Toyota Venza manuals

Toyota Venza: Installation

INSTALLATION

CAUTION / NOTICE / HINT

HINT:

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly or cylinder head sub-assembly (See page ).


PROCEDURE

1. INSPECT CYLINDER HEAD BOLT


2. INSPECT CYLINDER HEAD SUB-ASSEMBLY


3. INSTALL CYLINDER HEAD GASKET

(a) Clean the cylinder block and cylinder head sub-assembly with solvent.

Text in Illustration


*1

Cylinder Head Gasket

*2

Cylinder Block

*a

Lot No.

Seal Packing

Front

(b) Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

Seal Packing:

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

Standard Seal Dimension:

3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) thick

HINT:

Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block.

NOTICE:

  • Remove any oil from the contact surface.
  • Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

(c) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp facing upward.

NOTICE:

Pay attention to the installation direction.

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT:

The cylinder head bolts are tightened in 4 progressive steps.

(a) Place the cylinder head sub-assembly on the cylinder block.

NOTICE:

  • Ensure that no oil is on the mounting surface of the cylinder head sub-assembly.
  • Place the cylinder head sub-assembly on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

(b) Install the plate washers to the cylinder head bolts.

(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(d) Step 1:

(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.

Torque:

36 N·m {367 kgf·cm, 27 ft·lbf}

NOTICE:

Do not drop the plate washers for the cylinder head bolts into the cylinder head sub-assembly.


(e) Step 2:

(1) Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

Torque:

36 N·m {367 kgf·cm, 27 ft·lbf}

(f) Step 3:

(1) Mark each cylinder head bolt head with paint as shown in the illustration.

Text in Illustration

*a

Paint Mark

Front

(2) Tighten the cylinder head bolts 90° in the sequence shown in step 1.

(g) Step 4:

(1) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

(2) Check that the painted marks are now facing rearward.

NOTICE:

  • Do not apply oil for at least 4 hours after the installation.
  • Do not start the engine for at least 4 hours after the installation.
  • After the installation, if the seal packing has seeped out, wipe it off.

HINT:

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly (See page ).


5. INSTALL VALVE STEM CAP

(a) Apply a light coat of engine oil to the valve stem ends.

(b) Install the 16 valve stem caps to the cylinder head sub-assembly.

NOTICE:

Do not drop the valve stem caps into the cylinder head sub-assembly.

6. SET CAMSHAFT TIMING GEAR ASSEMBLY

HINT:

When installing the camshaft timing gear assembly, release the lock pin and set the camshaft timing gear assembly to the advanced position before installation.

(a) Check the camshaft timing gear assembly position.

Text in Illustration

*a

Advanced Position

*b

Knock Pin Hole

*c

Alignment Mark

*d

Retarded Position

NOTICE:

If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

If the camshaft timing gear assembly rotates to the retarded position, release the lock pin and set the camshaft timing gear assembly to the advanced position.


(b) Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly.

Text in Illustration

*1

Knock Pin

*a

Pin Hole


(c) Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

Text in Illustration

*1

Camshaft Timing Gear Assembly

*a

Incorrect

*b

Correct

*c

Clearance

*d

No Clearance

*e

Camshaft Flange


(d) Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear assembly by hand.

NOTICE:

Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

(e) Release the lock pin.

Text in Illustration

*1

Rubber

*2

Vinyl Tape

*3

Knock Pin

*a

Retard Side Path

*b

Advance Side Path

*c

Open

*d

Close


(1) Clean the camshaft journal with non-residue solvent.

(2) Cover the 4 oil paths of the camshaft journal with vinyl tape as shown in the illustration.

HINT:

There are 4 oil paths in the grooves of the camshaft. Plug 3 of the paths with rubber pieces.

(3) Open a hole at port (A) shown in the illustration.

(4) While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

CAUTION:

Cover the path with a piece of cloth when applying pressure to keep oil from spraying.

NOTICE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

HINT:

  • Depending on the air pressure applied, the camshaft timing gear assembly may be turned in the advance direction without applying any force.
  • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

(5) Remove the vinyl tape and rubber pieces from the camshaft.

(f) Remove the bolt and camshaft timing gear assembly.

NOTICE:

Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

7. INSTALL VALVE LASH ADJUSTER ASSEMBLY

(a) Inspect the valve lash adjuster assemblies before installing them (See page ).


(b) Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

NOTICE:

Install each valve lash adjuster assembly to the same place it was removed from.

8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

Text in Illustration

*1

No. 1 Valve Rocker Arm Sub-assembly

*2

Valve Lash Adjuster Assembly

*3

Valve Stem Cap


(b) Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

9. INSTALL NO. 2 CAMSHAFT BEARING


10. INSTALL NO. 1 CAMSHAFT BEARING


11. INSTALL OIL CONTROL VALVE FILTER


12. INSTALL CAMSHAFT

(a) Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

(b) Apply a light coat of engine oil to the camshaft journal, camshaft housing sub-assembly and camshaft bearing caps.

(c) Install the No. 1 camshaft and No. 2 camshaft to the camshaft housing sub-assembly.

HINT:

Perform "Inspection After Repair" after replacing the No. 1 camshaft or No. 2 camshaft (See page ).


13. INSTALL CAMSHAFT BEARING CAP

(a) Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.


(b) Install the 11 bolts in the order shown in the illustration.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

NOTICE:

Make sure that the camshaft rotates smoothly after installing the camshaft bearing caps.


