CAMSHAFT > INSTALLATION

for Preparation Click here



1. INSTALL CAMSHAFT SUB GEAR


    P012595E01

  1. Clamp the camshaft in a vise on the hexagonal lobe.

    NOTICE:
    Do not damage the camshaft.



    A078732E01

  1. Install the camshaft gear bolt washer and the camshaft sub-gear.

    HINT:
    Attach the pins on the gears to the gear bolt washer ends.

  1. Install the wave washer.



    A052353E01

  1. Using snap ring pliers, install the snap ring.



    A078733E01

  1. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.

    SST
    09960-10010   (09962-01000, 09963-00500)

  1. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

    NOTICE:
    Do not damage the camshaft journals.

    HINT:
    When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.



2. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    A078734E01

  1. Align the alignment pin with the groove and install the VVT-i on the camshaft.

    NOTICE:
    Install it with the lock-pin engaged and locked at the most retard angle position.

  1. Apply engine oil to the nut, the mounting surface of VVT-i and the screw threads.

    NOTICE:
    1. Be sure to apply oil, otherwise the specified torque cannot be obtained.
    2. A new nut must be used when replacing the VVT-i unit.



    A005738E01

  1. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.

    Torque:
    150 N*m{ 1,530 kgf*cm , 111 ft.*lbf }

    NOTICE:
    1. The lock nut has left-hand threads.
    2. Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.



3. INSTALL NO.4 CAMSHAFT SUB-ASSEMBLY

NOTICE:
Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. Apply new engine oil to the thrust portion and journal of the camshaft.



    A078741E01

  1. Place the No.4 camshaft at 90° angle of the timing mark (1-dot mark) on the cylinder head.

  1. Apply MP grease to a new oil seal lip.



    A078742E01

  1. Install the oil seal to the camshaft.

    NOTICE:
    1. Do not turn over the oil seal lip.
    2. Insert the oil seal until it stops.

  1. Remove any old packing material from the contact surface.



    A078737E01

  1. Apply seal packing to the No.1 bearing cap as shown in the illustration.

    Seal packing:
    Part No.08826-00080 or equivalent

    NOTICE:
    1. Install the No.1 bearing cap within 5 minutes after applying seal packing.
    2. Do not expose the seal to engine oil within 2 hours after installing.



    A005209E01

  1. Install the 5 bearing caps in their proper locations.

  1. Apply a light coat of engine oil to the threads of the bearing cap bolts.



    A078743E01

  1. Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf }



4. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY

NOTICE:
Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. Apply new engine oil to the thrust portion and journal of the camshaft.



    A078744E01

  1. Align the timing marks (1-dot mark) of the camshaft drive gear with the mark on the driven gear.

  1. Place the camshaft on the cylinder head.



    A005214E01

  1. Install the 5 bearing caps in their proper locations.

  1. Apply a light coat of engine oil to the threads of the bearing cap bolts.



    A078745E01

  1. Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf }

  1. Remove the service bolt.



5. INSTALL NO.2 CAMSHAFT

NOTICE:
Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. Apply new engine oil to the thrust portion and journal of the camshaft.



    A078735E01

  1. Place the No.2 camshaft at 90° angle of the timing mark (2-dot mark) on the cylinder head.

  1. Apply MP grease to a new oil seal lip.



    A078736E01

  1. Install the oil seal to the camshaft.

    NOTICE:
    1. Do not turn over the oil seal lip.
    2. Insert the oil seal until it stops.

  1. Remove any old packing material from the contact surface.



    A078737E01

  1. Apply seal packing to the No.1 bearing cap as shown in the illustration.

    Seal packing:
    Part No.08826-00080 or equivalent

    NOTICE:
    1. Install the No.1 bearing cap within 5 minutes after applying seal packing.
    2. Do not expose the seal to engine oil within 2 hours after installing.



    A005283E01

  1. Install the 5 bearing caps in their proper locations.

  1. Apply a light coat of engine oil to the threads of the bearing cap bolts.



    A078738E01

  1. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf }



6. INSTALL CAMSHAFT

NOTICE:
Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. Apply new engine oil to the thrust portion and journal of the camshaft.



    A078739E01

  1. Align the timing marks (2-dot mark) of the camshaft drive gear with the mark on the driven gear.

  1. Place the camshaft on the cylinder head.



    A005204E01

  1. Install the 5 bearing caps in their proper locations.

  1. Apply a light coat of engine oil to the threads of the bearing cap bolts.



    A078740E01

  1. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf }

  1. Remove the service bolt.



7. INSTALL TIMING BELT NO.3 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.

    HINT:
    If a trace of water is found in the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.



