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CAMSHAFT > INSTALLATION

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1. INSTALL NO. 1 CAMSHAFT BEARING

  1. Clean both surfaces of the bearings.

  1. Install the 2 No. 1 camshaft bearings.



    A214944E01

  1. Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.
    Text in Illustration 
    *1
    		Vernier Caliper

    Standard dimension (A - B):
    0.7 mm (0.0276 in.) or less

    NOTICE:
    Position the bearings to the center of the bearing cap by measuring dimensions A and B.



2. INSTALL NO. 2 CAMSHAFT BEARING

  1. Clean both surfaces of the bearings.

  1. Install the 2 No. 2 camshaft bearings.



    A330339E01

  1. Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.
    Text in Illustration 
    *1
    		Vernier Caliper

    Standard dimension (A):
    1.05 to 1.75 mm (0.0413 to 0.0689 in.)

    NOTICE:
    Position the bearings to the center of the bearing cap by measuring dimension A.



3. INSTALL NO. 2 CAMSHAFT

  1. Clean the camshaft journals.

  1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.



    A214945

  1. Install the No. 2 camshaft to the camshaft housing.



4. INSTALL CAMSHAFT

  1. Clean the camshaft journals.

  1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.



    A214946

  1. Install the camshaft to the camshaft housing.



5. INSTALL BEARING CAP

  1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.



    A214947E01

  1. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
    Text in Illustration 
    *1
    		Knock Pin
    *2
    		Camshaft



    A214948E01

  1. Tighten the 10 bolts in the order shown in the illustration.

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



6. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    A153836E01

  1. Check that the valve rocker arms are installed as shown in the illustration.
    Text in Illustration 
    *1
    		Valve Stem Cap
    *2
    		Valve Rocker Arm
    *3
    		Valve Lash Adjuster



    A206178E01

  1. Apply seal packing in a continuous line as shown in the illustration.

    Seal packing:
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

    Standard Seal Diameter:
    Area
    		Specified Condition
    Continuous line
    		3.5 to 4.5 mm (0.138 to 0.177 in.)
    A
    		8.0 mm (0.315 in.)
    B
    		7.0 mm (0.276 in.)

    Application Length A and B:
    15 mm (0.591 in.)

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
    3. Do not start the engine for at least 2 hours after installation.



    A214949E01

  1. Set the camshaft and No. 2 camshaft as shown in the illustration.

  1. Install the camshaft housing with the 17 bolts and tighten them in the order shown in the illustration.

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

    NOTICE:
    1. After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
    2. If any of the bolts is loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
    3. If the camshaft housing is removed because any of the bolts is loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
    4. After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and cylinder head.



7. INSTALL CAMSHAFT TIMING SPROCKET


    A214937

  1. Tighten the flange bolt with the camshaft timing sprocket secured in place.

    Torque:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }



8. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    A146265E04

  1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned as shown in the illustration.
    Text in Illustration 
    *1
    		Straight Pin
    *2
    		Key Groove

    NOTICE:
    Do not forcefully push in the camshaft timing gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear.



    A153570E03

  1. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
    Text in Illustration 
    *1
    		Straight Pin
    *2
    		Key Groove

    NOTICE:
    Do not turn the camshaft timing gear in the retard direction (clockwise).



    A146267E03

  1. Check that there is no clearance between the camshaft timing gear and camshaft flange.
    Text in Illustration 
    *1
    		Camshaft Timing Gear
    *2
    		Flange
    *a
    		Clearance
    *b
    		No Clearance



    A214936

  1. Tighten the flange bolt with the camshaft timing gear secured in place.

    Torque:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }



    A214982E02

  1. Check that the camshaft timing gear can move in the retard direction (clockwise) and is locked in the most retarded position.
    Text in Illustration 
    *a
    		Lock



9. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    A217740

  1. Install the chain vibration damper with the 2 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



10. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    A221683E01

  1. Temporarily install the crankshaft pulley bolt.
    Text in Illustration 
    *1
    		Timing Gear Key

  1. Turn the crankshaft to position the timing gear key to the top.



    A262288E01

  1. Check that the timing marks on the camshaft timing gear and camshaft timing sprocket are aligned as shown in the illustration.
    Text in Illustration 
    *1
    		Timing Mark (Rectangle)
    *2
    		Timing Mark
    *3
    		Mark (Circle)

