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Inspection

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August 2018
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EM-1 ENGINE MECHANICAL (1GR-FE) - CO/HC CO/HC EM0KQ-10 INSPECTION HINT: This check is used only to determine whether or not the idle CO/ HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected (f) SFI system wiring connectors fully plugged (g) Correct ignition timing (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. CO/HC Meter 5. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders prescribed by the applicable local regulations. A19383 Author: Date: 3209 EM-2 ENGINE MECHANICAL (1GR-FE) - CO/HC If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. (1) Check the A/F sensors and heated oxygen sensors operation (See page DI-84 and DI-90 ). (2) See the table below for possible causes, and then inspect and correct the corresponding causes if necessary. CO HC Problems Causes Normal High Rough idle 1. Faulty ignitions: Incorrect timing Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders Low High Rough idle (fluctuating HC reading) 1. Vacuum leaks: PCV hose Intake manifold Throttle body 2. Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Faulty SFI system: Faulty pressure regulator Defective ECT sensor Faulty ECM Faulty injectors Faulty throttle position sensor Faulty MAF meter Author: Date: 3210 EM-3 ENGINE MECHANICAL (1GR-FE) - COMPRESSION COMPRESSION EM06C-06 INSPECTION A22796 HINT: If there is a lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS (a) Remove the V-bank cover. (b) Remove the air cleaner. (c) Remove the intake air surge tank (See page EM-62 ). (d) Remove the 6 ignition coils. (e) Remove the 6 spark plugs. (f) Disconnect the 6 injector connectors. 3. CHECK CYLINDER COMPRESSION PRESSURE (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain an engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in the shortest possible time. Compression pressure: 1.3 MPa (13.3 kgf/cm2, 189 psi) or more Minimum pressure: 1.0 MPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 0.1 MPa (1.0 kgf/cm2, 15 psi) or less (e) If the cylinder compression pressure in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression pressure. If adding oil improves the compression pressure, it is likely that the piston rings and/or cylinder bore are worn or damaged. If compression pressure stays low, a valve may be sticking, seating may be improper, or there may be a leak past the gasket. 4. REINSTALL SPARK PLUGS (a) Connect the 6 injector connectors. (b) Install the 6 spark plugs. Torque: 20 N·m (200 kgf·cm, 15 ft·lbf) (c) Install the 6 ignition coils. (d) Install the intake air surge tank (See page EM-89 ). (e) Install the air cleaner. (f) Install the V-bank cover. Author: Date: 3211 EM-1 11 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK CYLINDER BLOCK EM1XY-01 COMPONENTS Piston Ring (No. 1 Compression Ring) Piston Ring (No. 2 Compression Ring) Piston Ring (Expander) Piston Ring (Side Rail) Piston Piston Pin Hole Snap Ring Piston Pin Water Outlet Pipe No.1 10 (102, 7) Piston Pin Hole Snap Ring 10 (102, 7) Connecting Rod Connecting Rod Bearing Connecting Rod Cap Knock Sensor 20 (204, 15) 20 (204, 15) Knock Sensor Water Drain Cock Knock Sensor Wire Engine Rear Oil 10 (102, 7) Seal Retainer Oil Seal 25 (255, 18) See page EM-128 1st 25 (250, 18) 2nd Turn 90 x5 x2 Water Drain Cock 25 (255, 18) 9.0 (92, 80 in.·lbf) Crankshaft Bearing x8 Oil Nozzle Upper Crankshaft Thrust Washer 25 (255, 18) 9.0 (92, 80 in.·lbf) Crankshaft Lower Crankshaft Thrust Washer Crankshaft Bearing Cap Crankshaft Bearing See page EM-128 N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part 1st 61 (622, 45) 2nd Turn 90 A23200 Author: Date: 3319 EM-1 12 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK EM1XZ-01 DISASSEMBLY 1. (a) (b) REMOVE WATER OUTLET PIPE NO.1 Separate the knock sensor wire. Remove the 3 bolts and water outlet pipe. 2. (a) (b) 3. REMOVE KNOCK SENSOR Disconnect the knock sensor connectors. Remove the 2 bolts and 2 knock sensors. REMOVE WATER DRAIN COCK 4. (a) (b) REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 5 bolts and 2 nuts. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap. A22979 A22980 Pry A22981 A23021 5. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 to 0.30 mm (0.0059 to 0.0118 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) 6. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembling. (b) Using SST, remove the 2 connecting rod cap bolts. SST 09011-38121 (c) Clean the crank pin, bearing and connecting rod. (d) Check the crank pin and bearing for pits and scratches. Author: Date: 3320 EM-1 13 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK (e) Lay a strip of Plastigage across the crank pin. (f) Check that the protrusion of the connecting rod cap is facing the correct direction. Apply a light coat of engine oil to the threads of the connecting rod cap bolts. Plastigage A23022 (g) Protrusion A23023 (h) Using SST, tighten the bolts alternately to the specified torque. SST 09011-38121 Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) A23024 (i) Mark the front side of each connecting cap bolt with paint. (j) Retighten the cap bolts 90 as shown in the illustration. NOTICE: Do not turn the crankshaft. (k) Remove the 2 bolts, connecting rod cap and lower bearing. Painted Mark 90 Front 90 A23025 (l) Measure the Plastigage at its widest point. Standard oil clearance: 0.026 to 0.046 mm (0.0010 to 0.0018 in.) Maximum oil clearance: 0.066 mm (0.0025 in.) NOTICE: Completely remove the Plastigage. A23026 Author: Date: 3321 EM-1 14 ENGINE MECHANICAL (1GR-FE) Number Mark (m) Number Mark - CYLINDER BLOCK If replacing a bearing, replace it with one that has the same number marked on the connecting rod. There are 4 sizes of standard bearings, marked ”1 ”, ”2”, ”3” and ”4” accordingly. HINT: Standard bearing center wall thickness A23027 7. (a) (b) Mark mm (in.) ”1” 1.484 to 1.487 (0.0584 to 0.0585) ”2” 1.487 to 1.490 (0.0585 to 0.0587) ”3” 1.490 to 1.493 (0.0587 to 0.0588) ”4” 1.493 to 1.496 (0.0588 to 0.0589) REMOVE PISTON W/CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Push in the piston w/ connecting rod and upper bearing through the top of the cylinder block. HINT: A23028 8. 9. (a) (b) Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. REMOVE CONNECTING ROD BEARING REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. A23029 10. REMOVE PISTON PIN HOLE SNAP RING Using a screwdriver, pry out the 2 snap rings. A23030 Author: Date: 3322 EM-1 15 ENGINE MECHANICAL (1GR-FE) 80C - CYLINDER BLOCK 11. (a) REMOVE PISTON PIN Gradually heat the piston to approx. 80C (176F). (b) Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. A23031 HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. A23032 12. (a) A23033 INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the pair of the thrust washers or the crankshaft. HINT: Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.) 13. (a) 5 8 7 2 REMOVE CRANKSHAFT Using several steps, uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence as shown in the illustration. 3 6 4 1 A23034 Author: Date: 3323 EM-1 16 ENGINE MECHANICAL (1GR-FE) (b) 4 12 16 11 14 15 7 10 13 5 9 1 8 6 2 - CYLINDER BLOCK Using several steps, uniformly loosen and remove the 16 main bearing cap bolts in the sequence as shown in the illustration. 3 A23035 (c) Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings. NOTICE: Pull up the main bearing cap while turning it little by little to the right and the left. A23036 14. 15. Main Bearing Cap Be careful not to damage the joint surface of the cylinder block and the main bearing cap. REMOVE CRANKSHAFT THRUST WASTER SET REMOVE CRANKSHAFT BEARING Cylinder Block A23037 16. REMOVE OIL NOZZLE Using a 5 mm socket hexagon wrench, remove the 3 oil nozzles. A23038 Author: Date: 3324 EM-1 17 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK EM1Y0-01 INSPECTION 1. INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the flatness of the surface that is in contact with the cylinder head gasket. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than the maximum, replace the cylinder block. A23039 2. INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter: 94.132mm (3.7060 in.) If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block. Thrust Direction Front Axial Direction A 10 mm B A23040 3. INSPECT PISTON Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 27.7 mm (1.091 in.) from the piston head. Piston diameter: 93.910 to 93.940 mm (3.6972 to 3.6984 in.) 27.7 mm (1.091 in.) A23041 Author: Date: 3325 EM-1 18 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK 4. INSPECT PISTON OIL CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.060 to 0.102 mm (0.0024 to 0.0040 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block. 5. INSPECT CONNECTING ROD Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If misalignment is greater than the maximum, replace the connecting rod assembly. Z00064 (2) Check twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than the maximum, replace the connecting rod assembly. Z00065 6. (a) INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston pin hole. Piston pin hole inside diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.) HINT: Piston pin hole inside diameter A13490 Mark mm (in.) A 22.001 to 22.004 (0.8662 to 0.8663) B 22.005 to 22.007 (0.8663 to 0.8664) C 22.008 to 22.010 (0.8665 to 0.8665) Author: Date: 3326 EM-1 19 ENGINE MECHANICAL (1GR-FE) (b) - CYLINDER BLOCK Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) HINT: Piston pin diameter EM0227 (c) Mark mm (in.) A 21.997 to 22.000 (0.8660 to 0.8661) B 22.001 to 22.003 (0.8661 to 0.8663) C 22.004 to 22.006 (0.8663 to 0.8664) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) HINT: Bushing inside diameter EM6525 22.005 to 22.008 (0.8663 to 0.8665) B 22.009 to 22.011 (0.8665 to 0.8666) C 22.012 to 22.014 (0.8666 to 0.8667) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement. Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 in.) Maximum oil clearance: 0.040 mm (0.0016 in.) (e) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and piston pin together. Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin together. Front Mark Connecting Rod Bushing Inside Diameter Mark mm (in.) A (d) (f) Piston Pin Hole Inside Diameter Mark Mark (g) Front Mark A23042 Author: Date: 3327 EM-120 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK 7. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove. Ring groove clearance: No.1: 0.02 to 0.07 mm (0.0008 to 0.0028 in.) No.2: 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil: 0.07 to 0.15 mm (0.0028 to 0.0060 in.) A23044 8. (a) INSPECT PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. (b) Using a feeler gauge, measure the end gap. Standard end gap: No. 1: 0.30 to 0.40 mm (0.0118 to 0.0157 in.) No. 2: 0.40 to 0.50 mm (0.0157 to 0.0197 in.) Oil (Side rail): 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum end gap: No. 1: 1.0 mm (0.039 in.) No. 2: 1.1 mm (0.043 in.) Oil (Side rail): 1.0 mm (0.039 in.) 110 mm A23045 EM7639 9. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt. A23046 10. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 10.0 to 10.2 mm (0.393 to 0.402 in.) If the diameter is less than the minimum, replace the bolt. A23046 Author: Date: 3328 EM-121 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK 11. (a) INSPECT CRANKSHAFT Using a dial indicator and V-blocks, measure the runout as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) (b) Using a micrometer, measure the diameter of each main journal. Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 in.) Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) A23047 (c) A23048 (d) (e) Using a micrometer, measure the diameter of each crank pin. Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 in.) Check each crank pin for taper and out-of-round as shownin the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) A23049 No. 1 and No. 4 22.4 mm No. 2 and No. 3 19.0 mm 12. INSPECT CRANKSHAFT OIL CLEARANCE HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions. (a) Clean each main journal and bearing. A23050 (b) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTICE: Do not apply engine oil to the bearing and its contact surface. A23051 Author: Date: 3329 EM-122 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK (c) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 bottom bearings. NOTICE: Do not apply engine oil to the bearing or its contact surface. HINT: A number marked on each main bearing cap indicates the installation position. (d) Place the crankshaft on the cylinder block. Mark 1, 2, 3, or 4 A23052 Plastigage (e) Lay a strip of Plastigage across each journal. (f) Examine the front marks and numbers and install the bearing caps on the cylinder block. Apply a light coat of engine oil to the threads of the bearing cap bolts. Temporarily install the 8 main bearing cap bolts to the inside positions. A23053 (g) (h) A23054 (i) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes less than 6 mm (0.23 in.). (j) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads of the main bearing cap bolts. Less than 6 mm A23055 (k) A23056 Author: Date: 3330 EM-123 ENGINE MECHANICAL (1GR-FE) (l) 9 11 15 3 4 7 8 13 1 2 5 6 14 - CYLINDER BLOCK Install the 16 main bearing cap bolts. Using several steps, uniformly tighten the bolts in the sequence as shown in the illustration. Torque: 61 N⋅m (622 kgf⋅cm, 45 ft⋅lbf) 10 12 16 A23057 (m) (n) Mark the front side of the bearing cap bolts with paint. Retighten the bearing cap bolts until 90 in the sequence as shown in the illustration. (o) Check that the painted mark is now at a 90 angle to the front. NOTICE: Do not turn the crankshaft. Painted Mark 90 Front 90 A23058 (p) 4 1 2 7 3 6 (q) 5 Install the 8 main bearing cap bolts. Using several steps, uniformly tighten the bolts in the sequence as shown in the illustration. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) Remove the main bearing caps. 8 A23059 (r) Measure the Plastigage at its widest point. Standard oil clearance: 0.018 to 0.030 mm (0.0007 to 0.0012 in.) Maximum clearance: 0.046 mm (0.0018 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. NOTICE: Completely remove the Plastigage. A23060 Author: Date: 3331 EM-124 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK (s) No. 1 No. 2 No. 3 No. 4 Number Mark No. 1 No. 2 No. 4 Number No. 3 Mark Number MarkA23061 Item Cylinder block main journal bore diameter (A) If replacing a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly Journal bearings Cylinder block (A) + Crankshaft 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28 Use Bearing ”1” ”2” ”3” ”4” ”5” HINT: EXAMPLE Cylinder block ”11” (A) + Crankshaft ”06” (B) = Total number 17 (Use bearing ”3”) Mark mm (in.) ”00” ”01” ”02” ”03” ”04” ”05” ”06” ”07” ”08” ”09” ”10” ”11” ”12” ”13” ”14” ”15” ”16” 77.000 (3.0315) 77.001 (3.0315) 77.002 (3.0316) 77.003 (3.0316) 77.004 (3.0317) 77.005 (3.0317) 77.006 (3.0317) 77.007 (3.0318) 77.008 (3.0318) 77.009 (3.0319) 77.010 (3.0319) 77.011 (3.0319) 77.012 (3.0320) 77.013 (3.0320) 77.014 (3.0320) 77.015 (3.0321) 77.016 (3.0321) Author: Date: 3332 EM-125 ENGINE MECHANICAL (1GR-FE) Crankshaft main journal diameter (B) Standard bearing center wall thickness - CYLINDER BLOCK ”00” ”01” ”02” ”03” ”04” ”05” ”06” ”07” ”08” ”09” ”10” ”11” 71.999 to 72.000 (2.8346 to 2.8346) 71.998 to 71.999 (2.8346 to 2.8346) 71.997 to 71.998 (2.8345 to 2.8346) 71.996 to 71.997 (2.8345 to 2.8346) 71.995 to 71.996 (2.8344 to 2.8345) 71.994 to 71.995 (2.8344 to 2.8344) 71.993 to 71.994 (2.8343 to 2.8344) 71.992 to 71.993 (2.8343 to 2.8343) 71.991 to 71.992 (2.8343 to 2.8343) 71.990 to 71.991 (2.8343 to 2.8343) 71.989 to 71.990 (2.8342 to 2.8343) 71.988 to 71.989 (2.8342 to 2.8342) ”1” ”2” ”3” ”4” ”5” 2.488 to 2.491 (0.0980 to 0.0981) 2.491 to 2.494 (0.0981 to 0.0982) 2.494 to 2.497 (0.0982 to 0.0983) 2.497 to 2.500 (0.0982 to 0.0984) 2.500 to 2.503 (0.0984 to 0.0985) Author: Date: 3333 EM-128 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK EM1Y2-01 REASSEMBLY 1. (a) INSTALL STUD BOLT Install the stud bolts as shown in the illustration. Torque: Stud bolt A: 11 N⋅m (112 kgf⋅cm, 8.1 ft⋅lbf) Stud bolt B: 4.5 N⋅m (46 kgf⋅cm, 40 in.⋅lbf) Stud bolt C: 4.0 N⋅m (41 kgf⋅cm, 35 in.⋅lbf) Front Side Upper Side C 42 mm (1.65 in.) C A A M6 23 mm (0.91 in.) Lower Side 56 mm (2.20 in.) B B A23062 Author: Date: 3336 EM-129 ENGINE MECHANICAL (1GR-FE) 2. (a) - CYLINDER BLOCK INSTALL STRAIGHT PIN Using a plastic-faced hammer, tap in the straight pin. Standard protrusion: Pin A: 22.5 to 23.5 mm (0.886 to 0.925 in.) Pin B: 10.5 to 11.5 mm (0.413 to 0.453 in.) Pin C: 8.5 to 9.5 mm (0.335 to 0.374 in.) Pin D: 5.5 to 6.5 mm (0.217 to 0.256 in.) Front Side Front Side 10 mm (0.39 in.) A D 36 mm (1.42 in.) 4 mm (0.16 in.) D 12 mm Protrusion Height: 5.5 to 6.5 mm (0.217 to 0.256 in.) (0.47 in.) Rear Side Protrusion Height: 22.5 to 23.5 mm (0.886 to 0.925 in.) Rear Side B 10 mm (0.39 in.) B 4 mm (0.16 in.) D 22 mm (0.87 in.) 12 mm Protrusion Height: 5.5 to 6.5 mm (0.47 in.) (0.217 to 0.256 in.) Lower Side D Protrusion Height: 10.5 to 11.5 mm (0.413 to 0.453 in.) Upper Side 8 mm (0.31 in.) C C C 4 mm (0.16 in.) 18 mm (0.71 in.) C 12 mm (0.47 in.) D Protrusion Height: 5.5 to 6.5 mm (0.217 to 0.256 in.) Protrusion Height: 8.5 to 9.5 mm (0.335 to 0.374 in.) A23063 Author: Date: 3337 EM-130 ENGINE MECHANICAL (1GR-FE) 3. (a) (b) Right Side - CYLINDER BLOCK INSTALL TIGHT PLUG Apply adhesive around the tight plugs. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. Using SST, install the tight plugs as shown in the illustration. SST 09950- 60010 (09951- 00350), 09950- 70010 (09951-07150) Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 in.) Left Side 0.2 to 1.2 mm (0.008 to 0.047 in.) A23064 4. INSTALL OIL JET Using a screwdriver and hammer, tap in an oil jet. 26.55 A23065 5. INSTALL OIL NOZZLE Using a 5 mm socket hexagon wrench, install the 3 oil nozzles. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) A23038 Author: Date: 3338 EM-131 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK 6. INSTALL PISTON PIN HOLE SNAP RING Using a screwdriver, install a new snap ring at one side of the piston pin hole. HINT: Check that the end gap of the snap ring does not overlap the pin hole cutout portion of the piston. A23066 7. (a) INSTALL PISTON Gradually heat the piston to about 80C (176F). (b) (c) Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with a thumb. P12417 Front Mark Front Mark A23067 8. INSTALL PISTON PIN HOLE SNAP RING Using a screwdriver, install a new snap ring on the other side of the piston pin hole. HINT: Be sure that the end gap of the snap ring does not overlap the pin hole cutout portion of the piston. A23066 9. (a) (b) INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings. NOTICE: Install the compression ring No. 2 with the painted mark facing upward. Upward Painted Mark A23068 Author: Date: 3339 EM-132 ENGINE MECHANICAL (1GR-FE) (c) Lower side rail No. 2 Compression - CYLINDER BLOCK Position the piston rings so that the ring ends are as shown in the illustration. Front Mark Expander Side Rail No. 1 Compression Upper side rail A23069 10. INSTALL CONNECTING ROD BEARING Align the bearing claw with the groove of the connecting rod or connecting cap. NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod and prevent oil from adhering to them. A23070 No. 1 and No. 4 No. 2 and No. 3 Upper Lower 22.4 mm 19.0 mm 11. INSTALL CRANKSHAFT BEARING HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions. (a) Clean each main journal and bearing. A23050 (b) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTICE: Do not apply engine oil to the bearing or its contact surface. A23071 (c) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings. NOTICE: Do not apply engine oil to the bearing or its contact surface. HINT: The number marked on each main bearing cap indicates the installation position. Mark 1, 2, 3 or 4 A23052 Author: Date: 3340 EM-133 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK 12. (a) INSTALL CRANKSHAFT Apply engine oil to the upper bearing and install the crankshaft on the cylinder block. (b) Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block. (1) Push the crankshaft toward the front (rear) side. (2) Install the 2 upper thrust washers with the oil grooves facing outward. (c) Install the 2 lower thrust washers on the No. 2 bearing cap with the grooves facing outward. (d) Examine the front marks and numbers and install the bearing caps on the cylinder block. Apply a light coat of engine oil to the threads of the bearing cap bolts. Temporarily install the 8 main bearing cap bolts to the inside positions. A23072 A23073 (e) (f) A23054 (g) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes less than 6 mm (0.23 in.). Less than 6 mm A23055 Author: Date: 3341 EM-134 ENGINE MECHANICAL (1GR-FE) (h) (i) - CYLINDER BLOCK Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads of the main bearing cap bolts. A23056 (j) Install the 16 main bearing cap bolts. Using several steps, uniformly tighten the bolts in the sequence shown in the illustration. Torque: 61 N⋅m (622 kgf⋅cm, 45 ft⋅lbf) (k) (l) Mark the front side of the bearing cap bolts with paint. Retighten the bearing cap bolts 90 in the sequence as shown in the illustration. Check that the painted mark is now at a 90 angle to the front. Check that the crankshaft turns smoothly. 13 9 11 15 3 7 8 5 6 1 2 14 4 10 12 16 A23057 Painted Mark 90 Front (m) 90 (n) A23058 (o) 4 1 2 Using several steps, uniformly tighten the 8 main bearing cap bolts in the sequence as shown in the illustration. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) 7 3 5 6 8 A23059 Author: Date: 3342 EM-135 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK 13. (a) Front Mark A23074 INSTALL PISTON W/CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. (b) Check the position of the piston ring ends. (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod cap and prevent oil from adhering to them. Match the numbered connecting rod cap with the connecting rod. (d) (e) Check that the protrusion of the connecting rod cap is facing the correct direction. Apply a light coat of engine oil to the threads of the connecting rod cap bolts. Protrusion A23023 (f) Using SST, tighten the bolts alternately to the specified torque. SST 09011-38121 Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) (g) (h) (i) 14. (a) Mark the front side of each connecting cap bolt with paint. Retighten the cap bolts 90 as shown. Check that the crankshaft turns smoothly. INSTALL ENGINE REAR OIL SEAL RETAINER Remove any old packing material (FIPG) and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block. A23024 Painted Mark 90 Front 90 A23025 Author: Date: 3343 EM-136 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK (b) Seal Packing Seal Width: 2 to 3 mm (0.08 to 0.12 in.) A23004 Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE: Parts must be assembled within 3 minutes of application. Otherwise the seal packing must be removed and reapplied. (c) Install the oil seal retainer with the 5 bolts and 2 nuts. Torque: Bolt: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) Nut: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 15. (a) Adhesive INSTALL WATER DRAIN COCK Apply adhesive to 2 or 3 threads of the drain cock ends. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent A23018 (b) 45 45 15 45 A23019 After tightening the drain cocks to the specified torque, rotate them clockwise as shown in the illustration. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) NOTICE: Do not rotate the drain cocks more than 1 complete revolution (360) after tightening the drain cocks to the specified torque. Do not loosen the drain cocks after setting them correctly. Author: Date: 3344 EM-137 ENGINE MECHANICAL (1GR-FE) LH Bank Engine Rear RH Bank Engine Front 16. (a) Upper 15 (b) - CYLINDER BLOCK INSTALL KNOCK SENSOR Install the 2 knock sensors with the 2 bolts within a 15° angle as shown in the illustration. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Connect the knock sensor connectors. Upper 15 A23005 17. INSTALL WATER OUTLET PIPE NO.1 Install the water outlet pipe with the 3 bolts. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft·lbf) A22979 Author: Date: 3345 EM-126 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK EM1Y1-01 REPLACEMENT 1. REPLACE CONNECTING ROD SMALL END BUSH Using SST and a press, press out the bushing. SST 09222-30010 SST EM6363 2. (a) INSTALL CONNECTING ROD SMALL END BUSH Align the oil holes of a new bushing and the connecting rod. (b) Using SST and a press, press in the bushing. SST 09222-30010 (c) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) A23043 SST EM6363 EM6535 HINT: Check that the piston pin fits at a normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb. P20668 Author: Date: 3334 EM-127 ENGINE MECHANICAL (1GR-FE) - CYLINDER BLOCK 3. REPLACE ENGINE REAR OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal. (a) If the rear oil seal retainer is removed from the cylinder block: (1) Using a screwdriver and hammer, tap out the oil seal. A22982 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-78010 (3) Apply MP grease to the oil seal lip. SST A23003 (b) If the rear oil seal retainer is installed to the cylinder block: (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Cut Position A23080 (3) 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 (4) Apply MP grease to a new oil seal lip. SST A23081 Author: Date: 3335 EM-53 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD CYLINDER HEAD EM1XO-01 COMPONENTS 7.5 (76, 66 in.·lbf) V-Bank Cover Air Cleaner Hose 8.0 (82, 71 in.·lbf) Vacuum Hose Mass Air Flow Meter Connector Air Cleaner Ventilation Hose No.2 Battery Clamp Battery Battery Tray N·m (kgf·cm, ft·lbf) : Specified torque A23192 Author: Date: 3261 EM-54 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD Radiator Fan Shroud Fan w/ Fluid Coupling Fan Pulley 21 (214, 15) Drive Belt N·m (kgf·cm, ft·lbf) : Specified torque A23193 Author: Date: 3262 EM-55 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD VSV Connector 28 (286, 21) Water By-pass Hose x4 Intake Air Surge Tank x2 VSV Connector Fuel Vaper Feed Hose Surge Tank Stay No.2 Throttle Body Connector 21 (214, 15) 21 (214, 15) Throttle Body Bracket Ventilation Hose No.1 21 (214, 15) Surge Tank Stay No.1 Gasket Oil Baffle Plate Vane Pump 9.0 (92, 80 in.·lbf) 43 (438, 32) 9.8 (100, 7) Generator Terminal Cap 43 (438, 32) Generator Wire Generator Connector Cooler Compressor 8.0 (82, 71 in.·lbf) 43 (438, 32) 8.0 (82, 71 in.·lbf) 25 (255, 18) N·m (kgf·cm, ft·lbf) : Specified torque Wire Harness Clamp Bracket Cooler Compressor Connector Non-reusable part A22959 Author: Date: 3263 EM-56 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 40 (408, 30) Manifold Stay Gasket 40 (408, 30) 21 (214, 15) Gasket x6 RH Exhaust Manifold RH Front Exhaust Pipe x2 62 (630, 46) Gasket 9.0 (92, 80 in.·lbf) 43 (440, 32) Water By-pass Joint Spring Ventilation Hose Gasket Upper Radiator Hose O-ring Gasket 9.0 (92, 80 in.·lbf) Ventilation Hose Manifold Stay 40 (408, 30) 40 (408, 30) 40 (408, 30) Gasket 48 (490, 35) Lower Radiator Hose x6 LH Exhaust Manifold Gasket 21 (214, 15) Gasket N·m (kgf·cm, ft·lbf) Non-reusable part : Specified torque x2 62 (630, 46) LH Front Exhaust Pipe A23196 Author: Date: 3264 EM-57 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 26 (265, 19) Intake Manifold x10 Oil Level Gauge 9.0 (92, 80 in.·lbf) Gasket 10 (102, 7) Ignition Coil Spark Plug Water By-pass Hose No.1 Water By-pass Hose No.2 9.0 (92, 80 in.·lbf) Camshaft Timing Oil Control Valve 10 (102, 7) Ignition Coil Water By-pass Hose No.3 Oil Filter Cap O-ring Spark Plug Gasket 9.0 (92, 80 in.·lbf) x5 Oil Filter Cap Housing Water Inlet 9.0 (92, 80 in.·lbf) Idler Pulley No.2 Gasket Idler Pulley No.1 Washer 39 (398, 29) V-Ribbed Belt Tensioner Washer 54 (551, 40) 36 (367, 27) N·m (kgf·cm, ft·lbf) : Specified torque 36 (367, 27) Non-reusable part A23197 Author: Date: 3265 EM-58 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 9.0 (92, 80 in.·lbf) 9.0 (92, 80 in.·lbf) 10 (102, 7) Seal Washer 9.0 (92, 80 in.·lbf) x3 10 (102, 7) x3 x3 x7 Seal Washer Ventilation Valve 27 (275, 20) x3 Cylinder Head Cover RH x7 9.0 (92, 80 in.·lbf) 9.0 (92, 80 in.·lbf) Cylinder Head Cover LH VVT Sensor Cylinder Head Cover Gasket VVT Sensor Cylinder Head Cover Gasket Gasket Filter 62 (632, 46) 9.0 (92, 80 in.·lbf) O-ring O-ring Filter Gasket 62 (632, 46) Oil Level Gauge Guide x2 21 (214, 15) 10 (102, 7) x2 Oil Pan x9 Gasket x4 x6 21 (214, 15) 37 (377, 27) Oil Strainer 21 (214, 15) 9.0 (92, 80 in.·lbf) Oil Pan No.2 9.0 (92, 80 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part x15 x2 10 (102, 7) Gasket Drain Plug 40 (408, 30) Author: A23198 Date: 3266 EM-59 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 23 (235, 17) Crankshaft Pulley Oil Seal x15 Timing Chain Cover 250 (2,549, 184) 19 (194, 14) 23 (235, 17) Chain Tensioner No.2 19 (194, 14) x9 Chain Tensioner No.2 Camshaft Timing Sprocket Timing Chain No.2 23 (235, 17) x2 Camshaft Timing Gear Assembly Timing Chain No.2 100 (1,020, 74) Camshaft Timing Gear Assembly 100 (1,020, 74) 100 (1,020, 74) 100 (1,020, 74) Camshaft Timing Sprocket Chain Tensioner No.1 10 (102, 7) Chain Vibration Damper No.2 Timing Chain Chain Tensioner Slipper Idle Gear Shaft No.2 60 (612, 44) Idle Gear Shaft No.1 Idle Gear No.1 O-ring Crankshaft Timing Sprocket N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part 19 (194, 14) Author: Chain Vibration Damper No.1 Date: A23195 3267 EM-60 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 9.0 (92, 80 in.·lbf) 24 (245, 18) Camshaft Bearing Cap No.1 24 (245, 18) 9.0 (92, 80 in.·lbf) Camshaft Bearing Cap No.2 Camshaft Bearing Cap No.2 9.0 (92, 80 in.·lbf) 24 (245, 18) 24 (245, 18) 9.0 (92, 80 in.