STIFFENING CRANKCASE ASSY Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. Remove the crankcase by prying the portions between the crankcase and cylinder block. NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder block. Remove the O-ring from the cylinder block.
INSPECT CHAIN TENSIONER ASSY NO. 1 Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
INSPECT CHAIN SUB-ASSY Using vernier calipers, measure the length of the 16 links with the chain fully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) If the chain elongation is greater than maximum, replace the chain. HINT: Take the same measurements by pulling at 3 or more places selected at random.
INSPECT CHAIN TENSIONER SLIPPER Using vernier calipers, measure the tensioner slipper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the tensioner slipper.
INSPECT CHAIN VIBRATION DAMPER NO. 1 Using vernier calipers, measure the vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the vibration damper.
INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET Wrap the chain around the timing gear. Using vernier calipers, measure the timing gear diameter with the chain. Minimum gear diameter (w/ chain): 51.6 mm (2.031 in.) NOTE: Vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than minimum, replace the chain and timing gear.
INSPECT OIL PUMP DRIVE GEAR Wrap the chain around the drive gear. Using vernier calipers, measure the drive gear diameter with the chain. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) NOTE: Vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than minimum, replace the chain and drive gear.
INSPECT OIL PUMP DRIVE SHAFT GEAR Wrap the chain around the drive shaft gear. Using vernier calipers, measure the drive shaft gear diameter with the chain. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) NOTE: Vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than minimum, replace the chain and drive shaft gear.
INSPECT CAMSHAFT TIMING GEAR OR SPROCKET Wrap the chain around the timing gear. Using vernier calipers, measure the timing gear diameter with the chain. Minimum gear diameter (w/chain): 97.3 mm (3.831 in.) NOTE: Vernier calipers must be in contact with the chain rollers when measuring. If the gear diameter is less than minimum, replace the chain and timing gear.
INSPECT CAMSHAFT Check the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: 46.495 to 46.595 mm (1.8305 to 1.8345 in.) Minimum cam lobe height: 46.385 mm (1.8262 in.) If the cam lobe height is less than minimum, replace the camshaft. Inspect the camshaft journals. Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance.
INSPECT NO. 2 CAMSHAFT Check the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: 45.983 to 46.083 mm (1.8104 to 1.8143 in.) Minimum cam lobe height: 45.873 mm (1.8060 in.) If the cam lobe height is less than minimum, replace the camshaft. Inspect the camshaft journals. Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameters: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance.
INSPECT CYLINDER HEAD SET BOLT Using vernier calipers, measure the length of the head bolts from the seat to the end. Standard bolt length: 161.3 to 162.7 mm (6.350 to 6.406 in.) Maximum bolt length: 164.2 mm (6.465 in.) If the bolt length is greater than maximum, replace the bolt.
INSTALL BALANCESHAFT BEARING NO. 1 Install the bearings onto the crankcase and balanceshaft housing. Apply a light coat of engine oil to the bearings.
INSTALL BALANCESHAFT Rotate the driven gear No. 1 of balanceshaft No. 1 in the rotating direction until it hits the stopper. Confirm that the matchmarks on driven gear No. 1 and No. 2 are aligned. Align the matchmarks of the No. 1 and No. 2 balance-shafts as shown in the illustration. Place the No. 1 and No. 2 balanceshafts onto the crank case. Apply a light coat of engine oil to the threads and under the heads of the bolts. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 21.6 N.m (224 kgf.cm, 16 ft.lbf) Mark the front of the bolts with paint. Retighten the bolts 90° as shown in the illustration. Check that the painted mark is now at a 90° angle to the front.
INSTALL STIFFENING CRANKCASE ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and crankcase. Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.098 to 0.118 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the crankcase within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the crankcase. Place a new O-ring on the cylinder block as shown in the illustration. With the No. 1 crank pin of the crankshaft placed at 6 o'clock, install the No. 1 and No. 2 balanceshaft and the adjusting hole as shown in the illustration. Temporarily install the crank case with the 11 bolts. HINT: Bolt length: 112 mm (4.41 in.) for A of 12 mm head 35 mm (1.38 in.) for B of 12 mm head Uniformly tighten the bolts. Torque: 32.5 N.m (331 kgf.cm, 24 ft.lbf) Confirm that the timing marks of the balanceshafts are aligned when the key groove is placed at 6 o'clock position, as shown in the illustration.