    HINT:
    There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

  1. Remove the crankshaft pulley bolt.



11. INSTALL CHAIN SUB-ASSEMBLY


    A262289E01

  1. Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.
    Text in Illustration 
    *1
    		Mark Plate (Orange)
    *2
    		Timing Mark (Rectangle)
    *3
    		Mark (Circle)
    *a
    		Place the Chain on the Sprocket
    *b
    		Pass the Chain through the Damper

    HINT:
    1. There are 3 marks on the camshaft timing sprocket. Make sure to align the mark plate with the timing mark (rectangle).
    2. Be sure to position the mark plate at the front of the engine.
    3. The mark plate on the camshaft side is colored orange.
    4. Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.
    5. Pass the chain through the No. 1 vibration damper.



    A150936

  1. Place the chain on the crankshaft without passing it around the shaft.



    A214963E04

  1. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain.
    Text in Illustration 
    *1
    		Mark Plate (Orange)
    *2
    		Timing Mark
    *a
    		Tension the Chain

  1. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.

    HINT:
    To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.



    A150939E06

  1. Align the mark plate (yellow or pink) and timing mark and install the chain to the crankshaft timing gear.
    Text in Illustration 
    *1
    		Mark Plate (Yellow or Pink)
    *2
    		Timing Mark



12. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


  1. Check each timing mark at TDC/compression.


    A262290E01


    Text in Illustration 
    *1
    		Timing Mark
    		*2
    		Mark Plate (Orange)
    *3
    		Mark Plate (Yellow or Pink)
    		*4
    		Timing Mark (Rectangle)
    *5
    		Mark (Circle)
    		-
    		-

    HINT:
    There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.



13. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    A214931

  1. Install the No. 2 chain vibration damper with the 2 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



14. INSTALL CHAIN TENSIONER SLIPPER


    A214929

  1. Install the chain tensioner slipper to the cylinder block.



15. INSTALL TIMING CHAIN COVER OIL SEAL


    A150934E01

  1. Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.

    SST
    09223-22010  

    NOTICE:
    1. Keep the lip free from foreign matter.
    2. Do not tap on the oil seal at an angle.
    3. Make sure that the oil seal edge does not stick out of the timing chain case.

    HINT:
    Tap in the oil seal so that it is positioned within 1.0 mm from the edge of the timing chain case.

  1. Apply MP grease to the lip of the oil seal.



16. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


  1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, and cylinder block.


    A214951E01



    A214924

  1. Install 3 new O-rings.



  1. Apply seal packing as shown in the illustration.


    A214953E01

    Seal packing:
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

    Seal diameter:
    5.0 mm (0.197 in.)

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the chain cover within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.



  1. Apply seal packing to the timing chain cover in a line as shown in the following illustration.

    NOTICE:
    1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
    2. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installation.



    A214952E01


    Seal Packing:

    Item
    		Seal Packing
    Dashed line
    		Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
    Continuous line
    Alternate long and short dashed line
    		Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent


    Application Specification:

    Area
    		Seal Packing Diameter
    		Distance from Edge of Cover to:
    		Seal Packing Application Length
    		Distance from Top of Cover to Top of Seal Packing
    Dashed line
    		2.5 to 3.0 mm (0.0984 to 0.118 in.)
    		Center of seal packing
    2.5 mm (0.0984 in.)
    		-
    		-
    Continuous line
    		4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.)
    		-
    		-
    		-
    Alternate long and short dashed line
    		4.0 mm (0.157 in.)
    		Center of seal packing
    3.0 mm (0.118 in.)
    		-
    		-
    A - A
    		2.5 to 3.0 mm (0.0984 to 0.118 in.)
    		Center of seal packing
    2.5 mm (0.0984 in.)
    		-
    		-
    B - B
    		4.5 to 5.5 mm (0.177 to 0.217 in.)
    		Opposite edge of seal packing
    5.0 mm (0.197 in.)
    		-
    		-
    C - C
    		7.0 to 8.0 mm (0.276 to 0.315 in.)
    		Opposite edge of seal packing
    7.5 mm (0.295 in.)
    		-
    		-
    F
    		4.5 to 5.5 mm (0.177 to 0.217 in.)
    		-
    		15.5 mm (0.610 in.)
    		50.4 mm (1.98 in.)
    G
    		4.5 to 5.5 mm (0.177 to 0.217 in.)
    		-
    		10.3 mm (0.406 in.)
    		143.1 mm (5.63 in.)
    H
    		7.0 to 8.0 mm (0.276 to 0.315 in.)
    		-
    		19.5 mm (0.768 in.)
    		153.4 mm (6.04 in.)
    I
    		4.5 to 5.5 mm (0.177 to 0.217 in.)
    		-
    		16.0 mm (0.630 in.)
    		385.8 mm (1.27 ft.)
    J
    		4.5 to 5.5 mm (0.177 to 0.217 in.)
    		-
    		18.6 mm (0.732 in.)
    		51.4 mm (2.02 in.)
    K
    		4.5 to 5.5 mm (0.177 to 0.217 in.)
    		-
    		25.3 mm (0.996 in.)
    		121.9 mm (4.80 in.)
    L
    		7.0 to 8.0 mm (0.276 to 0.315 in.)
    		-
    		25.8 mm (1.02 in.)
    		147.2 mm (5.80 in.)
    M
    		4.5 to 5.5 mm (0.177 to 0.217 in.)
    		-
    		5.1 mm (0.201 in.)
    		173.0 mm (6.81 in.)
    N
    		4.5 to 5.5 mm (0.177 to 0.217 in.)
    		-
    		14.6 mm (0.575 in.)
    		385.8 mm (1.27 ft.)
    O
    		4.0 mm (0.157 in.)
    		Center of seal packing
    3.0 mm (0.118 in.)
    		-
    		-

    NOTICE:
    1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
    2. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
    3. After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.
    4. Do not add engine oil for at least 2 hours after installation.

  1. Clean the bolt and fitting hole.

  1. Install the timing chain cover.



    A214919

  1. Temporarily tighten the engine mounting bracket RH with the 3 bolts.

    NOTICE:
    1. Install the mounting bracket within 10 minutes after installing the chain cover.
    2. Do not start the engine for at least 2 hours after installation.

    Bolt Length:
    Item
    		Length
    Bolt
    		80 mm (3.15 in.)



    A214921

  1. Install 2 new O-rings.



    A214920

  1. Temporarily tighten the oil filter bracket with the 4 bolts.

    NOTICE:
    1. Install the oil filter bracket within 10 minutes after installing the chain cover.
    2. Do not start the engine for at least 2 hours after installation.

    Bolt Length:
    Item
    		Length
    Bolt
    		35 mm (1.38 in.)



  1. Install the timing chain cover with the 25 bolts and seal washer as shown in the illustration.


    A214954E02


    Text in Illustration 
    *1
    		Seal Washer
    		-
    		-

    Torque:
    Bolt A, E, F:
    26 N*m{ 260 kgf*cm , 19 ft.*lbf }
    Bolt B, C:
    51 N*m{ 520 kgf*cm , 38 ft.*lbf }
    Bolt D:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    NOTICE:
    1. Apply adhesive 1324 to screw part of the bolt F.
    2. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
    3. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying the seal packing.
    4. Do not add engine oil for at least 2 hours after installing the chain cover.
    5. Do not start the engine for at least 2 hours after installing the chain cover.

    Bolt Length:
    Item
    		Length
    Bolt A, F
    		35 mm (1.38 in.)
    Bolt B
    		55 mm (2.16 in.)
    Bolt C
    		80 mm (3.15 in.)
    Bolt D
    		40 mm (1.57 in.)
    Bolt E
    		55 mm (2.16 in.)



17. INSTALL CRANKSHAFT PULLEY

  1. Align the pulley set key with the key groove of the pulley.



    A213054E02

  1. Using SST, hold the pulley in place and tighten the bolt.
    Text in Illustration 
    *a
    		Hold
    *b
    		Turn

    SST
    09213-58014   (91551-80840)
    09330-00021  

    Torque:
    190 N*m{ 1937 kgf*cm , 140 ft.*lbf }



18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    A162975E02

  1. Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.
    Text in Illustration 
    *1
    		Cam
    *2
    		Pin
    *3
    		Hook
    *a
    		Push
    *b
    		Raise
    *c
    		CORRECT
    *d
    		INCORRECT

    NOTICE:
    Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.



