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

REMOVAL

1. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Remove the 4 bolts, then remove the No. 1 engine under cover sub-assembly.
2. REMOVE FAN AND GENERATOR V BELT While releasing the belt tension by turning the belt tensioner counterclockwise, remove the V-ribbed belt from the belt tensioner.

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1. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If a normal exists, replace the tensioner.

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1. INSTALL FAN AND GENERATOR V BELT While turning the belt tensioner counterclockwise, align with its holes, and then insert a bar of 6 mm (0.24 in.) into the holes to fix the belt tensioner. Install the V-ribbed belt. While turning the belt tensioner counterclockwise, remove the bar. If it is hard to install the V-ribbed belt, perform the following procedure. Put the V-ribbed belt on all parts except the P/S pump, as shown in the illustration. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the P/S pump.
2. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Install the No. 1 engine under cover with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)

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1. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
2. REMOVE V-BANK COVER (See «REMOVAL»(ref-280570-S10572357662008022200000) )
3. DISCONNECT NO. 2 VENTILATION HOSE
4. REMOVE AIR CLEANER ASSEMBLY (See «REMOVAL»(ref-280570-S10572357662008022200000) )
5. REMOVE INTAKE AIR SURGE TANK (See «REMOVAL»(ref-280543-S18031132922008022200000) )
6. REMOVE IGNITION COIL ASSEMBLY
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See «DISASSEMBLY»(ref-280543-S08472385842008022200000) )
8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See «DISASSEMBLY»(ref-280543-S08472385842008022200000) )
9. 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 caps as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.
10. INSPECT VALVE CLEARANCE Check the valves indicated in the illustration. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust: 0.29 to 0.39 mm (0.011 to 0.015 in.) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust: 0.29 to 0.39 mm (0.011 to 0.015 in.) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust: 0.29 to 0.39 mm (0.011 to 0.015 in.) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
11. ADJUST VALVE CLEARANCE Set the No. 1 cylinder to the 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 caps 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. Remove the No. 1 chain tensioner assembly. NOTE: Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, turn the crankshaft counterclockwise 40° from the TDC first. Remove the 4 bolts, timing chain cover plate and gasket. While rotating the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration. While rotating the stopper plate of the tensioner counterclockwise, insert a bar of ø3.5 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. Remove the 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 receives 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 the No. 2 chain tensioner, insert a pin of ø1.0 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 a wrench so that the cam lobes of No. 1 cylinder face 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. Remove the No. 2 chain tensioner assembly. Remove the No. 2 chain tensioner bolt, and then remove the No. 2 chain tensioner and camshaft timing gear. Remove the 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 receives 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 a wrench so that the cam lobes of the No. 1 cylinder face 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. Remove the camshaft timing gear set bolt with the No. 1 camshaft lifted up, and then remove the No. 1 camshaft and camshaft timing gear with 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. Remove the No. 4 camshaft sub-assembly. 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 receives 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 No. 3 chain tensioner, insert a pin of ø1.0 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. Remove the No. 3 chain tensioner assembly. Remove the No. 3 chain tensioner bolt, and then remove the No. 3 chain tensioner and camshaft timing gear. Remove the No. 3 camshaft sub-assembly. 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 receives 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 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Remove the 4 bearing caps. Hold the No. 1 chain, and remove the No. 3 camshaft, camshaft timing gear and 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. Remove the valve lifters. Determine the size of the valve lifter to be installed according to the following formulas or charts. Using a micrometer, measure the thickness of the removed lifter. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. T: Thickness of removed lifter A: Measured valve clearance N: Thickness of new lifter Intake: N = T + (A - 0.20 mm (0.008 in.)) Exhaust: N = T + (A - 0.30 mm (0.012 in.)) Select a new lifter with a thickness as close as possible to the calculated value. HINT: 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). Install the Mo. 3 camshaft sub-assembly. 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 receives 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 mark) of the camshaft timing gear as shown in the illustration. Apply new engine oil to the thrust portions and journals of the camshafts. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear. Set the No. 3 camshaft onto the LH cylinder head with the cam lobes of the No. 2 cylinder facing downward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil to the threads of the bearing cap bolts. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) Set the paint mark of the No. 1 chain between the timing marks of the camshaft timing gear. Install the No. 3 chain tensioner assembly. While pushing in the tensioner, insert a pin of ø1.0 mm (0.039 in.) into the hole to fix it. Temporarily install the camshaft timing gear and No. 3 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gears. Tighten the No. 3 chain tensioner bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) Install the No. 4 camshaft sub-assembly. 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 receives 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 on the camshaft timing gear with the knock pin of the 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 to the threads and under the heads of the bearing cap bolts. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: For 10mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) 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, 74ft.*lbf) Remove the pin from the No. 3 chain tensioner. Install the 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 receives 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 portions and journals 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 facing downward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) Rotate the No. 1 camshaft clockwise using the hexagonal portion of the No. 1 camshaft so that the timing mark of the camshaft timing gear is aligned with the timing mark 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) Install the No. 2 chain tensioner assembly. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it. Temporarily install the camshaft timing gear and No. 2 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gears. Tighten the No. 2 chain tensioner bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) Install the 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 receives 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 facing upward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) Rotate the No. 2 camshaft clockwise using a 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, 74ft.*lbf) Remove the pin from the No. 2 chain tensioner. Install the No. 1 chain tensioner assembly. 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 ø3.5 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) 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 caps as shown in the illustration.
12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (See «REASSEMBLY»(ref-280543-S34695417412008022200000) )
13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See «REASSEMBLY»(ref-280543-S34695417412008022200000) )
14. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
15. INSTALL INTAKE AIR SURGE TANK (See «INSTALLATION»(ref-280543-S35576651372008022200000) )
16. INSTALL AIR CLEANER ASSEMBLY (See «INSTALLATION»(ref-280570-S15136388832008022200000) )
17. CONNECT NO. 2 VENTILATION HOSE
18. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
19. CHECK FOR ENGINE COOLANT LEAKS (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
20. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
21. INSPECT IGNITION TIMING (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )

