ENGINE UNIT REASSEMBLY


  1. INSTALL STIFFENING CRANKCASE RING PIN

    Note

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


    1. A01ELJEE02
      Text in Illustration
      *1 Protrusion Height

      Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

      Standard protrusion height
      4.3 to 5.3 mm (0.169 to 0.209 in.)

  2. INSTALL ENGINE BALANCER ASSEMBLY


    1. A01EMNHE03
      Text in Illustration
      *1 Alignment Mark

      Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

      If the alignment marks are not aligned, realign them.


      1. A01EM43E06
        Text in Illustration
        *1 Alignment Mark
        *2 Driven Gear
        *3 Damper Cover

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

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

    2. A01EJF8E01

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

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

  3. INSTALL STIFFENING CRANKCASE STUD BOLT

    Note

    If a stud bolt is deformed or the threads are damaged, replace it.

    A01EJX1E01

    1. Using an E5 and E8 "TORX" socket wrenches, install the stud bolts.

      Torque:
      for stud bolt A
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      for stud bolt B
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01EK0WE01

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

    2. A01EJMZE01

      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 within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.

      • Do not apply oil for at least 4 hours after the installation.

    3. A01ELDHE02
      Text in Illustration
      *1 Cutout

      Check that the rear cutout parts are as shown in the illustration.

    4. Clean the bolts and their installation holes.

    5. A01ELEDE01

      Apply adhesive to 3 threads or more of the end of bolt A.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01EIQ5E03

      Temporarily install the stiffening crankcase 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 bolt A before installing it.

    7. A01EIQ5E02

      Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase

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

  5. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01EMRHE01

      Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.

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

  6. INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. A01ELSTE01

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

    3. Install the oil strainer with the 3 bolts in several steps, in the sequence shown in the illustration.

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

  7. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01EM3EE01

      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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surfaces.

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

      • Do not apply oil for at least 4 hours after the installation.

    2. A01EMFRE01

      Install the oil pan with the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

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

      Tech Tips

      Bolt A and nut A are tightened twice.

  8. INSTALL OIL FILTER CAP ASSEMBLY


    1. Clean the inside of the oil filter cap assembly, the threads and O-ring groove.

    2. A01EL7LE01
      Text in Illustration
      *1 O-ring
      *a Correct
      *b Incorrect

      Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap assembly.

      Note


      • Be sure to install the O-ring in the proper location, otherwise oil may leak.

      • Do not twist the O-ring.

    3. Set a new oil filter element in the oil filter cap assembly.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap assembly.

      Note

      Make sure that the O-ring does not get caught between the parts.

    6. A01EJKJE01
      Text in Illustration
      *1 Oil Filter Cap Assembly
      *2 O-ring
      *3 Oil Filter Bracket
      *a No Gap

      Using SST, tighten the oil filter cap assembly.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      After tightening the oil filter cap assembly, make sure that there is no gap and that the O-ring is not protruding.

    7. A01ELROE01
      Text in Illustration
      *1 O-ring

      Apply a small amount of engine oil to a new O-ring, and install it to the oil filter cap assembly.

      Note

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap assembly.

    8. Install the oil filter drain plug.

      Torque:
      13 N*m  { 127 kgf*cm, 10 ft.*lbf }

      Note

      Be careful that the O-ring does not get caught between any surrounding parts.

  9. INSTALL REAR ENGINE OIL SEAL


    1. Apply MP grease to the lip of a new oil seal.

      Note


      • Do not allow foreign matter to contact the lip of the oil seal.

      • Do not allow MP grease to contact the dust seal.

    2. A01EJQ3E01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the edges of the cylinder block and crankcase.

      SST
      09223-15030
      09950-70010   ( 09951-07150 )

      Note


      • Keep the lip of the oil seal free from foreign matter.

      • Do not tap in the oil seal at an angle.

  10. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01EL8H

      Install the water jacket spacer to the cylinder block.

  11. INSTALL CYLINDER HEAD GASKET


    1. A01EJ0ZE01

      Clean the cylinder block and cylinder head with solvent.

    2. 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

      Tech Tips

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

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

      Note

      Pay attention to the installation direction.

  12. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 4 progressive steps.


    1. Place the cylinder head on the cylinder block.

      Note


      • Ensure that no oil is on the mounting surface of the cylinder head.

      • Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

    2. Install the plate washers to the cylinder head bolts.

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

    4. Step 1:


      1. A01EJ20E02

        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 }

        Note

        Do not drop the plate washer for the cylinder head bolt into the cylinder head.

    5. 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 }

    6. Step 3:


      1. A01EKM7E03

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

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

    7. 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.