    A078748E01

  1. If the timing belt cover gasket is needed to repair, follow the procedure below.

    1. Repair the cracks and breaks by applying the seal packing to the damaged area.

      Seal packing:
      Part No.08826-00080 or equivalent

      NOTICE:
      When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.



  1. If the timing belt cover gasket is needed to replace, follow the procedure below.

    1. Using a screwdriver and gasket scraper, remove the remaining gasket.

      NOTICE:
      Do not damage the timing belt cover.



      2. A078749E01

    2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.

      NOTICE:
      1. Affix the gasket in the center of the groove.
      2. At the corners, try to keep the gasket thickness uniform.

      HINT:
      Gasket length
      Gasket
      		D
      		E
      		F
      		G
      Length
      		335 mm
      (13.19 in.)
      		180 mm
      (7.09 in.)
      		133 mm
      (5.24 in.)
      		72 mm
      (2.83 in.)

    3. If there is a gap on the joint of the gasket, apply seal packing to close the gap.

      Seal packing:
      Part No.08826-00080 or equivalent

      NOTICE:
      When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.



    A108157E01

  1. Install the timing belt cover No.3 with the 6 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 76 in.*lbf }



8. INSTALL CAMSHAFT TIMING PULLEY


    A078750E01

  1. Paying attention to the direction of the belt guide, install the camshaft timing pulley and tighten the bolt temporally.

    HINT:
    1. Face the belt guide of the RH timing pulley toward front of the engine.
    2. Face the belt guide of the LH timing pulley toward rear of the engine.



    A108162E01

  1. Using SST, tighten the RH pulley bolt.

    SST
    09960-10010   (09962-01000, 09963-01000)
    09249-63010  

    Torque:
    125 N*m{ 1,275 kgf*cm , 92 ft.*lbf }

    NOTICE:
    The torque indicated above is for using SST without any extension tool. If extension tools are used, find the reading of the torque wrench by the formula (Click here).

    Extended length:
    SST (09249-63010) 150 mm (5.91 in.)



    A108164E01

  1. Using SST, tighten the LH pulley bolt.

    SST
    09960-10010   (09962-01000, 09963-01000)

    Torque:
    125 N*m{ 1,275 kgf*cm , 92 ft.*lbf }



9. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2

  1. Install the timing belt idler sub-assembly No.2.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }



10. INSPECT TIMING BELT

NOTICE:
  1. Do not bend, twist or turn the timing belt inside out.
  2. Do not allow the timing belt to come into contact with oil, water or steam.
  3. Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

Check the belt for any defects as shown in the illustration. Also, check the points below.


    EM03336E02

  1. If there is premature parting:

    1. Check for proper installation.
    2. Check the timing cover gasket for damage and proper installation.

  1. If the belt teeth are cracked or damaged, check if either camshaft is locked.

  1. If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.

  1. If there is wear or damage to only one side of the belt, check the belt guide and the alignment of each pulley.

  1. If there is noticeable wear on the belt teeth:

    1. Check the timing cover for damage.
    2. Check that the gasket has been installed correctly.
    3. Check for foreign object on the pulley teeth.
    If there is any trouble in the belt condition, replace the timing belt.



11. INSTALL TIMING BELT

  1. Remove any oil or water on the pulleys, and keep them clean.

    NOTICE:
    1. If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
    2. Wipe only the pulleys; do not use any cleaning agent.

  1. Inspect the idler pulleys.

    1. Check that the idler pulley turns smoothly.

    2. Visually check the seal portion of the idler pulley for oil leakage.

  1. Inspect the water pump.

    1. Turn the pulley, and check that the water pump bearing moves smoothly and does not make any noise.

    2. Visually check the drain hole for coolant leakage.

  1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.



    A082349E01

  1. Turn the crankshaft counterclockwise by approximately 60°.

    NOTICE:
    To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.



    A078751E01

  1. Using SST, turn the timing pulleys, and align the timing marks of the timing pulleys with the No.3 timing belt cover.

    SST
    09960-10010   (09962-01000, 09963-01000)

    NOTICE:
    Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.



    A005062E01

  1. Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.



    A052840E01

  1. Face the front mark on the timing belt forward.

  1. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.

  1. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.



