ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE RING PIN

    Note

    It is not necessary to remove the stiffening crankcase ring pin unless it is being replaced.


    1. A01W2P0E02
      Text in Illustration
      *a Protrusion Height

      Using a plastic hammer, tap in 2 new stiffening crankcase ring pins until they stop.

      Standard Protrusion Height
      4.3 to 5.3 mm (0.169 to 0.209 in.)

  2. INSTALL STIFFENING CRANKCASE STUD BOLT

    Note

    If a stiffening crankcase stud bolt is deformed or its threads are damaged, replace it.


    1. A01W069E03
      Text in Illustration
      *a Adhesive

      Stiffening crankcase assembly front side:


      1. When reusing the stiffening crankcase stud bolts:

        Apply adhesive 1324 to the threaded portion (stiffening crankcase assembly side) of the stud bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        Note

        Install the stud bolt within 3 minutes of applying adhesive.

    2. Using E5 and E8 "TORX" socket wrenches, install the stiffening crankcase stud bolts.

      A01W1IFE02
      Text in Illustration
      *A Type A *B Type B
      *a Front Side *b Lower Side
      *c 20 mm (0.787 in.) *d 13 mm (0.512 in.)
      *e 35 mm (1.38 in.) *f 8.5 mm (0.335 in.)
      *g 8.0 mm (0.315 in.) *h 18 mm (0.709 in.)
      Torque:
      Stud Bolt (A)
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      Torque:
      Stud Bolt (B)
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  3. INSTALL OIL FILTER BRACKET CLIP


    1. A01W0EL

      Install the oil filter bracket clip to the stiffening crankcase assembly.

  4. INSTALL ENGINE BALANCER ASSEMBLY


    1. A01W08XE04
      Text in Illustration
      *a Alignment Mark

      Check that the alignment marks of the balance shaft damper cover and No. 1 balance shaft driven gear are aligned.

      If the alignment marks are not aligned, align them.


      1. A01W1RIE12
        Text in Illustration
        *a No. 1 Balance Shaft Driven Gear
        *b Balance Shaft Damper Cover
        *c Alignment Mark

        Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the No. 2 balance shaft in place.

      2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the No. 1 balance shaft driven gear with the alignment mark of the balance shaft damper cover.

    2. A01W4R6E02

      Install the engine balancer assembly to the stiffening crankcase assembly with the 3 bolts, and tighten the bolts in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  5. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01W4SAE02
      Text in Illustration
      *1 Crankshaft Pulley Key

      Rotate the crankshaft clockwise so that the crankshaft pulley key is at the position 90° from the bottom as shown in the illustration.

    2. A01W4NEE04
      Text in Illustration
      B001NZR Stiffening Crankcase Assembly
      A01W46C Cylinder Block Sub-assembly
      *a 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *b 7.0 to 9.0 mm (0.276 to 0.354 in.)

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

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Dimension
      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick
      Application Length (A)
      28 mm (1.10 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

      • Do not apply oil for at least 2 hours after the installation.

    3. A01W3QQE01
      Text in Illustration
      *a Cutout

      Check that the rear cutouts are as shown in the illustration.

    4. Clean the bolts and the bolt holes.

    5. A01VZAYE04
      Text in Illustration
      *a Adhesive

      Apply adhesive to 3 or more threads at the tip of the bolts (A).

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01W354E02
      Text in Illustration
      *a Bolt Type
      *b Tightening Order

      Temporarily install the stiffening crankcase assembly with the 11 bolts.

      Bolt Length
      Item Length
      Bolt (A) 65 mm (2.56 in.)
      Bolt (B) 35 mm (1.38 in.)
      Bolt (C) 125 mm (4.92 in.)
      Bolt (D) 165 mm (6.50 in.)

      Tech Tips

      Apply adhesive to the bolts (A) before installation.

    7. Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.