        Note


        • 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.

  13. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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


    1. A01EKS7E02
      Text in Illustration
      *1 Advanced Position:
      *2 Knock Pin Hole
      *3 Alignment Mark
      *4 Retarded Position:

      Check the camshaft timing gear position.

      Note

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

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

    2. A01EKOME02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    3. A01ELO9E05
      Text in Illustration
      *1 INCORRECT
      *2 Camshaft Timing Gear
      *3 Clearance
      *4 Flange
      *5 CORRECT
      *6 No Clearance

      Check that there is no clearance between the camshaft timing gear and camshaft flange.

    4. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

      Note

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

    5. A01EKR1E01

      Release the lock pin.


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

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

        Tech Tips

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

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

      4. A01EKGU

        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 paths with a piece of cloth when applying pressure to keep oil from splashing.

        Note

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

        Tech Tips


        • 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.

    6. Remove the bolt and camshaft timing gear.

      Note

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

  14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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


    1. A01EKCXE02
      Text in Illustration
      *1 Protrusion Height

      Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    Note

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


    1. A01EK0FE02
      Text in Illustration
      *1 Protrusion Height

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

      Standard protrusion height
      5.0 to 7.0 mm (0.197 to 0.276 in.)

  16. INSTALL CAMSHAFT HOUSING STUD BOLT

    Note

    If a stud bolt is deformed or the threads are damaged, replace it.


    1. A01EIQ4E01

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

      Torque:
      9.0 N*m  { 91 kgf*cm, 80 in.*lbf }

  17. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01EKZYE01

      Clean the No. 1 camshaft bearing.

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

    3. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  18. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. Install the camshaft bearing to the camshaft housing.

    3. A01EJNBE01

      Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

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

  19. INSTALL OIL CONTROL VALVE FILTER


    1. A01EM6ZE01

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

  20. INSTALL CAMSHAFT


    1. Clean the camshaft journals, camshaft housing and bearing caps.

    2. Apply a light coat of engine oil to the camshaft journal, camshaft housing and bearing caps.

    3. Install the No. 1 and No. 2 camshafts to the camshaft housing.

  21. INSTALL CAMSHAFT BEARING CAP


    1. A01ELZO

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

    2. A01ELKUE02

      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 rotates smoothly after installing the bearing caps.

  22. INSTALL VALVE STEM CAP


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

    2. Install the 16 valve stem caps to the cylinder head.

      Note

      Do not drop the valve stem caps into the cylinder head.

  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster before installing it Click here.

    2. Install the 16 lash adjusters to the cylinder head.

      Note

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

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


    1. A01EKLEE04
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem Cap

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

    2. Install the 16 valve rocker arms as shown in the illustration.

  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01EK4EE02
      Text in Illustration
      *1 INCORRECT
      *2 Valve Rocker Arm
      *3 Valve Stem Cap
      *4 Valve Lash Adjuster
      *5 CORRECT

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

    2. A01ELT1E01

      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 surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

    3. A01EKM5E01

      Position the knock pin of the No. 1 and No. 2 camshafts as shown in the illustration.

    4. A01EMJOE02

      Install the camshaft housing, 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 4 hours after the installation.

      • Do not start the engine for at least 4 hours after the installation.

      • Thoroughly wipe clean any seal packing.

  26. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EKD9E02
      Text in Illustration
      *1 Knock Pin Hole
      *2 Alignment Mark

      Check the camshaft timing gear position.

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

    2. A01EKOME02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    3. A01ELO9E05
      Text in Illustration
      *1 INCORRECT
      *2 Camshaft Timing Gear
      *3 Clearance
      *4 Flange
      *5 CORRECT
      *6 No Clearance

      Check that there is no clearance between the camshaft timing gear and camshaft flange.

    4. A01EKKD

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

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

      Note


      • Be careful not to damage the cylinder head or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear.

  27. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01EMSGE02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

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

    2. A01ELO9E05
      Text in Illustration
      *1 INCORRECT
      *2 Camshaft Timing Exhaust Gear
      *3 Clearance
      *4 Flange
      *5 CORRECT
      *6 No Clearance

      Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.

    3. A01EMJ2

      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 or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear.

  28. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01ELAKE01

      Install the crankshaft timing sprocket to the crankshaft.

  29. ADD ENGINE OIL


    1. A01EJP6

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

      Note


      • Oil must be added if the lash adjusters were removed.

      • Make sure that the low pressure chamber and oil paths of the lash adjusters are full of engine oil.

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01EKG4E01

      Temporarily install the crankshaft pulley bolt.

