INSTALL NO. 2 CYLINDER HEAD GASKET
Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
Note
Be careful of the installation direction.
Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
Place the cylinder head on the cylinder block.
Note
Be careful not to allow oil to adhere to the bottom part of the cylinder head.
Tech Tips
The cylinder head bolts are tightened in 3 progressive steps.
Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
Step 1
Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
Step 2
Mark the cylinder head bolt head with paint as shown in the illustration.
Tighten the cylinder head bolts another 90°.
Step 3
Tighten the cylinder head bolts an additional 90°.
Check that the painted mark is now facing rearward.
Tighten the 2 bolts in the order shown in the illustration.
INSTALL VALVE STEM CAP
Install the 12 valve stem caps.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
Note
Keep the lash adjuster free of dirt and foreign objects.
Only use clean engine oil.
Place the lash adjuster into a container filled with engine oil.
Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.
Check the movement of the plunger and bleed the air.
OK |
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Plunger moves up and down. |
Note
When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.
After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly with by hand.
OK |
---|
Plunger is very difficult to move. |
If the result is not as specified, replace the valve lash adjuster.
Install the valve lash adjusters.
Note
Install the valve lash adjuster to the same place where it was removed from.
INSTALL CAMSHAFT BEARING CAP
Apply engine oil to the camshaft journals, camshaft housing sub-assembly LH and camshaft bearing caps.
Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing sub-assembly LH.
Make sure to install camshaft bearing caps in each proper position and direction according to the painted marks and numbers.
Temporarily tighten the 8 bolts in the order shown in the illustration.
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
Make sure that the valve rocker arm is installed as shown in the illustration.
Apply seal packing in a continuous line as shown in the illustration.
Seal packing |
---|
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Seal diameter |
---|
3.5 to 4.5 mm (0.138 to 0.177 in.) |
Note
Remove any oil from the contact surface.
Install the camshaft housing sub-assembly LH within 3 minutes.
Do not start the engine for at least 2 hours after installing.
Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.
Note
When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
Tighten the 8 bolts in the order shown in the illustration.
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
Install the No. 3 chain tensioner assembly with the bolt.
While pushing in the tensioner, insert a pin of 1.0 mm diameter (0.039 in.) into the hole to hold it.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gear assemblies as shown in the illustration.
Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.
Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Remove the pin from the No. 3 chain tensioner assembly.
INSTALL NO. 2 CHAIN VIBRATION DAMPER
Install the 2 No. 2 chain vibration dampers.
INSTALL IDLE SPROCKET ASSEMBLY
Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.
Note
Be careful of the idle gear installation position.
Tech Tips
Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.
Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
Tech Tips
After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
INSTALL CHAIN SUB-ASSEMBLY
Align the mark plate and timing marks as shown in the illustration and install the chain.
Tech Tips
The camshaft mark plates are orange.
Do not pass the chain over the crankshaft, just temporaily place it on the crankshaft.
Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks.
Note
When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.
Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.
Tech Tips
The crankshaft mark plate is yellow.
Temporarily tighten the pulley set bolt.
Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).
INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
Install the No. 1 chain tensioner assembly with the 2 bolts.
Remove the hexagon wrench from the No. 1 chain tensioner assembly. Check that each timing mark is aligned with the crankshaft at the TDC/compression.
Remove the pulley set bolt.
INSTALL TIMING CHAIN CASE OIL SEAL
Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge.
Note
Keep the lip free of foreign matter.
Do not tap on the oil seal at an angle.
Make sure that the oil seal edge does not stick out of the timing chain case.
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
Apply seal packing in a continuous line to the engine unit as shown in the following illustration.
Seal packing |
---|
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Seal diameter |
---|
3.0 mm (0.118 in.) |
Note
Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
Install the chain cover within 3 minutes.
Do not start the engine for at least 2 hours after installing.
Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.
Seal packing |
---|
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent |
Note
If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.
Apply seal packing as follows | |||||||||||||||
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|
Install a new gasket.
Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.
Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.
Bolt length | ||||||||
---|---|---|---|---|---|---|---|---|
|
Note
Make sure that there is no oil on the bolt and nut threads.
Fully tighten the bolts in this order: Area 1 and Area 2.
Fully tighten the bolts in Area 3.
Tech Tips
First tighten the upper bolts and nuts followed by lower bolts and nuts as shown in the illustration.
Fully tighten the bolts in Area 4.
Tech Tips
Tighten the bolts in the order of lower to upper as shown in the illustration.
Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.
INSTALL OIL PAN SUB-ASSEMBLY
When replacing a stud bolt, install it by using an E8 "TORX" socket wrench. installaction
Install 2 new O-rings.
Apply seal packing in a continuous line as shown in the illustration.
Seal packing |
---|
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Seal diameter |
---|
3.0 to 4.0 mm (0.118 to 0.156 in.) |
Note
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.
Install the oil pan with the 16 bolts and 2 nuts.
INSTALL OIL STRAINER SUB-ASSEMBLY
Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
Apply seal packing in a continuous line as shown in the illustration.
Seal packing |
---|
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Seal diameter |
---|
3.0 to 4.0 mm (0.118 to 0.158 in.) |
Note
Remove any oil from the contact surface.
Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.
Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
Apply seal packing as shown in the illustration.
Seal packing |
---|
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Note
Remove any oil from the contact surface.
Install the head cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.
Install 3 new gaskets as shown in the illustration.
Install a new gasket to the head cover.
Install a head cover with the 12 bolts and a new seal washer.
Tech Tips
After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
Apply seal packing as shown in the illustration.
Seal packing |
---|
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Note
Remove any oil from the contact surfaces.
Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.
