Engine Mechanical (1GR-FE): Removal & Installation Toyota 4Runner IV

REPLACEMENT

HINT

Refer to CAMSHAFT (RH BANK) or CAMSHAFT (LH BANK) for the replacement procedure of the No. 2 chain (See REPLACEMENT ).

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1. REMOVE POWER STEERING LINK ASSY (See «POWER STEERING LINK ASSY»(ref-194132-S01684230332006061400000) )
2. REMOVE DIFFERENTIAL CARRIER ASSY FRONT (4WD DRIVE TYPE) (See «DIFFERENTIAL CARRIER ASSY. FRONT (4WD) COMPONENTS»(ref-192207-S03923790072005092300000) )
3. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
4. DRAIN ENGINE OIL (See «REPLACEMENT»(ref-235181-S06820311482006061400000) )
5. REMOVE BATTERY
6. REMOVE RADIATOR SUPPORT SEAL UPPER Remove the 11 clips and radiator support seal upper.
7. LOOSEN FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
8. REMOVE FAN AND GENERATOR V BELT (See FAN AND GENERATOR V BELT (1GR-FE) «FAN AND GENERATOR V BELT»(ref-235151-S00974816002006061400000) )
9. REMOVE FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
10. DISCONNECT VENTILATION HOSE NO. 2
11. REMOVE AIR CLEANER ASSY
12. REMOVE OIL LEVEL GAUGE GUIDE Remove the oil level gauge. Remove the bolt and pull out the oil level gauge guide. Remove the O-ring from the oil level gauge guide.
13. REMOVE WATER INLET (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
14. SEPARATE VANE PUMP ASSY Disconnect the P/S oil pressure switch connector. Remove the 2 bolts, and separate the vane pump. NOTE: Do not hit the pulley to other parts when separating the vane pump. HINT The vane pump is suspended securely.
15. REMOVE GENERATOR ASSY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
16. SEPARATE COOLER COMPRESSOR ASSY (See «CRANKSHAFT POSITION SENSOR»(ref-151984-S30853055372003010900000) )
17. REMOVE V-RIBBED BELT TENSIONER ASSY Remove the 5 bolts and V-ribbed belt tensioner.
18. REMOVE IDLER PULLEY SUB-ASSY NO. 2 Remove the 2 bolts and 2 idler pulleys.
19. REMOVE IDLER PULLEY SUB-ASSY NO.1 Remove the bolt and idler pulley.
20. REMOVE CRANKSHAFT PULLEY Using SST, hold the crankshaft pulley and loosen the pulley set bolt. SST 09213-54015 (91651-60855), 09330-00021 Using the pulley set bolt and SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
21. REMOVE OIL PAN SUB-ASSY NO. 2 Remove the 10 bolts and 2 nuts. Insert the blade of SST between the oil pan and oil pan No. 2, cut off applied sealer and remove the oil pan No. 2. SST 09032-00100 NOTE: Be careful not to damage the contact surfaces of the oil pan and oil pan No. 2. Be careful not to damage the oil pan No. 2 flange.
22. REMOVE OIL STRAINER SUB-ASSY Remove the 2 nuts, oil strainer and gasket.
23. REMOVE OIL PAN SUB-ASSY Remove the 4 housing bolts. Remove the flywheel housing under cover. Remove the 17 bolts and 2 nuts. Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration. NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. Remove the O-ring from the oil pump.
24. REMOVE INTAKE AIR SURGE TANK (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
25. REMOVE IGNITION COIL ASSY
26. REMOVE CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
27. REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
28. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY Disconnect the 2 oil control valve connectors. Remove the 2 bolts and 2 camshaft timing oil control valves.
29. REMOVE VVT SENSOR (See «VARIABLE VALVE TIMING SENSOR»(ref-151984-S35181532432003010900000) )
30. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY (See «TIMING CHAIN OR BELT COVER SUB-ASSY (1GR-FE)»(ref-235181-S26208026232006061400000) )
31. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (See «TIMING CHAIN OR BELT COVER SUB-ASSY (1GR-FE)»(ref-235181-S26208026232006061400000) )
32. SET NO. 1 CYLINDER TO TDC/COMPRESSION Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
33. REMOVE CHAIN TENSIONER ASSY NO.1 NOTE: Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first. While turning the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration. While turning the stopper plate of the tensioner counterclockwise, insert a bar of phi3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. Remove the 2 bolts and chain tensioner.
34. REMOVE CHAIN TENSIONER SLIPPER
35. REMOVE IDLE GEAR NO.1 Using a 10 mm hexagon wrench, remove the idle gear shaft No.2, idle gear No. 1 and idle gear shaft No.1.
36. REMOVE CHAIN VIBRATION DAMPER NO. 2 Remove the 2 chain vibration damper No. 2.
37. REMOVE CHAIN SUB-ASSY
38. INSTALL CHAIN TENSIONER SLIPPER
39. INSTALL CHAIN TENSIONER ASSY NO.1 While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. While turning the stopper plate of the tensioner counterclockwise, insert a bar of phi3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. Install the chain tensioner with the 2 bolts. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
40. INSTALL CHAIN SUB-ASSY Set the No. 1 cylinder to the TDC/ compression. Align the timing marks of the camshaft timing gears and bearing caps. Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block. Align the mark link (yellow) with the timing mark of the crankshaft timing gear. Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.