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1. REMOVE POWER STEERING LINK ASSEMBLY HINT: (See «REMOVAL»(ref-280575-S22337806492008022200000) )
2. REMOVE DIFFERENTIAL CARRIER ASSEMBLY FRONT (for 4WD) HINT: (See «REMOVAL»(ref-280538-S06637382072008022200000) )
3. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
4. DRAIN ENGINE OIL (See «REMOVAL»(ref-280546-S21331359582008022200000) )
5. REMOVE BATTERY
6. REMOVE V-BANK COVER (See «REMOVAL»(ref-280570-S10572357662008022200000) )
7. REMOVE RADIATOR SUPPORT SEAL UPPER Remove the 11 clips and radiator support seal upper.
8. LOOSEN FLUID COUPLING ASSEMBLY (See «REMOVAL»(ref-280548-S00628602892008022200000) )
9. REMOVE FAN AND GENERATOR V BELT (See «REMOVAL»(ref-280543-S21676096562008022200000) )
10. REMOVE FLUID COUPLING ASSEMBLY (See «REMOVAL»(ref-280548-S00628602892008022200000) )
11. DISCONNECT NO. 2 VENTILATION HOSE
12. REMOVE AIR CLEANER ASSEMBLY (See «REMOVAL»(ref-280570-S10572357662008022200000) )
13. 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.
14. REMOVE WATER INLET
15. SEPARATE VANE PUMP ASSEMBLY 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.
16. REMOVE GENERATOR ASSEMBLY (See «REMOVAL»(ref-280550-S14020872822008022200000) )
17. SEPARATE COOLER COMPRESSOR ASSEMBLY (See «INSTALLATION»(ref-280570-S18262565642008022200000) )
18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the 5 bolts and V-ribbed belt tensioner.
19. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the 2 bolts and 2 idler pulleys.
20. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY Remove the bolt and idler pulley.
21. 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)
22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Remove the 10 bolts and 2 nuts. Insert the blade of SST between the oil pan and No. 2 oil pan, cut off applied sealer and remove the No. 2 oil pan. SST 09032-00100 NOTE: Be careful not to damage the contact surfaces of the oil pan and No. 2 oil pan. Be careful not to damage the No. 2 oil pan flange.
23. REMOVE OIL STRAINER SUB-ASSEMBLY Remove the 2 nuts, oil strainer and gasket.
24. REMOVE OIL PAN SUB-ASSEMBLY 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.
25. REMOVE INTAKE AIR SURGE TANK (See «REMOVAL»(ref-280543-S18031132922008022200000) )
26. REMOVE IGNITION COIL ASSEMBLY
27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See «DISASSEMBLY»(ref-280543-S08472385842008022200000) )
28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See «DISASSEMBLY»(ref-280543-S08472385842008022200000) )
29. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Disconnect the 2 oil control valve connectors. Remove the 2 bolts and 2 camshaft timing oil control valves.
30. REMOVE VVT SENSOR (See «REMOVAL»(ref-280570-S00169381272008022200000) )
31. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY (See «DISASSEMBLY»(ref-280543-S08472385842008022200000) )
32. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
33. 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.
34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 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 (j>3.5 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.
35. REMOVE CHAIN TENSIONER SLIPPER
36. REMOVE NO. 1 IDLE GEAR SHAFT Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.
37. REMOVE NO. 2 CHAIN VIBRATION DAMPER Remove the 2 No. 2 chain vibration dampers.
38. REMOVE CHAIN SUB-ASSEMBLY