14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

(a) Check that the valve rocker arms are installed as shown in the illustration.

Text in Illustration

*1

No. 1 Valve Rocker Arm Sub-assembly

*2

Valve Stem Cap

*3

Valve Lash Adjuster Assembly

*a

Incorrect

*b

Correct


(b) Apply seal packing in a continuous line as shown in the illustration.

Text in Illustration

*a

Dashed Line

*b

Groove

Seal Packing:

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

Standard Seal Dimension:

Area

Seal Packing Diameter

Application Position

Continuous Line

3.0 to 4.0 mm (0.118 to 0.157 in.)

Distance from edge of camshaft housing sub-assembly to center of seal packing: 3.5 to 4.0 mm (0.138 to 0.157 in.)

Dashed Line

Distance from outside edge of groove to center of seal packing: 2.5 to 3.5 mm (0.0984 to 0.138 in.)

NOTICE:

  • Remove any oil from the contact surface.
  • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

(c) Position the knock pin of the No. 1 camshaft and No. 2 camshaft as shown in the illustration.

Text in Illustration

*a

Approximately 17°

*b

Approximately 2°

*c

Knock Pin


(d) Install the camshaft housing sub-assembly, and then install the 20 bolts in the order shown in the illustration.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

NOTICE:

  • Do not apply oil for at least 4 hours after the installation.
  • Do not start the engine for at least 4 hours after the installation.
  • Thoroughly wipe clean any seal packing.

15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the camshaft timing gear assembly position.

Text in Illustration

*a

Knock Pin Hole

*b

Alignment Mark

If the camshaft timing gear assembly is not set to the advanced position, release the lock pin and reset the camshaft timing gear assembly (Refer to the "Set Camshaft Timing Gear Assembly" procedure).


(b) Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly.

Text in Illustration

*1

Knock Pin

*a

Pin Hole


(c) Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

Text in Illustration

*1

Camshaft Timing Gear Assembly

*a

Incorrect

*b

Correct

*c

Clearance

*d

No Clearance

*e

Camshaft Flange


(d) Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the bolt.

Text in Illustration

*a

Hold

*b

Turn

Torque:

85 N·m {867 kgf·cm, 63 ft·lbf}

NOTICE:

  • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
  • Do not disassemble the camshaft timing gear assembly.

HINT:

Perform "Inspection After Repair" after replacing the camshaft timing gear assembly (See page ).



16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

Text in Illustration

*1

Knock Pin

*a

Pin Hole


(b) Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

Text in Illustration

*1

Camshaft Timing Exhaust Gear Assembly

*a

Incorrect

*b

Correct

*c

Clearance

*d

No Clearance

*e

Camshaft Flange


(c) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

Text in Illustration

*a

Hold

*b

Turn

Torque:

85 N·m {867 kgf·cm, 63 ft·lbf}

NOTICE:

  • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
  • Do not disassemble the camshaft timing exhaust gear assembly.

HINT:

Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly (See page ).



17. ADD ENGINE OIL

(a) Add 50 cc (3.1 cu. in) of engine oil into the oil hole shown in the illustration.

NOTICE:

  • Oil must be added if the valve lash adjuster assemblies were removed.
  • Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.

18. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily install the crankshaft pulley bolt.


(b) Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.

(c) Check that the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.

Text in Illustration

*a

Approximately 7°

*b

Approximately 32°

*c

Timing Mark

HINT:

"A" is not a timing mark.


19. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}


20. INSTALL CHAIN SUB-ASSEMBLY

(a) Place the chain sub-assembly onto the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

HINT:

  • Make sure the mark plate of the chain sub-assembly faces away from the engine.
  • It is not necessary to install the chain sub-assembly to the teeth of the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

(b) Align the mark plate (yellow or gold) of the chain sub-assembly with the timing mark of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

Text in Illustration

*a

Mark Plate

*b

Timing Mark


(c) Align the mark plate (pink or gold) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.

Text in Illustration

*a

Mark Plate

*b

Timing Mark


(d) Tie a string above the crankshaft timing sprocket to secure the chain sub-assembly.


(e) Using the hexagonal portion of the No. 1 camshaft, rotate the No. 1 camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear assembly with the mark plate (yellow or gold) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.

Text in Illustration

*a

Mark Plate

*b

Timing Mark

HINT:

Hold the No. 1 camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.


(f) Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.

NOTICE:

Make sure the chain sub-assembly is secure.


21. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}


22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}


(b) Remove the pin from the stopper plate.

23. INSTALL TIMING CHAIN GUIDE

(a) Install the timing chain guide with the bolt

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}


24. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily install the crankshaft pulley bolt.

Text in Illustration

*1

Crankshaft Pulley Set Key

-

-

*a

Approximately 7°

*b

Approximately 32°

*c

Timing Mark

-

-

(b) Rotate the crankshaft clockwise and align the crankshaft pulley set key as shown in the illustration.

HINT:

"A" is not a timing mark.

(c) Check that the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.

(d) Remove the crankshaft pulley bolt.

25. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(See page )


26. INSTALL INTAKE MANIFOLD


27. CONNECT NO. 2 VENTILATION HOSE


28. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


29. INSTALL THROTTLE BODY ASSEMBLY


30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Install the exhaust manifold converter sub-assembly (See page ).


31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Install the engine assembly with transaxle (See page ).


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