PROCEDURE
INSTALL CYLINDER BLOCK WATER JACKET SPACER (w/ Cylinder Block Water Jacket Spacer)
Install the cylinder block water jacket spacer to the cylinder head.
| *a | Engine Front Side |
INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY
Place the cylinder head gently in order not to damage the gasket.
Place the cylinder head on the cylinder block.
Install the 8 plate washers to the cylinder head subassembly.
Do not drop the washers into the cylinder head.
Apply engine oil to each bolt thread and seating surface.
| *a | Apply Engine Oil |
Using several passes, uniformly install and tighten the 8 cylinder head bolts with an 8 mm bi-hexagon wrench in the order shown in the illustration.
| 32 N*m | 326 kgf*cm | 24 ft.*lbf |
Mark the front of each cylinder head bolt with paint.
| *a | Paint Mark |
Retighten the cylinder head bolts by additional 180° as shown in the illustration.
Check that the painted marks are now 180° from the front.
After tightening the cylinder head bolts, wipe off the seal packing material that seeped out from the contact surface between the cylinder head and cylinder block.
| *a | Direction to wipe off |
| *b | Before wiping off |
| *c | After wiping off |
Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.
Be sure to avoid clogging the bolt holes when wiping off the seal packing.
INSTALL VALVE LIFTER
Apply engine oil to the circumference of the valve lifters.
Install the valve lifters straight into the lifter holes.
Check that the valve lifters turn smoothly after installing them.
INSTALL ENGINE REAR OIL SEAL
Apply engine oil to the lip of a new oil seal.
|
Apply Engine Oil |
Using SST, tap the oil seal straight in.
| *1 | Rear Oil Seal Retainer | *2 | Wooden Block |
| 09223-15020 | |
| 09950-70010 | 09951-07200 |
| Standard depth |
|---|
| -1.0 to 0.5 mm (-0.0394 to 0.0197 in.) |
Keep the lip free from foreign materials.
Do not tap on the oil seal at an angle.
INSTALL ENGINE REAR OIL SEAL RETAINER
Install the stud bolt to the rear oil seal retainer.
Apply a continuous bead of seal packing as shown in the illustration.
| *1 | Seal Packing |
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Install the oil seal retainer with the 5 bolts.
| 10 N*m | 102 kgf*cm | 7 ft.*lbf |
Install the oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not add engine oil for at least 2 hours after installation.
Do not start the engine for at least 2 hours after installation.
INSTALL VENTILATION BAFFLE PLATE
Clean the installation surface of the cylinder block and ventilation baffle plate.
Apply a continuous bead of seal packing as shown in the illustration.
| *1 | Seal Packing |
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Install the ventilation baffle plate in the order shown in the illustration with the 6 bolts and 2 nuts.
| 24 N*m | 245 kgf*cm | 18 ft.*lbf |
Install the ventilation baffle plate within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
INSTALL CAMSHAFTS
Before installing the camshaft, turn the crankshaft approximately 90° in the engine revolution direction from the point where the No. 1 piston is set at the TDC so that the lifted valve and piston do not touch each other.
Apply engine oil to the contact areas of the cam and journal of the camshaft and No. 2 camshaft.
| *a | Apply Engine Oil |
Install the camshafts as shown in the illustration.
| *1 | No. 1 Camshaft |
| *2 | No. 2 Camshaft |
| *3 | No. 3 Cylinder |
| *4 | No. 1 Cylinder |
| *5 | No. 2 Cylinder |
Set the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps and tighten the bolts in the order shown in the illustration.
| *1 | No. 1 Camshaft Bearing Cap |
| *2 | No. 2 Camshaft Bearing Cap |
| No. 1 Camshaft bearing cap | ||
| 15 N*m | 153 kgf*cm | 11 ft.*lbf |
| No. 2 Camshaft bearing cap | ||
| 13 N*m | 127 kgf*cm | 9 ft.*lbf |
Install the bearing caps with the front marks facing the engine front.
Install the bolts in the correct positions by referring to the numbers inscribed on the bolts and the table below.
| Installation position | Inscribed No. |
|---|---|
| Intake No. 1 cylinder | I2 |
| Intake No. 2 cylinder | I3 |
| Intake No. 3 cylinder | I4 |
| Exhaust No. 1 cylinder | E2 |
| Exhaust No. 2 cylinder | E3 |
| Exhaust No. 3 cylinder | E4 |
INSTALL CAMSHAFT TIMING GEAR
Insert the camshaft timing gear so that the knock pin on the No. 2 camshaft end fits into the groove.
While holding the hexagonal portion of the No. 2 camshaft, tighten the bolts to install the camshaft timing gear.
| *a | Hold |
| *b | Turn |
| 47 N*m | 479 kgf*cm | 35 ft.*lbf |
INSTALL CAMSHAFT TIMING SPROCKET ASSEMBLY
Apply engine oil to the camshaft timing sprocket installation portion of the camshaft.