·lbf) Camshaft Camshaft Camshaft Bearing Cap No.1 Camshaft Bearing No.1 Camshaft Bearing Cap No.2 Camshaft Camshaft Camshaft Bearing Cap No.1 Camshaft Bearing Cap No.2 See page EM-89 1st 36 (367, 27) 2nd Turn 180 See page EM-89 x8 x8 x8 1st 36 (367, 27) 2nd Turn 180 30 (306, 22) Camshaft Bearing No.2 x8 x2 Plate Washer Cylinder Head LH Cylinder Head RH RH Cylinder Head Gasket N·m (kgf·cm, ft·lbf) LH Cylinder Head Gasket : Specified torque Non-reusable part A23199 Author: Date: 3268 EM-61 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD Valve Lifter Valve Spring Retainer Lock Valve Spring Retainer Inner Compression Spring Valve Stem Oil Seal Exhaust Valve Guide Bush Valve Spring Seat Intake Valve Guide Bush Intake Valve Exhaust Valve Non-reusable part A22923 Author: Date: 3269 EM-68 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD EM1XQ-01 DISASSEMBLY 1. REMOVE VALVE LIFTER HINT: Arrange the valve lifter in the correct order. A22924 SST Wooden Block A22925 2. REMOVE VALVE HINT: Arrange the valves, inner compression springs, valve spring retainers and valve spring retainer locks in the correct order. (a) Place the cylinder head on a wooden block. (b) Using SST, compress the inner compression spring and remove the 2 valve spring retainer locks. SST 09202-70020 (09202-00010) (c) Remove the valve, inner compression spring, valve spring and valve spring retainer. 3. REMOVE VALVE SPRING SEAL Using compressed air and a magnetic finger, remove the valve spring seat by blowing air. A22926 4. REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the valve stem oil seal. A22927 5. (a) CLEAN CYLENDER HEAD Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. A22928 Author: Date: 3276 EM-69 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD (b) Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the combustion chambers. A22929 (c) Using a valve guide bushing brush and solvent, clean all the valve guide bushes. (d) Using a soft brush and solvent, thoroughly clean the cylinder head. 6. (a) CLEAN VALVE Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. A22930 A22931 (b) EM0580 Author: Date: 3277 EM-70 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD EM1XR-01 INSPECTION 1. (a) INSPECT CYLINDER HEAD Inspect flatness. Using a precision straight edge and feeler gauge, measure the flatness of the contact surfaces of the cylinder block and manifolds. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than the maximum, replace the cylinder head. Cylinder Block Side: Intake Manifold Side: Exhaust Manifold Side: A22932 (b) Inspect cranks. Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. A22933 Author: Date: 3278 EM-71 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 2. INSPECT INTAKE MANIFOLD FOR FLATNESS Using a precision straight edge and feeler gauge, measure the flatness of the contact surfaces 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. Intake Air Surge Tank Side Cylinder Head Side A22967 A22968 3. INSPECT EXHAUST MANIFOLD FOR FLATNESS Using a precision straight edge and feeler gauge, measure the flatness of the contact surface 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.) 4. (a) INSPECT VALVE Inspect valve stem diameter. Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Exhaust 5.465 to 5.480 mm (0.2152 to 0.2158 in.) Z00052 (b) Inspect valve face angle. (1) Grind the valve enough to remove pits and carbon. (2) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5 44.5 Z00054 Author: Date: 3279 EM-72 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD (c) Inspect valve head margin thickness. Using vernier calipers, check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. EM0181 (d) Overall Length Inspect overall length. Using vernier calipers, check the overall length. Standard overall length: Intake 106.95 mm (4.2106 in.) Exhaust 105.80 mm (4.1654 in.) Minimum overall length: EM2534 Intake 106.40 mm (4.1890 in.) Exhaust 105.30 mm (4.1457 in.) If the overall length is less than the minimum, replace the valve. (e) Inspect valve stem tip. Check the surface of the valve stem tip for wear. NOTICE: Do not grind off more than the minimum length. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. EM0255 5. (a) (b) CLEAN VALVE SEAT Using a 45 carbide cutter, resurface the valve seats. Clean the valve seats. A22934 6. (a) Width P12729 INSPECT VALVE SEAT Apply a light coat of prussian blue (or white lead) to the valve face. (b) Lightly press the valve against the valve seat. NOTICE: Do not rotate the valve. (c) Check the valve face and seat according to the following procedure. (1) If prussian blue (or white lead) appears around the entire face, the valve is centered. Author: Date: 3280 EM-73 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD If not, replace the valve. (2) If the prussian blue (or white lead) appears around the entire valve seat, the guide and face are centered. If not, resurface the valve seat. (3) Check that the seat contacts the middle of the valve face with the width below. Standard width: 1.0 to 1.4 mm (0.039 to 0.055 in.) 45 30 7. REPAIR VALVE SEAT NOTICE: Take off a cutter gradually to make the intake valve seat smooth. (a) If the seating is too high to the valve face, use 30 and 45 cutters to correct the seat. 1.0 to 1.4 mm A01476 Intake Side: (b) Intake side: If the seating is too low to the valve face, use 60 and 45 cutters to correct the seat. (c) Exhaust side: If the seating is too low to the valve face, use 75 and 45 cutters to correct the seat. (d) Handrub the valve and valve seat with an abrasive compound. After handrubbing, clean the valve and valve seat. 60 45 1.0 to 1.4 mm A23191 Exhaust Side: 75 45 1.0 to 1.4 mm A01477 (e) A22935 Author: Date: 3281 EM-74 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 8. (a) INSPECT INNER COMPRESSION SPRING Inspect squareness. Using a steel square, measure the squareness of the inner compression spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than the maximum, replace the inner compression spring. Deviation EM0988 (b) Inspect free length. Using vernier calipers, measure the free length of the inner compression spring. Free length: 47.80 mm (1.8819 in.) If the free length is not as specified, replace the inner compression spring. EM0801 (c) Inspect tension. Using a spring tester, measure the tension of the inner compression spring at the specified installed length. Installed tension: 186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at 33.3 mm (1.311 in.) If the installed tension is not as specified, replace the inner compression spring. EM0281 9. (a) (b) A22936 INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. Inside diameter: 5.51 to 5.53 mm (0.2169 to 0.2177 in.) Subtract the valve stem diameter measurement (Step 8) from the valve guide bush inside diameter measurement. Standard oil clearance: Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in..) If the oil clearance is greater than the maximum, replace the valve and valve guide bush. Author: Date: 3282 EM-75 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 10. INSPECT VALVE LIFTER Using a micrometer, measure the valve lifter diameter. Valve lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) P16860 11. (a) Diameter A22942 INSPECT VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) (b) Subtract the valve lifter diameter measurement (Step 10) from the lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than the maximum, replace the valve lifter. If necessary, replace the cylinder head. 12. (a) Plastigage A22943 INSPECT CAMSHAFT OIL CLEARANCE Clean the camshaft bearing caps, camshaft bearings and camshaft journals. (b) Install the camshaft bearing (See page EM-89 ). (c) Place the camshaft on the cylinder head. (d) Lay a strip of Plastigage across each of the camshaft journals. (e) Install the camshaft bearing caps (See page EM-89 ). NOTICE: Do not turn the camshafts. (f) Remove the camshaft bearing caps (See page EM-62 ). Author: Date: 3283 EM-76 ENGINE MECHANICAL (1GR-FE) (g) - CYLINDER HEAD Measure the Plastigage at its widest point. Standard oil clearance (Cylinder head RH): No. 1 (Intake) 0.008 to 0.038 mm (0.0003 to 0.0015 in.) No. 1 (Exhaust) 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Standard oil clearance (Cylinder head LH): A22944 No. 1 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Others 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum oil clearance (Cylinder head RH): No. 1 (Intake) 0.07 mm (0.0028 in.) Others 0.10 mm (0.0039 in.) Maximum oil clearance (Cylinder head LH): 0.10 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the camshaft bearings and/or camshaft. If necessary, replace the camshaft bearing caps and cylinder head together. Reference: Cylinder head journal bore diameter 40.009 to 40.017 mm (1.5752 to 1.5755 in.) Camshaft bearing center wall thickness (Mark ”2”) 2.004 to 2.008 mm (0.0789 to 0.0791 in.) Camshaft journal diameter 35.971 to 35.985 mm (1.4165 to 1.4167 in.) (h) (i) (j) Remove the Plastigage completely. Remove the camshafts. Remove the camshaft bearing. 13. (a) (b) A22945 INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts (See page EM-89 ). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.04 to 0.09 mm (0.0016 to 0.0035 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than the maximum, replace the camshafts. Author: Date: 3284 EM-77 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD If necessary, replace the camshaft bearing caps and cylinder head as a set. 14. (a) INSPECT CAMSHAFT Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the runout at the center journal. Maximum runout: 0.06 mm (0.0024 in.) If the runout is greater than the maximum, replace the camshaft . A22983 (b) EM2011 Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake: 44.168 to 44.268 mm (1.7389 to 1.7428 in.) Exhaust: 44.580 to 44.680 mm (1.7551 to 1.7591 in.) Minimum cam lobe height: Intake: 44.018 mm (1.7330 in.) Exhaust: 44.430 mm (1.7492 in.) If the cam lobe height is less than the minimum, replace the camshaft. (c) Inspect the camshaft journals. Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance. 15. INSPECT CAMSHAFT TIMING GEAR (a) Fix the intake camshaft with a vise. NOTICE: Be careful not to damage the camshaft. A22984 Author: Date: 3285 EM-78 ENGINE MECHANICAL (1GR-FE) (b) Knock Pin (c) - CYLINDER HEAD Align the knock pin hole in the camshaft timing gear assembly with the knock pin of the camshaft, and install the camshaft timing gear assembly with the bolt. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) Confirm that the camshaft timing gear assembly is locked. A22985 (d) Retard Side Paths Advance Side Paths Open Close Close Open Rubber Piece Release the lock pin. (1) Cover the 4 oil paths of the cam journal with masking tape as shown in the illustration. HINT: One of the 2 grooves on the cam journal is for retards (upper) and the other is for advances (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with tape. (2) Prick a hole in the tape placed on the advance side path. Prick a hole in the retard side path, on the opposite side to that of the advance side path, as shown in the illustration. Masking Tape A22986 (3) Advance Side Path Retard Side Path Apply about 200 kPa (2.0 kgf/cm2) of air pressure to the two broken paths (the advance side path and the retard side path). NOTICE: Cover the paths with a shop rag to avoid oil splashing. A22987 Advance Side Path Hold Pressure (4) Retard Side Path Decompress A22988 Confirm that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard path. HINT: When the lock pin is released, the camshaft timing gear rotates in the advance direction. (5) When the camshaft timing gear comes to the most advanced position, release the air pressure from the retard side path, and then release the air pressure from the advance side path. Author: Date: 3286 EM-79 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD NOTICE: The camshaft timing assembly gear occasionally shifts to the retard side abruptly if the air pressure of the advanced side path is released first. This often results in breakage of the lock pin. (e) Check for smooth revolution. Allow the camshaft timing gear assembly to turn back and forth at any position, except where the lock pin meets at the most retarded angle. Check the movable range and that there is no disturbance. Standard: Moves smoothly in a range of about 31 NOTICE: Be sure to perform this check by hand, instead of air pressure. (f) Check the lock in the most retarded position. Confirm that the camshaft timing gear assembly is locked at the most retarded position. (g) Remove the set bolt and camshaft timing gear assembly. NOTICE: Be sure not to remove the other 3 bolts. Set Bolt A22989 16. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, 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.) A22890 Author: Date: 3287 EM-89 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD EM1XU-01 INSTALLATION 1. (a) (b) INSTALL CYLINDER HEAD GASKET Remove any old packing material (FIPG) and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. Install the RH cylinder head gasket. (1) 10 to 15 mm φ 2.5 to 3 mm Gasket 1.25 to 1.5 mm 10 to 15 mm Seal Packing Apply a continuous bead of 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: Part No. 08826-00080 or equivalent NOTICE: 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. A22891 (2) Lot No. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward. NOTICE: 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. A22892 Author: Date: 3297 EM-90 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD (c) 10 to 15 mm φ 2.5 to 3 mm Gasket 1.25 to 1.5 mm Install the LH cylinder head gasket. (1) Apply a continuous bead of 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: Part No. 08826-00080 or equivalent NOTICE: 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. 10 to 15 mm Seal Packing A22914 (2) Lot No. A22915 6 4 2 7 8 1 3 5 Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper sied facing upward. NOTICE: 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 (a) Place the RH cylinder head on the cylinder head gasket. (b) Install the 8 cylinder head bolts. HINT: The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)). If any cylinder head bolt is broken or deformed, replace it. (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Install the plate washer to the cylinder head bolt. (3) Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration. Torque: 36 N⋅m (367 kgf⋅cm, 27 ft⋅lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTICE: Do not drop the washers into the cylinder head. A22888 Author: Date: 3298 EM-91 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD (4) 180 Engine Front Paint Mark A22893 (c) (d) HINT: Mark the front side of each cylinder head bolt with paint. (5) Retighten the cylinder head bolts by 180 as shown. (6) Check that the painted marks are now at 180 opposite to the engine front. Place the LH cylinder head on the cylinder head gasket. Install the 8 cylinder head bolts. The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)). If any cylinder head bolt is broken or deformed, replace it. (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Install the plate washer to the cylinder head bolt. (3) 8 1 3 5 6 4 2 7 Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration. Torque: 36 N⋅m (367 kgf⋅cm, 27 ft⋅lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTICE: Do not drop the washers into the cylinder head. A22912 (4) 180 (5) Engine Front (6) Mark the front side of each cylinder head bolt with paint. Retighten the cylinder head bolts by 180 as shown. Check that the painted marks are now at 180 opposite to the engine front. Paint Mark A22893 (e) 1 2 Install the 2 cylinder head bolts. (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Install the 2 cylinder head bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A22911 Author: Date: 3299 EM-92 ENGINE MECHANICAL (1GR-FE) Claw A23006 A22894 - CYLINDER HEAD 3. INSTALL CAMSHAFT BEARING NO.1 Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing. NOTICE: Install the bearing while aligning it with the oil hole in the bearing cap. Clean the backside of the bearing and the bearing surface of the bearing cap and prevent oil from adhering to them. 4. INSTALL CAMSHAFT BEARING NO.2 Install the camshaft bearing No. 2 to the cylinder head. NOTICE: Clean the backside of the bearing and the bearing surface of the cylinder head and prevent oil from adhering to them. 5. INSTALL CAMSHAFT NOTICE: 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. (a) 90 Set Key Turn A22895 Set the crankshaft position. Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position. NOTICE: 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. (b) Apply new engine oil to the thrust portion and journal of the camshafts. Author: Date: 3300 EM-93 ENGINE MECHANICAL (1GR-FE) (c) RH Bank - CYLINDER HEAD Install the camshaft of the RH bank. (1) Place the 2 camshafts onto the RH cylinder head with the cam lobes of No. 1 cylinder facing each direction as shown in the illustration. A22896 (2) (3) RH Bank Install the 8 bearing caps in their proper locations. Apply a light coat of engine oil to the threads of the bearing cap bolts. A22897 (4) Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head RH Bank 14 15 13 16 11 6 2 10 9 3 1 4 12 5 7 8 A22898 (5) RH Bank Turn Turn the camshafts clockwise with a wrench until the camshaft knock pin comes 90 position to the cylinder head. Turn 90 90 A22899 (d) LH Bank Install the camshafts of the LH bank. (1) Place the 2 camshafts onto the LH cylinder head with the cam lobes of No. 2 cylinder facing as shown in the illustration. A22917 Author: Date: 3301 EM-94 ENGINE MECHANICAL (1GR-FE) (2) (3) LH Bank - CYLINDER HEAD 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. A22918 (4) LH Bank 6 5 7 2 10 14 1 3 9 11 13 15 8 4 12 16 A22910 6. 7. 8. Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head INSTALL TIMING CHAIN (See page EM-44 ) INSTALL TIMING CHAIN COVER (See page EM-44 ) INSTALL OIL PAN (See page EM-44 ) 9. (a) INSTALL EXHAUST MANIFOLD Install the RH exhaust manifold. (1) Set a new gasket to the RH cylinder head with the oval shape facing forward. NOTICE: Be careful of the installation direction. Oval Shape Forward A22906 (2) Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) (3) Connect the A/F sensor connector. (4) Install the manifold stay with the 3 bolts. Torque: 40 N⋅m (408 kgf⋅cm, 30 ft⋅lbf) A23251 (b) Oval shape Install the LH exhaust manifold. (1) Set a new gasket to the LH cylinder head with the oval shape facing backward. NOTICE: Be careful of the installation direction. Forward A22922 Author: Date: 3302 EM-95 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD (2) 10. A23252 11. 12. (a) Mesh Part Apply Adhesive 13. INSTALL OIL CONTROL VALVE FILTER Check that no foreign objects on the mesh part of the 2 filters. Install 2 new gaskets to each new plug. Insert the filters to the plugs. Apply adhesive to 2 or 3 threads of the plugs. Adhesive: Part No. 08833-00080, THREE BOND 1344 LOCTITE 242 or equivalent Install the plugs to each cylinder head. Torque: 62 N⋅m (632 kgf⋅cm, 46 ft⋅lbf) INSTALL CAMSHAFT TIMING OIL CONTROL VALVE 14. (a) (b) INSTALL WATER BY-PASS JOINT Install a new O-ring to the water outlet pipe. Apply soapy water to the O-ring. (c) Install 2 new gaskets and water by-pass joint 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. (b) (c) (d) A23017 Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) (3) Connect the A/F sensor connector. (4) Install the manifold stay with the 3 bolts. Torque: 40 N⋅m (408 kgf⋅cm, 30 ft⋅lbf) INSTALL RH AND LH FRONT EXHAUST PIPE (See page EM-138 ) INSTALL VVT SENSOR (See page IG-12 ) (e) A22904 (d) (e) A22883 Author: Date: 3303 EM-96 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 15. INSTALL INTAKE MANIFOLD (a) Set a new gasket on each cylinder head. NOTICE: Align the port holes of the gasket and cylinder head. Be careful of the installation direction. (b) Set the intake manifold on the cylinder heads. A22905 (c) (d) 16. (a) A22882 (2) Seal Packing Seal Width: 2 to 3 mm B B B B B A Nut 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. INSTALL CYLINDER HEAD COVER Install the RH cylinder head cover. (1) Remove any old packing material (FIPG) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. A23016 B A A B NutA23092 (c) Seal Packing Seal Width: 2 to 3 mm 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: Part No. 08826-00080 or equivalent NOTICE: 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. (3) Install the seal washers to the bolts. (4) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: Bolt A, Nut: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Bolt B: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) (b) Install a new gasket and oil filler cap housing with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) A23015 Install the LH cylinder head cover. (1) 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: Part No. 08826-00080 or equivalent NOTICE: 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. Author: Date: 3304 EM-97 ENGINE MECHANICAL (1GR-FE) - (2) B B B A Nut 17. A B Install the seal washers to the bolts. (3) B B A CYLINDER HEAD Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: Bolt A, Nut: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Bolt B: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) INSTALL IGNITER B Nut A22970 18. (a) (b) (c) 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) A23091 (d) (e) 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) A23090 (f) Install the throttle body bracket with the 2 bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) A23089 Author: Date: 3305 EM-98 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD (g) (h) (i) Install the 3 wire harness clamps and hose clamp. Connect the throttle body w/ motor connector. Connect the 2 VSV connectors. (j) Connect the ventilation hose. (k) Connect the fuel vapor feed hose. (l) 19. Connect the 2 water by-pass hoses. CONNECT HEATER WATER OUTLET AND INLET HOSE INSTALL COOLER COMPRESSOR (See page AC-58 ) INSTALL GENERATOR (See page CH-15 ) INSTALL VANE PUMP (See page SR-57 ) INSTALL FAN W/FLUID COUPLING A23088 A23087 A23086 20. 21. 22. 23. A23085 Author: Date: 3306 EM-99 ENGINE MECHANICAL (1GR-FE) 24. (a) (b) (c) - CYLINDER HEAD INSTALL DRIVE BELT While turning the belt tensioner counterclockwise, align with the holes. 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. Turn Holes A22798 Water Pump Generator Idler No. 2 P/S Pump (d) Tensioner Idler No. 2 Crankshaft Idler No. 1 If it is hard to install the V-ribbed belt, perform the following procedure. (1) Put the V-ribbed belt on every parts except the P/S pump as shown in the illustration. (2) While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the P/S pump. A/C Compressor A22799 25. TIGHTEN FAN W/FLUID COUPLING Tighten the 4 fluid coupling bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) 26. INSTALL RADIATOR (See page CO-18 ) 27. INSTALL FAN SHROUD 28. CONNECT FUEL PIPE (See page SF-1 ) A23114 29. (a) (b) INSTALL AIR CLEANER Install the air cleaner with the 2 bolts. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) Tighten the 2 hose clamps. A23210 Author: Date: 3307 EM-100 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD (c) (d) (e) Install the 2 wire harness clamps. Connect the mass air flow meter connector. Connect the vacuum hose. (f) 30. 31. 32. Connect the ventilation hose No.2. ADD ENGINE COOLANT ADD ENGINE OIL CHECK FOR LEAK A23209 A23095 33. INSTALL V-BANK COVER Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in.·lbf) A23407 Author: Date: 3308 EM-82 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD EM1XT-01 REASSEMBLY 1. INSTALL RING PIN Using a plastic-faced hammer, tap in the new ring pins until they reach the specified protrusion height. Specified protrusion height: 2.7 to 3.3 mm (0.106 to 0.130 in.) Cylinder Head RH Side: Cylinder Head LH Side: 11 mm 8 mm Protrusion Height Engine Front Engine Front A22946 Author: Date: 3290 EM-83 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 2. INSTALL STRAIGHT PIN Using a plastic-faced hammer, tap in the new straight pins until they reach the specified protrusion height. Specified protrusion height: A 17.5 to 19.5 mm (0.689 to 0.768 in.) B 7.5 to 8.5 mm (0.295 to 0.335 in.) C 7.0 to 9.0 mm (0.276 to 0.354 in.) Cylinder Head RH Side: Upper Side: Front Side: A B Intake Manifold Side: C Cylinder Head LH Side: Upper Side: Front Side: A B Intake Manifold Side: 8 mm 5 mm Protrusion Height 13.8 mm 34 mm C Protrusion Height B and C A A22947 Author: Date: 3291 EM-84 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 3. INSTALL STUD BOLT Using the Torx® socket wrench E5 and E7, install the stud bolts. Torque: 4.0 N⋅m (41 kgf⋅cm, 35 in.⋅lbf) for stud bolt A, C 19.5 N⋅m (199 kgf⋅cm, 14 ft·lbf) for stud bolt B Cylinder Head RH Side: Upper Side: Rear Side: C A Exhaust Manifold Side: Cylinder Head LH Side: B Upper Side: Rear Side: C A Exhaust Manifold Side: 20 mm 12 mm 33.3 mm B 9 mm A 16 mm 42 mm 13 mm B 27 mm 9 mm C A22948 Author: Date: 3292 EM-85 ENGINE MECHANICAL (1GR-FE) 4. (a) (b) - CYLINDER HEAD INSTALL UNION Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Using a deep socket wrench 12, install the unions. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Adhesive A22949 Cylinder Head RH (Front) Side: Cylinder Head LH (Intake Manifold) Side: A B 67 mm 9 mm 9 mm A B Author: 30 mm A22950 Date: 3293 EM-86 ENGINE MECHANICAL (1GR-FE) 5. (a) (b) Adhesive - CYLINDER HEAD INSTALL TIGHT PLUG Apply adhesive around the tight plugs. Using SST, tap in the tight plugs to the specified depth. SST 09950-60010 (09951-00250), 09950-70010 (09951-07150) Specified depth: 1.5 mm (0.059 in.) A22951 Cylinder Head RH (Rear) Side: Cylinder Head LH (Rear) Side: SST Depth 1.5 mm A22952 Author: Date: 3294 EM-87 ENGINE MECHANICAL (1GR-FE) 6. (a) - CYLINDER HEAD INSTALL STRAIGHT SCREW PLUG Using a straight hexagon wrench 14, install a new gasket and straight screw plug. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) Cylinder Head RH Side: Upper Side: Cylinder Head LH Side: Upper Side: Front Side: Front Side: A22953 Light Brown Gray Intake Side: 7. INSTALL VALVE STEM OIL SEAL HINT: The intake valve stem oil seal is light brown and the exhaust valve stem oil seal is gray. (a) Apply a light coat of engine oil to the valve guide bush. Exhaust Side: A22954 (b) SST Using SST, push in a new valve stem oil seal. SST 09201-41020 A22955 Author: Date: 3295 EM-88 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 8. INSTALL VALVE SPRING SEAT 9. (a) INSTALL VALVE Apply engine oil to the valve as shown in the illustration. (b) (c) Place the cylinder head on a wooden block. Install the valve, inner compression spring and valve spring retainer. Using SST, compress the inner compression spring and place the 2 valve spring retainer locks around the valve stem. SST 09202-70020 (09202-00010) A22956 35 mm (1.378 in.) A22957 SST (d) Wooden Block A22925 (e) Using a pin punch 5, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. A22958 10. (a) (b) INSTALL VALVE LIFTER Apply engine oil to the valve stem end and valve lifter, and install the valve lifter to the valve stem. Check that the valve lifter rotates smoothly by hand. A22924 Author: Date: 3296 EM-62 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD EM1XP-01 REMOVAL 1. 2. 3. PREVENT GASOLINE FROM SPILLING OUT DRAIN ENGINE COOLANT (See page CO-2 ) DRAIN ENGINE OIL (See page LU-3 ) 4. REMOVE V-BANK COVER Remove the 2 nuts and V-bank cover. A23208 5. (a) REMOVE AIR CLEANER Disconnect the ventilation hose No.2. (b) (c) (d) Disconnect the vacuum hose. Disconnect the mass air flow meter connector. Remove the 2 wire harness clamps. (e) (f) 6. 7. 8. Loosen the 2 hose clamps. Remove the 2 bolts and air cleaner DISCONNECT FUEL PIPE (See page SF-1 ) REMOVE FAN SHROUD REMOVE RADIATOR (See page CO-17 ) A23095 A23209 A23210 Author: Date: 3270 EM-63 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD 9. LOOSEN FAN W/FLUID COUPLING Loosen the 4 nuts of the fan w/ fluid coupling. A23114 A22797 10. REMOVE DRIVE BELT Release the belt tension by turning the belt tensioner counterclockwise. Remove the V-ribbed belt from the belt tensioner. 11. REMOVE FAN W/FLUID COUPLING 12. SEPARATE VANE PUMP (See page SR-47 ) 13. REMOVE GENERATOR (See page CH-7 ) 14. SEPARATE COOLER COMPRESSOR (See page AC-54 ) 15. DISCONNECT HEATER WATER OUTLET AND INLET HOSE 16. (a) REMOVE INTAKE AIR SURGE TANK Disconnect the 2 water by-pass hoses. (b) Disconnect the fuel vapor feed hose. A23085 A23086 Author: Date: 3271 EM-64 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD (c) Disconnect the ventilation hose. (d) (e) (f) Disconnect the 2 VSV connectors. Disconnect the throttle body w/ motor connector. Separate the 3 wire harness clamps and hose clamp. (g) Remove the 2 bolts and throttle body bracket. (h) (i) Remove the bolt and oil baffle plate. Remove the 4 bolts and 2 surge tank stays. A23087 A23088 A23089 A23090 Author: Date: 3272 EM-65 ENGINE MECHANICAL (1GR-FE) (j) (k) 17. - CYLINDER HEAD Remove the 2 nuts. Using a socket hexagon wrench 8, remove the 4 bolts, intake air surge tank and gasket. REMOVE IGNITER (See page IG-6 ) A23091 18. (a) (b) REMOVE CYLINDER HEAD COVER Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover RH and gasket. Remove the 2 nuts, oil filter cap housing and gasket. A22970 (c) 19. (a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover LH and gasket. REMOVE INTAKE MANIFOLD Disconnect the 6 fuel injector connectors. A23092 (b) 20. (a) (b) Remove the 10 bolts, intake manifold and 2 gaskets. REMOVE WATER BY-PASS JOINT Disconnect the engine coolant temperature sensor connector. Disconnect the heater hose. A22882 (c) (d) 21. Remove the 2 bolts, 4 nuts, water by-pass joint RR and 2 gaskets. Remove the O-ring from the water outlet pipe. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE A22883 Author: Date: 3273 EM-66 ENGINE MECHANICAL (1GR-FE) RH Bank LH Bank A22969 CYLINDER HEAD 22. REMOVE OIL CONTROL VALVE FILTER Remove the plug, filter and gasket from each cylinder head. 23. REMOVE VVT SENSOR 24. REMOVE RH AND LH FRONT EXHAUST PIPE 25. REMOVE RH AND LH EXHAUST MANIFOLD (a) Remove the 6 bolts and 2 exhaust manifold stays. (b) Remove the 12 nuts, RH and LH exhaust manifold and 2 gaskets. 