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1. INSTALL CHAIN TENSIONER SLIPPER
2. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 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 ø3.5 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)
3. INSTALL CHAIN SUB-ASSEMBLY 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.
4. INSTALL NO. 2 CHAIN VIBRATION DAMPER Instal the 2 No. 2 chain vibration dampers.
5. INSTALL NO. 1 IDLE GEAR SHAFT Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block. NOTE: Be careful of the idle gear direction. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) Remove the bar from the chain tensioner.
6. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (See «REASSEMBLY»(ref-280543-S34695417412008022200000) )
7. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY (See «REASSEMBLY»(ref-280543-S34695417412008022200000) )
8. INSTALL VVT SENSOR (See «INSTALLATION»(ref-280570-S07928377062008022200000) )
9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 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)
10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (See «REASSEMBLY»(ref-280543-S34695417412008022200000) )
11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See «REASSEMBLY»(ref-280543-S34695417412008022200000) )
12. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
13. INSTALL INTAKE AIR SURGE TANK (See «INSTALLATION»(ref-280543-S35576651372008022200000) )
14. INSTALL OIL PAN SUB-ASSEMBLY 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: Toyota Genuine Seal Packing Black, Three Bond 1207B 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: For bolt A 21 N*m (214 kgf*cm, 15 ft.*lbf) For bolt B 21 N*m (214 kgf*cm, 15 ft.*lbf) For bolt C 10 N*m (102 kgf*cm, 7 ft.*lbf) For nut 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Each bolt length is as follows: 25 mm (0.98 in.) 45 mm (1.77 in.) 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.
15. INSTALL OIL STRAINER SUB-ASSEMBLY Install a new gasket and the oil strainer with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
16. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and No. 2 oil pan. 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: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTE: Install the No. 2 oil pan within 3 minutes after applying seal packing. After installing it, the No. 2 oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Install the No. 2 oil pan 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)
17. 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)
18. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY Install the idler pulley with the bolt. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) HINT: "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.
19. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Install the 2 idler pulleys with the 2 bolts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 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: 70 mm (2.76 in.) 33 mm (1.30 in.)
21. INSTALL COOLER COMPRESSOR ASSEMBLY (See «INSTALLATION»(ref-280570-S18262565642008022200000) )
22. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(ref-280550-S29570129352008022200000) )
23. INSTALL VANE PUMP ASSEMBLY 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.
24. INSTALL WATER INLET (See «INSTALLATION»(ref-280548-S04558888122008022200000) )
25. 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.
26. INSTALL AIR CLEANER ASSEMBLY (See «INSTALLATION»(ref-280570-S15136388832008022200000) )
27. CONNECT NO. 2 VENTILATION HOSE
28. INSTALL FLUID COUPLING ASSEMBLY (See «INSTALLATION»(ref-280548-S04558888122008022200000) )
29. INSTALL FAN AND GENERATOR V BELT (See «REMOVAL»(ref-280543-S21676096562008022200000) )
30. FULLY TIGHTEN FLUID COUPLING ASSEMBLY (See «INSTALLATION»(ref-280548-S04558888122008022200000) )
31. INSTALL RADIATOR SUPPORT SEAL UPPER
32. INSTALL BATTERY
33. INSTALL DIFFERENTIAL CARRIER ASSEMBLY FRONT HINT: (See «INSTALLATION»(ref-280538-S30964839122008022200000) )
34. INSTALL POWER STEERING LINK ASSEMBLY HINT: (See «INSTALLATION»(ref-280575-S35587798372008022200000) )
35. ADD ENGINE OIL (See «INSTALLATION»(ref-280546-S02834416202008022200000) )
36. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
37. CHECK FOR ENGINE OIL LEAKS
38. CHECK FOR ENGINE COOLANT LEAKS (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
39. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
40. INSPECT IGNITION TIMING (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )

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Scheme 492

1. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
2. REMOVE V-BANK COVER (See «REMOVAL»(ref-280570-S10572357662008022200000) )
3. DISCONNECT NO. 2 VENTILATION HOSE
4. REMOVE AIR CLEANER ASSEMBLY (See «REMOVAL»(ref-280570-S10572357662008022200000) )
5. 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 with 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.
6. REMOVE IGNITION COIL ASSEMBLY
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.
8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.
9. 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 caps 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.
10. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 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 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 ø3.5 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.
11. 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 receives 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 No. 2 chain tensioner, insert a pin of ø1.0 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 a wrench so that the cam lobes of No. 1 cylinder face 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.
12. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the No. 2 chain tensioner bolt, and then remove the No. 2 chain tensioner and camshaft timing gear.
13. 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 receives 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 a wrench so that the cam lobes of No. 1 cylinder face 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 lifted up, and then remove the No. 1 camshaft and camshaft timing gear with 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.
14. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY 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 receives 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 No. 3 chain tensioner, insert a pin of ø1.0 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.
15. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the No. 3 chain tensioner bolt, and then remove the No. 3 chain tensioner and camshaft timing gear.
16. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY 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 receives 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 lifted up, and then remove the No. 3 camshaft and camshaft timing gear with 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.

