CAMSHAFT INSTALLATION

Tech Tips

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, No. 3 camshaft, No. 4 camshaft, camshaft timing gear assembly or camshaft timing exhaust gear assembly Click here.


  1. INSTALL NO. 3 CAMSHAFT


    1. Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the No. 3 camshaft Click here.

  2. INSTALL NO. 4 CAMSHAFT


    1. Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.

    2. Install the No. 4 camshaft to the camshaft housing sub-assembly LH.

      Tech Tips

      Perform "Inspection After Repair" after replacing the No. 4 camshaft Click here.

  3. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01G9BW

      Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

    3. A01G6DVE01

      Temporarily tighten the 8 bolts in the order shown in the illustration.

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

  4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01G4JOE06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

      Make sure that the valve rocker arm is installed as shown in the illustration.

    2. A01G9KCE01
      Text in Illustration
      *a

      Seal packing diameter

      (3.5 to 4.5 mm)

      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
      3.5 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 and tighten the bolts.

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

    3. A01G5KSE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

      Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing sub-assembly 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, valve contact with a piston at TDC will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly LH 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.

    4. A01G9RTE02

      Tighten the 8 bolts in the order shown in the illustration.

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

  5. INSTALL CAMSHAFT


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

    2. Install the camshaft to the camshaft housing sub-assembly RH.

      Tech Tips

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

  6. INSTALL NO. 2 CAMSHAFT


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

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

      Tech Tips

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

  7. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01G63O

      Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

    3. A01G799E01

      Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.

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

  8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01G4JOE06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. A01G9UWE01
      Text in Illustration
      *a

      Seal packing diameter

      (3.5 to 4.5 mm)

      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
      3.5 to 4.5 mm (0.138 to 0.177 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts.

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

    3. A01G6CEE04
      Text in Illustration
      *1 Knock Pin
      *a Front View

      Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing sub-assembly RH, 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, valve contact with a piston at TDC will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly RH 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.

    4. A01G57SE02

      Tighten the 8 bolts in the order shown in the illustration.

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

  9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01G4M2E08
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

      Install the No. 3 chain tensioner assembly with the bolt.

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

    2. While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

  10. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)


    1. A01G9ONE12
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assemblies. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

    4. A01G5BWE06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 3 chain tensioner assembly.

      Tech Tips

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

  11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01G5IPE08
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

      Install the No. 2 chain tensioner assembly with the bolt.

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

    2. While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

  12. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A01G8ZLE15
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assemblies. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

    4. A01G4KJE06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 2 chain tensioner assembly.

      Tech Tips

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

  13. INSTALL IDLE SPROCKET ASSEMBLY


    1. A01G5ZVE06
      Text in Illustration
      *a Knock Pin

      Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

    2. Temporarily install the No. 1 idle gear shaft and idle sprocket assembly 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 sub-assembly.

      Note

      Be careful of the idle gear shaft installation position.

      Tech Tips

      Check that no foreign matter is on the No. 1 idle gear shaft and No. 2 idle gear shaft.

    3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Tech Tips

      After installing the idle sprocket assembly, check that the idle sprocket assembly turns smoothly.

  14. INSTALL CHAIN SUB-ASSEMBLY


    1. A01G93KE07
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly.

      Tech Tips

      The camshaft mark plates are orange.

    2. A01G77C

      Do not pass the chain sub-assembly over the crankshaft, just temporarily place it on the crankshaft.

    3. A01G4QOE20
      Text in Illustration
      *a Mark Plate
      *b Turn
      *c When the idle sprocket is reused
      *d Mark
      *e Align

      Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain sub-assembly 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 sub-assembly between the banks.

    4. A01G8A0E08
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Align the mark plate and timing marks as shown in the illustration and install the chain sub-assembly onto the crankshaft timing sprocket.

      Tech Tips

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the crankshaft pulley set bolt.

    6. A01G8YAE09
      Text in Illustration
      *a Center Line
      *b Timing Mark
      *c Sensor Plate

      Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

  15. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01G99WE08
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

    2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

    3. A01G5OG

      Install the No. 1 chain tensioner assembly with the 2 bolts.