Insert the knock pin on the camshaft end into the knock hole in the camshaft timing sprocket.
Slightly turn the sprocket to make sure that the knock pin is securely installed after inserting the knock pin.
The end surface of the sprocket may be damaged if the sprocket is turned with excessive force when the knock pin is not inserted.
While holding the hexagonal portion of the camshaft, tighten the bolts to install the camshaft timing sprocket.
| *a | Hold |
| *b | Turn |
| 47 N*m | 479 kgf*cm | 35 ft.*lbf |
INSPECT VALVE CLEARANCE
ADJUST VALVE CLEARANCE
INSTALL CRANKSHAFT STRAIGHT PIN
Install the crankshaft straight pin to the crankshaft groove.
INSTALL CRANKSHAFT TIMING SPROCKET
Align the groove of the crankshaft timing sprocket with the key of the crankshaft and install the crankshaft timing sprocket.
INSTALL TIMING CHAIN GUIDE
Install the timing chain guide with the 2 bolts.
| 9.0 N*m | 92 kgf*cm | 80 in.*lbf |
INSTALL CHAIN SUB-ASSEMBLY
Align the yellow mark plate with the timing mark of the crankshaft timing sprocket and install the timing chain, as shown in the illustration.
| *a | Yellow Mark Plate |
| *b | Timing Mark |
Align the 2 orange mark plates with the timing marks of the camshaft timing sprockets and install the timing chain, as shown in the illustration.
| *a | Timing Mark |
| *b | Orange Mark Plate |
INSTALL TIMING CHAIN TENSION ARM
Install the timing chain tension arm with the bolt.
| 19 N*m | 194 kgf*cm | 14 ft.*lbf |
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
Slightly turn the hexagonal portion of the camshaft assembly (intake side) counterclockwise to leave some slack on the chain of the timing chain tensioner side.
Install the chain tensioner with the 2 bolts.
| *1 | Hexagon Wrench |
| 11 N*m | 107 kgf*cm | 8 ft.*lbf |
Remove the hexagon wrench, turn the crankshaft 2 complete revolutions and operate the chain tension.
Make sure that the timing mark of the sprocket camshaft timing is at the top with the timing chain tensed (set No. 1 piston to the TDC/exhaust).
| *a | Timing Mark |
INSTALL TIMING CHAIN COVER OIL SEAL
Apply engine oil to the lip of a new oil seal.
| *a | Engine oil |
Using SST, tap the oil seal straight in.
| 09950-60010 | 09951-00500 | 09952-06010 |
| 09950-70010 | 09951-07200 |
| Standard depth |
|---|
| -1.0 to 0.5 mm (-0.0394 to 0.0197 in.) |
Do not tap the oil seal at an angle.
INSTALL STUD BOLT (for TMC Made)
Apply adhesive to 2 or 3 threads (chain cover side) of the 2 stud bolts.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1344 or equivalent |
Install the 2 stud bolts to the timing chain cover.
INSTALL STUD BOLT (for TMMF Made)
Apply adhesive to 2 or 3 threads (chain cover side) of the stud bolt.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1344 or equivalent |
Install the stud bolt to the timing chain cover.
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
Remove any old packing material remaining on the sealing surfaces before applying seal packing.
Clean and degrease the contact surfaces of the timing chain cover, cylinder head, cylinder block and confirm that no oil, moisture, or other foreign matter remains on the surfaces.
Install a new oil pump gasket to the cylinder block.
Apply seal packing to the timing chain cover as shown in the following illustration.
| *1 | Toyota Genuine Seal Packing Black, Three Bond 1207B | *2 | Toyota Genuine Seal Packing 1282B, Three Bond 1282B |
| Seal packing |
|---|
| Water pump part |
| Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent |
| Other part |
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.
Temporarily install the timing chain cover with the 11 bolts.
| Bolt Length | ||||||||||
|---|---|---|---|---|---|---|---|---|---|---|
|
Install a new oil filter bracket gasket to the timing chain cover.
Temporarily install the oil filter bracket with the 3 bolts.
| Bolt Length | ||||
|---|---|---|---|---|
|
Install a new water pump gasket to the timing chain cover as shown in the illustration.
| *a | Water Pump Side |
Temporarily install the water pump with the 5 bolts.
| Bolt Length | ||||||||
|---|---|---|---|---|---|---|---|---|
|
Fully tighten the timing chain cover with the 19 bolts in the order shown in the illustration.
| Bolt A, C | ||
| 24 N*m | 245 kgf*cm | 18 ft.*lbf |
| Bolt B, D | ||
| 40 N*m | 408 kgf*cm | 30 ft.*lbf |
| Bolt E, F, G | ||
| 28 N*m | 286 kgf*cm | 21 ft.*lbf |
| Bolt Length | ||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Wipe off the excess seal packing.