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1. 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 receives 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 portions and journals 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 facing downward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil to 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: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) Rotate the No. 1 camshaft clockwise using a wrench so that the timing mark of the camshaft timing gear is aligned with the timing mark 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)
2. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY While pushing in the tensioner, insert a pin of ø1.0 mm (0.039 in.) into the hole to fix it. Temporarily install the camshaft timing gear and No. 2 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gears. Tighten the No. 2 chain tensioner bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
3. 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 receives 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 the No. 1 cylinder facing upward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil to 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: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) Rotate the No. 2 camshaft clockwise using a 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 No. 2 chain tensioner.
4. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 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 receives 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 mark) of the camshaft timing gear as shown in the illustration. Apply new engine oil to the thrust portions and journals 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. 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 facing downward as shown in the illustration. Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil to 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: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) Set the paint mark of the No. 1 chain between 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)
5. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY While pushing in the tensioner, insert a pin of (j)1.0 mm (0.039 in.) into the hole to fix it. Temporarily install the camshaft timing gear and No. 3 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gears. Tighten the chain tensioner No. 3 bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
6. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 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 receives 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 of the camshaft timing gear with the knock pin of the 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 to 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: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) 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 No. 3. chain tensioner Release the chain tension between the camshaft timing gear (RH bank) and crankshaft timing gear by turning the crankshaft pulley clockwise slightly.
7. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 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 ø3.5 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) 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 caps as shown in the illustration.
8. SET NO. 1 CYLINDER TO TDC / COMPRESSION (See «VALVE CLEARANCE»(ref-280543-S08781237132008022200000) )
9. INSPECT VALVE CLEARANCE (See «ADJUSTMENT»(ref-280543-S05029895172008022200000) )
10. ADJUST VALVE CLEARANCE (See «ADJUSTMENT»(ref-280543-S05029895172008022200000) )
11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 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 seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, the 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: For bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) For bolt B 9.0 N*m (92 kgf*cm, 80 in.*lbf) Nut 9.0 N*m (92 kgf*cm, 80 in.*lbf)
12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 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 seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B 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: For bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) For bolt B 9.0 N*m (92 kgf*cm, 80 in.*lbf) Nut 9.0 N*m (92 kgf*cm, 80 in.*lbf)
13. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
14. 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 with motor connector, Connect the 2 VSV connectors, Connect the ventilation hose, Connect the fuel vapor feed hose. Connect the 2 water by-pass hoses.
15. INSTALL AIR CLEANER ASSEMBLY (See «INSTALLATION»(ref-280570-S15136388832008022200000) )
16. CONNECT NO. 2 VENTILATION HOSE
17. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
18. CHECK FOR ENGINE COOLANT LEAKAGE (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
19. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
20. INSPECT IGNITION TIMING (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «REMOVAL»(ref-280571-S35920585772008022200000) )
2. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
3. DRAIN ENGINE OIL (See «REMOVAL»(ref-280546-S21331359582008022200000) )
4. REMOVE CHAIN SUB-ASSEMBLY HINT: (See «REMOVAL»(ref-280543-S25902476342008022200000) )
5. REMOVE NO. 1 COOL AIR INLET Remove the 2 bolts and cool air inlet with air cleaner hose.
6. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY Remove the ATF level gauge. Remove the bolt and pull out the oil filler tube. Remove the O-ring from the oil filler tube.
7. REMOVE EXHAUST PIPE ASSEMBLY FRONT HINT: (See «REMOVAL»(ref-280574-S02270279812008022200000) )
8. REMOVE MANIFOLD STAY Remove the 3 bolts and manifold stay.
9. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Disconnect the A/F sensor connector. Remove the 6 nuts, exhaust manifold and gasket.
10. REMOVE NO. 2 EXHAUST FRONT PIPE ASSEMBLY (See «REMOVAL»(ref-280574-S02270279812008022200000) )
11. REMOVE NO. 2 MANIFOLD STAY Remove the 3 bolts and No. 2 manifold stay.
12. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Disconnect the A/F sensor connector. Remove the 6 nuts, exhaust manifold and gasket.
13. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (See «REMOVAL»(ref-280571-S35920585772008022200000) )
14. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY (See «REMOVAL»(ref-280571-S35920585772008022200000) )
15. REMOVE INTAKE MANIFOLD Disconnect the 6 fuel injector connectors. Remove the 10 bolts, intake manifold and 2 gaskets.
16. 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.
17. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) While raising the No. 2 chain tensioner, insert a pin of ø1.0 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 No. 2 timing chain. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly.
18. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 2 chain tensioner.
19. REMOVE CAMSHAFTS (for Bank 1) 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 receives 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 a 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.
20. REMOVE NO. 2 CAMSHAFT BEARING
21. REMOVE NO. 1 CHAIN VIBRATION DAMPER Remove the 2 bolts and No. 1 chain vibration damper.
22. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) While pushing down the No. 3 chain tensioner, insert a pin of ø1.0 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 No. 2 timing chain. NOTE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly.
23. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the bolt and No. 3 chain tensioner.
24. REMOVE CAMSHAFTS (for Bank 2) 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 receives 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.
25. REMOVE CYLINDER HEAD SUB-ASSEMBLY 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.
26. REMOVE CYLINDER HEAD GASKET
27. 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.
28. REMOVE NO. 2 CYLINDER HEAD GASKET