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

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.

  17. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly and each camshaft timing exhaust gear assembly.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

    2. Check that each camshaft timing mark is positioned as shown in the illustration.

      A01G8X2E06
      Text in Illustration
      *a Timing Mark *b Viewpoint

      Tech Tips

      For the camshaft or No. 3 camshaft:

      Be sure to check mark (A) at the point when marks (B), (C), and (D) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      A01G8APE03

    3. If the valve timing is misaligned, reinstall the chain sub-assembly.

    4. Remove the crankshaft pulley set bolt.

  18. INSTALL TIMING CHAIN CASE OIL SEAL


    1. A01G83UE04

      Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing chain cover sub-assembly edge.

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap on the timing chain case oil seal at an angle.

      • Make sure that the timing chain case oil seal edge does not stick out of the timing chain cover sub-assembly.

      Tech Tips

      Tap in the timing chain case oil seal so that it is positioned within 1.0 mm from the edge of the timing chain cover sub-assembly.

    2. Apply a light coat of MP grease to the timing chain cover oil seal lip.

  19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

      A01G889E12
      Text in Illustration
      *a Seal Packing Diameter: 3.0 mm (0.118 in.) or more A01G8AH Seal Packing
      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 there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain cover sub-assembly within 3 minutes.

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

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

      A01G6B2E01
      Text in Illustration
      *a

      Dashed Line Area

      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)

      		 *b

      Continuous Line Area

      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *c

      Alternate Long and Short Dashed Line Area

      (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)

      		 *d

      Diagonal Line Area

      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      A01G8AH Be sure to apply seal packing - -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain cover sub-assembly 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.

      Seal Packing Application Chart
      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm or more (0.177 in.) 1.0 to 2.0 mm (0.0394 to 0.0787 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.)
    3. A01G8BM

      Install a new gasket.

    4. A01G626E07
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft

      Align the drive rotor spline and the crankshaft as shown in the illustration. Install the spline and timing chain cover sub-assembly to the crankshaft.

    5. A01G5DDE01
      Text in Illustration
      *1 Nut

      Temporarily tighten the timing chain cover sub-assembly with the 23 bolts and 2 nuts.

      Bolt Length
      Item Length
      Bolt A 40 mm (1.57 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 28 mm (1.102 in.)

      Note

      Make sure that there is no oil on the threads of bolt B and C.

    6. Fully tighten the bolts in Area 1.

    7. A01G4VME01
      Text in Illustration
      *a Area 1
      *b Area 2
      *c Area 3
      *d Area 4

      Fully tighten the bolts in Area 2.

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

    8. Fully tighten the bolts and nuts in Area 3.

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

      Tech Tips

      Tighten the bolts and nuts from top to bottom as shown in the illustration.

    9. Fully tighten the bolts in Area 4.

      Torque:
      Bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Torque:
      Except bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Tighten the bolts from bottom to top as shown in the illustration.

  20. INSTALL OIL PAN SUB-ASSEMBLY


    1. w/ Oil Cooler:


      1. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

        A01G7KQE04
        Text in Illustration
        *A w/ Oil Cooler - -
        *a Lower Cylinder Block Sub-assembly Side *b Timing Chain Cover Sub-assembly Side
        *c Oil Pan Sub-assembly LH Side - -
        Torque:
        Bolt A
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
        Bolt B
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. w/o Oil Cooler:


      1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

        Torque:
        Bolt A
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A01G76L

      Install 2 new O-rings.

    4. A01G59RE01
      Text in Illustration
      *a Seal Diameter

      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 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan sub-assembly within 3 minutes of applying seal packing.

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

    5. A01G7AIE15
      Text in Illustration
      *A w/o Oil Cooler
      *B w/ Oil Cooler
      *1 Nut

      Install the oil pan sub-assembly with the 16 bolts and 2 nuts.