26. REMOVE OIL PAN (See page EM-32 ) 27. REMOVE TIMING CHAIN COVER (See page EM-32 ) 28. REMOVE TIMING CHAIN (See page EM-32 ) 29. REMOVE CAMSHAFT NOTICE: 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. (a) RH Bank - Remove the camshafts of the RH bank. (1) Rotate the camshafts counterclockwise using the wrench so that the cam lobes of the No. 1 cylinder face each direction as shown in the illustration. A22886 (2) RH Bank 3 11 15 7 (3) 2 4 6 1 8 14 12 10 16 13 5 Using several steps, uniformly loosen and remove the 16 bearing cap bolts in the sequence as shown in the illustration. Remove the 8 bearing caps and 2 camshafts. 9 A22887 (b) LH Bank 11 12 10 15 14 9 16 13 7 8 3 6 5 4 2 30. Remove the camshafts of the LH bank. (1) Using several steps, uniformly loosen and remove the 16 bearing cap bolts in the sequence as shown in the illustration. (2) Remove the 8 bearing caps and 2 camshafts. REMOVE CAMSHAFT BEARING NO.1 AND NO.2 1 A22910 Author: Date: 3274 EM-67 ENGINE MECHANICAL (1GR-FE) 31. (a) LH Cylinder Head 2 - CYLINDER HEAD REMOVE CYLINDER HEAD Using several steps, remove the 2 cylinder head bolts on the LH cylinder head in the sequence as shown in the illustration. 1 A22911 RH Cylinder Head 3 5 1 8 (b) 7 2 6 4 Using several steps, loosen the 8 cylinder head bolts on each cylinder head with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 16 cylinder head bolts and plate washers. NOTICE: Be careful not to drop the plate washers into the cylinder head. Cylinder head warpage or cracking could result from removing the bolts in the incorrect order. LH Cylinder Head 1 8 6 4 3 5 7 2 A22977 (c) A22978 Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench. NOTICE: 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. (d) Remove the RH and LH cylinder head gaskets. 32. REMOVE CYLINDER HEAD GASKET Author: Date: 3275 EM-80 ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD EM1XS-01 REPLACEMENT 1. (a) REPLACE VALVE GUIDE BUSH Gradually heat the cylinder head to between 80 and 100C (176 to 212F). (b) (c) Place the cylinder head on a wooden block. Using SST, tap out the valve guide bush. SST 09201-10000, 09201-01055, 09950-70010 (09951-07100) A22937 SST Wooden Block A22938 (d) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Bush bore diameter: 10.295 to 10.315 mm (0.4053 to 0.4061 in.) If the bush bore diameter of the cylinder head is greater than 10.315 mm (0.4061 in.), machine the bush bore to dimensions of 10.345 to 10.365 mm (0.4073 to 0.4081 in.). Valve guide bush diameter Diameter A22939 (e) STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) Gradually heat the cylinder head to between 80 and 100C (176 to 212F). A22937 Author: Date: 3288 EM-81 ENGINE MECHANICAL (1GR-FE) Protrusion Height SST - CYLINDER HEAD (f) (g) Place the cylinder head on a wooden block. Using SST, tap in a new valve guide bush to the specified protrusion height. SST 09201-10000, 09201-01055, 09950-70010 (09951-07100) Protrusion height: 9.3 to 9.7 mm (0.366 to 0.382 in.) (h) Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance between the valve guide bush and valve stem. Standard oil clearance: Wooden Block A22940 Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) A22941 Author: Date: 3289 EM-101 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT ENGINE UNIT EM1XV-01 COMPONENTS V-Bank Cover 7.5 (76, 66 in.·lbf) Hood Air Cleaner Hose No.2 Ventilation Hose No.2 Air Cleaner Assembly MAF Meter Connector Heater Hose Battery Clamp Battery Battery Tray Fuel Pipe Fuel Pipe Clamp N·m (kgf·cm, ft·lbf) : Specified torque A23384 Author: Date: 3309 EM-102 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT No.1 Fan Shroud 5.0 (50, 44 in.·lbf) Radiator Assembly No.2 Fan Shroud 12 (120, 9) Oil Cooler Pipe for AutomaticTransmission V-Belt Fan w/ Fluid Coupling Fan Pulley N·m (kgf·cm, ft·lbf) : Specified torque A23385 Author: Date: 3310 EM-103 ENGINE MECHANICAL (1GR-FE) - 12 (122, 9) ENGINE UNIT 34 (346, 25) Clamp Transmission 71 (724, 52) Oil Cooler Pipe 2.0 Kw: Torque Converter Clutch Shift Control Cable x6 14.5 (148, 11) 19.5 (199, 14) 37 (377, 27) 48 (490, 35) Starter 37 (377, 27) 9.8 (100, 7) 9.8 (100, 7) 48 (490, 35) 40 (408, 30) 43 (440, 32) Front Exhaust Pipe RH 1.6 Kw: Starter Flywheel Housing Side Cover Engine Rear Mounting Insulator 65 (660, 48) Manifold Stay Gasket 40 (408, 30) 72 (734, 53) Spring Gasket Manifold Stay Gasket Front Exhaust Pipe LH 18 (185, 13) Crossmember 62 (630, 46) Gasket Exhaust Pipe Support 62 (630, 46) Propeller Shaft 37 (377, 27) 88 (897, 65) 40 (410, 30) Bushing Stabilizer Bar Bracket Stabilizer Bar N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part Engine Under Cover D14136 Author: Date: 3311 EM-104 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT Water By-pass Hose VSV Connector Throttle Body Motor Connector VSV Connector Vane Pump Connector Generator 43 (438, 32) Generator Wire 43 (438, 32) Vane Pump Generator Connector A/C Compressor 25 (255, 18) Wire Harness Clamp Bracket A/C Compressor Connector N·m (kgf·cm, ft·lbf) : Specified torque A23386 Author: Date: 3312 EM-108 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT EM1XX-01 INSTALLATION 1. INSTALL DRIVE PLATE HINT: The mounting bolts are tightened in 2 progressive steps (steps (c) and (e)). If any of the mounting bolts is broken or deformed, replace it. (a) Adhesive Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent A04869 (b) 1 Install the front spacer, drive plate and rear spacer on the crankshaft. (c) Install and uniformly tighten the 8 mounting bolts in several steps, in the sequence shown in the illustration. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) If any of the mounting bolts do not meet the torque specification, replace it. 5 8 3 4 7 6 2 A23391 (d) (e) (f) Painted Mark 90° 90° 2. (a) (b) A23392 (c) (d) (e) (f) Mark the mounting bolt with paint. Retighten the mounting bolts 90° in the order shown in the illustration. Check that the painted mark is now at a 90° angle to what it was in step (e). INSTALL ENGINE ASSEMBLY IN VEHICLE Attach the engine chain hoist to the engine hangers. Slowly lower the engine assembly into the engine compartment. Attach the engine mounting brackets to the frame brackets. Install the engine mounting brackets to the frame brackets with the 2 nuts and 4 bolts. Torque: 38 N·m (388 kgf·cm, 28 ft·lbf) Remove the engine chain hoist. Remove the 4 bolts and 2 engine hangers. Author: Date: 3316 EM-109 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT 3. INSTALL PS PUMP Install the PS pump with the 3 bolts. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) A23390 4. (a) (b) 5. A23389 (a) (b) (c) (d) (e) (f) (g) (h) 6. (a) (b) (c) (d) Connect A09152 A23387 (e) (f) (g) (h) 7. (a) (b) (c) (d) (e) (f) 8. 9. 10. INSTALL A/C COMPRESSOR Install the A/C compressor with the 3 bolts. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Connect the A/C compressor connector. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES Connect the generator wire and connector. Connect the 2 heater hoses. Connect the ground strap to the cowl panel. Connect the fuel inlet hose and clamps. Connect the fuel return hose and clamp. Connect the air inlet hose to the charcoal canister. Connect the EVAP hose to the charcoal canister. Connect the brake booster tube. CONNECT ENGINE WIRE TO CABIN Push the engine wire through the cowl panel. Install the engine wire bracket with the 2 nuts and bolt and connect the engine wire to the bracket. Connect the 3 connectors to the ECM. Connect the 2 wire harness connectors (cassette connector). Install the ECM with the 3 screws. Install the heater to register duct. Install the lower No.2 finish panel. Install the glove compartment door. INSTALL AIR CLEANER ASSEMBLY Install the air cleaner assembly with the 2 bolts. Connect the air cleaner case to the air cleaner hose No.1. Connect the air cleaner case with the 2 wire clamps. Connect the PCV hose to the air cleaner case. Connect the MAF meter connector. Connect the air cleaner hose No.2 to the air cleaner case. INSTALL BATTERY INSTALL RADIATOR ASSEMBLY (See page CO-18 ) INSTALL FRONT EXHAUST PIPES (See page EM-139 ) Author: Date: 3317 EM-1 10 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT 11. INSTALL AUTOMATIC TRANSMISSION (See page AT-29 ) 12. INSTALL MANUAL TRANSMISSION (See page MT-7 ) 13. FILL WITH ENGINE COOLANT (See page CO-2 ) 14. FILL WITH ENGINE OIL (See page LU-3 ) 15. START ENGINE AND CHECK FOR LEAKS 16. INSTALL ENGINE UNDER COVERS 17. INSTALL V-BANK COVER 18. INSTALL HOOD 19. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 20. RECHECK ENGINE COOLANT AND OIL LEVELS Author: Date: 3318 EM-105 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT EM1XW-01 REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. (a) (b) (c) (d) (e) A23387 (f) 11. (a) (b) (c) 12. (a) (b) (c) (d) (e) PREVENT GASOLINE FROM SPILLING OUT (See page SF-1 ) REMOVE ENGINE HOOD REMOVE ENGINE V-BANK COVER REMOVE ENGINE UNDER COVER REMOVE AUTOMATIC TRANSMISSION (See page AT-25 ) REMOVE MANUAL TRANSMISSION (See page MT-4 ) REMOVE FRONT EXHAUST PIPES (See page EM-139 ) REMOVE RADIATOR ASSEMBLY (See page CO-17 ) REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY Disconnect the air cleaner hose No.2 from the air cleaner case. Disconnect the MAF meter connector. Disconnect the PCV hose from the air cleaner case. Disconnect the 2 wire clamps from the air cleaner case. Disconnect the air cleaner case from the air cleaner hose No.1. Remove the 2 bolts and air cleaner assembly. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY Loosen the 4 nuts holding the fluid coupling to the fan bracket. Remove the drive belt. (See page CH-7 ) Remove the 4 nuts, fan, fluid coupling assembly and fan pulley. DISCONNECT ENGINE WIRE FROM CABIN Remove the glove compartment door. Remove the lower No.2 finish panel. Remove the heater to register duct. Remove the 3 screws, and disconnect the ECM from the body bracket. Disconnect the 3 wire harness connectors from the ECM. Author: Date: 3313 EM-106 ENGINE MECHANICAL (1GR-FE) (f) (g) 13. Disconnect B07536 (a) (b) (c) (d) (e) (f) (g) 14. (a) (b) - ENGINE UNIT Disconnect the engine wire from the engine wire bracket and remove the 2 nuts, bolt and bracket. Pull out the engine wire from the cowl panel. DISCONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES Disconnect the generator connector. Disconnect the 2 heater hoses. Disconnect the ground strap from the cowl panel. Disconnect the fuel inlet hose and clamps. Disconnect the fuel return hose and clamp. Disconnect the air inlet hose from the charcoal canister. Disconnect the EVAP hose from the charcoal canister. DISCONNECT A/C COMPRESSOR FROM ENGINE Disconnect the A/C compressor connector. Remove the 3 bolts, and disconnect the A/C compressor from the engine. HINT: Suspend the A/C compressor securely. A23389 15. DISCONNECT PS PUMP FROM ENGINE Remove the 3 bolts, and disconnect the PS pump from the engine. HINT: Suspend the PS pump securely. A23390 16. (a) A22965 (b) REMOVE ENGINE ASSEMBLY FROM VEHICLE Install the 2 engine hangers with the 4 bolts as shown in the illustration. Part No. : Engine hanger No. 1 12281-31060 Engine hanger No. 2 12282-31040 Bolt 90119-08177 Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) Attach the engine sling device and suspend the engine using a chain block. Author: Date: 3314 EM-107 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT (c) Remove the 4 bolts and 4 nuts, and separate the engine mounting brackets from the frame brackets. (d) Lift the engine out of the vehicle carefully. NOTICE: Make sure the engine is clear of all wiring and hoses. (e) Place the engine onto a working bench. A22966 17. REMOVE DRIVE PLATE Remove the 8 bolts, front spacer, drive plate and rear spacer. A23391 Author: Date: 3315 EM-101 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT ENGINE UNIT EM1XV-01 COMPONENTS V-Bank Cover 7.5 (76, 66 in.·lbf) Hood Air Cleaner Hose No.2 Ventilation Hose No.2 Air Cleaner Assembly MAF Meter Connector Heater Hose Battery Clamp Battery Battery Tray Fuel Pipe Fuel Pipe Clamp N·m (kgf·cm, ft·lbf) : Specified torque A23384 Author: Date: 3309 EM-102 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT No.1 Fan Shroud 5.0 (50, 44 in.·lbf) Radiator Assembly No.2 Fan Shroud 12 (120, 9) Oil Cooler Pipe for AutomaticTransmission V-Belt Fan w/ Fluid Coupling Fan Pulley N·m (kgf·cm, ft·lbf) : Specified torque A23385 Author: Date: 3310 EM-103 ENGINE MECHANICAL (1GR-FE) - 12 (122, 9) ENGINE UNIT 34 (346, 25) Clamp Transmission 71 (724, 52) Oil Cooler Pipe 2.0 Kw: Torque Converter Clutch Shift Control Cable x6 14.5 (148, 11) 19.5 (199, 14) 37 (377, 27) 48 (490, 35) Starter 37 (377, 27) 9.8 (100, 7) 9.8 (100, 7) 48 (490, 35) 40 (408, 30) 43 (440, 32) Front Exhaust Pipe RH 1.6 Kw: Starter Flywheel Housing Side Cover Engine Rear Mounting Insulator 65 (660, 48) Manifold Stay Gasket 40 (408, 30) 72 (734, 53) Spring Gasket Manifold Stay Gasket Front Exhaust Pipe LH 18 (185, 13) Crossmember 62 (630, 46) Gasket Exhaust Pipe Support 62 (630, 46) Propeller Shaft 37 (377, 27) 88 (897, 65) 40 (410, 30) Bushing Stabilizer Bar Bracket Stabilizer Bar N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part Engine Under Cover D14136 Author: Date: 3311 EM-104 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT Water By-pass Hose VSV Connector Throttle Body Motor Connector VSV Connector Vane Pump Connector Generator 43 (438, 32) Generator Wire 43 (438, 32) Vane Pump Generator Connector A/C Compressor 25 (255, 18) Wire Harness Clamp Bracket A/C Compressor Connector N·m (kgf·cm, ft·lbf) : Specified torque A23386 Author: Date: 3312 EM-108 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT EM1XX-01 INSTALLATION 1. INSTALL DRIVE PLATE HINT: The mounting bolts are tightened in 2 progressive steps (steps (c) and (e)). If any of the mounting bolts is broken or deformed, replace it. (a) Adhesive Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent A04869 (b) 1 Install the front spacer, drive plate and rear spacer on the crankshaft. (c) Install and uniformly tighten the 8 mounting bolts in several steps, in the sequence shown in the illustration. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) If any of the mounting bolts do not meet the torque specification, replace it. 5 8 3 4 7 6 2 A23391 (d) (e) (f) Painted Mark 90° 90° 2. (a) (b) A23392 (c) (d) (e) (f) Mark the mounting bolt with paint. Retighten the mounting bolts 90° in the order shown in the illustration. Check that the painted mark is now at a 90° angle to what it was in step (e). INSTALL ENGINE ASSEMBLY IN VEHICLE Attach the engine chain hoist to the engine hangers. Slowly lower the engine assembly into the engine compartment. Attach the engine mounting brackets to the frame brackets. Install the engine mounting brackets to the frame brackets with the 2 nuts and 4 bolts. Torque: 38 N·m (388 kgf·cm, 28 ft·lbf) Remove the engine chain hoist. Remove the 4 bolts and 2 engine hangers. Author: Date: 3316 EM-109 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT 3. INSTALL PS PUMP Install the PS pump with the 3 bolts. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) A23390 4. (a) (b) 5. A23389 (a) (b) (c) (d) (e) (f) (g) (h) 6. (a) (b) (c) (d) Connect A09152 A23387 (e) (f) (g) (h) 7. (a) (b) (c) (d) (e) (f) 8. 9. 10. INSTALL A/C COMPRESSOR Install the A/C compressor with the 3 bolts. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Connect the A/C compressor connector. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES Connect the generator wire and connector. Connect the 2 heater hoses. Connect the ground strap to the cowl panel. Connect the fuel inlet hose and clamps. Connect the fuel return hose and clamp. Connect the air inlet hose to the charcoal canister. Connect the EVAP hose to the charcoal canister. Connect the brake booster tube. CONNECT ENGINE WIRE TO CABIN Push the engine wire through the cowl panel. Install the engine wire bracket with the 2 nuts and bolt and connect the engine wire to the bracket. Connect the 3 connectors to the ECM. Connect the 2 wire harness connectors (cassette connector). Install the ECM with the 3 screws. Install the heater to register duct. Install the lower No.2 finish panel. Install the glove compartment door. INSTALL AIR CLEANER ASSEMBLY Install the air cleaner assembly with the 2 bolts. Connect the air cleaner case to the air cleaner hose No.1. Connect the air cleaner case with the 2 wire clamps. Connect the PCV hose to the air cleaner case. Connect the MAF meter connector. Connect the air cleaner hose No.2 to the air cleaner case. INSTALL BATTERY INSTALL RADIATOR ASSEMBLY (See page CO-18 ) INSTALL FRONT EXHAUST PIPES (See page EM-139 ) Author: Date: 3317 EM-1 10 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT 11. INSTALL AUTOMATIC TRANSMISSION (See page AT-29 ) 12. INSTALL MANUAL TRANSMISSION (See page MT-7 ) 13. FILL WITH ENGINE COOLANT (See page CO-2 ) 14. FILL WITH ENGINE OIL (See page LU-3 ) 15. START ENGINE AND CHECK FOR LEAKS 16. INSTALL ENGINE UNDER COVERS 17. INSTALL V-BANK COVER 18. INSTALL HOOD 19. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 20. RECHECK ENGINE COOLANT AND OIL LEVELS Author: Date: 3318 EM-105 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT EM1XW-01 REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. (a) (b) (c) (d) (e) A23387 (f) 11. (a) (b) (c) 12. (a) (b) (c) (d) (e) PREVENT GASOLINE FROM SPILLING OUT (See page SF-1 ) REMOVE ENGINE HOOD REMOVE ENGINE V-BANK COVER REMOVE ENGINE UNDER COVER REMOVE AUTOMATIC TRANSMISSION (See page AT-25 ) REMOVE MANUAL TRANSMISSION (See page MT-4 ) REMOVE FRONT EXHAUST PIPES (See page EM-139 ) REMOVE RADIATOR ASSEMBLY (See page CO-17 ) REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY Disconnect the air cleaner hose No.2 from the air cleaner case. Disconnect the MAF meter connector. Disconnect the PCV hose from the air cleaner case. Disconnect the 2 wire clamps from the air cleaner case. Disconnect the air cleaner case from the air cleaner hose No.1. Remove the 2 bolts and air cleaner assembly. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY Loosen the 4 nuts holding the fluid coupling to the fan bracket. Remove the drive belt. (See page CH-7 ) Remove the 4 nuts, fan, fluid coupling assembly and fan pulley. DISCONNECT ENGINE WIRE FROM CABIN Remove the glove compartment door. Remove the lower No.2 finish panel. Remove the heater to register duct. Remove the 3 screws, and disconnect the ECM from the body bracket. Disconnect the 3 wire harness connectors from the ECM. Author: Date: 3313 EM-106 ENGINE MECHANICAL (1GR-FE) (f) (g) 13. Disconnect B07536 (a) (b) (c) (d) (e) (f) (g) 14. (a) (b) - ENGINE UNIT Disconnect the engine wire from the engine wire bracket and remove the 2 nuts, bolt and bracket. Pull out the engine wire from the cowl panel. DISCONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES Disconnect the generator connector. Disconnect the 2 heater hoses. Disconnect the ground strap from the cowl panel. Disconnect the fuel inlet hose and clamps. Disconnect the fuel return hose and clamp. Disconnect the air inlet hose from the charcoal canister. Disconnect the EVAP hose from the charcoal canister. DISCONNECT A/C COMPRESSOR FROM ENGINE Disconnect the A/C compressor connector. Remove the 3 bolts, and disconnect the A/C compressor from the engine. HINT: Suspend the A/C compressor securely. A23389 15. DISCONNECT PS PUMP FROM ENGINE Remove the 3 bolts, and disconnect the PS pump from the engine. HINT: Suspend the PS pump securely. A23390 16. (a) A22965 (b) REMOVE ENGINE ASSEMBLY FROM VEHICLE Install the 2 engine hangers with the 4 bolts as shown in the illustration. Part No. : Engine hanger No. 1 12281-31060 Engine hanger No. 2 12282-31040 Bolt 90119-08177 Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) Attach the engine sling device and suspend the engine using a chain block. Author: Date: 3314 EM-107 ENGINE MECHANICAL (1GR-FE) - ENGINE UNIT (c) Remove the 4 bolts and 4 nuts, and separate the engine mounting brackets from the frame brackets. (d) Lift the engine out of the vehicle carefully. NOTICE: Make sure the engine is clear of all wiring and hoses. (e) Place the engine onto a working bench. A22966 17. REMOVE DRIVE PLATE Remove the 8 bolts, front spacer, drive plate and rear spacer. A23391 Author: Date: 3315 EM-138 ENGINE MECHANICAL (1GR-FE) - EXHAUST SYSTEM EXHAUST SYSTEM EM1Y3-01 COMPONENTS Exhaust Pipe Support 32 (326, 24) Clamp Exhaust Pipe Support Gasket Exhaust Tail Pipe Exhaust Pipe Support Exhaust Pipe Support Heated Oxygen Sensor (Bank 1) 48 (490, 35) 44 (450, 33) 43 (440, 32) Gasket Exhaust Center Pipe 48 (490, 35) Gasket Gasket Spring Front Exhaust Pipe RH Heated Oxygen Sensor (Bank 2) 62 (630, 46) 44 (450, 33) 62 (630, 46) Gasket Exhaust Pipe Support N·m (kgf·cm, ft·lbf) 62 (630, 46) : Specified torque Front Exhaust Pipe LH Non-reusable part A23202 Author: Date: 3346 EM-139 ENGINE MECHANICAL (1GR-FE) - EXHAUST SYSTEM EM1Y4-01 REPLACEMENT 1. (a) (b) REMOVE EXHAUST TAIL PIPE Remove the bolt and clamp. Remove the 3 exhaust pipe supports and exhaust tail pipe. 2. (a) (b) (c) REMOVE EXHAUST CENTER PIPE Remove the 2 bolts and springs. Remove the 2 bolts. Remove the 2 exhaust pipe support and exhaust center pipe. Remove the gasket from the exhaust tail pipe. REMOVE HEATED OXYGEN SENSOR (BANK 1 OXYGEN SENSOR) Disconnect the heated oxygen sensor. Remove the heated oxygen sensor. REMOVE RH FRONT EXHAUST PIPE Remove the 2 nuts and RH front exhaust pipe. Remove the 2 gaskets from the RH front exhaust pipe. REMOVE HEATED OXYGEN SENSOR (BANK 2 OXYGEN SENSOR) Disconnect the heated oxygen sensor connector. Remove the heated oxygen sensor. A23249 (d) 3. A23248 (a) (b) 4. (a) (b) 5. (a) (b) A23247 6. (a) (b) REMOVE LH FRONT EXHAUST PIPE Remove the 2 nuts, exhaust pipe support and LH front exhaust pipe. Remove the 2 gaskets from the LH front exhaust pipe. A23246 7. (a) (b) (c) 8. (a) A23247 (b) INSTALL RH FRONT EXHAUST PIPE Install 2 new gaskets to the LH front exhaust pipe. Install the LH front exhaust pipe with the 2 new nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Install the exhaust pipe support. INSTALL HEATED OXYGEN SENSOR (BANK 1 OXYGEN SENSOR) Install the heated oxygen sensor. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) Connect the heated oxygen sensor connector. Author: Date: 3347 EM-140 ENGINE MECHANICAL (1GR-FE) 9. (a) (b) 10. (a) A23246 (b) - EXHAUST SYSTEM INSTALL RH FRONT EXHAUST PIPE Install 2 new gaskets to the RH front exhaust pipe. Install the RH front exhaust pipe with the 2 new nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) INSTALL HEATED OXYGEN SENSOR (BANK2 OXYGEN SENSOR) Install the heated oxygen sensor. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) Connect the heated oxygen sensor connector. 11. (a) INSTALL EXHAUST CENTER PIPE Using a vernier caliper, measure the free length of the spring. Minimum length: 40.5 mm (1.5945 in.) If the free length is less than minimum, replace the spring. (b) Install the 2 exhaust pipe supports. Front A23075 (c) (d) Install the 2 bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) Install the 2 bolts and springs. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) A23248 12. (a) (b) (c) INSTALL EXHAUST TAIL PIPE Install a new gasket to the exhaust center pipe. Install the 3 exhaust pipe supports. Install a new clamp and bolt. Torque: 32 N·m (326 kgf·cm, 24 ft·lbf) 30° A23250 Author: Date: 3348 EM-25 ENGINE MECHANICAL (1GR-FE) Hand-Held Tester - IDLE SPEED IDLE SPEED EM1XI-01 INSPECTION 1. (a) CAN VIM DLC3 D13872 When using a hand-held tester or OBD II scan tool. Connect a hand-held tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3). (b) Please refer to the hand-held tester operator’s manual for further details. (c) Switch the air conditioning OFF. (d) Race the engine at 2,500 rpm for approx. 90 seconds. (e) Check the idle speed. Idle speed: 650 to 750 rpm (Transmission in neutral position) If the idle speed is not as specified, check the air intake system. (f) Disconnect the hand-held tester or OBD II scan tool from the DLC3. 2. TAC DLC3 SST A23201 When not using a hand-held tester or OBD II scan tool. (a) Using SST, connect the tachometer probe to terminal TAC of the DLC3. SST 09843-18030 (b) Switch the air conditioning OFF. (c) Race the engine at 2,500 rpm for approx. 90 seconds. (d) Check the idle speed. Idle speed: 650 to 750 rpm (Transmission in neutral position) If the idle speed is not as specified, check the air intake system. (e) Disconnect the tachometer from the DLC3. Author: Date: 3233 EM-23 ENGINE MECHANICAL (1GR-FE) - IGNITION TIMING IGNITION TIMING EM1XH-01 INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. Hand-Held Tester 2. (a) INSPECT IGNITION TIMING When using a hand-held tester or OBD II scan tool. (1) Connect a hand-held tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3). (2) Please refer to the hand-held tester operator’s manual for further details. Ignition timing: 7 to 24° BTDC at idle (Transmission in neutral) (3) Disconnect the hand-held tester or OBD II scan tool from the DLC3. (b) When not using a hand-held tester or OBD II scan tool. (1) Remove the air cleaner cap. (2) Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder. CAN VIM DLC3 D13872 A22794 (3) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 TC SST CG DLC3 A14755 Author: Date: 3231 EM-24 ENGINE MECHANICAL (1GR-FE) A22795 - IGNITION TIMING (4) Using the timing light, check the ignition timing. Ignition timing: 8 to 12° BTDC at idle (Transmission in neutral position) (5) Remove the SST from the DLC3. (6) Check the ignition timing. Ignition timing: 7 to 24° BTDC at idle (Transmission in neutral position) (7) Disconnect the timing light from the engine. (8) Install the air cleaner cap. Author: Date: 3232 EM-23 ENGINE MECHANICAL (1GR-FE) - IGNITION TIMING IGNITION TIMING EM1XH-01 INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. Hand-Held Tester 2. (a) INSPECT IGNITION TIMING When using a hand-held tester or OBD II scan tool. (1) Connect a hand-held tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3). (2) Please refer to the hand-held tester operator’s manual for further details. Ignition timing: 7 to 24° BTDC at idle (Transmission in neutral) (3) Disconnect the hand-held tester or OBD II scan tool from the DLC3. (b) When not using a hand-held tester or OBD II scan tool. (1) Remove the air cleaner cap. (2) Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder. CAN VIM DLC3 D13872 A22794 (3) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 TC SST CG DLC3 A14755 Author: Date: 3231 EM-24 ENGINE MECHANICAL (1GR-FE) A22795 - IGNITION TIMING (4) Using the timing light, check the ignition timing. Ignition timing: 8 to 12° BTDC at idle (Transmission in neutral position) (5) Remove the SST from the DLC3. (6) Check the ignition timing. Ignition timing: 7 to 24° BTDC at idle (Transmission in neutral position) (7) Disconnect the timing light from the engine. (8) Install the air cleaner cap. Author: Date: 3232 EM-26 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN TIMING CHAIN EM1XJ-01 COMPONENTS 7.5 (76, 66 in.·lbf) V-Bank Cover Air Cleaner Hose 8.0 (82, 71 in.·lbf) Vacuum Hose Mass Air Flow Meter Connector Air Cleaner Ventilation Hose No.2 Battery Clamp Battery Battery Tray N·m (kgf·cm, ft·lbf) : Specified torque A23192 Author: Date: 3234 EM-27 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN Radiator Fan Shroud Fan w/ Fluid Coupling Fan Pulley 21 (214, 15) Drive Belt N·m (kgf·cm, ft·lbf) : Specified torque A23193 Author: Date: 3235 EM-28 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN Oil Level Gauge Oil Level Gauge Guide 9.0 (92, 80 in.·lbf) O-ring Vane Pump 43 (438, 32) 9.8 (100, 7) Generator Terminal Cap 43 (438, 32) Generator Wire Generator Connector Cooler Compressor 8.0 (82, 71 in.·lbf) 43 (438, 32) 25 (255, 18) 8.0 (82, 71 in.·lbf) Wire Harness Clamp Bracket Cooler Compressor Connector N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part A22851 Author: Date: 3236 EM-29 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN Water By-pass Hose No.1 Water By-pass Hose No.3 Water By-pass Hose No.2 O-ring Gasket x5 Water Inlet 9.0 (92, 80 in.·lbf) Oil Cooler Hose Idler Pulley No.2 Washer V-Ribbed Belt Tensioner Idler Pulley No.1 39 (398, 29) Washer 54 (551, 40) O-ring 36 (367, 27) 36 (367, 27) 21 (214, 15) 10 (102, 7) x2 x2 Oil Pan Gasket 21 (214, 15) x6 x4 x9 37 (377, 27) Oil Strainer 21 (214, 15) 9.0 (92, 80 in.·lbf) Oil Pan No.2 9.0 (92, 80 in.·lbf) x15 x2 10 (102, 7) Gasket N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part Drain Plug 40 (408, 30) A22852 Author: Date: 3237 EM-30 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN VSV Connector 28 (286, 21) Water By-pass Hose Intake Air Surge Tank x4 x2 VSV Connector Fuel Vapor Feed Hose Throttle Body Connector Surge Tank Stay No.2 21 (214, 15) 21 (214, 15) Throttle Body Bracket Ventilation Hose No.1 21 (214, 15) Gasket 10 (102, 7) Surge Tank Stay No.1 10 (102, 7) 9.0 (92, 80 in.·lbf) Oil Baffle Plate 9.0 (92, 80 in.·lbf) Ignition Coil 9.0 (92, 80 in.·lbf) x3 9.0 (92, 80 in.·lbf) x7 10 (102, 7) x3 10 (102, 7) Ignition Coil 9.0 (92, 80 in.·lbf) x3 x3 Cylinder Head Cover RH x7 Cylinder Head Cover LH Cylinder Head Cover Gasket Cylinder Head Cover Gasket N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part A23194 Author: Date: 3238 EM-31 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN 23 (235, 17) Crankshaft Pulley Oil Seal Timing Chain Cover x15 250 (2,549, 184) 19 (194, 14) 23 (235, 17) Chain Tensioner No.2 19 (194, 14) x9 Chain Tensioner No.2 Camshaft Timing Sprocket Timing Chain No.2 23 (235, 17) x2 Camshaft Timing Gear Assembly Timing Chain No.2 100 (1,020, 74) Camshaft Timing Gear Assembly 100 (1,020, 74) 100 (1,020, 74) 100 (1,020, 74) Camshaft Timing Sprocket Chain Tensioner No.1 10 (102, 7) Chain Vibration Damper No.2 Timing Chain Chain Tensioner Slipper Idle Gear Shaft No.2 60 (612, 44) Idle Gear Shaft No.1 Idle Gear No.1 O-ring Crankshaft Timing Sprocket N·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part 19 (194, 14) Author: Chain Vibration Damper No.1 Date: A23195 3239 EM-38 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN EM1XL-01 INSPECTION Measuring Area 0 1 2 3 4 5 15 A23207 1. INSPECT NO.1 AND NO.2 TIMING CHAINS Using a spring scale, pull the chain sub assembly with 147 N (15.0 kgf, 33.1 lbf) of force and measure the length of the chain sub assembly using a vernier caliper. Maximum chain elongation: 146.8 mm (5.780 in.) NOTICE: Perform the same measurements by pulling at random in 3 or more places to obtain an average length. If the elongation is greater than the maximum, replace the chain. 