41. INSTALL CHAIN VIBRATION DAMPER NO. 2 Instal the 2 chain vibration damper No. 2.
42. INSTALL IDLE GEAR NO.1 Apply a light coat of engine oil to the rotating surface of the idle gear shaft No.1. Temporarily install the idle gear shaft No. 1 and idle gear No. 1 with the idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block. NOTE: Be careful of the idle gear direction. Using a 10 mm hexagon wrench, tighten the idle gear shaft No. 2. Torque: 60 N.m (612 kgf.cm, 44 ft.lbf) Remove the bar from the chain tensioner.
43. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (See «TIMING CHAIN OR BELT COVER SUB-ASSY (1GR-FE)»(ref-235181-S26208026232006061400000) ) SST 09226-10010
44. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY (See «TIMING CHAIN OR BELT COVER SUB-ASSY (1GR-FE)»(ref-235181-S26208026232006061400000) )
45. INSTALL VVT SENSOR (See «VARIABLE VALVE TIMING SENSOR»(ref-151984-S35181532432003010900000) )
46. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
47. INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
48. INSTALL CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
49. INSTALL IGNITION COIL ASSY Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
50. INSTALL INTAKE AIR SURGE TANK (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
51. INSTALL OIL PAN SUB-ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan. Install a new O-ring to the oil pump. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) for bolt A 21 N.m (214 kgf.cm, 15 ft.lbf) for bolt B 10 N.m (102 kgf.cm, 7 ft.lbf) for bolt C 21 N.m (214 kgf.cm, 15 ft.lbf) for nut HINT Each bolt length is as follows: A 25 mm (0.98 in.) B 45 mm (1.77in.) C 14 mm (0.55 in.) Install the 4 housing bolts. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) Install the flywheel housing under cover.
52. INSTALL OIL STRAINER SUB-ASSY Install a new gasket and the oil strainer with the 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
53. INSTALL OIL PAN SUB-ASSY NO. 2 Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No. 2. Apply a continuous bead of seal packing (diameter 3: to 4 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the oil pan No. 2 within 3 minutes after applying seal packing. After installing it, the oil pan No. 2 bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the oil pan No. 2 with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
54. INSTALL CRANKSHAFT PULLEY Using SST, install the pulley set bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 250 N.m (2,549 kgf.cm, 184 ft.lbf)
55. INSTALL IDLER PULLEY SUB-ASSY NO.1 Install the idler pulley with the bolt. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) HINT "DOUBLE" is marked on the idler pulley No. 1 to distinguish it from the idler pulley No. 2.
56. INSTALL IDLER PULLEY SUB-ASSY NO. 2 Install the 2 idler pulleys with the 2 bolts. Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
57. INSTALL V-RIBBED BELT TENSIONER ASSY Temporarily install the V-ribbed belt tensioner with the 5 bolts. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration. Torque: 36 N.m (367 kgf.cm, 27 ft.lbf) Tighten the other bolts. Torque: 36 N.m (367 kgf.cm, 27 ft.lbf) HINT Each bolt length is as follows: A 70 mm (2.76 in.) B 33 mm (1.30 in.)
58. INSTALL COOLER COMPRESSOR ASSY (See «CRANKSHAFT POSITION SENSOR»(ref-151984-S30853055372003010900000) )
59. INSTALL GENERATOR ASSY (See «GENERATOR»(ref-163567-S22705679482004070600000) )
60. INSTALL VANE PUMP ASSY Install the vane pump with the 2 bolts. Torque: 43 N.m (438 kgf.cm, 32 ft.lbf) NOTE: Do not hit the pulley to other parts when installing the vane pump. Connect the P/S oil pressure switch connector.
61. INSTALL WATER INLET (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
62. INSTALL OIL LEVEL GAUGE GUIDE Install a new O-ring to the oil level gauge guide. Apply a light coat of engine oil to the O-ring. Push in the oil level gauge guide end into the guide hole of the oil pan. Install the oil level gauge guide with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) Install the oil level gauge.
63. INSTALL AIR CLEANER ASSY
64. CONNECT VENTILATION HOSE NO. 2
65. INSTALL FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
66. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235151-S00974816002006061400000) )
67. FULLY TIGHTEN FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
68. INSTALL RADIATOR SUPPORT SEAL UPPER
69. INSTALL BATTERY
70. INSTALL DIFFERENTIAL CARRIER ASSY FRONT (4WD DRIVE TYPE) (See «DIFFERENTIAL CARRIER ASSY. FRONT (4WD) COMPONENTS»(ref-192207-S03923790072005092300000) )
71. INSTALL POWER STEERING LINK ASSY (See «POWER STEERING LINK ASSY»(ref-194132-S01684230332006061400000) )
72. ADD ENGINE OIL (See «REPLACEMENT»(ref-235181-S06820311482006061400000) )
73. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
74. CHECK FOR ENGINE OIL LEAKS
75. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-235178-S35591562862006061400000) )
76. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
77. INSPECT IGNITION TIMING (See «INSPECTION»(ref-235151-S08614278762006061400000) ) SST 09843-18040