    A214955

  1. Install a new gasket, the bracket and chain tensioner with the 2 nuts.

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf }

    NOTICE:
    If the hook releases the plunger while the chain tensioner is being installed, set the hook again.



    A214956E02

  1. Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.
    Text in Illustration 
    *1
    		Pin
    *2
    		Hook
    *a
    		Push
    *b
    		Turn
    *c
    		Disconnect



    A214957E02

  1. Turn the crankshaft clockwise and check that the plunger is extended.
    Text in Illustration 
    *1
    		Plunger
    *a
    		Turn
    *b
    		Plunger Extended



19. INSTALL SPARK PLUG TUBE GASKET


    A153838E04

  1. Using a cutter knife, cut off the seal part of the removed gasket.
    Text in Illustration 
    V100155
    		Part to Cut Off



    A214958E02

  1. Using a hammer and the plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.
    Text in Illustration 
    *1
    		Plug Tube Gasket without Sealing Part
    *2
    		New Plug Tube Gasket

    NOTICE:
    1. Keep the lip free of foreign matter.
    2. Do not tap in the plug tube gasket.

    HINT:
    If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

  1. Return the claws of the ventilation baffle plate to their original positions.



20. INSTALL CYLINDER HEAD COVER GASKET


    A214978E01

  1. Install a new cylinder head cover gasket to the cylinder head cover.
    Text in Illustration 
    *1
    		Cylinder Head Cover
    *2
    		Cylinder Head Cover Gasket

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Misalignment between the center of the cylinder head cover rib and the center of the cylinder head gasket tab is within 4 mm (0.157 in.).



21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    A214910

  1. Install 2 new gaskets to the camshaft bearing cap.



    A214959

  1. Apply seal packing as shown the illustration.

    Seal packing:
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

    Standard diameter:
    4.0 mm (0.157 in.)

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
    3. Do not start the engine for at least 2 hours after the installation.



    A214909

  1. Install the cylinder head cover with a new seal washer and the 13 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }


    NOTICE:
    A214979E01
    Misalignment between the contact surfaces of the timing chain cover and the camshaft housing and the center of the cylinder head gasket tab is within 4 mm (0.157 in.).

    Text in Illustration 
    *1
    		Timing Chain Cover
    *2
    		Camshaft Housing
    *3
    		Cylinder Head Cover Gasket



22. INSTALL IGNITION COIL ASSEMBLY


    A212292

  1. Install the 4 ignition coils with the 4 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    NOTICE:
    When installing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.

  1. Connect the 4 ignition coil connectors.



23. INSTALL FUEL INJECTOR ASSEMBLY


    A153011E06

  1. Install a new insulator and O-ring to each fuel injector assembly.
    Text in Illustration 
    *1
    		O-ring
    *2
    		Insulator

  1. Apply a light coat of gasoline or spindle oil to the contact surfaces of the new O-ring on each fuel injector assembly.



    A173350

  1. While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe sub-assembly.

    NOTICE:
    1. Do not damage the fuel injector assembly or O-ring.
    2. Do not twist the O-ring.
    3. After installing each fuel injector, check that it turns smoothly. If not, replace the O-ring with a new one.



24. INSTALL NO. 1 DELIVERY PIPE SPACER


    A245591E01

  1. Install the 2 No. 1 delivery pipe spacers onto the cylinder head.
    Text in Illustration 
    *a
    		Delivery Pipe Side
    *b
    		Cylinder Head Side

    NOTICE:
    Install the No. 1 delivery pipe spacers in the correct direction.



25. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    A216400

  1. Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

    NOTICE:
    1. Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
    2. Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.