      Torque:
      Bolt (A)
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Torque:
      except Bolt (A)
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  6. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01W0L1E02

      Install the No. 1 oil pan baffle plate and uniformly tighten the 4 bolts in several steps, in the order shown in the illustration.

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

    2. Install the clamp to the No. 1 oil pan baffle plate.

  7. INSTALL OIL LEVEL SENSOR BRACKET


    1. A01W4VJ

      Install the oil level sensor bracket to the stiffening crankcase assembly with the 2 bolts.

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

  8. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  9. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to a new gasket.

    2. A01W0HEE02
      Text in Illustration
      *a Protrusion

      Align the protrusion of the gasket with the cutout of the oil strainer sub-assembly, and install the gasket to the oil strainer sub-assembly.

    3. Install the oil strainer sub-assembly with the 3 bolts in several steps, in the order shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  10. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01W3GVE03
      Text in Illustration
      *a Seal Packing

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

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Diameter
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

    2. A01VZ7WE04
      Text in Illustration
      *A Type A
      *B Type B
      B001O8N Bolt
      B001OAO Nut

      Install the oil pan sub-assembly with the 11 bolts and 2 nuts in several steps, in the order shown in the illustration.

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

      Tech Tips

      The bolt (A) and nut (A) are tightened twice.

  11. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and the oil pan drain plug to the oil pan sub-assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  12. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  13. INSTALL REAR ENGINE OIL SEAL

    Click here

  14. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01VZST

      Install the cylinder block water jacket spacer to the cylinder block sub-assembly.

  15. INSTALL CYLINDER HEAD GASKET

    Click here

  16. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  17. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.


    1. A01W0OBE02
      Text in Illustration
      *a Protrusion Height

      Using a plastic hammer, tap in 8 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

      Standard Protrusion Height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  18. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    Note

    It is not necessary to remove the camshaft housing straight pin unless it is being replaced.


    1. A01W15OE02
      Text in Illustration
      *a Protrusion Height

      Using a plastic hammer, tap in 2 new camshaft housing straight pins to the camshaft housing sub-assembly.

      Standard Protrusion Height
      5.0 to 7.0 mm (0.197 to 0.276 in.)

  19. INSTALL CAMSHAFT HOUSING STUD BOLT

    Note

    If a camshaft housing stud bolt is deformed or its threads are damaged, replace it.


    1. A01W069E04
      Text in Illustration
      *a Adhesive

      When reusing the camshaft housing stud bolts:


      1. Apply adhesive 1324 to the threaded portion (camshaft housing sub-assembly side) of the stud bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        Note

        Install the camshaft housing stud bolt within 3 minutes of applying adhesive.

    2. A01W29UE02
      Text in Illustration
      *a 20 mm (0.787 in.)
      *b 13 mm (0.512 in.)
      *c 35 mm (1.38 in.)

      Using an E8 "TORX" socket wrench, install the camshaft housing stud bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  20. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem cap ends.

    2. Install the 16 valve stem caps to the cylinder head sub-assembly.

      Note

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

  21. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the 16 valve lash adjuster assemblies before installing them Click here.

    2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

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

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


    1. B001OQWE02
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

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

  23. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01W4L4E02
      Text in Illustration
      *a Vernier Caliper

      Clean the No. 1 camshaft bearing.

    2. Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.

    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Difference Between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

  24. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

    3. A01W57XE09
      Text in Illustration
      *a Vernier Caliper

      Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

      Standard Distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  25. INSTALL OIL CONTROL VALVE FILTER


    1. A01W4X1

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  26. INSTALL CAMSHAFT


    1. Clean the camshaft journals and camshaft housing sub-assembly.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.

    3. Install the camshaft to the camshaft housing sub-assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft Click here.

  27. INSTALL NO. 2 CAMSHAFT


    1. Clean the No. 2 camshaft journals and camshaft housing sub-assembly.

    2. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.

    3. Install the No. 2 camshaft to the camshaft housing sub-assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the No. 2 camshaft Click here.