INSTALL DRAIN PLUG
Install the drain plug with a new gasket.
| 54 N*m | 551 kgf*cm | 40 ft.*lbf |
INSTALL TIGHT PLUG
Clean the plug and the bolt holes of the timing chain cover and apply adhesive to the threads of the tight plug.
| *1 | Adhesive |
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Using an 8 mm socket hexagon wrench, install the tight plug.
| *1 | 8 mm Socket Hexagon Wrench |
| 15 N*m | 153 kgf*cm | 11 ft.*lbf |
Do not start the engine for at least 1 hour after installing.
INSTALL CRANKSHAFT PULLEY
Align the pulley set key with the key groove of the crankshaft pulley, and then slide on the crankshaft pulley.
Using SST, install the crankshaft pulley bolt.
| *a | Hold |
| *b | Turn |
| 09960-10010 | 09962-01000 | 09963-01000 |
| 180 N*m | 1835 kgf*cm | 133 ft.*lbf |
INSTALL OIL FILTER SUB-ASSEMBLY
Check and clean the oil filter installation surface.
Apply clean engine oil to the gasket of a new oil filter.
Gently screw the oil filter into place, then tighten it until the gasket comes into contact with the seat.
Using SST, tighten the oil filter.
| 09228-06501 |
| 10 N*m | 102 kgf*cm | 7 ft.*lbf |
INSTALL WATER BY-PASS HOSE
Install the water by-pass hose to the No. 1 water by-pass pipe.
INSTALL NO. 1 WATER BY-PASS PIPE
Install a new water by-pass pipe gasket to the cylinder head as shown in the illustration.
| *a | Water By-pass Side |
Connect the water by-pass hose to the timing chain cover.
Temporarily install the water by-pass pipe with the bolt and 2 nuts.
| *1 | Nut |
| *2 | Bolt |
Fully tighten the 2 nuts.
| 24 N*m | 245 kgf*cm | 18 ft.*lbf |
Fully tighten the bolt.
| 24 N*m | 245 kgf*cm | 18 ft.*lbf |
INSTALL THERMOSTAT
Install a new water outlet gasket to the thermostat.
Install the thermostat to the water inlet with the jiggle pin facing straight upward.
| *a | Upper Indication |
| *b | Jiggle Pin |
INSTALL WATER INLET
Install the water inlet with the 2 bolts.
| 7.0 N*m | 71 kgf*cm | 62 in.*lbf |
Avoid catching the rubber gasket of thermostat under the water inlet.
Do not use a water inlet that has been dropped.
Ensure that gasket is secured between the water inlet and block.
INSTALL OIL STRAINER SUB-ASSEMBLY
Install a new oil strainer gasket to the oil strainer.
Install the oil strainer to the timing chain cover with the 3 bolts.
| 8.5 N*m | 87 kgf*cm | 75 in.*lbf |
INSTALL OIL PAN SUB-ASSEMBLY (for TMC Made)
Remove any old packing material remaining on the sealing surfaces before applying seal packing.
Clean and degrease the contact surfaces of the oil pan, cylinder block and confirm that no oil, moisture, or other foreign matter remains on the surfaces.
Apply seal packing to the oil pan as shown in the following illustration.
| *1 | Toyota Genuine Seal Packing Black, Three Bond 1207B |
| *a | Contact surface between timing chain cover and cylinder block |
| *b | Contact surface between oil seal retainer and cylinder block |
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Start and finish applying the seal packing on the seal surface with the cylinder block subassembly.
Apply seal packing to the contact surfaces between the timing chain cover and cylinder block, and between the oil seal retainer and cylinder block.
Install the oil pan sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
Temporarily install the oil pan with the 12 bolts and 3 nuts.
| *1 | Nut |
Fully tighten the 6 bolts in the order shown in the illustration.
| 24 N*m | 245 kgf*cm | 18 ft.*lbf |
Fully tighten the 6 bolts and 3 nuts.
| *1 | Nut |
| Bolt A | ||
| 24 N*m | 245 kgf*cm | 18 ft.*lbf |
| Bolt B, Nut | ||
| 10 N*m | 102 kgf*cm | 7 ft.*lbf |
INSTALL OIL PAN SUB-ASSEMBLY (for TMMF Made)
Remove any old packing material remaining on the sealing surfaces before applying seal packing.
Clean and degrease the contact surfaces of the oil pan, cylinder block and confirm that no oil, moisture, or other foreign matter remains on the surfaces.
Apply seal packing to the oil pan as shown in the following illustration.
| *1 | Toyota Genuine Seal Packing Black, Three Bond 1207B |
| *a | Contact surface between timing chain cover and cylinder block |
| *b | Contact surface between oil seal retainer and cylinder block |
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Start and finish applying the seal packing on the seal surface with the cylinder block subassembly.