Install 3 new gaskets as shown in the illustration.
Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.
Tech Tips
After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
INSTALL WATER OUTLET
Install 2 new gaskets and a new O-ring.
Tech Tips
Apply soapy water to the O-ring.
Install the water outlet with the 2 bolts and 4 nuts.
Note
Be careful that the O-ring does not get caught between the parts.
INSTALL WATER INLET HOUSING
Install 2 new O-rings.
Tech Tips
Apply a small amount of water or soapy water to O-ring (A) in the illustration before installation.
Install the 2 stud bolts.
Install the water inlet housing with the 2 bolts and nut.
Note
Be careful that the O-ring does not get caught between the parts.
Connect the No. 1 water by-pass hose.
Apply adhesive around the drain cock.
Adhesive |
---|
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Install the drain cock assembly to the water inlet housing.
Install the drain cock plug to the drain cock assembly.
Install a new gasket to the thermostat.
Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.
Tech Tips
The jiggle valve may be set within 10° of either side of the prescribed position.
Install the water inlet with the 2 nuts.
INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)
Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration.
Install a new gasket to the No. 1 oil cooler bracket.
Install the oil cooler pipe with the bolt and 2 nuts.
Install a new gasket to the No. 1 oil pan.
Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.
INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)
Install a new O-ring.
Install the oil cooler assembly with the union bolt.
Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.
INSTALL CRANKSHAFT PULLEY
Align the pulley set key with the key groove of the pulley, and slide on the pulley.
Using SST, install the pulley bolt.
INSTALL OIL PIPE
Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
Note
Do not touch the mesh when installing the oil control valve filter.
Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
Install the bolt (A) to the cylinder head.
Tighten the oil pipe union (on the head cover side).
Tighten the oil pipe union (on the cylinder head side).
Note
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
INSTALL NO. 1 OIL PIPE
Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
Note
Do not touch the mesh when installing the oil control valve filter.
Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
Tighten the oil pipe union (on the head cover side).
Tighten the oil pipe union (on the cylinder head side).
Note
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
INSTALL CRANKSHAFT POSITION SENSOR
Install the crankshaft position sensor with the bolt.
INSTALL KNOCK CONTROL SENSOR
Install the 2 knock control sensors with the 2 bolts as shown in the illustration.
Connect the 2 knock control sensor connectors.
INSTALL KNOCK CONTROL SENSOR WIRE
Connect the 2 knock control sensor connectors and 3 clamps.
INSTALL NO. 1 VACUUM SWITCHING VALVE
Install the bolt and No. 1 vacuum switching valve.
INSTALL RADIO SETTING CONDENSER
Install the 2 bolts and 2 radio setting condensers.
INSTALL NO. 1 ENGINE FRONT MOUNTING BRACKET LH
Install the No. 1 front engine mounting bracket LH with the 6 bolts.
Tech Tips
Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
Do not start the engine for at least 2 hours after installation.
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
Install the No. 2 idler pulley sub-assembly and cover plate with the bolt.
INSTALL NO. 2 TIMING GEAR COVER
Install the No. 2 timing gear cover with the 2 bolts.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.
Tech Tips
Each bolt length is as follows:
A: 70 mm (2.76 in.)
B: 33 mm (1.30 in.)
Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Tighten the other bolts.
INSTALL GENERATOR ASSEMBLY
Install the wire harness clamp bracket with the bolt.
Connect the generator bracket with the wire harness clamp.
Install generator assembly with the 2 bolts.
Temporarily install the 2 bolts.
Fully tighten the 2bolts.
Connect the generator connector to the generator assembly.
Install the generator wire with the nut.
Install the terminal cap.
Connect the 3 wire harness clamps.
Connect the magnetic clutch connector to the compressor and magnetic clutch.
INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
Install the engine mounting bracket RH with the 3 bolts.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
Install a new gasket as shown in the illustration.
Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
Install the No. 2 exhaust manifold heat insulator with the 3 bolts.
INSTALL NO. 2 MANIFOLD STAY
Install the No. 2 manifold stay with the bolt and nut in the order shown in the illustration.
INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
Install a new O-ring to the No. 2 engine oil level dipstick guide.
Apply a light coat of engine oil to the O-rings.
Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.
Install the No. 2 engine oil level dipstick guide with the bolt.
Install the engine oil level dipstick.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
Install a new gasket as shown in the illustration.
Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
INSTALL INTAKE MANIFOLD
Note
DO NOT apply oil to the bolts listed below:
Tightening Parts | ||
---|---|---|
Intake Manifold and Cylinder Head Sub-assembly RH | ||
Intake Manifold and Cylinder Head Sub-assembly LH |
Set a new gasket on each cylinder head.
Note
Align the port holes of the gasket and cylinder head.
Make sure that the gasket is installed in the correct direction.
Set the intake manifold on the cylinder heads.
Install and tighten the 6 bolts and 4 nuts uniformly in several steps.
INSTALL NO. 2 ENGINE MOUNTING STAY RH
Install the No. 2 mounting stay RH with the bolt.
INSTALL IGNITION COIL ASSEMBLY (for LHD)
Install the 6 ignition coils with the 6 bolts.
Connect the 6 ignition coil connectors.
Install the 4 bolts [A].
Install the nut [B].
Install the 2 clamps [C].
INSTALL IGNITION COIL ASSEMBLY (for RHD)
Install the 6 ignition coils with the 6 bolts.
Connect the 6 ignition coil connectors.
Install the 2 bolts [D].
Install the nut [E].
Install the 2 clamps [F].
REMOVE ENGINE STAND
INSTALL ENGINE ASSEMBLY
Tech Tips