  28. INSTALL CAMSHAFT BEARING CAP


    1. Clean the camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft bearing caps.

    3. Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap in their correct positions.

    4. A01W15ZE04

      Install the 11 bolts in the order shown in the illustration.

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

      Note

      Make sure that the camshaft and No. 2 camshaft rotate smoothly after installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

  29. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B001OQWE02
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

    2. A01VZLNE02
      Text in Illustration
      *a Seal Packing
      *b 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *c 3.5 to 4.0 mm (0.138 to 0.157 in.)

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

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

    3. A01W1ODE02
      Text in Illustration
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin

      Position the knock pins of the camshaft and No. 2 camshaft as shown in the illustration.

    4. A01W4RNE04

      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 }

      Note


      • Do not apply oil for at least 2 hours after installation.

      • Do not start the engine for at least 2 hours after installation.

      • After installation, if the seal packing has seeped out, wipe it off.

  30. INSTALL OIL PIPE SUB-ASSEMBLY


    1. A01W080

      Install the oil pipe sub-assembly to the No. 4 camshaft bearing cap with the bolt.

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

  31. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B001NM9E02
      Text in Illustration
      *a Knock Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear assembly.

      Note

      Be careful not to damage the contact surface of the camshaft timing exhaust gear assembly with the knock pin of the No. 2 camshaft.

    2. B001OO0E02
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c No. 2 Camshaft Flange
      *d Gap
      *e No Gap

      Check that there is no gap between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

    3. A01W23GE01
      Text in Illustration
      *a Hold
      B001O8N Turn

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

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note


      • 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.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly Click here.

  32. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Note

    There are different types of camshaft timing gear bolts. Make sure to check the identification mark to determine the tightening torque.

    B001O31C03
    *a Identification Mark Stamp
    Identification Mark
    Item Identification Mark Stamp
    Type A A
    Type B D

    1. A01W3R7E02
      Text in Illustration
      *a Knock Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the camshaft with the knock pin hole of the camshaft timing gear assembly.

      Note

      Be careful not to damage the contact surface of the camshaft timing gear assembly with the knock pin of the camshaft.

    2. B001NMNE02
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Portion (A) of Camshaft
      *d Gap
      *e No Gap

      Check that there is no gap between the camshaft timing gear assembly and portion (A) of the camshaft shown in the illustration.

    3. A01W1VZ

      Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.

    4. Temporarily install the camshaft timing gear bolt.

      Tech Tips

      Make sure that the camshaft timing gear bolt is screwed in by at least 3 threads.

    5. A01W0ORE02
      Text in Illustration
      *a Hold
      B001O8N Turn

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the camshaft timing gear bolt.

      Torque:
      Type A
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
      Type B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note


      • 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.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly Click here.

  33. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01W144

      Install the crankshaft timing sprocket to the crankshaft.

  34. ADD ENGINE OIL


    1. A01W36V

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

      Note


      • Engine 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.

  35. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01W2T8

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

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

  36. INSTALL CHAIN SUB-ASSEMBLY


    1. A01W4BJE02

      Temporarily install the crankshaft pulley set bolt.

    2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.

    3. A01VZ7YE02
      Text in Illustration
      *a Approximately 7°
      *b Approximately 32°
      *c Timing Mark

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

      Tech Tips

      "A" is not a timing mark.

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

      Tech Tips


      • 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 gears and sprocket.

    5. A01W3AGE02
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Align the mark plate (orange) 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.

    6. A01W227E02
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Align the mark plate (yellow) 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.

    7. A01VZLG

      Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.

    8. A01W2USE02
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Using a wrench, hold the hexagonal portion of the camshaft and rotate the camshaft counterclockwise to align the timing mark of the camshaft timing gear assembly with the mark plate (orange) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

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

    9. A01W1DC

      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.

      Note

      Make sure the chain sub-assembly is secure.

  37. INSTALL CHAIN TENSIONER SLIPPER


    1. A01W1D5

      Install the chain tensioner slipper with the bolt.