Scheme 526

1. INSPECT CYLINDER HEAD SET BOLT Using vernier calipers, measure the outside thread diameter of the bolt. Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 in.) Minimum outside diameter: 10.7 mm (0.421 in.)

Scheme 527

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Scheme 531

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Scheme 538

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Scheme 540

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Scheme 546

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Scheme 549

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Scheme 551

Scheme 552

1. INSTALL NO. 2 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 seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the 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 upper side facing upward. NOTE: Be careful of the installation direction. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.
2. 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 (Procedures "A" and "B"). If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil to 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 (Procedure "A"). 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° as shown (Procedure "B"). 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 to 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)
3. 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 seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the 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 upper side facing upward. NOTE: Be careful of the installation direction. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY 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 (Procedures "A" and "B"). If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil to 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 (Procedure "A"). 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° as shown (Procedure "B"). 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)
5. INSTALL CAMSHAFTS (for Bank 2) 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 receives 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. Install the crankshaft pulley set bolt, and turn the crankshaft, and set the crankshaft set key at the left horizontal position. NOTE: Setting the crankshaft at a 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 portions and journals of the camshafts. Place the 2 camshafts onto the cylinder head with the cam lobes of No. 2 cylinder facing each correct direction as shown in the illustration. Install the 8 bearing caps in their proper locations. Apply a light coat of engine oil to 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: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf)
6. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY While pushing in the tensioner, insert a pin of ø1.0 mm (0.039 in.) into the hole to fix it. Install the No. 3 chain tensioner with the bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
7. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) Align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the 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 the 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 No. 3 tensioner.
8. INSTALL NO. 1 CHAIN VIBRATION DAMPER Install the No. 1 chain vibration damper with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
9. INSTALL NO. 2 CAMSHAFT BEARING Install the No. 2 camshaft bearing to the cylinder head. NOTE: Clean the backside of the bearing and the contact surface of the cylinder head and prevent oil from adhering to them.
10. INSTALL CAMSHAFTS (for Bank 1) 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 receives 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 portions and journals of the camshafts. Place the 2 camshafts onto the cylinder head with the cam lobes of No. 1 cylinder facing each direction as shown in the illustration. Install the 8 bearing caps in their proper locations. Apply a light coat of engine oil to 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: For 10 mm (0.39 in.) head 9.0 N*m (92 kgf*cm, 80 in.*lbf) For 12 mm (0.47 in.) head 24 N*m (245 kgf*cm, 18 ft.*lbf) Turn the camshafts clockwise until the knock pin comes to 90° position to the cylinder head.
11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY While pushing in the tensioner, insert a pin of ø1.0 mm (0.039 in.) into the hole to fix it. Install the No. 2 chain tensioner with the bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) Align the mark links (yellow) with the timing marks (1-dot mark) of the 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 the 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 No. 2 tensioner.
13. 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.
14. 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.
15. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-280571-S34368921122008022200000) )
16. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-280571-S34368921122008022200000) )
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Set a new gasket to the LH cylinder head with the oval shape 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.
18. INSTALL NO. 2 MANIFOLD STAY Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
19. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY (See «INSTALLATION»(ref-280574-S16909162092008022200000) )
20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Set a new gasket to the RH cylinder head with the oval shape 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.
21. INSTALL MANIFOLD STAY Install the manifold stay with the 3 bolts. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
22. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See «INSTALLATION»(ref-280574-S16909162092008022200000) )
23. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY Coat a new O-ring with ATF, and install it 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.
24. INSTALL NO. 1 COOL AIR INLET Install the cool air inlet with air cleaner hose with the 2 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
25. INSTALL CHAIN SUB-ASSEMBLY HINT: (See «INSTALLATION»(ref-280543-S05355169312008022200000) )
26. ADD ENGINE OIL (See «INSTALLATION»(ref-280546-S02834416202008022200000) )
27. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
28. CHECK FOR ENGINE OIL LEAKAGE
29. CHECK FOR ENGINE COOLANT LEAKAGE (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
30. CHECK FOR FUEL LEAKAGE
31. CHECK FOR EXHAUST GAS LEAKAGE
32. INSPECT ENGINE IDLE SPEED (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )
33. INSPECT COMPRESSION (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )
34. INSPECT CO/HC (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )

Scheme 553

Scheme 554

Scheme 555

Scheme 556

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE V-BANK COVER (See «REMOVAL»(ref-280570-S10572357662008022200000) )
3. REMOVE RADIATOR SUPPORT SEAL UPPER Remove the 11 clips and radiator support seal upper.
4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Remove the 4 bolts and engine under cover.
5. LOOSEN FAN WITH FLUID COUPLING (See «REMOVAL»(ref-280548-S00628602892008022200000) )
6. REMOVE FAN AND GENERATOR V BELT (See «REMOVAL»(ref-280543-S21676096562008022200000) )
7. REMOVE FAN WITH FLUID COUPLING (See «REMOVAL»(ref-280548-S00628602892008022200000) )
8. REMOVE CRANKSHAFT PULLEY HINT: (See «REMOVAL»(ref-280543-S25902476342008022200000) ) SST 09213-54015 (91651 -60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
9. 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.

Scheme 557

1. 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
2. INSTALL CRANKSHAFT PULLEY HINT: (See «INSTALLATION»(ref-280543-S05355169312008022200000) ) SST 09213-54015 (91651 -60855), 09330-00021
3. INSTALL FAN WITH FLUID COUPLING (See «INSTALLATION»(ref-280548-S04558888122008022200000) )
4. INSTALL FAN AND GENERATOR V BELT (See «REMOVAL»(ref-280543-S21676096562008022200000) )
5. FULLY TIGHTEN FAN WITH FLUID COUPLING (See «INSTALLATION»(ref-280548-S04558888122008022200000) )
6. INSTALL RADIATOR SUPPORT SEAL UPPER
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Connect the cable to the negative battery terminal. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
8. CHECK FOR ENGINE OIL LEAKAGE
9. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Install the engine under cover with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
10. 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 558

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Scheme 566

1. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: (See «REMOVAL»(ref-280555-S37543999482008022200000) )
2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: (See «REMOVAL»(ref-280554-S23792483382008022200000) )
3. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY 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.

Scheme 567

Scheme 568

Scheme 569

1. 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
2. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY 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: Toyota Genuine Adhesive 1324, 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)
3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: (See «INSTALLATION»(ref-280555-S05989732172008022200000) )
4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: (See «INSTALLATION»(ref-280554-S41868190542008022200000) )
5. CHECK FOR ENGINE OIL LEAKAGE