    A078702E02

  1. Install the timing belt in the following order.
    1st
    		Crankshaft timing pulley
    2nd
    		Water pump pulley
    3rd
    		LH camshaft timing pulley
    4th
    		No.2 idler pulley
    5th
    		RH camshaft timing pulley
    6th
    		No.1 idler pulley

    NOTICE:
    Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.



12. INSTALL CHAIN TENSIONER ASSEMBLY NO.1

  1. Set the timing belt tensioner upright on the press.



    A036238E01

  1. Slowly press in the push rod.

    NOTICE:
    Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.

  1. Align the holes of the push rod and housing, and pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.

  1. Release the press.

  1. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.

    Torque:
    27 N*m{ 280 kgf*cm , 20 ft.*lbf }

    NOTICE:
    Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause improper operation.

  1. Remove the 1.5 mm hexagon wrench from the tensioner.



    A078326E01

  1. Turn the crankshaft 2 revolutions slowly and align the timing mark of the crankshaft timing pulley with the oil pump body.

    NOTICE:
    Always turn the crankshaft clockwise.



    A005052E01

  1. Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No.3 timing belt cover as shown in the illustration.
    If the marks do not align, remove the timing belt and reinstall it.

  1. Remove the crankshaft pulley bolt.



13. INSTALL TIMING BELT GUIDE NO.2


    A036239E01

  1. Install the timing belt guide with the cup side facing toward the engine front.



14. INSTALL ENGINE MOUNTING BRACKET RH


    A108728

  1. Install the engine mounting bracket RH with the 2 bolts and 2 nuts.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }



15. INSTALL TIMING BELT NO.2 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.
    If a trace of water is found in the visual check, replace the timing belt cover.



    A108158E01

  1. Install the timing belt cover with the 5 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Connect the 2 clamps.



16. INSTALL TIMING BELT NO.1 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.
    If a trace of water is found in the visual check, replace the timing belt cover.

  1. Install the timing belt cover.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Install the engine wire protector cover to the timing belt No.3 cover.



17. INSTALL CRANKSHAFT PULLEY


    A108137E01

  1. Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.

  1. Using SST, install the pulley bolt.

    SST
    09213-54015   (91651-60855)
    09330-00021  

    Torque:
    220 N*m{ 2,250 kgf*cm , 162 ft.*lbf }



18. INSTALL ENGINE MOUNTING STAY NO.2 RH


    A108727

  1. Install the engine mounting stay No.2 and the engine mounting bracket No.2 with the bolt.

    Torque:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }



19. INSTALL ENGINE MOVING CONTROL ROD


    A108130E01

  1. Temporarily tighten bolts B and C.

  1. First tighten bolt A, bolt B, then bolt C in this order.

    Torque:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }

  1. Tighten bolt D.

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }



20. REMOVE AIR CLEANER BRACKET


    A108129

  1. Install the 2 bolts and air cleaner bracket.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }



21. REMOVE RESERVOIR BRACKET


    A108127

  1. Install the 2 bolts, nut and reservoir bracket.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Connect the clamp.



22. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    A108126

  1. Install the 2 bolts and brake master cylinder reservoir to the bracket.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Connect the connector.



23. INSPECT VALVE CLEARANCE


    A108135

  1. Turn the crankshaft pulley, and align the timing notch with the timing mark "0" of the No.1 timing belt cover.

  1. Check that the valve lifters on the No.1 cylinder (IN and EX) are both loose.
    If not, turn the crankshaft 1 revolution (360°) and align the mark as above.



    A078666E01

  1. Check the valves indicated in the illustration.

    1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

      Valve clearance (Cold):
      Intake:
      0.15 to 0.25 mm (0.0059 to 0.0098 in.)
      Exhaust:
      0.25 to 0.35 mm (0.0098 to 0.0138 in.)

    2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.



    A078667E01

  1. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration.

    1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

      Valve clearance (Cold):
      Intake:
      0.15 to 0.25 mm (0.0059 to 0.0098 in.)
      Exhaust:
      0.25 to 0.35 mm (0.0098 to 0.0138 in.)

    2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.



    A078668E01

  1. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration.

    1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

      Valve clearance (Cold):
      Intake:
      0.15 to 0.25 mm (0.0059 to 0.0098 in.)
      Exhaust:
      0.25 to 0.35 mm (0.0098 to 0.0138 in.)

    2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.



24. ADJUST VALVE CLEARANCE


    A078669E01

  1. Turn the camshaft so that the cam lobe faces upward.

  1. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.



    A078670E01

  1. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A).