INSTALL ENGINE REAR OIL SEAL Apply multi-purpose grease to a new oil seal lip. NOTE: Keep the lip free of foreign objects. Using SST and a hammer, tap the oil seal in until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTE: Wipe any extra grease off the crankshaft.
INSTALL W/HEAD TAPER SCREW PLUG NO. 1 Apply adhesive to 2 or 3 threads of the plug, and install it. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent NOTE: Install the plug within 3 minutes of applying adhesive. Do not put in coolant for at least an hour after installing the plug.
INSTALL OIL CONTROL VALVE FILTER Check that there is no foreign objects on the mesh part of the oil control valve filter. Using a socket hexagon wrench 6, install a new gasket and the oil control valve filter with the plug. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY Apply adhesive to 2 or 3 threads of the drain cock. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent After tightening the drain cock to the specified torque, turn the drain cock clockwise as shown in the illustration. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) NOTE: Install the drain cock within 3 minutes of applying adhesive. Do not put in coolant for at least an hour after installing the drain cock. Do not turn the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque. Do not loosen the drain cock after setting it correctly.
INSTALL CYLINDER HEAD GASKET Place a new gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Remove any oil from contact surface. Be careful of the installation direction. Place the cylinder head gently in order to avoid damaging the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD SUB-ASSY NOTE: The cylinder head bolts are tightened in 2 successive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Torque: 78.5 N.m (800 kgf.cm, 58 ft.lbf) Mark the front of the cylinder head bolts with paint. Retighten the cylinder head bolts 90° in the same sequence as step ( c ). Check that the painted mark is now at a 90° angle to the front.
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve. Install the camshaft timing oil control valve with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL CAMSHAFT TIMING GEAR ASSY Put the camshaft timing gear and camshaft together with the straight pin off the key groove. Turn the camshaft timing gear in the left as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove. CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle). Check that there is no clearance between the gear fringe and camshaft. Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
INSTALL CAMSHAFT TIMING GEAR OR SPROCKET Clamp the camshaft in a vise, then install the camshaft timing gear with the bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) NOTE: Be careful not to damage the No. 2 camshaft.
INSTALL CAMSHAFT BEARING NO. 2 Clean the contact surfaces of the bearing and the cylinder head. Install the camshaft bearing No. 2 onto the cylinder head. NOTE: Do not apply engine oil to the bearing and its contact surface.
INSTALL CAMSHAFT BEARING NO. 1 Clean the contact surfaces of the bearing and the bearing cap No. 1. Align the bearing claw with the claw groove of bearing cap No. 1, and push in the bearing. NOTE: Do not apply engine oil to the bearing and its contact surface.
INSTALL CAMSHAFTS Apply a light coat of engine oil to the journal portion of the camshaft. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 1 and No. 2 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3 NOTE: Tighten the bolts after deciding the position in the thrust direction of the camshaft by the bearing cap No. 1 and No. 2. Install the camshaft with its timing mark of the camshaft timing gear on the top.
INSTALL OIL PUMP ASSY Install a new gasket and oil pump with the 3 bolts. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
INSTALL NO. 2 CHAIN SUB-ASSY Set the crankshaft key in the left horizontal position. Turn the cutout of the drive shaft to the top. Align the yellow mark links with the timing marks of the each gear as shown in the illustration. Install the gears onto the crankshaft and oil pump shaft with the chain wrapped. Temporarily tighten the oil pump drive shaft gear with the nut. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then tighten the nut. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
INSTALL CHAIN VIBRATION DAMPER NO. 1 Install the chain vibration damper with the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL CHAIN SUB-ASSY Set the No. 1 cylinder to TDC/compression. Turn the camshafts with a wrench on the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward. Install the chain onto the crankshaft timing gear with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear. Using SST, tap in the crankshaft timing gear. SST 09309-37010 Align the gold or yellow mark links with each timing mark located on the camshaft timing gears, then install the chain.
INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper with the bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
INSTALL TIMING CHAIN GUIDE Install the timing chain guide with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 Install the sensor plate with the "F" mark facing forward.
INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Apply multi-purpose grease to a new oil seal lip. NOTE: Keep the lip free of foreign objects. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010
INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Apply a continuous bead of seal packing (Diameter 2.0 mm (0.079 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the chain cover. Apply a continuous bead of seal packing as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the chain cover. Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N in (92 kgf.cm, 80 in.lbf) for bolt A 25 N.m (255 kgf.cm, 18 ft.lbf) for bolt B 55 N.m (561 kgf.cm, 41 ft.lbf) for bolt C 43 N.m (438 kgf.cm, 32 ft.lbf) for bolt D 11 N.m (112 kgf.cm, 8 ft.lbf) for nut HINT: Bolt length: BOLT SPECIFICATION Bolt A 30 mm (1.18 in.) length for 10 mm head Bolt B 30 mm (1.18 in.) length for 12 mm head Bolt C 40 mm (1.57 in.) length for 14 mm head Bolt D 65 mm (2.56 in.) length for 14 mm head
INSTALL CHAIN TENSIONER ASSY NO. 1 Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position. Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
INSTALL CRANKSHAFT PULLEY Using SST, fix the pulley and tighten the bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 180 N.m (1,835 kgf.cm, 133 ft.lbf) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, then check that the plunger is extended.
INSTALL OIL PAN SUB-ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the oil pan. Install the oil pan to the cylinder block. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL OIL PAN DRAIN PLUG Place a new gasket on the oil pan drain plug, then install it onto the oil pan. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)
INSTALL WATER PUMP ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and water pump. Apply a continuous bead of seal packing (Diameter 2.2 to 2.5 mm (0.087 to 0.098 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the water pump within 3 minutes of applying seal packing. Do not put in coolant for at least 2 hours after installing the water pump. Install the water pump with the 4 bolts and 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: Tighten the outside bolt and nut with the clamp.
INSTALL WATER PUMP PULLEY Using SST, install the water pump pulley with the 4 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) NOTE: Be careful that the O-ring is not cracked or jammed when installing.
INSTALL CRANKSHAFT POSITION SENSOR Apply a light coat of engine oil to the O-ring of the crankshaft position sensor. Install the crankshaft position sensor with the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: Be careful that the O-ring is not cracked or jammed when installing. Confirm that the wire harness of the sensor is placed as shown.
INSTALL CAMSHAFT POSITION SENSOR Apply a light coat of engine oil to the O-ring of the camshaft position sensor. Install the camshaft position sensor with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: Be careful that the O-ring is not cracked or jammed when installing.
INSTALL OIL FILTER UNION Using a socket hexagon wrench 12, install the oil filter union. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf)
INSTALL OIL FILTER SUB-ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, then tighten it until the gasket comes into contact with the seat. Using SST, tighten it an additional 3/4 turn. SST 09228-06501 Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
INSPECT VALVE CLEARANCE Set the No. 1 cylinder to TDC/compression. Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above. Check only the valves indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): 0.19 to 0.29 mm (0.0075 to 0.0114 in.) for intake 0.30 to 0.40 mm (0.0118 to 0.0158 in.) for exhaust Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters. Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to the TDC/compression. Check only the valves indicated. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): 0.19 to 0.29 mm (0.0075 to 0.0114 in.) for intake 0.30 to 0.40 mm (0.0118 to 0.0158 in.) for exhaust Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
ADJUST VALVE CLEARANCE Set the No. 1 cylinder to the TDC/compression. Place paint marks on the chain and camshaft timing gears. Remove the 2 nuts, chain tensioner and gasket. NOTE: Do not turn the crankshaft without the chain tensioner. Remove the No. 2 camshaft. While holding the camshaft with a wrench, loosen the camshaft timing gear set bolt. NOTE: Be careful not to damage the valve lifter. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps. While holding the No. 2 camshaft by hand, remove the camshaft timing gear set bolt. Remove the camshaft timing gear from the No. 2 camshaft with the timing chain wrapped. Remove the camshaft timing gear from the timing chain. Remove the camshaft. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps. Remove the camshaft and camshaft timing gear while holding the timing chain by hand. Tie the timing chain with a string as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover. Remove the valve lifters. Using a micrometer, measure the thickness of the removed valve lifters. Calculate the thickness of a new lifter so that the valve clearance comes within the specified values. VALVE CLEARANCE A Thickness of new lifter B Thickness of used lifter C Measured valve clearance Valve clearance: Intake A = B + (C - 0.24 mm (0.0095 in.)) Exhaust A = B + (C - 0.35 mm (0.0138 in.)) Example (Intake): Measured intake valve clearance = 0.40 mm (0.0158 in.) 0.40 mm (0.0158 in.) - 0.24 mm (0.0095 in.) = 0.16 mm (0.0063 in.) (Measured - Specification = Excess clearance) Used lifter measurement = 5.250 mm (0.2067 in.) 0.16 mm (0.0063 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.) (Excess clearance + Used lifter = Ideal new lifter) Closest new lifter = 5.410 mm (0.2130 in.) Select No. 42 lifter HINT: Select a new lifter with a thickness as close to the calculated values as possible. Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). Refer to New Lifter Thickness, see "Valve Lifter Selection Chart (Intake)" & " Valve Lifter Selection Chart (Exhaust)". Install the camshaft. Apply a light coat of engine oil to the journal portion of the camshaft. Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 1 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3 Install the No. 2 camshaft. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft. Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing gear. While holding the No. 2 camshaft by hand, temporally tighten the camshaft timing gear set bolt. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) for bearing cap No. 2 9.0 N.m (92 kgf.cm, 80 in.lbf) for bearing cap No. 3 While holding the camshaft with a wrench, tighten the camshaft timing gear set bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) NOTE: Be careful not to damage the valve lifter. Check that the paint marks on the chain and camshaft timing gears are aligned. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover. Install the chain tensioner. Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position. Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, then check that the plunger is extended.
INSTALL CYLINDER HEAD COVER GASKET Install the gasket onto the cylinder head cover.
INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing material from the contact surface. Apply seal packing to the 2 locations shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the cylinder head cover. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) for bolt A 14 N.m (143 kgf.cm, 10 ft.lbf) for bolt B 11 N.m (112 kgf.cm, 8 ft.lbf) for nut
INSTALL VENTILATION VALVE SUB-ASSY Apply adhesive to the threads of the ventilation valve. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
INSTALL OIL FILLER CAP GASKET
INSTALL OIL FILLER CAP SUB-ASSY
INSTALL SPARK PLUG Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)

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Scheme 188: COMPONENTS

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Note. When disconnecting the battery negative terminal, initialize the following system(s) after the terminal is reconnected.

System Name	Action
Power Window Control System	INITIALIZATION
Sliding Roof System	INITIALIZATION

INITIALIZATION SYSTEM DESCRIPTION

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DISCONNECT BATTERY NEGATIVE TERMINAL
REMOVE HOOD SUB-ASSY
REMOVE FRONT WHEEL RH
REMOVE ENGINE UNDER COVER RH
REMOVE ENGINE UNDER COVER LH
REMOVE FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
REMOVE ENGINE COVER SUB-ASSY NO. 1 Remove the 2 nuts, then remove the engine cover No. 1.
DRAIN ENGINE OIL (See «OIL FILTER SUB-ASSY (2AZ-FE)»(ref-224771-S15692372992006031100000) )
REMOVE EXHAUST PIPE ASSY FRONT (See «EXHAUST»(ref-224769) )
REMOVE FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
SEPARATE VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) ) SST 09249-63010
REMOVE ENGINE MOUNTING INSULATOR RH Remove the bolt and radiator reserve tank. Separate the vane pump oil reservoir from the oil reservoir bracket No. 1. NOTE: Do not disconnect the 2 hoses. Remove the 2 bolts, then separate the return tube. Remove the 2 bolts and oil reservoir bracket No. 1. Remove the bolt, then separate the wire harness protector. Disconnect the 2 clamps of the engine wire. Place a transmission jack underneath the engine, then put a wooden block on the jack. Remove the bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR. Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator RH. NOTE: Do not apply excessive force to the return tube when removing the engine mounting insulator RH. HINT: Keep clearance by lowering the engine using the transmission jack when removing the engine mounting insulator RH.