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

    3. A01EIXLE01

      Check that the timing marks of the camshaft timing gears are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  31. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01EM6Y

      Install the chain vibration damper with the 2 bolts.

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

  32. INSTALL CHAIN SUB-ASSEMBLY


    1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

      Tech Tips


      • Make sure the mark plate of the chain faces away from the engine.

      • It is not necessary to install the chain to the teeth of the gears and sprocket.

    2. A01ELEKE02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

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

    3. A01ELZAE02
      Text in Illustration
      *1 Mark Plate
      *2 Timing Mark

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

    4. A01EJU2

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

    5. A01EJ6PE01

      Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.

      Tech Tips

      Hold the intake camshaft in place with a wrench until the chain tensioner is installed.

    6. A01EJVD

      Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain so that the chain tensioner slipper can be installed.

      Note

      Make sure the chain is secure.

  33. INSTALL CHAIN TENSIONER SLIPPER


    1. A01EKD5

      Install the chain tensioner slipper with the bolt.

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

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01ELLA

      Install a new gasket and the chain tensioner with the 2 bolts.

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

    2. Remove the pin from the stopper plate.

  35. INSTALL TIMING CHAIN GUIDE


    1. A01ELJY

      Install the timing chain guide with the bolt

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

  36. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01EKWBE01

    2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    3. Remove the crankshaft pulley bolt.

  37. INSTALL TIMING CHAIN COVER PLATE


    1. A01EMPJ

      Install a new gasket and the timing chain cover plate with the 4 bolts.

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

  38. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. A01EIZZ

      Using a 14 mm hexagon wrench, install a new gasket and the plug.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01EMIS

      Apply a light coat of engine oil to 2 new oil pump gaskets and new oil hole cover gasket.

    2. Install the 2 new oil pump gaskets and new oil hole cover gasket to the stiffening crankcase.

    3. A01EKPUE01

      Align the drive rotor spline and the crankshaft timing sprocket as shown in the illustration.

    4. Apply seal packing in a line to the timing chain cover sub-assembly as shown in the following illustration.

      A01EJQ8E09
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Seal Packing Application Chart
      Area Seal Packing Diameter (Round) Distance from Edge of Cover to Center of Seal Packing Seal Packing Application Length
      Seal Packing Dimension (Flat)
      Dashed Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) -
      -
      A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) -
      -
      B - B 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 28 mm (1.10 in.)
      7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick
      C - C 7.0 mm (0.276 in.) 5.0 mm (0.197 in.) 25 mm (0.984 in.)
      13.0 mm (0.512 in.) or more wide and 3.0 mm (0.118 in.) or more thick
      D - D 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 26 mm (1.02 in.)
      7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick
      E 2.5 to 3.5 mm (0.0984 to 0.138 in.) 3.0 mm (0.118 in.) -
      -

      Note


      • When the contact surfaces are wet, clean the surfaces with non-residue solvent before applying seal packing.

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

      • 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.

    5. A01EKP7E01

      Temporarily install the timing chain cover sub-assembly with the 17 bolts and 2 nuts.

      Bolt Length
      Item Length Thread Diameter
      Bolt A 30 mm (1.18 in.) 8 mm (0.315 in.)
      Bolt B 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt C 45 mm (1.77 in.) 8 mm (0.315 in.)

      Note

      Make sure there is no oil on the bolts. If there is oil on the bolts, clean them before installing them.

    6. A01EM0YE01

      Tighten the 17 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

      Torque:
      for bolt 1, 2, 3 and 4
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      except bolt 1, 2, 3 and 4
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  40. INSTALL ENGINE MOUNTING BRACKET RH


    1. A01EMRJE01

      Install the engine mounting bracket RH, and install the 5 bolts in the order shown in the illustration.

      Torque:
      for bolt 1, 2 and 3
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      for bolt 4 and 5
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

      After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

  41. INSTALL TIMING CHAIN COVER OIL SEAL


    1. Apply MP grease to the lip of a new oil seal.

      Note


      • Do not allow foreign matter to contact the lip of the oil seal.

      • Do not allow MP grease to contact the dust seal.

    2. A01EJBCE01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.

      SST
      09223-22010

      Note


      • Keep the lip of the oil seal free from foreign matter.

      • Do not tap in the oil seal at an angle.

  42. INSTALL SPARK PLUG TUBE GASKET


    1. A01EK4UE03
      Text in Illustration
      *1 Upper Surface
      *2 Inner Lip
      *3 Outer Lip

      Visually check the spark plug tube gasket.

      OK
      Area Specified Condition
      Upper surface No scratches or deformation
      Outer lip No scratches or deformation
      Inner lip No scratches

      If the result is not as specified, replace the spark plug tube gasket.