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Scheme 576

Scheme 577

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Scheme 581

1. DISCHARGE FUEL SYSTEM PRESSURE (See «REMOVAL»(ref-280571-S35920585772008022200000) )
2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: (See «REMOVAL»(ref-280555-S37543999482008022200000) )
3. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: (See «REMOVAL»(ref-280554-S23792483382008022200000) )
4. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
5. DRAIN ENGINE OIL (See «REMOVAL»(ref-280546-S21331359582008022200000) )
6. REMOVE BATTERY
7. REMOVE HOOD SUB-ASSEMBLY Disconnect the windshield washer hose. Separate the 2 hood supports. Remove the 4 bolts and hood.
8. REMOVE V-BANK COVER (See «REMOVAL»(ref-280570-S10572357662008022200000) )
9. REMOVE NO. 2 VENTILATION HOSE
10. REMOVE AIR CLEANER ASSEMBLY (See «REMOVAL»(ref-280570-S10572357662008022200000) )
11. REMOVE RADIATOR SUPPORT SEAL UPPER Remove the 11 clips and radiator support seal upper.
12. REMOVE RADIATOR ASSEMBLY (See «REMOVAL»(ref-280548-S40703427042008022200000) )
13. REMOVE FAN SHROUD Unfasten the hose clamp, and disconnect the 2 oil cooler hoses from the fan shroud. Remove the fan shroud.
14. LOOSEN FAN WITH FLUID COUPLING (See «REMOVAL»(ref-280548-S00628602892008022200000) )
15. REMOVE FAN AND GENERATOR V BELT (See «REMOVAL»(ref-280543-S21676096562008022200000) )
16. REMOVE FAN WITH FLUID COUPLING Remove the 4 bolts and fan with fluid coupling.
17. REMOVE FAN PULLEY
18. SEPARATE VANE PUMP ASSEMBLY (See «REMOVAL»(ref-280543-S25902476342008022200000) )
19. REMOVE GENERATOR ASSEMBLY (See «REMOVAL»(ref-280550-S14020872822008022200000) )
20. SEPARATE COOLER COMPRESSOR (See «INSTALLATION»(ref-280570-S18262565642008022200000) )
21. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (See «REMOVAL»(ref-280571-S35920585772008022200000) )
22. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY (See «REMOVAL»(ref-280571-S35920585772008022200000) )
23. DISCONNECT HEATER WATER INLET HOSE B
24. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
25. REMOVE INTAKE AIR SURGE TANK (See «REMOVAL»(ref-280543-S18031132922008022200000) )
26. SEPARATE ENGINE WIRE Remove the front door scuff plate RH (See «REMOVAL»(ref-280569-S23218485322008022200000) ). Remove the cowl side trim board RH (See «REMOVAL»(ref-280569-S23218485322008022200000) ). Remove the glove compartment door (See «REMOVAL»(ref-280569-S23218485322008022200000) ). Disconnect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire before pulling out the engine wire into the engine room. Disconnect the front differential connector.
27. SEPARATE NO. 2 ENGINE WIRE Disconnect the ground cable from the cylinder block.
28. REMOVE ENGINE ASSEMBLY Install the 2 engine hangers with the 4 bolts as shown in the illustration. Part No.: Engine hanger No. 1:12281-31070 Engine hanger No. 2:12282-31050 Bolt: 91671-10825 Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf) Attach the engine sling device and hang the engine with the chain block. Remove the 4 bolts and 4 nuts, and separate the engine mounting brackets from the frame brackets. Lift the engine out of the vehicle carefully. NOTE: Make sure the engine is clear of all wiring and hoses. Place the engine onto a working bench.
29. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (See «REMOVAL»(ref-280543-S14311246982008022200000) )
30. REMOVE ENGINE WIRE
31. REMOVE NO. 1 RADIATOR HOSE
32. REMOVE RADIATOR OUTLET, NO. 2 HOSE CLAMP OR CLIP
33. REMOVE HEATER WATER INLET HOSE A
34. REMOVE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
35. REMOVE VENTILATION HOSE
36. REMOVE NO. 2 VENTILATION HOSE
37. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Remove the 6 nuts, exhaust manifold and gasket.
38. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Remove the 6 nuts, exhaust manifold and gasket.
39. INSPECT EXHAUST MANIFOLD FOR FLATNESS Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head. Maximum warpage: 0.7 mm (0.028 in.) If warpage is greater than the maximum, replace the exhaust manifold. HINT: Maximum warpage of each installation surface: 0.3 mm (0.012 in.)
40. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH Remove the 4 bolts and engine mounting bracket with engine mounting insulator.
41. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH Remove the 3 bolts and engine mounting bracket with engine mounting insulator.
42. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the 2 bolts and 2 idler pulleys.
43. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY Remove the bolt and idler pulley.
44. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See «REMOVAL»(ref-280543-S25902476342008022200000) )
45. REMOVE WATER INLET (See «REMOVAL»(ref-280548-S00628602892008022200000) )
46. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY Remove the 3 bolts, 2 nuts, oil filter bracket and gasket.
47. REMOVE INTAKE MANIFOLD (See «REMOVAL»(ref-280543-S05001068542008022200000) )
48. INSPECT INTAKE MANIFOLD FOR FLATNESS Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head and intake air surge tank. Maximum warpage: Intake air surge tank side: 0.8 mm (0.031 in.) Cylinder head side: 0.2 mm (0.008 in.) If warpage is greater than the maximum, replace the intake manifold.
49. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Remove the 2 bolts and 2 camshaft timing oil control valves.
50. REMOVE WATER BY-PASS JOINT RR (See «REMOVAL»(ref-280543-S05001068542008022200000) )
51. REMOVE OIL FILLER CAP SUB-ASSEMBLY
52. REMOVE OIL FILLER CAP HOUSING Remove the 2 nuts, oil filler cap housing and gasket.
53. REMOVE IGNITION COIL ASSEMBLY
54. REMOVE SPARK PLUG
55. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
56. REMOVE PARTIAL ENGINE ASSEMBLY