REMOVE IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
REMOVE CYLINDER HEAD COVER SUB-ASSY Disconnect the 2 ventilation hoses from the cylinder head cover. Disconnect the clamp of the engine wire. Remove the bolt, then disconnect the engine wire. Remove the 8 bolts and 2 nuts, then remove the cylinder head cover.
REMOVE V-RIBBED BELT TENSIONER ASSY Lift the engine upward using the transmission jack, then remove the bolt and nut shown in the illustration. NOTE: Do not lift the engine more than necessary. Remove the V-ribbed belt tensioner.
REMOVE CRANKSHAFT POSITION SENSOR (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
REMOVE OIL PAN SUB-ASSY Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) PARTS NO. : PARTS DESCRIPTION Engine hanger No. 1 12281-28010 Engine hanger No. 2 12282-28010 Bolt 91512-61020 Using a chain block and sling device, hold the engine. Remove the 12 bolts and 2 nuts. Insert the blade of SST between the crankcase, chain cover and oil pan, then cut off the applied sealer and remove the oil pan. SST 09032-00100 NOTE: Be careful not to damage the contact surface of the crank-case, chain cover and oil pan.
SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.
REMOVE CRANKSHAFT PULLEY Using SST, fix the pulley and loosen the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Using SST and the pulley bolt, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
REMOVE CHAIN TENSIONER ASSY NO. 1 Remove the bolt. Disconnect the wire harness protector clamp. Remove the 2 nuts, chain tensioner and gasket. NOTE: Do not turn the crankshaft without the chain tensioner.
REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY Using a Torx socket E10, remove the stud bolt for the V-ribbed belt tensioner. Remove the 14 bolts and 2 nuts. Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver and hammer, tap out the oil seal.
REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
REMOVE TIMING CHAIN GUIDE Remove the bolt and timing chain guide.
REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and chain tensioner slipper.
REMOVE CHAIN SUB-ASSY
REMOVE CHAIN VIBRATION DAMPER NO. 1 Remove the 2 bolts and chain vibration damper.
REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
REMOVE NO. 2 CHAIN SUB-ASSY Turn the crankshaft by 90° counterclockwise to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pomp. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then remove the nut. Remove the bolt, then remove the chain tensioner plate and spring. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.
INSTALL NO. 2 CHAIN SUB-ASSY Set the crankshaft key in the left horizontal position. Turn the cutout of the drive shaft to the top. Align the yellow mark links with the timing marks of the each gear as shown in the illustration. Install the gears onto the crankshaft and oil pump shaft with the chain wrapped. Temporarily tighten the oil pump drive shaft gear with the nut. Insert the damper spring into the adjusting hole, then install the chain tensioner plate with the bolt. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock in position, then tighten the nut. Torque: 29.5 N.m (301 kgf.cm, 22 ft.lbf) Turn the crankshaft clockwise by 90° to position the crankshaft key upward.
INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
INSTALL CHAIN VIBRATION DAMPER NO. 1 Install the chain vibration damper with the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL CHAIN SUB-ASSY Set the No. 1 cylinder to TDC/compression. Turn the camshafts with a wrench on the hexagonal lobe to align the timing marks of the camshaft timing gear with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward. Install the chain onto the crankshaft timing gear with the gold or orange mark link aligned with the timing mark on the crankshaft timing gear. Using SST, tap in the crankshaft timing gear. SST 09309-37010 Align the gold or yellow mark links with each timing mark located on the camshaft timing gears, then install the chain.
INSTALL CHAIN TENSIONER SLIPPER Install the chain tensioner slipper with the bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
INSTALL TIMING CHAIN GUIDE Install the timing chain guide with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 Install the sensor plate with the "F" mark facing forward.
INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Apply multi-purpose grease to a new oil seal lip. NOTE: Keep the lip free of foreign objects. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010
INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Apply a continuous bead of seal packing (Diameter 2.0 mm (0.079 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the chain cover. Apply a continuous bead of seal packing as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the chain cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the chain cover. Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N in (92 kgf.cm, 80 in.lbf) for bolt A 25 N.m (255 kgf.cm, 18 ft.lbf) for bolt B 55 N.m (561 kgf.cm, 41 ft.lbf) for bolt C 43 N.m (438 kgf.cm, 32 ft.lbf) for bolt D 11 N.m (112 kgf.cm, 8 ft.lbf) for nut HINT: Bolt length: BOLT SPECIFICATION Bolt Length A 30 mm (1.18 in.) length for 10 mm head B 30 mm (1.18 in.) length for 12 mm head C 40 mm (1.57 in.) length for 14 mm head D 65 mm (2.56 in.) length for 14 mm head Using a Torx socket E10, install the stud bolt for the V-ribbed belt tensioner. Torque: 21.5 N.m (219 kgf.cm, 16 ft.lbf)
INSTALL CHAIN TENSIONER ASSY NO. 1 Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is located in position. Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) NOTE: When installing the chain tensioner, set the hook again if the hook releases the plunger.
INSTALL CRANKSHAFT PULLEY Using SST, fix the pulley and tighten the bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 180 N.m (1,835 kgf.cm, 133 ft.lbf) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook. Turn the crankshaft clockwise, then check that the plunger is extended. Connect the wire harness protector clamp. Install the bolt. Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf)
INSTALL OIL PAN SUB-ASSY Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes of applying seal packing. Do not put into engine oil for at least 2 hours after installing the oil pan. Install the oil pan to the cylinder block. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) Place a transmission jack underneath the engine, then put a wooden block on the jack. Remove the chain block and sling device. Remove the engine hanger No. 1 and No. 2.
INSTALL CRANKSHAFT POSITION SENSOR (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
INSTALL V-RIBBED BELT TENSIONER ASSY Install the V-ribbed belt tensioner with the bolt and nut. Torque: 59.5 N.m (607 kgf.cm, 44 ft.lbf) NOTE: Do not lift the engine more than necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing material from the contact surface. Apply seal packing to the 2 locations shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes of applying seal packing. Do not put in engine oil for at least 2 hours after installing the cylinder head cover. Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) for bolt A 14 N.m (143 kgf.cm, 10 ft.lbf) for bolt B 11 N.m (112 kgf.cm, 8 ft.lbf) for nut Install the engine wire with the bolt. Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf) Connect the clamp of the engine wire. Connect the 2 ventilation hoses to the cylinder head cover.
INSTALL IGNITION COIL ASSY (See «IGNITION COIL ASSY (2AZ-FE)»(ref-224772-S39140322102006031100000) )
INSTALL ENGINE MOUNTING INSULATOR RH Install the engine mounting insulator RH with the 4 bolts and 2 nuts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) Install the engine mounting insulator FR with the bolt and nut. Torque: 52 N m (530 kgf.cm, 38 ft.lbf) Connect the 2 clamps of the engine wire. Install the wire harness protector with the bolt. Install the oil reservoir bracket No. 1 with the 2 bolts. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) Install the return tube with the 2 bolts. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) Install the vane pump oil reservoir onto the oil reservoir bracket No. 1. Install the radiator reserve tank with the bolt. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
INSTALL VANE PUMP ASSY (See «OVERHAUL»(ref-224784-S39497530042006031100000) ) SST 09249-63010
INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-224773-S33649139362006031100000) )
INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT (2AZ-FE)»(ref-224768-S30284662712006031100000) ) SST 09249-63010
INSTALL EXHAUST PIPE ASSY FRONT (See «EXHAUST»(ref-224769) )
ADD ENGINE OIL (See «OIL FILTER SUB-ASSY (2AZ-FE)»(ref-224771-S15692372992006031100000) )
CONNECT BATTERY NEGATIVE TERMINAL Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
CHECK FOR ENGINE OIL LEAKAGE
CHECK FOR EXHAUST GAS LEAKAGE
INSTALL ENGINE COVER SUB-ASSY NO. 1 Install the engine cover No. 1 with the 2 nuts. Torque: 7.0 N.m (70 kgf.cm, 62 in.lbf)
INSTALL FRONT FENDER APRON SEAL RH (See «REPLACEMENT»(ref-224772-S06982846242006031100000) )
INSTALL ENGINE UNDER COVER LH
INSTALL ENGINE UNDER COVER RH
INSTALL FRONT WHEEL RH Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
INSTALL HOOD SUB-ASSY (See «HOOD»(ref-224796-S19869784622006031100000) )

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Scheme 259: COMPONENTS

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