    2. A01EJWW

      Install the 4 plug tube gaskets to the cylinder head cover.

      Note

      After pressing in the spark plug tube gasket, make sure the gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover.

  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01EM0R

      Apply a light coat of engine oil to 3 new gaskets.

    2. Install the 3 gaskets to the camshaft bearing caps.

    3. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surfaces.

    4. A01EL3TE01

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application width A
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

    5. A01EM9PE01

      Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.

    6. Install 3 new seal washers and the 16 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 apply oil for at least 4 hours after the installation.

  44. INSTALL CRANKSHAFT PULLEY


    1. A01EM6PE01

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

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

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

      Tech Tips

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

  45. INSTALL CRANKSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring of the sensor.

      Note

      Make sure that the O-ring is not cracked or does not jump out of position during installation.

    2. A01EJVYE06
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent.
    3. A01EJZL

      Install the sensor with the bolt.

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

    4. Connect the sensor connector.

  46. INSTALL INLET WATER HOUSING


    1. A01EKO0

      Install a new gasket and the inlet water housing with the 4 bolts and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  47. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)


    1. Clean the oil cooler contact surface on the cooler mounting.

    2. Apply a light coat of engine oil to 3 new gaskets.

    3. Install the 3 new gaskets to the oil cooler assembly.

    4. Temporarily install the oil cooler assembly with the union bolt, nut and a new seal washer.

    5. A01EL7IE02

      Tighten the bolt and nut in several steps, in the sequence shown in the illustration.

      Torque:
      Union Bolt
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
      Nut
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  48. INSTALL WATER PUMP ASSEMBLY


    1. A01EKU5

      Install a new gasket and the water pump with the 7 bolts.

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

  49. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01EM6M

      Install the V-ribbed belt tensioner with the bolt.

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

  50. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A01EL60E03

      Install the thermostat with the jiggle valve facing upward.

      Tech Tips

      The jiggle valve may be set to within 10° on either side of the prescribed position.

  51. INSTALL WATER INLET


    1. A01EL0B

      Install the water inlet with the 2 nuts.

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

  52. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A01EKHJ

      Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.

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

  53. INSTALL SEPARATOR CASE


    1. A01EJ7Q

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

    2. Install the gasket to the separator case.

    3. Install the separator case with the 2 bolts.

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

  54. INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. A01EJ7HE01

      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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.

    2. A01EL4DE02

      Install the ventilation case, and install the 8 bolts and 2 nuts in the order shown in the illustration.

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

      Tech Tips

      Bolt A is tightened twice.

  55. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. A01EM9TE11
      Text in Illustration
      *1 Adhesive 1324

      Apply adhesive to 2 or 3 threads of the ventilation valve.

      Adhesive
      Toyota genuine adhesive 1324, three bond 1324 or equivalent
    2. A01EL3ZE02
      Text in Illustration
      *1 19 mm Deep Socket Wrench

      Using a 19 mm deep socket wrench, install the ventilation valve.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. A01EK5M

      Connect the No. 2 ventilation hose to the ventilation valve.

  56. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)


    1. Apply a light coat of engine oil to the O-ring of the sensor.

      Note

      Make sure that the O-ring is not cracked or does not jump out of position during installation.

    2. A01EJVYE06
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent.
    3. A01EJWD

      Install the sensor with the bolt.

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

    4. Connect the sensor connector.

  57. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)


    1. Apply a light coat of engine oil to the O-ring of the sensor.

      Note

      Make sure that the O-ring is not cracked or does not jump out of position during installation.

    2. A01EJVYE06
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent.
    3. A01EJB5

      Install the sensor with the bolt.

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

    4. Connect the sensor connector.

  58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)


    1. A01EMPGE06
      Text in Illustration
      *1 New O-ring

      Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve.

    2. A01EIXE

      Install the oil control valve with the bolt.

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

      Note


      • Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover).

      • Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

    3. Connect the oil control valve connector.

  59. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)


    1. A01EMPGE06
      Text in Illustration
      *1 New O-ring

      Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve.

    2. A01EKZV

      Install the oil control valve with the bolt.

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

      Note


      • Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover).

      • Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

    3. Connect the oil control valve connector.

  60. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new gasket to the oil filler cap.

    2. Install the oil filler cap to the cylinder head.

  61. INSTALL SPARK PLUG


    1. A01EJOV

      Using a spark plug wrench, install the 4 spark plugs.

      Torque:
      25 N*m  { 254 kgf*cm, 18 ft.*lbf }

  62. INSTALL ENGINE COVER JOINT


    1. A01EJ2D

      Install the 3 joints.

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