    SST
    09248-55040   (09248-05410, 09248-05420)

    HINT:
    1. Apply SST (B) at a slight angle on the side marked with "9" or "7" at the position shown in the illustration.
    2. When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side at a slight angle.

    SST (A)
    		09248-05410
    SST (B)
    		09248-05420



    A078671E01

  1. Using a screwdriver and magnetic finger, remove the adjusting shim.



    EM00494E01

  1. Using a micrometer, measure the thickness of the removed shim.

  1. Calculate the thickness of a new shim so the valve clearance comes within the specified value.
    A
    		Thickness of new shim
    B
    		Thickness of used shim
    C
    		Measured valve clearance

    Specified value (Cold):
    Intake A = B + (C - 0.20 mm (0.0079 in.))
    Exhaust A = B + (C - 0.30 mm (0.0118 in.))



  1. Select a new shim with a thickness as close as possible to the calculated values.

    EXAMPLE (Intake):
    Measured valve clearance = 0.45 mm (0.0177 in.)
    0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.)
    (Measured - Specification = Excess clearance)
    Used shim measurement = 2.80 mm (0.1102 in.)
    0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.)
    (Excess clearance + Used shim = Ideal new shim)
    Closest new shim = 3.05 mm (0.1201 in.)
    Select No.12 shim

    HINT:
    1. Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
    2. Refer to new shim thickness table below.



    V000719E03

    Intake valve clearance (Cold):
    0.15 to 0.25 mm (0.0059 to 0.0098 in.)

    EXAMPLE:
    The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.).
    Replace the 2.800 mm (0.1102 in.) shim with a new No.12 shim.

    New shim thickness mm (in.) 
    Shim No.
    		Thickness
    		Shim No.
    		Thickness
    1
    		2.500 (0.0984)
    		10
    		2.950 (0.1161)
    2
    		2.550 (0.1004)
    		11
    		3.000 (0.1181)
    3
    		2.600 (0.1024)
    		12
    		3.050 (0.1201)
    4
    		2.650 (0.1043)
    		13
    		3.100 (0.1220)
    5
    		2.700 (0.1063)
    		14
    		3.150 (0.1240)
    6
    		2.750 (0.1083)
    		15
    		3.200 (0.1260)
    7
    		2.800 (0.1102)
    		16
    		3.250 (0.1280)
    8
    		2.850 (0.1122)
    		17
    		3.300 (0.1299)
    9
    		2.900 (0.1142)


    HINT:
    New shims have the thickness in millimeters imprinted on the face.



    V000720E03

    Exhaust valve clearance (Cold):
    0.25 to 0.35 mm (0.0098 to 0.0138 in.)

    EXAMPLE:
    The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.).
    Replace the 2.800 mm (0.1102 in.) shim with a new No.10 shim.

    New shim thickness mm (in.) 
    Shim No.
    		Thickness
    		Shim No.
    		Thickness
    1
    		2.500 (0.0984)
    		10
    		2.950 (0.1161)
    2
    		2.550 (0.1004)
    		11
    		3.000 (0.1181)
    3
    		2.600 (0.1024)
    		12
    		3.050 (0.1201)
    4
    		2.650 (0.1043)
    		13
    		3.100 (0.1220)
    5
    		2.700 (0.1063)
    		14
    		3.150 (0.1240)
    6
    		2.750 (0.1083)
    		15
    		3.200 (0.1260)
    7
    		2.800 (0.1102)
    		16
    		3.250 (0.1280)
    8
    		2.850 (0.1122)
    		17
    		3.300 (0.1299)
    9
    		2.900 (0.1142)


    HINT:
    New shims have the thickness in millimeters imprinted on the face.



    A078672E01

  1. Place a new adjusting shim on the valve lifter with imprinted number facing down.

  1. Press down the valve lifter with SST (A), and remove SST (B).

    SST
    09248-55040   (09248-05410, 09248-05420)

  1. Recheck the valve clearance.



25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    A078673E01

  1. Apply seal packing to the cylinder head as shown in the illustration.

    Seal packing:
    Part No.08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes after applying seal packing.
    3. Do not start the engine within 2 hours after installing.



    A108160

  1. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.

    Torque:
    8.0 N*m{ 80 kgf*cm , 71 in.*lbf }



    A078541

  1. Install the engine wire harness with the 3 nuts and 2 clamps.

    Torque:
    8.4 N*m{ 85 kgf*cm , 74 in.*lbf }



26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    A078674E01

  1. Apply seal packing to the cylinder head as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes after applying seal packing.
    3. Do not start the engine within 2 hours after installing.