2. (a) A22990 INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Put the No. 1 chain on the larger gear of the camshaft timing gear assembly. (b) Using a vernier caliper, measure the timing gear with the chain. Minimum gear diameter (w/ chain): 115.5 mm (4.547 in.) NOTICE: The vernier caliper must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 1 chain and camshaft timing gear assembly. Author: Date: 3246 EM-39 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN (c) A22991 Put the No. 2 chain on the smaller gear of the camshaft timing gear assembly. (d) Using a vernier caliper, measure the timing gear with the chain. Minimum gear diameter (w/ chain): 73.1 mm (2.878 in.) NOTICE: The vernier caliper must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 2 chain and camshaft timing gear assembly. 3. (a) (b) A22992 INSPECT CAMSHAFT TIMING SPROCKET Put the No. 2 chain on the camshaft timing sprocket. Using a vernier caliper, measure the camshaft timing sprocket diameter with the chain . Minimum gear diameter (w/ chain): 73.1 mm (2.878 in.) NOTICE: The vernier caliper must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 2 chain and the camshaft timing sprocket. Author: Date: 3247 EM-40 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN 4. (a) (b) A22993 INSPECT CRANKSHAFT TIMING SPROCKET Put the No. 1 chain on the crankshaft timing sprocket. Using a vernier caliper, measure the crankshaft timing gear diameter with the chain. Minimum gear diameter (w/ chain): 61.0 mm (2.402 in.) NOTICE: The vernier caliper must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 1 chain and crankshaft timing sprocket. 5. (a) (b) A22994 INSPECT IDLE GEAR NO.1 Put the No. 1 chain on the idle gear. Using a vernier caliper, measure the idle gear with the chain. Minimum gear diameter (w/ chain): 61.0 mm (2.402 in.) NOTICE: The vernier caliper must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 1 chain and idle gear. 6. (a) INSPECT IDLE GEAR SHAFT OIL CLEARANCE Using a micrometer, measure the idle gear shaft diameter. Idle gear shaft diameter: 22.987 to 23.000 mm (0.9050 to 0.9055 in.) A22995 Author: Date: 3248 EM-41 ENGINE MECHANICAL (1GR-FE) (b) (c) A22996 7. (a) Raise Lock (b) Move - TIMING CHAIN Using a caliper gauge, measure the inside diameter of the idle gear. Idle gear inside diameter: 23.02 to 23.03 mm (0.9063 to 0.9067 in.) Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement. Standard oil clearance: 0.020 to 0.043 mm (0.0008 to 0.0017 in.) Maximum oil clearance: 0.093 mm (0.0037 in.) INSPECT CHAIN TENSIONER NO.1 Check that the plunger moves smoothly when the ratchet pawl is raised with a finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushing with a finger. A22997 8. (a) (b) INSPECT CHAIN TENSIONER NO.2 Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain tensioner No. 2. Move A22998 9. INSPECT CHAIN TENSIONER SLIPPER Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain tensioner slipper. A23000 Author: Date: 3249 EM-42 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN 10. INSPECT CHAIN VIBRATION DAMPER NO.1 AND NO.2 Measure the worn depth of the chain vibration damper No. 1 and No. 2. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain vibration damper No. 1 or No.2. No.1 No.2 A23001 Author: Date: 3250 EM-44 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN EM1XN-01 INSTALLATION 90 Set Key Turn A22895 1. SET CRANKSHAFT POSITION Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position. NOTICE: 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. 2. (a) INSTALL CHAIN TENSIONER NO.2 While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it. (b) Install the chain tensioner No. 2 with the bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 3. (a) INSTALL NO.2 TIMING CHAIN Align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assembly and camshaft timing sprocket as shown in the illustration. Push A22900 A22885 Mark Links Timing Marks A22901 (b) Timing Marks Timing Marks Align the timing marks on the camshaft timing gear assembly and camshaft timing sprocket with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts. (c) Temporarily install the 2 camshaft timing gear bolts. NOTICE: Do not push camshaft timing gear assembly to the camshaft forcibly when installing it. A22902 Author: Date: 3252 EM-45 ENGINE MECHANICAL (1GR-FE) (d) (e) - TIMING CHAIN 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 chain tensioner No. 2. A22903 4. (a) INSTALL CHAIN VIBRATION DAMPER NO.1 Install the chain vibration damper No. 1 with the 2 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 5. (a) INSTALL CRANKSHAFT TIMING SPROCKET Align the timing gear set key with the key groove of the timing sprocket. Install the timing gear onto the crankshaft with the sprocket side facing inward. INSTALL CHAIN TENSIONER SLIPPER A22921 Inward (b) 6. A23007 7. (a) (b) Stopper Plate Stopper Plate Push A22850 (c) INSTALL CHAIN TENSIONER NO.1 While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. Install the chain tensioner with the 2 bolts. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft·lbf) Author: Date: 3253 EM-46 ENGINE MECHANICAL (1GR-FE) RH Bank Timing Marks - TIMING CHAIN 8. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Align the timing marks of the camshaft timing gear assembly, camshaft timing sprocket and bearing caps. (b) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block. 9. (a) INSTALL TIMING CHAIN NO.1 Align the mark link (yellow) with the timing mark of the crankshaft timing sprocket. Timing Marks LH Bank Timing Marks A22801 Timing Line Set Key A22869 Mark Link Timing Mark A22870 Mark Links (b) Align the mark links (orange) with the timing marks of the camshaft timing gear assembly and camshaft timing sprocket, and install the chain. 10. INSTALL CHAIN VIBRATION DAMPER NO.2 Install the 2 chain vibration damper No.2. Timing Marks A22871 Author: Date: 3254 EM-47 ENGINE MECHANICAL (1GR-FE) Forward Knock Pin A22872 - TIMING CHAIN 11. (a) INSTALL IDLE GEAR NO.1 Apply a light coat of engine oil to the rotating surface of the idle gear shaft No. 1. (b) Temporarily install the idle gear shaft No. 1 and idle gear No. 1 with the idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block. NOTICE: Be careful of the idle gear direction. (c) Using a 10 mm hexagon wrench, tighten the idle gear shaft No. 2. Torque: 60 N⋅m (612 kgf⋅cm, 44 ft⋅lbf) (d) Remove the bar from the chain tensioner. 12. INSTALL TIMING CHAIN COVER (a) 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. (b) Install a new O-ring to the LH cylinder head as shown in the illustration. (c) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to 4 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent A23009 Seal Packing A23010 Author: Date: 3255 EM-48 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN (d) Seal Packing A B B Water Pump Part Water Pump Part 3 to 4 mm Seal Packing Seal Width 3 to 4 mm 3 to 4 mm Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the timing chain cover as shown in the illustration. Seal packing: Water pump part: Part No. 08826-00100 or equivalent Other part: Part No. 08826-00080 or equivalent NOTICE: Install the timing chain cover within 3 minutes after applying seal packing. After installing it, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Do not apply seal packing to the ”A” as shown in the illustration. 3 to 4 mm 16.7 mm B - B A23011 (e) 15 Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place. A23012 (f) A A A B A A A B B B B BB B Nut B B B B B AB B Nut A A A23186 Install the timing chain cover with the 24 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) NOTICE: Pay attention not to wrap the chain and slipper over the timing chain cover seal line. Install the water pump within 15 minutes after installing the timing chain cover. HINT: Each bolt length is as follows: A: 25 mm (0.98 in.) B: 55 mm (2.17 in.) Author: Date: 3256 EM-49 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN 13. (a) (b) (c) INSTALL WATER INLET Install a new O-ring to the water outlet pipe. Install a new gasket to the water pump. Apply soapy water to the O-ring. (d) Install the water inlet with the 5 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Connect the 5 water by-pass hoses. Connect the 2 radiator hoses. Connect the 2 oil cooler hoses (w/ oil cooler). A23120 (e) (f) (g) A23121 14. (a) A (b) B INSTALL OIL PAN Install the 4 stud bolts. Torque: 4.0 N⋅m (41 kgf⋅cm, 35 in.⋅lbf) Remove any old packing material (FIPG) and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan. A 16.5 13 22.5 8 Stud Bolt A 27.5 9 Stud Bolt B [mm] A23013 (c) Install a new O-ring to the oil pump. A22873 Author: Date: 3257 EM-50 ENGINE MECHANICAL (1GR-FE) Seal Width: 3 to 4 mm B A A A22874 Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE: 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. (e) B A B A C A C B B Nut B TIMING CHAIN (d) Seal Packing A - B Nut B B A22863 Flywheel Housing Under Cover Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: Bolt A, B, Nut: 21 N⋅m (214 kgf⋅cm, 15 ft·lbf) Bolt C: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) HINT: Each bolt length is as follows: A: 25 mm (0.98 in.) B: 45 mm (1.77 in.) C: 14 mm (0.55 in.) (f) Install the 4 housing bolts. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) (g) Install the flywheel housing under cover. A22862 15. (a) 16. (a) INSTALL OIL STRAINER Install a new gasket and the oil strainer with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL OIL PAN NO.2 Remove any old packing material (FIPG) and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No. 2. A22861 (b) Apply a continuous bead of the seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE: Install the oil pan No. 2 within 3 minutes after applying seal packing. After installing it, the oil pan No. 2 bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Seal Packing Seal Width: 3 to 4 mm A22875 Author: Date: 3258 EM-51 ENGINE MECHANICAL (1GR-FE) (c) - TIMING CHAIN Install the oil pan No. 2 with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: Bolt: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Nut: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) A22859 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) SST A22876 18. INSTALL IDLER PULLEY NO.1 Install the idler pulley with the bolt. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) HINT: ”DOUBLE” is marked on the idler pulley No. 1 to distinguish it from the idler pulley No. 2. ”DOUBLE” A22877 19. INSTALL IDLER PULLEY NO.2 Install the 2 idler pulleys with the 2 bolts. Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) A22878 A-1 A B B-1 B B B A22856 20. INSTALL V-RIBBED BELT TENSIONER ASSY Tighten bolts A-1 and B-1 in order first, then tighten the remaining bolts. Torque: 36 N⋅m (367 kgf⋅cm, 27 ft⋅lbf) HINT: Each bolt length is as follows: A: 70 mm (2.76 in.) B: 33 mm (1.30 in.) 21. INSTALL COOLER COMPRESSOR (See page AC-58 ) Author: Date: 3259 EM-52 ENGINE MECHANICAL (1GR-FE) 22. - TIMING CHAIN INSTALL GENERATOR (See page CH-15 ) 23. (a) INSTALL VANE PUMP Install the vane pump with the 2 bolts. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) NOTICE: Do not hit the pulley to other parts when installing the vane pump. (b) Connect the P/S oil pressure switch connector. 24. INSTALL WATER INLET (See page EM-89 ) A22855 O-Ring 25. (a) (b) (c) (d) Push A22879 (e) 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 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. INSTALL CYLINDER HEAD COVER (See page EM-89 ) INSTALL INTAKE AIR SURGE TANK (See page EM-89 ) INSTALL AIR CLEANER (See page EM-89 ) INSTALL FAN W/FLUID COUPLING (See page EM-89 ) INSTALL DRIVE BELT (See page EM-89 ) FULLY TIGHTEN FAN W/FLUID COUPLING INSTALL RADIATOR (See page CO-18 ) INSTALL V-BANK COVER INSTALL BATTERY ADD ENGINE OIL (See page LU-3 ) ADD ENGINE COOLANT (See page CO-2 ) CHECK FOR LEAKS CHECK IGNITION TIMING (See page EM-23 ) CHECK IDLE SPEED (See page EM-25 ) Author: Date: 3260 EM-32 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN EM1XK-01 REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. (a) (b) (c) A22855 DRAIN ENGINE COOLANT (See page CO-2 ) DRAIN ENGINE OIL REMOVE BATTERY REMOVE V-BANK COVER REMOVE RADIATOR (See page CO-17 ) LOOSEN FAN W/FLUID COUPLING (See page EM-62 ) REMOVE DRIVE BELT (See page EM-62 ) REMOVE FAN W/FLUID COUPLING REMOVE AIR CLEANER (See page EM-62 ) REMOVE INTAKE AIR SURGE TANK (See page EM-62 ) REMOVE CYLINDER HEAD COVER (See page EM-62 ) REMOVE VVT SENSOR 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. SEPARATE VANE PUMP (a) Disconnect the P/S oil pressure switch connector. (b) Remove the 2 bolts, and separate the vane pump. NOTICE: Do not hit the pulley to other parts when separating the vane pump. HINT: The vane pump is suspended securely. 15. REMOVE GENERATOR (See page CH-7 ) 16. SEPARATE COOLER COMPRESSOR (See page AC-54 ) 17. REMOVE V-RIBBED BELT TENSIONER Remove the 5 bolts and V-ribbed belt tensioner. 18. REMOVE IDLER PULLEY NO.1 AND NO.2 A22856 Author: Date: 3240 EM-33 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN 19. (a) REMOVE CRANKSHAFT PULLEY Using SST, hold the crankshaft pulley and loosen the pulley set bolt. SST 09213-54015 (91651-60855), 09330-00021 (b) Using the pulley set bolt and SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031) 20. (a) REMOVE OIL PAN NO.2 Remove the 15 bolts and 2 nuts. SST A22857 SST A22858 A22859 (b) Insert the blade of SST between the oil pan and oil pan No. 2, cut off applied sealer and remove the oil pan No. 2. SST 09032-00100 NOTICE: Be careful not to damage the contact surface of the oil pan and oil pan No. 2. Be careful not to damage the oil pan No. 2 flange. SST A22860 21. REMOVE OIL STRAINER Remove the 2 nuts, oil strainer and gasket. A22861 Author: Date: 3241 EM-34 ENGINE MECHANICAL (1GR-FE) Flywheel Housing Under Cover - TIMING CHAIN 22. (a) (b) REMOVE OIL PAN Remove the 4 housing bolts. Remove the flywheel housing under cover. (c) Remove 17 bolts and 2 nuts. A22862 A22863 (d) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence shown. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. (e) Remove the O-ring from the oil pump. Pry LH Side RH Side A22864 23. (a) REMOVE WATER INLET Disconnect the 2 oil cooler hoses (w/ oil cooler). A23116 Author: Date: 3242 EM-35 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN (b) Disconnect the 2 radiator hoses. (c) Disconnect the 5 water by-pass hoses. (d) (e) (f) Remove the 5 bolts and water inlet. Remove the O-ring from the water outlet pipe. Remove the gasket from the water pump. 24. (a) REMOVE TIMING CHAIN COVER Remove the 24 bolts and 2 nuts. A23117 A23118 A23119 A23186 Author: Date: 3243 EM-36 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. (c) Remove the O-ring from the LH cylinder head. A23187 25. (a) Timing Line 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. Set Key A22865 RH Bank (b) Check that the timing marks of the camshaft timing gear assembly and camshaft timing sprocket 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. 26. REMOVE CHAIN TENSIONER NO.1 NOTICE: 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. Timing Marks Timing Marks LH Bank Timing Marks A22866 Author: Date: 3244 EM-37 ENGINE MECHANICAL (1GR-FE) (a) Push Stopper Plate (b) Stopper Plate A22807 (c) 27. - TIMING CHAIN 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 φ 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. Remove the 2 bolts and chain tensioner. REMOVE CHAIN TENSIONER SLIPPER 28. REMOVE IDLE GEAR NO.1 Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle gear No. 1 and idle gear shaft No. 1. 29. REMOVE CHAIN VIBRATION DAMPER NO.2 Remove the 2 chain vibration damper No.2. 30. REMOVE NO.1 TIMING CHAIN 31. REMOVE CRANKSHAFT TIMING SPROCKET A22867 32. (a) REMOVE NO.2 TIMING CHAIN While raising the chain tensioner No. 2, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it. Raise A22884 (b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing sprocket, camshaft timing gear assembly and timing chain No.2. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. A22903 33. REMOVE CHAIN TENSIONER NO.2 Remove the bolt and chain tensioner No.2. A22885 Author: Date: 3245 EM-43 ENGINE MECHANICAL (1GR-FE) - TIMING CHAIN EM1XM-01 REPLACEMENT Pry A22976 HINT: There are 2 methods ((a) and (b)) to replace the oil seal. REPLACE TIMING CHAIN COVER OIL SEAL (a) If the rear timing chain cover is removed: (1) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the oil pump. Wrap the tip of the screwdriver with tape. (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09226-10010 (3) Apply MP grease to the oil seal lip. SST A23008 (b) If the rear timing chain cover is installed: (1) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Wrap the tip of the screwdriver with tape. A23076 (2) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09226-10010 (3) Apply MP grease to a new oil seal lip. SST A23077 Author: Date: 3251 EM-4 ENGINE MECHANICAL (1GR-FE) - VALVE CLEARANCE VALVE CLEARANCE EM1XG-01 INSPECTION 1. 2. 3. 4. 5. 6. 7. (a) DRAIN ENGINE COOLANT (See page CO-2 ) REMOVE V-BANK COVER REMOVE AIR CLEANER (See page EM-62 ) REMOVE INTAKE AIR SURGE TANK (See page EM-62 ) REMOVE IGNITION COIL REMOVE CYLINDER HEAD COVER (See page EM-62 ) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover. A22800 RH Bank (b) 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. Timing Marks Timing Marks LH Bank Timing Marks A22801 Author: Date: 3212 EM-5 ENGINE MECHANICAL (1GR-FE) 3 3 RH Bank: VALVE CLEARANCE 8. (a) INSPECT VALVE CLEARANCE Check the valves indicated in the illustration. (1) 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.) (2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. (b) 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 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.) (2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. EX IN 1 1 Front LH Bank: - 6 6 IN EX 2 2 A22802 5 5 RH Bank: EX IN LH Bank: 3 3 Front 2 2 IN EX 4 4 A22803 Author: Date: 3213 EM-6 ENGINE MECHANICAL (1GR-FE) RH Bank: 1 1 VALVE CLEARANCE (c) 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 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.) (2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. 9. (a) ADJUST VALVE CLEARANCE Set the No. 1 cylinder to the TDC/compression. (1) Turn the crankshaft pulley, and align the notch with the timing mark ”0” of the timing chain cover. EX IN 5 5 LH Bank: - Front 4 4 IN EX 6 6 A22804 A22800 RH Bank (2) 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. Timing Marks Timing Marks LH Bank Timing Marks A22801 Author: Date: 3214 EM-7 ENGINE MECHANICAL (1GR-FE) Paint Marks Timing Marks A22805 - VALVE CLEARANCE (3) Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears. (b) Remove the chain tensioner No. 1. NOTICE: 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. (1) Remove the 4 bolts, timing chain cover plate and gasket. A22806 (2) Push Stopper Plate Stopper Plate A22807 While rotating the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration. (3) While rotating the stopper plate of the tensioner downward, insert a bar of φ 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. (4) Remove the 2 bolts and chain tensioner No.1. (c) Remove the No. 2 camshaft. NOTICE: 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. (1) While raising up the chain tensioner No. 2, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it. Raise A22808 Author: Date: 3215 EM-8 ENGINE MECHANICAL (1GR-FE) (2) - VALVE CLEARANCE Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing sprocket set bolt. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. (3) Separate the camshaft timing sprocket from the No. 2 camshaft. A22809 (4) Rotate the camshaft counterclockwise using the wrench so that the cam lobes of the No. 1 cylinder face upward as shown in the illustration. (5) 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. A22810 (6) 2 4 8 6 1 3 7 5 A22811 (d) A22812 Remove the chain tensioner No. 2. (1) Remove the chain tensioner No. 2 bolt, and then remove the chain tensioner No. 2 and camshaft timing sprocket. (e) Remove the camshaft. NOTICE: 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. Author: Date: 3216 EM-9 ENGINE MECHANICAL (1GR-FE) - (1) VALVE CLEARANCE Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear assembly set bolt. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. A22813 (2) Slide the camshaft timing gear assembly and separate the No. 1 chain from the camshaft timing gear sprocket. (3) Rotate the No. 1 camshaft counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face upward as shown in the illustration. (4) 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. Slide A22814 A22815 1 3 7 2 4 8 5 (5) 6 A22816 (6) Remove the camshaft timing gear assembly set bolt with the No. 1 camshaft lifted up, and then remove the No. 1 camshaft and camshaft timing gear assembly w/ No. 2 chain. A22817 Author: Date: 3217 EM-10 ENGINE MECHANICAL (1GR-FE) (7) A22818 - VALVE CLEARANCE Tie the No. 1 chain with a string as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover. (f) Remove the No. 4 camshaft. NOTICE: 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. (1) While pushing down the chain tensioner No. 2, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it. (2) Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing sprocket set bolt. Push A22819 NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. (3) Separate the camshaft timing sprocket from the No. 4 camshaft. A22820 (4) (5) 6 8 4 2 5 7 3 1 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. A22821 Author: Date: 3218 EM-1 1 ENGINE MECHANICAL (1GR-FE) - VALVE CLEARANCE (g) A22822 Remove the chain tensioner No. 2. (1) Remove the chain tensioner No. 3 bolt, and then remove the chain tensioner No. 3 and camshaft timing sprocket. (h) Remove the No. 3 camshaft. NOTICE: 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. (1) 5 7 3 1 (2) 6 8 4 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. 2 A22823 (3) Hold the No. 1 chain, and remove the No. 3 camshaft, camshaft timing gear assembly and No. 2 chain. (4) Tie the No. 1 chain with a string as shown in the illustration. A22824 NOTICE: Be careful not to drop anything inside the timing chain cover. (i) Remove the valve lifters. A22825 Author: Date: 3219 EM-12 ENGINE MECHANICAL (1GR-FE) (j) A01082 - VALVE CLEARANCE Determine the size of the valve lifter to be installed according to the following formulas or charts: (1) Using a micrometer, measure the thickness of the removed lifter. (2) 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.)) (3) 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.). Author: Date: 3220 Valve Lifter Selection Chart (Intake) Removed lifter thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL (1GR-FE) - Author: No. Thickness No. Thickness No. Thickness VALVE CLEARANCE New Lifter Thickness mm (in.) Date: Intake valve clearance (Cold): 0.15 to 0.25 mm (0.0059 to 0.0098 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) shim with a new No. 46 lifter. EM-13 A22826 3221 EM-14 Valve Lifter Selection Chart (Exhaust) Removed lifter thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL (1GR-FE) - No. Thickness No. Thickness No. Thickness Author: Date: Exhaust valve clearance (Cold): 0.29 to 0.39 mm (0.0114 to 0.0154 in.) EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) shim with a new No. 48 lifter. VALVE CLEARANCE New Lifter Thickness mm (in.) A22827 3222 EM-15 ENGINE MECHANICAL (1GR-FE) - VALVE CLEARANCE (k) Install the No. 3 camshaft. NOTICE: 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. (1) Mark Links (2) Timing Marks Align the mark link (yellow) with the timing mark (2-dot mark) of the camshaft timing gear assembly as shown in the illustration. Apply new engine oil to the thrust portions and journals of the camshafts. A22828 (3) Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear assembly. (4) 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. (5) (6) Install the 4 bearing caps in their proper locations. Apply a light coat of engine oil to the threads of the bearing cap bolts. A22829 A22830 A22831 Author: Date: 3223 EM-16 ENGINE MECHANICAL (1GR-FE) - VALVE CLEARANCE (7) 4 3 2 6 8 1 5 7 Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head A22832 (8) Paint Mark Set the paint mark of the No. 1 chain between the timing marks of the camshaft timing gear assembly. Timing Marks A22833 (l) Install the chain tensioner No. 2. (1) While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it. Push A22834 (2) Mark Links Timing Marks A22835 Temporarily install the camshaft timing assembly and chain tensioner No. 2 and align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing sprocket and camshaft timing gear assembly. (3) Tighten the chain tensioner No. 3 bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) (m) Install the No. 4 camshaft. NOTICE: 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. Author: Date: 3224 EM-17 ENGINE MECHANICAL (1GR-FE) - (1) (2) VALVE CLEARANCE Align the knock pin hole on the camshaft timing sprocket with the knock pin of the No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing sprocket. Temporarily install the camshaft timing sprocket set bolt. A22836 (3) (4) 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. A22837 (5) 3 1 5 7 4 2 6 8 Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head A22821 (6) A22820 Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing sprocket set bolt. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) (7) Remove the pin from the chain tensioner No. 2. (n) Install the camshaft. NOTICE: 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. Author: Date: 3225 EM-18 ENGINE MECHANICAL (1GR-FE) (1) Mark Links (2) - VALVE CLEARANCE Align the mark link (yellow) with the timing mark (1-dot mark) of the camshaft timing gear assembly as shown in the illustration. Apply new engine oil to the thrust portions and journals of the camshafts. Timing Mark A22838 (3) Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear assembly. (4) Align the knock pin hole on the camshaft timing gear assembly with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear assembly. Temporarily install the camshaft timing gear assembly set bolt. A22839 Knock Pin (5) A22840 (6) 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. (7) (8) 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. A22841 A22842 Author: Date: 3226 EM-19 ENGINE MECHANICAL (1GR-FE) - VALVE CLEARANCE (9) 8 6 2 7 5 1 Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head 4 3 A22816 (10) 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 assembly is aligned with the timing mark of the camshaft bearing cap. Timing Marks A22843 (11) Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear assembly. Paint Mark Timing Mark A22844 (12) Hold the hexagonal portion of the No. 1 camshaft with a wrench, and tighten the camshaft timing gear assembly set bolt. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) A22813 (o) Install the chain tensioner No. 2. (1) While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it. Push A22900 Author: Date: 3227 EM-20 ENGINE MECHANICAL (1GR-FE) - VALVE CLEARANCE (2) Mark Links Timing Marks A22846 Temporarily install the camshaft timing gear and chain tensioner No. 2 and align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assembly and camshaft timing sprocket. (3) Tighten the chain tensioner No. 2 bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) (p) Install the No. 2 camshaft. NOTICE: 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. (1) 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. (2) (3) 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. A22847 A22848 (4) 7 5 1 3 8 6 2 4 Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for 10 mm (0.39 in.) head 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) for 12 mm (0.47 in.) head A22811 Author: Date: 3228 EM-21 ENGINE MECHANICAL (1GR-FE) - (5) VALVE CLEARANCE 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 sprocket. Knock Pin A22849 (6) Hold the hexagonal portion of the No. 2 camshaft with a wrench, and install the camshaft timing sprocket set bolt. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) (7) Remove the pin from the chain tensioner No. 2. A22809 (q) Stopper Plate Stopper Plate Push A22850 Install the chain tensioner No. 1. (1) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. (2) While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ 3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (3) Install the chain tensioner with the 2 bolts. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft·lbf) (4) Remove the bar from the chain tensioner. (5) 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) (6) Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the timing mark ”0” of the timing chain cover. A22800 Author: Date: 3229 EM-22 ENGINE MECHANICAL (1GR-FE) RH Bank VALVE CLEARANCE (7) Timing Marks 10. 11. 12. Timing Marks 13. 14. 15. 16. LH Bank Timing Marks - Check that the timing marks of the camshaft timing gear assembly and camshaft timing sprocket are aligned with the timing marks of the bearing caps as shown in the illustration. INSTALL CYLINDER HEAD COVER (See page EM-89 ) INSTALL IGNITION COIL INSTALL INTAKE AIR SURGE TANK (See page EM-89 ) INSTALL AIR CLEANER (See page EM-89 ) ADD ENGINE COOLANT (See page CO-2 ) INSTALL V-BANK COVER INSPECT IGNITION TIMING (See page EM-23 ) A22801 Author: Date: 3230

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