Installation
INSTALLATION
PROCEDURE
1. INSTALL NO. 2 CYLINDER HEAD GASKET
(a) Place a new No. 2 cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
*a | Lot No. |
|
Front of Engine |
NOTICE:
- Remove any oil from the contact surfaces.
- Make sure to install the No. 2 cylinder head gasket in the correct direction.
(b) Apply seal packing to the No. 2 cylinder head gasket as shown in the illustration.
Seal Packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surfaces.
- Install the No. 2 cylinder head gasket within 3 minutes and tighten the
cylinder head set bolts within 15 minutes of applying seal packing.
*1 | No. 2 Cylinder Head Gasket |
*a | 5.0 to 7.0 mm (0.197 to 0.276 in.) |
*b | 3.0 to 5.0 mm (0.118 to 0.197 in.) |
*c | 7.0 to 9.0 mm (0.276 to 0.354 in.) |
*d | 38.2 mm (1.50 in.) |
*e | 110.0 mm (4.33 in.) |
|
Front of Engine |
|
Seal Packing |
2. INSTALL CYLINDER HEAD LH
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3. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
*a | Lot No. |
|
Front of Engine |
NOTICE:
- Remove any oil from the contact surfaces.
- Make sure to install the cylinder head gasket in the correct direction.
(b) Apply seal packing to the cylinder head gasket as shown in the illustration.
Seal Packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surfaces.
- Install the cylinder head gasket within 3 minutes and tighten the
cylinder head set bolts within 15 minutes of applying seal packing.
*1 | Cylinder Head Gasket |
*a | 5.0 to 7.0 mm (0.197 to 0.276 in.) |
*b | 3.0 to 5.0 mm (0.118 to 0.197 in.) |
*c | 7.0 to 9.0 mm (0.276 to 0.354 in.) |
*d | 38.5 mm (1.52 in.) |
*e | 144.0 mm (5.67 in.) |
|
Front of Engine |
|
Seal Packing |
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY
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5. INSTALL WATER OUTLET
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6. INSTALL VALVE STEM CAP
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7. INSTALL VALVE LASH ADJUSTER ASSEMBLY
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8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
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9. INSTALL NO. 1 CHAIN VIBRATION DAMPER
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10. INSTALL NO. 2 CHAIN VIBRATION DAMPER
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11. INSTALL SENSOR WIRE
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12. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
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13. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
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14. INSTALL CAMSHAFT BEARING CAP (for Bank 2)
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15. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)
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16. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
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17. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
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18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
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19. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
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20. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
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21. INSTALL CAMSHAFT
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22. INSTALL NO. 2 CAMSHAFT
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23. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
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24. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)
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25. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
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26. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
Click here
27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
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28. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
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29. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
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30. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
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31. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
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32. INSTALL CHAIN SUB-ASSEMBLY
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33. INSTALL CHAIN TENSIONER SLIPPER
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34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
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35. INSPECT VALVE TIMING
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36. INSTALL TIMING CHAIN COVER ASSEMBLY
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37. INSTALL TIMING CHAIN CASE OIL SEAL
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38. INSTALL OIL PAN SUB-ASSEMBLY
(a) Install 2 new oil pan gaskets to the timing chain cover assembly.
(b) Apply seal packing in a continuous line as shown in the illustration.
Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal Packing Diameter: 3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTICE:
- Remove any oil from the contact surfaces.
- Install the oil pan sub-assembly within 3 minutes of applying seal packing.
- Do not start the engine for at least 2 hours after installation.
| |
(c) Install the oil pan sub-assembly with the 16 bolts and 2 nuts in the order shown in the illustration.
*a | Torque |
*b | Bolt and Nut Tightening Order |
|
Bolt |
|
Nut |
Torque:
Bolt (A) :
10 N·m {102 kgf·cm, 7 ft·lbf}
Bolt (B), (C), (D) :
21 N·m {214 kgf·cm, 15 ft·lbf}
Nut :
21 N·m {214 kgf·cm, 15 ft·lbf}
Bolt Length:
Item | Length |
Bolt (A) | 16 mm (0.630 in.) |
Bolt (B) | 45 mm (1.77 in.) |
Bolt (C) | 25 mm (0.984 in.) |
Bolt (D) | 70 mm (2.76 in.) |
(d) Wipe off any excess seal packing with a clean piece of cloth.