Apply seal packing to the contact surfaces between the timing chain cover and cylinder block, and between the oil seal retainer and cylinder block.
Install the oil pan sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
Temporarily install the oil pan with the 13 bolts and 2 nuts.
| *1 | Nut |
Fully tighten the 6 bolts in the order shown in the illustration.
| 24 N*m | 245 kgf*cm | 18 ft.*lbf |
Fully tighten the 7 bolts and 2 nuts.
| *1 | Nut |
| Bolt A | ||
| 24 N*m | 245 kgf*cm | 18 ft.*lbf |
| Bolt B, Nut | ||
| 10 N*m | 102 kgf*cm | 7 ft.*lbf |
INSTALL OIL PAN DRAIN PLUG
Install the engine oil drain plug with a new oil pan drain plug gasket.
| 30 N*m | 301 kgf*cm | 22 ft.*lbf |
INSTALL VENTILATION VALVE SUB-ASSEMBLY
Install a new grommet, as shown in the illustration.
| *1 | Ventilation Valve |
| *2 | Grommet |
Install the ventilation valve.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Clean the cylinder head cover, cylinder head assembly and timing chain cover.
Install a new cylinder head cover gasket into the groove on the cylinder head cover and onto the center bosses.
Insert the gasket securely until it completely fits into the bosses.
Apply a continuous bead of seal packing to the contact surface between the cylinder head assembly and timing chain cover assembly, as shown in the illustration.
| *1 | Seal Packing |
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Temporarily install the cylinder head cover with the 13 bolts and 2 nuts.
Fully tighten the 2 bolts A, then fully tighten the 2 nuts, then fully tighten the 11 bolts B.
| *1 | Nut |
| 7.7 N*m | 79 kgf*cm | 68 in.*lbf |
INSTALL OIL FILLER CAP SUB-ASSEMBLY
Install a new oil filler cap gasket to the oil filler cap.
Install the oil filler cap.
INSTALL OIL CONTROL VALVE FILTER
Install the oil control valve filter onto the tight plug.
| *1 | Oil Control Valve Filter |
| *2 | Gasket |
| *3 | Head Taper Screw Plug |
Install a new gasket and install the oil control valve filter using an 8 mm hexagon wrench.
| *1 | 8 mm Hexagon Wrench |
| 25 N*m | 250 kgf*cm | 18 ft.*lbf |
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
Apply adhesive to 2 or 3 threads of the oil pressure switch.
| *1 | Adhesive |
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. |
Using a 24 mm deep socket wrench, install the engine oil pressure switch.
| *1 | 24 mm Deep Socket Wrench |
| 15 N*m | 153 kgf*cm | 11 ft.*lbf |
Do not start the engine for at least 1 hour after installation.
INSTALL KNOCK SENSOR
Install the knock sensor with the bolt as shown in the illustration.
| *a | Upper |
|
Front of Engine |
| 20 N*m | 204 kgf*cm | 15 ft.*lbf |
If a component has been dropped or subjected to a strong impact, replace it.
Make sure that each knock sensor is in the correct position.
INSTALL CRANKSHAFT POSITION SENSOR
Apply a light coat of engine oil to the O-ring.
If reusing the crankshaft position sensor, be sure to inspect the O-ring.
Install the crankshaft position sensor with the bolt.
| 7.5 N*m | 76 kgf*cm | 66 in.*lbf |
If a component has been dropped or subjected to a strong impact, replace it.
Make sure that the O-ring is not damaged or does not jump out of position during installation.
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Apply a light coat of engine oil to the O-ring.
If reusing the camshaft timing oil control valve assembly, be sure to inspect the O-ring.
Install the camshaft timing oil control valve with the bolt.
| 10 N*m | 102 kgf*cm | 7 ft.*lbf |
If a component has been dropped or subjected to a strong impact, replace it.
Make sure that the O-ring is not damaged or does not jump out of position during installation.
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Install a new gasket to the engine coolant temperature sensor.
Using a 19 mm deep socket wrench, install the engine coolant temperature sensor.
| *1 | 19 mm Deep Socket Wrench |
| 20 N*m | 200 kgf*cm | 14 ft.*lbf |
INSTALL CAMSHAFT POSITION SENSOR
Apply a light coat of engine oil to the O-ring.
If reusing the camshaft position sensor, be sure to inspect the O-ring.
Install the camshaft position sensor with the bolt.
| 7.5 N*m | 76 kgf*cm | 66 in.*lbf |
If a component has been dropped or subjected to a strong impact, replace it.
Make sure that the O-ring is not damaged or does not jump out of position during installation.
INSTALL SPARK PLUG