    A216399

  1. Install the bolt to secure the fuel delivery pipe sub-assembly.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



26. INSTALL FUEL VAPOR FEED PIPE


    A218073

  1. Install the fuel vapor feed pipe with the bolt.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



27. INSTALL INTAKE MANIFOLD

  1. Install a new No. 1 intake manifold to head gasket to the intake manifold.



    A212684

  1. Install the intake manifold with the 2 bolts and 2 nuts.

    Torque:
    28 N*m{ 285 kgf*cm , 21 ft.*lbf }



    A212683

  1. Connect the fuel vapor feed hose and ventilation hose.

  1. Install a new O-ring to the engine oil level dipstick guide sub-assembly.

  1. Apply a light coat of engine oil to the O-ring.



    A212681E01

  1. Install the engine oil level dipstick guide sub-assembly with the 2 bolts and connect the wire harness clamp.

    Torque:
    Bolt (A):
    28 N*m{ 285 kgf*cm , 21 ft.*lbf }
    Bolt (B):
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Install the engine oil level dipstick.



    A212682

  1. Connect the 2 wire harness clamps and 3 connectors.



28. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY


    A237553E01

  1. Temporarily install a new gasket and the EGR cooler sub-assembly with the 2 nuts (A).
    Text in Illustration 
    *A
    		Nut (C), Type A
    *B
    		Nut (C), Type B
    *1
    		Bolt
    *2
    		Stud Bolt and Nut

  1. Install 2 new gaskets and set the EGR valve with cooler assembly in place.

  1. Using an E8 "TORX" wrench, install the 4 stud bolts.

    Torque:
    Stud Bolt (B):
    9.5 N*m{ 97 kgf*cm , 84 in.*lbf }
    Stud Bolt (C):
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Temporarily install the 4 nuts (B and C) and bolt.

  1. Tighten the 2 nuts (A).

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Tighten the 2 nuts (B) and bolt.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

    NOTICE:
    Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.

  1. Tighten the 2 nuts (C).

    Torque:
    Type A:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }
    Type B:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



    A212666

  1. Connect the connector, wire harness clamp and 4 water hoses.



29. INSTALL EGR VALVE ASSEMBLY


    A237552E01

  1. Temporarily install a new gasket and the EGR valve assembly with the 2 nuts (A).
    Text in Illustration 
    *A
    		Nut (C), Type A
    *B
    		Nut (C), Type B
    *1
    		Bolt
    *2
    		Stud Bolt and Nut

  1. Install 2 new gaskets and set the EGR valve with cooler assembly in place.

  1. Using an E8 "TORX" wrench, install the 4 stud bolts.

    Torque:
    Stud Bolt (B):
    9.5 N*m{ 97 kgf*cm , 84 in.*lbf }
    Stud Bolt (C):
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Temporarily install the 4 nuts (B and C) and bolt.

  1. Tighten the 2 nuts (A).

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Tighten the 2 nuts (B) and bolt.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

    NOTICE:
    Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.

  1. Tighten the 2 nuts (C).

    Torque:
    Type A:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }
    Type B:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



    A212666

  1. Connect the connector, wire harness clamp and 4 water hoses.



30. INSTALL EGR PIPE ASSEMBLY


    A212665

  1. Install 2 new gaskets and EGR pipe assembly with the 4 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    NOTICE:
    Make sure to tighten the 4 bolts evenly until the flanges of the EGR pipe assembly contact with the installation surfaces.



    A212664

  1. Install the wire harness support with the bolt.



    A212663

  1. Connect the 2 wire harness clamps.



31. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

  1. Apply a light coat of engine oil to a new O-ring.

  1. Install the O-ring to the engine oil level dipstick guide.



    A213046E01

  1. Install the engine oil level dipstick guide with the 2 bolts.

    Torque:
    Bolt A:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }
    Bolt B:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Connect the clamp to the engine oil level dipstick guide.

  1. Install the oil dipstick.



32. INSTALL THROTTLE BODY ASSEMBLY


    A212317

  1. Install a new gasket onto the intake manifold.



    A212316

  1. Install the throttle body assembly with the 2 bolts and 2 nuts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

  1. Connect the 2 water by-pass hoses and throttle body connector.



33. INSTALL ENGINE HANGERS


    A214905

  1. Install the 2 engine hangers with the 2 bolts.

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

    Part Name
    		Part No.
    No. 1 engine hanger
    		12281-37021
    No. 2 engine hanger
    		12282-37011
    Bolt
    		91552-81050



34. REMOVE ENGINE ON ENGINE STAND

  1. Remove the bolts and engine on engine stand.



35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

  1. Install the engine assembly with transaxle (Click here).