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1. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
2. DISCONNECT VENTILATION HOSE NO. 2
3. REMOVE AIR CLEANER ASSY
4. REMOVE INTAKE AIR SURGE TANK Disconnect the 2 water by-pass hoses. Disconnect the fuel vapor feed hose. Disconnect the ventilation hose. Disconnect the 2 VSV connectors. Disconnect the throttle body w/ motor connector. Separate the 3 wire harness clamps and hose clamp. Remove the 2 bolts and throttle body bracket. Remove the bolt and oil baffle plate. Remove the 4 bolts and 2 surge tank stays. Remove the 2 nuts. Using a socket hexagon wrench 8, remove the 4 bolts, intake air surge tank and gasket.
5. REMOVE IGNITION COIL ASSY
6. REMOVE CYLINDER HEAD COVER SUB-ASSY Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.
7. REMOVE CYLINDER HEAD COVER SUB-ASSY LH Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.
8. SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover. 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. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above. Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears.
9. REMOVE CHAIN TENSIONER ASSY NO.1 NOTE: Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first. Remove the 4 bolts, timing chain cover plate and gasket. While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration. While turning the stopper plate of the tensioner downward, insert a bar of phis 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. Remove the 2 bolts and chain tensioner.
10. REMOVE NO. 2 CAMSHAFT NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. While raising up the chain tensioner No. 2, insert a pin of (]) 1.0 mm (0.039 in.) into the hole to fix it. Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing gear set bolt. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Separate the camshaft timing gear from the No. 2 camshaft. Rotate the camshaft counterclockwise using the wrench so that the cam lobes of No. 1 cylinder faces upward as shown in the illustration. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 4 bearing caps and No. 2 camshaft.
11. REMOVE CHAIN TENSIONER ASSY NO. 2 Remove the chain tensioner No. 2 bolt, and then remove the chain tensioner No. 2 and camshaft timing gear.
12. REMOVE CAMSHAFT NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear set bolt. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear. Rotate the No. 1 camshaft counterclockwise using the wrench so that the cam lobes of No. 1 cylinder faces downward as shown in the illustration. Using several steps, loosen and remove the 8 bearing cap bolts in the sequence as shown in the illustration. Remove the 4 bearing caps. Remove the camshaft timing gear set bolt with the No. 1 camshaft is lifted up, and then remove the No. 1 camshaft and camshaft timing gear w/ No. 2 chain. Tie the No. 1 chain with a string as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover.
13. INSTALL CAMSHAFT NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Align the mark link (yellow) with the timing mark (1 dot mark) of the camshaft timing gear as shown in the illustration. Apply new engine oil to the thrust portion and journal of the camshafts. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear. Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear. Temporarily install the camshaft timing gear set bolt. Set the No. 1 camshaft onto the RH cylinder head with the cam lobes of the No. 1 cylinder faced downward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 24 N.m (245 kgf.cm, 18 ft.lbf) for 12 mm (0.47 in.) head Rotate the No. 1 camshaft clockwise using the wrench so that the timing mark of the camshaft timing gear is aligned with the timing marks of the camshaft bearing cap. Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear. Hold the hexagonal portion of the No. 1 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf)
14. INSTALL CHAIN TENSIONER ASSY NO. 2 While pushing in the tensioner, insert a pin of phis 1.0 mm (0.039 in.) into the hole to fix it. Temporarily install the camshaft timing gear and chain tensioner No. 2 and align the mark links (yellow) with the timing marks (1 dot mark) of the camshaft timing gears. Tighten the chain tensioner No. 2 bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
15. INSTALL NO. 2 CAMSHAFT NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Set the No. 2 camshaft onto the RH cylinder head with the cam lobes of No. 1 cylinder faced upward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 24 N.m (245 kgf.cm, 18 ft.lbf) for 12 mm (0.47 in.) head Rotate the No. 2 camshaft clockwise using the wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing gear. Hold the hexagonal portion of the No. 2 camshaft with a wrench, and install the camshaft timing gear set bolt. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf) Remove the pin from the chain tensioner No. 2.
16. INSTALL CHAIN TENSIONER ASSY NO.1 While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. While turning the stopper plate of the tensioner counterclockwise, insert a bar of phis 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. Install the chain tensioner with the 2 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) Remove the bar from the chain tensioner. Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the timing mark "0" of the timing chain cover. 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.
17. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
18. INSPECT VALVE CLEARANCE (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
19. ADJUST VALVE CLEARANCE (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
20. INSTALL CYLINDER HEAD COVER SUB-ASSY LH Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. Apply a continuous bead of the seal packing (diameter 2-3 mm (0.08-0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the seal washers to the bolts. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
21. INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. Apply a continuous bead of the seal packing (diameter 2-3 mm (0.08-0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the seal washers to the bolts. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
22. INSTALL IGNITION COIL ASSY Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
23. INSTALL INTAKE AIR SURGE TANK Install a new gasket to the intake air surge tank. Using the socket hexagon wrench 8, install the intake air surge tank with the 4 bolts. Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) Install the 2 intake air surge tank nuts. Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) Install the 2 surge tank stays with the 4 bolts. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) Install the oil baffle plate with the bolt. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) Install the throttle body bracket with the 2 bolts. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) Install the 3 wire harness clamps and hose clamp. Connect the throttle body w/ motor connector. Connect the 2 VSV connectors. Connect the ventilation hose. Connect the fuel vapor feed hose. Connect the 2 water by-pass hoses.
24. INSTALL AIR CLEANER ASSY
25. CONNECT VENTILATION HOSE NO. 2
26. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
27. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-235178-S35591562862006061400000) )
28. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
29. INSPECT IGNITION TIMING (See «INSPECTION»(ref-235151-S08614278762006061400000) ) SST 09843-18040