    A108159

  1. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.

    Torque:
    8.0 N*m{ 80 kgf*cm , 71 in.*lbf }



    A108125

  1. Install the 2 brackets with the 2 bolts.



    A114812

  1. Install the 2 engine wire harness clamps.

    CAUTION:
    Wear insulating gloves.



    A036719

  1. Using an E6 "torx" socket wrench, install the engine wire harness protector with the 2 bolts.

    Torque:
    8.4 N*m{ 85 kgf*cm , 74 in.*lbf }



27. INSTALL IGNITION COIL ASSEMBLY

Torque:
8.0 N*m{ 80 kgf*cm , 71 in.*lbf }



28. INSTALL ENGINE MOUNTING STAY NO.2 RH


    A108727

  1. Install the engine mounting stay No.2 and the engine mounting bracket No.2 with the bolt.

    Torque:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }



29. INSTALL ENGINE MOVING CONTROL ROD


    A108130E01

  1. Temporarily tighten bolts B and C.

  1. First tighten bolt A, bolt B, then bolt C in this order.

    Torque:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }

  1. Tighten bolt D.

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }



30. INSTALL AIR CLEANER BRACKET


    A108129

  1. Install the 2 bolts and air cleaner bracket.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }



31. INSTALL RESERVOIR BRACKET


    A108127

  1. Install the 2 bolts, nut and reservoir bracket.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Connect the clamp.



32. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    A108126

  1. Install the 2 bolts and brake master cylinder reservoir to the bracket.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Connect the connector.



33. CONNECT RADIATOR HOSE INLET


34. INSTALL INTAKE AIR SURGE TANK

  1. Install a new gasket to the intake air surge tank.



    A109274E02

  1. Using a socket hexagon wrench 8 mm, install the intake manifold with the 4 bolts and 2 nuts . Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }

  1. Connect the ground cable connector.



    A109273E02

  1. Install the surge tank stay No. 2 (A) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Install the surge tank stay No. 1 (B) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Install the engine hunger No. 1 (C) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }



    A109268

  1. Connect the ventilation hose.



    A106879E02

  1. Connect the fuel vapor feed hose (A).

  1. Connect the water by-pass hose No.3 (B).

  1. Connect the water by-pass hose No.2 (C).

  1. Connect the throttle motor connector (D).



35. INSTALL EMISSION CONTROL VALVE SET


    A109272E02

  1. Install the emission control valve set with the 2 nuts (A).

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

  1. Connect the fuel vapor feed hose No.2 (B).

  1. Connect the fuel vapor feed hose No.1 (C).

  1. Connect the wire harness clamp (D).

  1. Connect the VSV connector (E).



36. INSTALL AIR CLEANER CASE W/ RESONATOR


    A109267

  1. Install the air cleaner hose No.1 to the throttle body assembly with the hose clamp.



    A106878

  1. Install the air cleaner case w/ resonator with the 5 bolts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



    A109270

  1. Connect the MAF meter connector.

  1. Connect the 2 wire harness clamps to the air cleaner.



    A109893

  1. Connect the ventilation hose No.2.



37. INSTALL AIR CLEANER CAP W/ INLET

  1. Install the air cleaner filter element to the air cleaner case.



    A108124

  1. Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }



38. REMOVE COOL AIR INTAKE DUCT SEAL

  1. Install the 4 clips and cool air intake duct seal.



39. REMOVE BATTERY CARRIER SUB-ASSEMBLY


    A108128

  1. Install the 5 bolts and battery carrier.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



40. REMOVE BATTERY

  1. Install the battery clamp and battery.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }



41. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER

  1. Remove the 4 shock absorber nuts.



    A112528E01

  1. Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).



42. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    E110471

  1. Install the windshield wiper motor and link assembly with the 5 bolts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

  1. Connect the connector.



43. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


44. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    B108016E03

  1. Operate the front wiper, and stop the front wiper motor at the automatic stop position.

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069045E01

  1. Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.



45. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    B108016E03

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069046E01

  1. Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.