NOTICE:
Do not allow seal packing to contact the No. 1 crankshaft position sensor plate.
|
Wipe off the Seal Packing |
39. INSTALL OIL STRAINER SUB-ASSEMBLY
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40. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
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41. INSTALL SPARK PLUG TUBE GASKET
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42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
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43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
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44. INSTALL SENSOR WIRE
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45. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
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46. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)
Click here
47. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)
Click here
48. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)
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49. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)
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50. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
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51. CONNECT WATER BY-PASS HOSE
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52. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
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53. INSTALL CRANKSHAFT PULLEY
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54. INSTALL WATER FILLER BRACKET
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55. INSTALL WIRE HARNESS CLAMP BRACKET
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56. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
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57. INSTALL WATER PUMP PULLEY
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58. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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59. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
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60. INSTALL COMPRESSOR ASSEMBLY WITH MAGNETIC CLUTCH
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61. INSTALL GENERATOR ASSEMBLY
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62. INSTALL V-RIBBED BELT
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63. INSTALL VACUUM PUMP ASSEMBLY
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64. INSTALL IGNITION COIL ASSEMBLY
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65. INSTALL KNOCK CONTROL SENSOR
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66. INSTALL ENGINE HANGERS
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67. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND
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Removal
REMOVAL
CAUTION / NOTICE / HINT
The
necessary procedures (adjustment, calibration, initialization or
registration) that must be performed after parts are removed and
installed, or replaced during cylinder head gasket removal/installation
are shown below.
Necessary Procedure After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure |
Necessary Procedure | Effect/Inoperative Function when Necessary Procedure not Performed |
Link |
Battery terminal is disconnected/reconnected |
Perform steering sensor zero point calibration |
Lane departure alert system (w/ Steering Control) |
|
Pre-collision system |
Intelligent Clearance Sonar System*1 |
Lighting System (for Gasoline Model with Cornering Light) |
Memorize steering angle neutral point |
Parking Assist Monitor System |
|
Panoramic View Monitor System |
|
Replacement of ECM | Vehicle Identification Number (VIN) registration |
MIL comes on |
|
ECU communication ID registration (Immobiliser system) |
Engine start function |
|
- Replacement of throttle body with motor assembly
- Cleaning the deposits from the throttle body with motor assembly
- Replacement of camshaft (for intake or exhaust camshaft)
- Replacement of camshaft timing gear assembly
- Replacement of camshaft timing exhaust gear assembly
- Replacement of fuel injector assembly (for port injection)
- Replacement of fuel injector assembly (for direct injection)
- Replacement of fuel pump assembly (for high pressure side)
- Replacement of ignition coil assembly
- Air leaks from intake system
- Gas leak from exhaust system is repaired
- Replacement of knock control sensor
| Inspection after repair |
- Poor idle, etc.
- Engine start function, etc.
|
|
Replacement of automatic transaxle assembly |
- Perform reset memory
- Input transaxle compensation code into ECM
- Perform road test to allow ECM to learn
|
- Large shift shock
- Deterioration of fuel efficiency
|
for Initialization
for Registration |
Replacement of ECM (If transaxle compensation code read from ECM) |
- Perform reset memory*2
- Transfer transaxle compensation code
- Perform road test to allow ECM to learn
|
Replacement of ECM
(If transaxle compensation code not read from ECM) |
- Perform reset memory*2
- Reset transaxle compensation code
- Perform road test to allow ECM to learn
|
Replacement of automatic transaxle fluid |
ATF thermal degradation estimate reset |
The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly |
|
Replacement of ECM | Code registration (Smart Key System (for Start Function)) |
- Wireless Door Lock Control System
- Smart Key System (for Entry Function)
- Smart Key System (for Start Function)
- Steering lock function
|
|
Suspension, tires, etc. |
- Measure ultrasonic sensor detection angle
- Ultrasonic sensor detection angle registration
|
- Intelligent Clearance Sonar System
- Intuitive Parking Assist System
|
|
Rear television camera assembly optical axis adjustment (Back camera position setting) |
Parking Assist Monitor System |
for Initialization
for Calibration |
- Parking assist ECU initialization
- Adjust steering angle
- Television camera assembly optical axis adjustment (Back camera position setting)
| Panoramic View Monitor System |
for Initialization
for Calibration |
Perform headlight ECU sub-assembly LH initialization |
Lighting system (for Gasoline Model with Cornering Light) |
|
Front wheel alignment adjustment |
Perform system variant learning and acceleration sensor zero point calibration. |
- VSC is disabled or malfunctions
- DTCs are output
- Slip indicator light illuminates
- ABS warning light illuminates
|
|
- *1: When performing learning using the Techstream.