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1. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
2. DISCONNECT VENTILATION HOSE NO. 2
3. REMOVE AIR CLEANER ASSY
4. REMOVE INTAKE AIR SURGE TANK (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
5. REMOVE IGNITION COIL ASSY
6. REMOVE CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
7. REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
8. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
9. REMOVE CHAIN TENSIONER ASSY NO. 1 (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
10. REMOVE NO. 4 CAMSHAFT SUB-ASSY NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. While pushing down the chain tensioner No. 3, insert a pin of phis 1.0 mm (0.039 in.) into the hole to fix it. Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing gear set bolt. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Separate the camshaft timing gear from the No. 4 camshaft. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 4 bearing caps and No. 4 camshaft.
11. REMOVE CHAIN TENSIONER ASSY NO. 3 Remove the chain tensioner No. 3 bolt, and then remove the chain tensioner No. 3 and camshaft timing gear.
12. REMOVE NO. 3 CAMSHAFT SUB-ASSY NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Release the chain tension between the camshaft timing gear (LH bank) and crankshaft timing gear by turning the crankshaft pulley counterclockwise slightly. Hold the hexagonal portion of the No. 3 camshaft with a wrench, and loosen the camshaft timing gear set bolt. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 4 bearing caps. Remove the camshaft timing gear set bolt with the No. 3 camshaft is lifted up, and then remove the No. 3 camshaft and camshaft timing gear w/ No. 2 chain. Tie the No. 1 chain with a string as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover.
13. INSTALL NO. 3 CAMSHAFT SUB-ASSY NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Align the mark link (yellow) with the timing mark (2 dot marks) of the camshaft timing gear as shown in the illustration. Apply new engine oil to the thrust portion and journal of the camshafts. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear. Align the knock pin hole in the camshaft timing gear with the knock pin of the No. 3 camshaft, and insert the No. 3 camshaft into the camshaft timing gear. Temporarily install the camshaft timing gear set bolt. Set the No. 3 camshaft onto the LH cylinder head with the cam lobes of the No. 2 cylinder faced downward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 24 N.m (245 kgf.cm, 18 ft.lbf) for 12 mm (0.47 in.) head Align the paint mark of the No. 1 chain with the timing marks of the camshaft timing gear. Hold the hexagonal portion of the No. 3 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf)
14. INSTALL CHAIN TENSIONER ASSY NO. 3 While pushing in the tensioner, insert a pin of phis 1.0 mm (0.039 in.) into the hole to hold it. Temporarily install the camshaft timing gear and chain tensioner No. 3 and align the mark links (yellow) with the timing marks (1 dot mark and 2 dot marks) of the camshaft timing gears. Tighten the chain tensioner No. 3 bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
15. INSTALL NO. 4 CAMSHAFT SUB-ASSY NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Align the knock pin hole in the camshaft timing gear with the knock pin of he No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing gear. Temporarily install the camshaft timing gear set bolt. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 24 N.m (245 kgf.cm, 18 ft.lbf) for 12 mm (0.47 in.) head Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf) Remove the pin from the chain tensioner No. 3. Release the chain tension between the camshaft timing gear (RH bank) and crankshaft timing gear by turning the crankshaft pulley clockwise slightly.
16. INSTALL CHAIN TENSIONER ASSY NO. 1 (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
17. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
18. INSPECT VALVE CLEARANCE (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
19. ADJUST VALVE CLEARANCE (See «VALVE CLEARANCE»(ref-235151-S32651556802006061400000) )
20. INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
21. INSTALL CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
22. INSTALL IGNITION COIL ASSY Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf)
23. INSTALL INTAKE AIR SURGE TANK (See «REPLACEMENT»(ref-235151-S06226681952006061400000) )
24. INSTALL AIR CLEANER ASSY
25. CONNECT VENTILATION HOSE NO. 2
26. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-235178-S21524750362006061400000) )
27. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-235178-S35591562862006061400000) )
28. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf)
29. INSPECT IGNITION TIMING (See «INSPECTION»(ref-235151-S08614278762006061400000) ) SST 09843-18040