      Torque:
      Bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Except bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  21. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01G5U8E07
      Text in Illustration
      *a Timing Chain Cover

      Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01G751E02
      Text in Illustration
      *1 Nut

      Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

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

  22. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01G68HE02

      Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01G8R6E01
      Text in Illustration
      *a Seal Diameter

      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 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan sub-assembly within 3 minutes of applying seal packing.

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

    3. A01G5WAE02
      Text in Illustration
      *1 Nut

      Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

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

  23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01G93C

      Apply seal packing as shown in the illustration.

      Text in Illustration
      A01G8AH Seal Packing
      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 of applying seal packing.

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

    2. A01G6GM

      Install 3 new gaskets as shown in the illustration.

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

    4. A01G5LGE04
      Text in Illustration
      *1 Seal Washer

      Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

  24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01G7R7

      Apply seal packing as shown in the illustration.

      Text in Illustration
      A01G8AH Seal Packing
      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 LH within 3 minutes of applying seal packing.

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

    2. A01G4HP

      Install 3 new gaskets as shown in the illustration.

    3. Install a new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly LH.

    4. A01G5VNE08
      Text in Illustration
      *1 Seal Washer

      Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

  25. INSTALL WATER INLET HOUSING


    1. A01G4OHE01

      Install 2 new O-rings.

      Tech Tips

      Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.

    2. A01G97IE02

      Install the 2 stud bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A01G9QHE03
      Text in Illustration
      *1 Nut
      *2 Bolt

      Install the water inlet housing with the 2 bolts and nut.

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

      Note

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

    4. Connect the No. 1 water by-pass hose to the water inlet housing and slide the clip to secure it.

    5. Apply adhesive around the drain cock assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the drain cock assembly to the water inlet housing.

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

    7. Install the drain cock plug to the drain cock assembly.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    8. Install a new gasket to the thermostat.

    9. A01G6JTE01

      Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat into the water inlet housing.

      Tech Tips

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

    10. A01G540

      Install the water inlet with the 2 nuts.

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

  26. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01G69ZE04
      Text in Illustration
      *1 Stud Bolt

      Using an E8 "TORX" socket wrench, install the 2 stud bolts.

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

    2. Install the No. 1 front engine mounting bracket LH with the 6 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

      Note


      • Install the water inlet and No. 1 front engine mounting bracket LH within 15 minutes of installing the timing chain cover sub-assembly.

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

  27. INSTALL CRANKSHAFT PULLEY


    1. Align the pulley set key with the key groove of the crankshaft pulley, and slide on the crankshaft pulley.

    2. A01G6SXE03
      Text in Illustration
      *a Hold
      A01G8AH Turn

      Using SST, install the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      250 N*m  { 2549 kgf*cm, 184 ft.*lbf }

  28. INSTALL NO. 1 OIL PIPE


    1. 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 LH.

    2. A01G5QEE04
      Text in Illustration
      *1 Oil Pipe Union

      Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe (on the cylinder head cover sub-assembly side) with the oil pipe union.

    3. Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head sub-assembly side) with the oil pipe union.

    4. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    5. Tighten the oil pipe union (on the cylinder head sub-assembly side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

  29. INSTALL OIL PIPE


    1. 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 RH.

    2. A01G79BE07
      Text in Illustration
      *1 Oil Pipe Union
      *2 Bolt

      Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the cylinder head cover sub-assembly side) with the oil pipe union.

    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head sub-assembly side) with the oil pipe union.

    4. Install the bolt to the cylinder head sub-assembly.

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

    5. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    6. Tighten the oil pipe union (on the cylinder head sub-assembly side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

  30. INSTALL CRANK POSITION SENSOR


    1. Clean and degrease the threads of the bolt for the crank position sensor.

    2. A01G8AJE02
      Text in Illustration
      *1 O-ring

      Apply a light coat of engine oil to the O-ring on the crank position sensor.

    3. Install the crank position sensor with the bolt.

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

      Note

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

    4. Connect the crank position sensor connector.

  31. INSTALL NO. 1 VACUUM SWITCHING VALVE


    1. Install the No. 1 vacuum switching valve with the bolt.

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

  32. INSTALL WATER PUMP PULLEY


    1. Temporarily install the water pump pulley with the 4 bolts.

    2. Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    3. Tighten the 4 bolts.