Click here
- *2: Not necessary when ECM replaced with new one.
PROCEDURE
1. INSTALL ENGINE ASSEMBLY TO ENGINE STAND
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2. REMOVE ENGINE HANGERS
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3. REMOVE KNOCK CONTROL SENSOR
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4. REMOVE IGNITION COIL ASSEMBLY
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5. REMOVE VACUUM PUMP ASSEMBLY
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6. REMOVE V-RIBBED BELT
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7. REMOVE GENERATOR ASSEMBLY
Click here
8. REMOVE COMPRESSOR ASSEMBLY WITH MAGNETIC CLUTCH
Click here
9. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
Click here
10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
Click here
11. REMOVE WATER PUMP PULLEY
Click here
12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
Click here
13. REMOVE WIRE HARNESS CLAMP BRACKET
Click here
14. REMOVE WATER FILLER BRACKET
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15. REMOVE CRANKSHAFT PULLEY
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16. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH
Click here
17. DISCONNECT WATER BY-PASS HOSE
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18. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
Click here
19. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)
Click here
20. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)
Click here
21. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)
Click here
22. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)
Click here
23. REMOVE VVT SENSOR (for Intake Side of Bank 1)
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24. REMOVE VVT SENSOR (for Exhaust Side of Bank 1)
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25. REMOVE VVT SENSOR (for Intake Side of Bank 2)
Click here
26. REMOVE VVT SENSOR (for Exhaust Side of Bank 2)
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27. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
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28. REMOVE SENSOR WIRE
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29. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
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30. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
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31. REMOVE SPARK PLUG TUBE GASKET
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32. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
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33. REMOVE OIL STRAINER SUB-ASSEMBLY
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34. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 16 bolts and 2 nuts from the oil pan sub-assembly.
NOTICE: Make sure to clean the bolts and stud bolts and check the threads for cracks or other damage. |
|
(b)
Remove the oil pan sub-assembly by prying between the oil pan
sub-assembly and timing chain cover assembly or cylinder block
sub-assembly with a screwdriver wrapped with protective tape. NOTICE:
Be
careful not to damage the contact surfaces of the cylinder block
sub-assembly, timing chain cover assembly and oil pan sub-assembly. |
|
(c) Remove the 2 oil pan gaskets from the timing chain cover assembly. |
|
35. REMOVE TIMING CHAIN COVER ASSEMBLY
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36. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
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37. SET NO. 1 CYLINDER TO TDC (COMPRESSION)
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38. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
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39. REMOVE CHAIN TENSIONER SLIPPER
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40. REMOVE CHAIN SUB-ASSEMBLY
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41. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)
Click here
42. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
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43. REMOVE CAMSHAFT BEARING CAP (for Bank 1)
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44. REMOVE CAMSHAFT
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45. REMOVE NO. 2 CAMSHAFT
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46. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
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47. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)
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48. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
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49. REMOVE CAMSHAFT BEARING CAP (for Bank 2)
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50. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY
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51. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY
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52. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
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53. REMOVE SENSOR WIRE
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54. REMOVE NO. 1 CHAIN VIBRATION DAMPER
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55. REMOVE NO. 2 CHAIN VIBRATION DAMPER
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56. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
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57. REMOVE VALVE LASH ADJUSTER ASSEMBLY
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58. REMOVE VALVE STEM CAP
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59. REMOVE WATER OUTLET
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60. REMOVE CYLINDER HEAD SUB-ASSEMBLY
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61. REMOVE CYLINDER HEAD GASKET
(a) Remove the cylinder head gasket from the cylinder block sub-assembly.
62. REMOVE CYLINDER HEAD LH
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63. REMOVE NO. 2 CYLINDER HEAD GASKET
(a) Remove the No. 2 cylinder head gasket from the cylinder block sub-assembly.
64. INSPECT CYLINDER HEAD SET BOLT
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