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Scheme 235

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Scheme 245

Scheme 246

Scheme 247

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
2. REMOVE CHAIN SUB-ASSY (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
3. REMOVE COOL AIR INLET NO.1 Remove the 2 bolts and cool air inlet w/ air cleaner hose.
4. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY Remove the ATF level gauge. Remove the bolt and pull out the oil filler tube. Remove the O-ring from the oil filler tube.
5. REMOVE EXHAUST PIPE ASSY FRONT (See EXHAUST PIPE ASSY )
6. REMOVE MANIFOLD STAY Remove the 3 bolts and manifold stay.
7. REMOVE EXHAUST MANIFOLD SUB-ASSY RH Disconnect the A/F sensor connector. Remove the 6 nuts, exhaust manifold and gasket.
8. DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
9. DISCONNECT FUEL PIPE SUB-ASSY NO. 2 (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
10. REMOVE INTAKE MANIFOLD Disconnect the 6 fuel injector connectors. Remove the 10 bolts, intake manifold and 2 gaskets.
11. REMOVE WATER BY PASS JOINT RR Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. Remove the 2 bolts, 4 nuts, water by-pass joint RR and 2 gaskets. Remove the O-ring from the water outlet pipe.
12. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (RH BANK) While raising up the chain tensioner No. 2, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No. 2. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly.
13. REMOVE CHAIN TENSIONER ASSY NO. 2 Remove the bolt and chain tensioner No. 2.
14. REMOVE CAMSHAFTS NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Rotate the camshafts counterclockwise using the wrench so that the cam lobes of No. 1 cylinder face each direction as shown in the illustration. Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 8 bearing caps and 2 camshafts.
15. REMOVE CAMSHAFT BEARING NO. 2
16. REMOVE CYLINDER HEAD SUB-ASSY Remove the 2 bolts and separate the 2 ground cables. Using several steps, loosen the 8 cylinder head bolts on the cylinder head uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop the plate washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in incorrect order. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.
17. REMOVE CYLINDER HEAD GASKET
18. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the thread outside diameter of the bolt. Standard outside diameter: 10.85-11.00 mm (0.4272-0.4331 in.) Minimum outside diameter: 10.7 mm (0.421 in.)
19. INSTALL CYLINDER HEAD GASKET Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. Apply a continuous bead of the seal packing (diameter 2.5-3 mm (0.098-0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Be careful of the installation direction. Place the cylinder head carefully in order to not damage the gasket with the bottom part of the head.
20. INSTALL CYLINDER HEAD SUB-ASSY Place the cylinder head on the cylinder head gasket. Install the 8 cylinder head bolts. HINT: The cylinder head bolts are tightened in 2 successive steps (steps (3) and 5 ). If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Using several steps, tighten each bolt uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Torque: 36 N.m (367 kgf.cm, 27 ft.lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTE: Do not drop the washers into the cylinder head. Mark the front side of each cylinder head bolt with paint. Retighten the cylinder head bolts 180° revolution as shown. Check that the painted marks are now at 180° opposite to the engine front. Install the ground cables with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