  1. Operate the front wipers while spraying water or washer fluid on the windshield.

  1. Make sure that the wipers function properly and there is no interference with the vehicle body.



46. REMOVE FRONT FENDER APRON SEAL RH


    A108724

  1. Install the 2 bolts, clip and fender apron seal RH.



47. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    A109416

  1. Install the fender splash shield with the screw.



48. REMOVE ENGINE UNDER COVER NO.1


    A108722

  1. Install the 6 bolts, 2 screws, 2 clips and engine under cover.



49. INSTALL FRONT WHEEL RH


50. ADD ENGINE OIL


51. ADD COOLANT

  1. Tighten the lower drain plug of the radiator.

  1. Loosen the upper drain plug of the radiator.



    A080492E01

  1. Install a vinyl tube to the vent plug located on the upper drain plug.

  1. Fill the radiator with engine coolant until the vinyl tube is filled with the coolant.

  1. Tighten the upper drain plug.

    CAUTION:
    1. Do not use an alcohol type coolant or plain water alone.
    2. The coolant must be mixed with plain water (preferably de-mineralized water).

      Capacity:
      9.7 liters (10.3 US qts, 8.5 lmp.qts)

    HINT:
    1. Improper coolants may damage engine cooling system.
    2. Use "Toyota Long Life Coolant" or equivalent. Mix it with plain water according to the manufacturer's instruction.
    3. Using of coolant which includes more than 50% (freezing protection down to -35°C (-31°F) or 60% (freezing protection down to -50°C (-58°F) of ethylene-glycol is recommended but not more than 70%.
    4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.

  1. Install the radiator cap securely.

  1. Fill the radiator reservoir tank with coolant.

  1. Warm up the engine.

    HINT:
    Press the inlet and outlet radiator hoses several times by hand while warming up the engine.

  1. Stop the engine and wait until the coolant cools down.

  1. Remove the radiator cap and check the coolant level inside the radiator.

  1. If the coolant level is below the full level, perform the steps from (a) through (j) and repeat the operation until the coolant level stays the full level.

  1. Recheck the coolant level inside the radiator reservoir tank. If it is below the full level, add the coolant.



52. CHECK FOR ENGINE COOLANT LEAKS


A078989

CAUTION:
Do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

  1. Fill the radiator with coolant and attach a radiator cap tester.

  1. Warm up the engine.

  1. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.



53. CHECK FOR ENGINE OIL LEAKS


54. INSPECT IGNITION TIMING

  1. Set the vehicle to inspection mode (Click here).

  1. Warm up the engine.

  1. When using the intelligent tester:

    1. Connect the intelligent tester (with CAN VIM) to the DLC3.

    2. Enter DATA LIST MODE on the intelligent tester.

      Ignition timing:
      8 to 12° BTDC

      NOTICE:
      1. Turn all the electrical systems off.
      2. Inspect the engine idle speed with the cooling fan off.

      HINT:
      Refer to the intelligent tester operator's manual if you need help to select DATA LIST.

    3. Check that the ignition timing advances immediately when the engine speed is increased.



    A051075E02

  1. When not using the intelligent tester:

    1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

      SST
      09843-18040  

      NOTICE:
      1. Make sure of the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
      2. Turn off all electrical systems before connecting the terminals.
      3. Perform this inspection after the cooling fan motor is turned off.



      2. A108139

    2. Pull out the red-colored wire harness as shown in the illustration.

    3. Connect the tester terminal of the timing light to the engine.

      NOTICE:
      Use a timing light which detects the first signal.

    4. Inspect ignition timing at idle.

      Ignition timing:
      8 to 12° BTDC

      NOTICE:
      When checking the ignition timing, the transmission is in neutral.

      HINT:
      Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that the engine rpm returns to idle speed.

    5. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

    6. Inspect ignition timing at idle.

      Ignition timing:
      7 to 24° BTDC

    7. Confirm that the ignition timing advances when the engine rpm is increased.

    8. Remove the timing light.



55. INSPECT IDLE SPEED

  1. Set the vehicle to inspection mode (Click here).

  1. Warm up the engine.

  1. Connect the intelligent tester (with CAN VIM) to the DLC3.

  1. Enter DATA LIST MODE on the intelligent tester.

    Idle speed:
    850 to 950 rpm.

    NOTICE:
    1. When checking the idle speed, the transmission is in neutral.
    2. Check the idle speed with the cooling fan off.
    3. Switch off all accessories and air conditioning before connecting the intelligent tester.

    HINT:
    Refer to the intelligent tester operator's manual for further details.



56. PERFORM INITIALIZATION

  1. Some system need initialization when reconnecting the battery cable. (Click here)



57. REMOVE ENGINE ROOM COVER SIDE


    A109835

  1. Install the 5 clips and engine room cover side



58. REMOVE ENGINE ROOM SIDE LH COVER


    A108719

  1. Fit the clips and install the engine room side LH cover.