INSTALLATION

1. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
2. INSTALL SPARK PLUG Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
3. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. INSTALL OIL FILLER CAP HOUSING Install a new gasket and oil filler cap housing with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
5. INSTALL OIL FILLER CAP SUB-ASSEMBLY
6. INSTALL WATER BY-PASS JOINT RR (See «INSTALLATION»(ref-280543-S17198593412008022200000) )
7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
8. INSTALL INTAKE MANIFOLD (See «INSTALLATION»(ref-280543-S17198593412008022200000) )
9. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY Install a new gasket and oil filter bracket with the 3 bolts and 2 nuts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
10. INSTALL WATER INLET (See «INSTALLATION»(ref-280548-S04558888122008022200000) )
11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See «INSTALLATION»(ref-280543-S05355169312008022200000) )
12. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (See «INSTALLATION»(ref-280543-S05355169312008022200000) )
13. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (See «INSTALLATION»(ref-280543-S05355169312008022200000) )
14. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH Install the engine mounting bracket with engine mounting insulator with the 3 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
15. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH Install the engine mounting bracket with engine mounting insulator with the 4 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (See «INSTALLATION»(ref-280543-S17198593412008022200000) )
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See «INSTALLATION»(ref-280543-S17198593412008022200000) )
18. INSTALL NO. 2 VENTILATION HOSE
19. INSTALL VENTILATION HOSE
20. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
21. INSTALL HEATER WATER INLET HOSE A
22. INSTALL RADIATOR OUTLET, NO. 2 HOSE CLAMP OR CLIP
23. INSTALL NO. 1 RADIATOR HOSE
24. INSTALL ENGINE WIRE
25. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (See «INSTALLATION»(ref-280543-S21032417282008022200000) )
26. INSTALL ENGINE ASSEMBLY Attach the engine sling device and hang the engine with the chain block. Lower the engine into the engine room carefully. Attach the engine mounting brackets to the frame brackets. Install the engine mounting brackets to the frame brackets with the 4 bolts and 4 nuts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) Remove the 4 bolts and 2 engine hangers.
27. INSTALL NO. 2 ENGINE WIRE Install the ground cable to the cylinder block. Torque: 13 N*m (133 kgf*cm, 9 ft.*lbf)
28. INSTALL ENGINE WIRE Connect the front differential connector. Insert the engine wire to the cabin space, and install the grommet. Connect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire. Install the glove compartment door. Install the cowl side trim board RH. Install the front door scuff plate RH.
29. INSTALL INTAKE AIR SURGE TANK (See «INSTALLATION»(ref-280543-S35576651372008022200000) )
30. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
31. CONNECT HEATER WATER INLET HOSE B
32. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-280571-S34368921122008022200000) )
33. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-280571-S34368921122008022200000) )
34. INSTALL COOLER COMPRESSOR (See «INSTALLATION»(ref-280570-S18262565642008022200000) )
35. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(ref-280550-S29570129352008022200000) )
36. INSTALL VANE PUMP ASSEMBLY (See «INSTALLATION»(ref-280543-S05355169312008022200000) )
37. INSTALL FAN PULLEY
38. INSTALL FAN WITH FLUID COUPLING Temporarily install the fan with fluid coupling with the 4 nuts.
39. INSTALL FAN AND GENERATOR V BELT (See «REMOVAL»(ref-280543-S21676096562008022200000) )
40. FULLY TIGHTEN FAN WITH FLUID COUPLING (See «INSTALLATION»(ref-280548-S04558888122008022200000) )
41. INSTALL FAN SHROUD Put the fan shroud into the engine room. Connect the 2 oil cooler hoses with the hose clamp.
42. INSTALL RADIATOR ASSEMBLY (See «INSPECTION»(ref-280548-S01967719882008022200000) )
43. INSTALL RADIATOR SUPPORT SEAL UPPER
44. INSTALL AIR CLEANER ASSEMBLY (See «INSTALLATION»(ref-280570-S15136388832008022200000) )
45. CONNECT NO. 2 VENTILATION HOSE
46. INSTALL HOOD SUB-ASSEMBLY Install the hood with the 4 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Tighten the 2 hood supports. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) Connect the windshield washer hose.
47. ADJUST HOOD SUB-ASSEMBLY (See «ADJUSTMENT»(ref-280533-S21342786052008022200000) )
48. INSTALL BATTERY
49. ADD ENGINE OIL (See «INSTALLATION»(ref-280546-S02834416202008022200000) )
50. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
51. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: (See «INSTALLATION»(ref-280555-S05989732172008022200000) )
52. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: (See «INSTALLATION»(ref-280554-S41868190542008022200000) )
53. CHECK FOR ENGINE COOLANT LEAKAGE (See «REPLACEMENT»(ref-280548-S21263854542008022200000) )
54. CHECK FOR FUEL LEAKAGE (See «ON-VEHICLE INSPECTION»(ref-280571-S13399001902008022200000) )
55. CHECK FOR ENGINE OIL LEAKAGE
56. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
57. INSPECT IGNITION TIMING (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )
58. INSPECT ENGINE IDLE SPEED (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )
59. INSPECT CO/HC (See «ON-VEHICLE INSPECTION»(ref-280543-S22845599842008022200000) )

Scheme 582

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589