21. INSTALL CAMSHAFT BEARING NO. 2 Install the camshaft bearing No. 2 to the cylinder head. NOTE: Clean the backside of the bearing and the bearing surface of the cylinder head and let not stick the oils and fats.
22. INSTALL CAMSHAFTS NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Set the crankshaft position. Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position. NOTE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle. Apply new engine oil to the thrust portion and journal of the camshafts. Place the 2 camshafts onto the cylinder head with the cam lobes of No. 1 cylinder faced each direction as shown in the illustration. Install the 8 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 24 N.m (245 kgf.cm, 18 ft.lbf) for 12 mm (0.47 in.) head Turn the camshafts clockwise until the knock pin comes to 90° position to the cylinder head.
23. INSTALL CHAIN TENSIONER ASSY NO. 2 While pushing in the tensioner, insert a pin of phis 1.0 mm (0.039 in.) into the hole to fix it. Install the chain tensioner No. 2 with the bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
24. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (RH BANK) Align the mark links (yellow) with the timing marks (1 dot mark) of camshaft timing gears as shown in the illustration. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts. Temporarily install the 2 camshaft timing gear bolts. NOTE: Do not push camshaft timing gear assembly to the camshaft forcibly when installing it. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf) Remove the pin from the tensioner No. 2.
25. INSTALL WATER BY PASS JOINT RR Install a new O-ring to the water outlet pipe. Apply soapy water to the O-ring. Install 2 new gaskets and water by-pass joint RR with the 2 bolts and 4 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) Connect the heater hose. Connect the engine coolant temperature sensor connector.
26. INSTALL INTAKE MANIFOLD Set a new gasket on each cylinder head. NOTE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction. Set the intake manifold on the cylinder heads. Install and tighten the 10 bolts uniformly in several steps. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) Connect the 6 fuel injector connectors.
27. CONNECT FUEL PIPE SUB-ASSY NO. 2 (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
28. CONNECT FUEL PIPE SUB-ASSY NO.1 (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
29. INSTALL EXHAUST MANIFOLD SUB-ASSY RH Set a new gasket to the RH cylinder head with the oval shape is facing forward. NOTE: Be careful of the installation direction. Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) Connect the A/F sensor connector.
30. INSTALL MANIFOLD STAY Install the manifold stay with the 3 bolts. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)
31. INSTALL EXHAUST PIPE ASSY FRONT (See EXHAUST PIPE ASSY )
32. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY Coat a new O-ring with ATF, and install them to the oil filler tube. Push in the oil filler tube end into the oil pan lower tube. Install the oil filler tube with the bolt. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) Install the ATF level gauge.
33. INSTALL COOL AIR INLET NO.1 Install the cool air inlet w/ air cleaner hose with the 2 bolts. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
34. INSTALL CHAIN SUB-ASSY (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
35. CHECK FOR FUEL LEAKS (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
36. CHECK FOR EXHAUST GAS LEAKS
37. INSPECT ENGINE IDLE SPEED (See «INSPECTION»(ref-235151-S08614278762006061400000) ) SST 09843-18030
38. INSPECT COMPRESSION (See «INSPECTION»(ref-235151-S08614278762006061400000) )
39. INSPECT CO/HC (See «INSPECTION»(ref-235151-S08614278762006061400000)