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

  38. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01W00K

      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 }

    2. Remove the pin from the stopper plate.

  39. INSTALL TIMING CHAIN GUIDE


    1. A01W5B5

      Install the timing chain guide with the bolt.

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

  40. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

      A01W1D3E02
      Text in Illustration
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.

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

      Tech Tips

      "A" is not a timing mark.

  41. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  42. INSTALL ENGINE MOUNTING BRACKET RH

    Click here

  43. INSTALL TIMING CHAIN COVER PLATE

    Click here

  44. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

    Click here

  45. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  46. INSTALL CASE SEPARATOR


    1. A01W471E02
      Text in Illustration
      *a O-ring

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

    2. Install the O-ring to the case separator.

      Note

      Make sure to securely fit the O-ring into the groove of the case separator.

    3. A01W28W

      Apply a light coat of engine oil to a new oil separator gasket.

    4. Install the oil separator gasket to the case separator.

      Note

      Make sure to securely fit the oil separator gasket into the groove of the case separator.

    5. A01W58W

      Install the case separator to the cylinder head cover case sub-assembly with the 2 bolts.

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

  47. INSTALL SPARK PLUG TUBE GASKET


    1. A01W44PE02
      Text in Illustration
      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly
      *a 1.0 mm (0.394 in.) or less

      Tap in 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

      Note


      • Do not allow foreign matter to contact the lip of the spark plug tube gasket.

      • Do not tap in the spark plug tube gasket at an angle.

  48. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01W2SYE02
      Text in Illustration
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *a Gasket

      Apply a light coat of engine oil to a new camshaft bearing cap oil hole gasket and a new gasket.

    2. Install the camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.

    3. Install the gasket to the No. 2 camshaft bearing cap.

    4. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

      Note

      Remove any oil from the contact surface.

    5. A01W5DSE02
      Text in Illustration
      *1 Timing Chain Cover assembly
      *2 Camshaft Housing Sub-assembly
      *a 45 mm (1.77 in.)
      *b 24 mm (0.945 in.)
      *c Seal Packing Diameter: 3.0 mm (0.118 in.)
      *d Application Width 5.0 mm (0.197 in.)
      *e Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
      B001O8N Seal Packing

      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 cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

    6. A01VZSME02

      Align the cylinder head cover sub-assembly with the pin (A). Then align the cylinder head cover sub-assembly with the pin (B) and install the cylinder head cover sub-assembly.

      Text in Illustration
      B001O8N Bolt
      B001OAO Bolt with Seal Washer

    7. Install 3 new seal washers and the 17 bolts, and then tighten the bolts in the order shown in the illustration.

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

      Note

      Do not start the engine for at least 2 hours after installation.

  49. INSTALL CRANKSHAFT PULLEY


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

    2. A01W15DE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley and install the crankshaft pulley set bolt.

      SST
      09213-54015
      09330-00021
      Torque:
      260 N*m  { 2651 kgf*cm, 192 ft.*lbf }

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

  50. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  51. INSTALL NO. 1 VENTILATION CASE


    1. A01W0FME02
      Text in Illustration
      *a Seal Packing

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

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Diameter
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 1 ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.

    2. A01W59TE02

      Install the No. 1 ventilation case, and install the 8 bolts and 2 nuts in the order shown in the illustration.

      Text in Illustration
      B001O8N Bolt
      B001OAO Nut
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      The bolts (A) are tightened twice.

  52. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  53. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  54. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  56. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new gasket to the oil filler cap sub-assembly.

    2. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  57. INSTALL SPARK PLUG

    Click here

  58. INSTALL ENGINE COVER JOINT


    1. A01W1BD

      Install the 2 engine cover joints.

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

  59. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  60. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  61. INSTALL KNOCK CONTROL SENSOR

    Click here

  62. INSTALL VACUUM PUMP ASSEMBLY

    Click here