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Scheme 261

Scheme 262

Scheme 263

Scheme 264

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Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
2. REMOVE CHAIN SUB-ASSY (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
3. REMOVE EXHAUST FRONT PIPE ASSY NO. 2 (See EXHAUST PIPE ASSY )
4. REMOVE MANIFOLD STAY NO. 2 Remove the 3 bolts and manifold stay No. 2.
5. REMOVE EXHAUST MANIFOLD SUB-ASSY LH Disconnect the A/F sensor connector. Remove the 6 nuts, exhaust manifold and gasket.
6. DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
7. DISCONNECT FUEL PIPE SUB-ASSY NO. 2 (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
8. REMOVE INTAKE MANIFOLD (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
9. REMOVE WATER BY PASS JOINT RR (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
10. REMOVE CHAIN VIBRATION DAMPER NO.1 Remove the 2 bolts and chain vibration damper No. 1.
11. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (LH BANK) While pushing down the chain tensioner No. 3, insert a pin of phis 1.0 mm (0.039 in.) into the hole to fix it. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No. 2. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly.
12. REMOVE CHAIN TENSIONER ASSY NO. 3 Remove the bolt and chain tensioner No. 3.
13. REMOVE CAMSHAFTS NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 8 bearing caps and 2 camshafts.
14. REMOVE CYLINDER HEAD LH Remove the bolt and separate the ground cable. Using several steps, remove the 2 cylinder head bolts on the cylinder head in the sequence as shown in the illustration. Using several steps, loosen the 8 cylinder head bolts on the cylinder head uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTE: Be careful not to drop the plate washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in incorrect order. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.
15. REMOVE CYLINDER HEAD GASKET NO. 2
16. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the thread outside diameter of the bolt. Standard outside diameter: 10.85-11.00 mm (0.4272-0.4331 in.) Minimum outside diameter: 10.7 mm (0.421 in.)
17. INSTALL CYLINDER HEAD GASKET NO. 2 Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. Apply a continuous bead of the seal packing (diameter 2.5-3 mm (0.098-0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. NOTE: Be careful of the installation direction. Place the cylinder head carefully in order to not damage the gasket with the bottom part of the head.
18. INSTALL CYLINDER HEAD LH Place the cylinder head on the cylinder head gasket. Install the 8 cylinder head bolts. HINT: The cylinder head bolts are tightened in 2 successive steps (steps 3 and 5 ). If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Using several steps, tighten each bolt uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Torque: 36 N.m (367 kgf.cm, 27 ft.lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTE: Do not drop the washers into the cylinder head. Mark the front side of each cylinder head bolt with paint. Retighten the cylinder head bolts 180° revolution as shown. Check that the painted marks are now at 180° opposite to the engine front. Install the 2 cylinder head bolts. Apply a light coat of engine oil on the threads of the cylinder head bolts. Using several steps, install and tighten the 2 cylinder head bolts uniformly in the sequence as shown in the illustration. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) Install the ground cable with the bolt. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
19. INSTALL CAMSHAFTS NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which are received the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Set the crankshaft position. Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position. NOTE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle. Apply new engine oil to the thrust portion and journal of the camshafts. Place the 2 camshafts onto the cylinder head with the cam lobes of No. 2 cylinder faced each direction as shown in the illustration. Install the 8 bearing caps in their proper locations. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) for 10 mm (0.39 in.) head 24 N.m (245 kgf.cm, 18 ft.lbf) for 12 mm (0.47 in.) head
20. INSTALL CHAIN TENSIONER ASSY NO. 3 While pushing in the tensioner, insert a pin of phis 1.0 mm (0.039 in.) into the hole to fix it. Install the chain tensioner No. 3 with the bolt. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
21. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (LH BANK) Align the mark links (yellow) with the timing marks (1 dot mark and 2 dot marks) of camshaft timing gears as shown in the illustration. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the LH camshafts. Temporarily install the 2 camshaft timing gear bolts. NOTE: Do not push camshaft timing gear assembly to the camshaft forcibly when installing it. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N.m (1, 020 kgf.cm, 74 ft.lbf) Remove the pin from the tensioner No. 3.
22. INSTALL CHAIN VIBRATION DAMPER NO.1 Install the chain vibration damper No. 1 with the 2 bolts. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
23. INSTALL WATER BY PASS JOINT RR (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
24. INSTALL INTAKE MANIFOLD (See «REPLACEMENT»(ref-235151-S10445535042006061400000) )
25. CONNECT FUEL PIPE SUB-ASSY NO. 2 (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
26. CONNECT FUEL PIPE SUB-ASSY NO.1 (See «PRECAUTION»(ref-190101-S23995436232005091500000) )
27. INSTALL EXHAUST MANIFOLD SUB-ASSY LH Set a new gasket to the LH cylinder head with the oval shape is facing backward. NOTE: Be careful of the installation direction. Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) Connect the A/F sensor connector.
28. INSTALL MANIFOLD STAY NO. 2 Install the manifold stay No. 2 with the 3 bolts. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)
29. INSTALL EXHAUST FRONT PIPE ASSY NO. 2 (See EXHAUST PIPE ASSY )
30. INSTALL CHAIN SUB-ASSY (See «REPLACEMENT»(ref-235151-S06007633702006061400000) )
31. CHECK FOR FUEL LEAKS (See «FUEL SYSTEM - 1GR-FE»(ref-190101) )
32. CHECK FOR EXHAUST GAS LEAKS
33. INSPECT ENGINE IDLE SPEED (See «INSPECTION»(ref-235151-S08614278762006061400000) ) SST 09843-18030
34. INSPECT COMPRESSION (See «INSPECTION»(ref-235151-S08614278762006061400000) )
35. INSPECT CO/HC (See «INSPECTION»(ref-235151-S08614278762006061400000) )

Scheme 273

Scheme 274

1. REMOVE RADIATOR SUPPORT SEAL UPPER Remove the 11 clips and radiator support seal upper.
2. REMOVE ENGINE UNDER COVER SUB-ASSY NO.1 Remove the 4 bolts and engine under cover.
3. LOOSEN FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
4. REMOVE FAN AND GENERATOR V BELT «FAN AND GENERATOR V BELT»(ref-235151-S00974816002006061400000) )
5. REMOVE FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
6. REMOVE CRANKSHAFT PULLEY (See REPLACEMENT «REPLACEMENT»(ref-235151-S06007633702006061400000) ) SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
7. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. Wrap the tip of the screwdriver with tape.
8. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09226-10010
9. INSTALL CRANKSHAFT PULLEY (See REPLACEMENT «REPLACEMENT»(ref-235151-S06007633702006061400000) ) SST 09213-54015 (91651-60855), 09330-00021
10. INSTALL FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
11. INSTALL FAN AND GENERATOR V BELT (See «FAN AND GENERATOR V BELT»(ref-235151-S00974816002006061400000) )
12. FULLY TIGHTEN FAN W/ FLUID COUPLING (See «WATER PUMP ASSY (1GR-FE)»(ref-235178-S08159351802006061400000) )
13. INSTALL RADIATOR SUPPORT SEAL UPPER
14. CHECK FOR ENGINE OIL LEAKS
15. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1 Install the engine under cover with the 4 bolts. Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)
16. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N.m (76 kgf.cm, 66 In.lbf)

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

1. REMOVE AUTOMATIC TRANSMISSION ASSY (2WD DRIVE TYPE) (See «A340E»(ref-158065-S01947165072003090900000) )
2. REMOVE AUTOMATIC TRANSMISSION ASSY (4WD DRIVE TYPE) (See «A340F»(ref-158065-S23854566212003090900000) )
3. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 Remove the 8 bolts, front spacer, drive plate and rear spacer.
4. REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
5. INSTALL ENGINE REAR OIL SEAL Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-78010
6. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the front spacer, drive plate and rear spacer on the crankshaft. Using several steps, install and tighten the 8 mounting bolts uniformly in the sequence as shown in the illustration. Torque: 83 N.m (846 kgf.cm, 61 ft.lbf)
7. INSTALL AUTOMATIC TRANSMISSION ASSY (2WD DRIVE TYPE) (See «A340E»(ref-158065-S01947165072003090900000) )
8. INSTALL AUTOMATIC TRANSMISSION ASSY (4WD DRIVE TYPE) (See «A340F»(ref-158065-S23854566212003090900000) )