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

  33. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  34. INSTALL NO. 2 TIMING GEAR COVER


    1. Install the No. 2 timing gear cover with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  35. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01G587

      Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

    2. w/ Oil Cooler:


      1. A01G90F

        Install the engine oil level dipstick guide.

    3. w/o Oil Cooler


      1. A01G7NO

        Install the engine oil level dipstick guide with the bolt.

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

  36. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)


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

    2. Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.

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

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


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

    2. Install a new O-ring to the oil cooler assembly.

    3. Install the oil cooler assembly with the oil cooler union bolt.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

    4. Install the No. 4 water by-pass hose and No. 5 water by-pass hose with the bolt, 2 clamps and 4 clips.

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

  38. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01G4FIE01

      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.)

    2. Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

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

    3. Tighten the other bolts.

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

  39. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01G4QR

      Install a new gasket as shown in the illustration.

      Text in Illustration
      A01G47H Engine Front
    2. A01G6LJE01

      Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.

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

  40. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  41. INSTALL NO. 2 MANIFOLD STAY


    1. A01G4BDE03

      Tighten the bolt and nut in the order shown in the illustration.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  42. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.

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

    3. Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.

    4. Install the No. 2 engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.

  43. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01G7HT

      Install a new gasket as shown in the illustration.

      Text in Illustration
      A01G47H Engine Front
    2. A01G9M0E01

      Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.

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

  44. INSTALL INTAKE MANIFOLD


    1. Set 2 new gaskets on each cylinder head sub-assembly.

      Note


      • Align the port holes of the gasket and cylinder head sub-assembly.

      • Make sure that the gasket is installed in the correct direction.

    2. Set the intake manifold on the cylinder head sub-assembly.

    3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

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

  45. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH with the bolt.

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

  46. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 6 ignition coil assemblies with the 6 bolts.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing an ignition coil assembly Click here.

    2. Connect the 6 ignition coil assembly connectors.

    3. Connect the 2 wire harness clamps.

    4. Install the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  47. INSTALL THROTTLE BODY BRACKET

    Note

    Do not apply oil to the bolt as listed below:

    Oil Application Prohibited Bolt
    Bolt for throttle body bracket and cylinder head cover

    1. Install the throttle body bracket with the bolt.

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

  48. INSTALL NO. 1 SURGE TANK STAY

    Note

    Do not apply oil to the bolt as listed below:

    Oil Application Prohibited Bolt
    Bolt for No. 1 surge tank stay and cylinder head cover

    1. Install the No. 1 surge tank stay with the bolt.

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

  49. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    Do not apply oil to the bolts listed below:

    Oil Application Prohibited Bolt
    Bolt for Intake Air Surge Tank Assembly and Intake Manifold
    Bolt for No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    Bolt for Throttle Body Bracket and Intake Air Surge Tank Assembly

    1. Install 3 new gaskets to the intake air surge tank assembly.

    2. Temporarily install the intake air surge tank assembly with the 4 bolts and 2 nuts.

    3. A01G57KE03

      Using a 5 mm hexagon socket wrench, in several steps, uniformly tighten the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Install the No. 1 surge tank stay to the intake air surge tank assembly with the bolt.

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

    5. Install the throttle body bracket to the intake air surge tank assembly with the bolt.

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

    6. Install the vacuum hose clamp to the throttle body bracket with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      Install the vacuum hose clamp so that its tab is in contact with the No. 1 surge tank stay.

    7. Connect the intake air control valve assembly connector.

    8. Connect the fuel vapor feed hose to the intake air surge tank assembly.

    9. Connect the 2 water by-pass hoses to the throttle body assembly and slide the 2 clips to secure them.

    10. Connect the throttle body assembly connector.

    11. Engage the wire harness clamp.

    12. for LHD:


      1. Engage the hose clamp.

      2. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

    13. for RHD:


      1. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

    14. Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.

  50. INSTALL ENGINE HANGERS


    1. Install the 2 engine hangers with the 4 bolts.

      Part No.
      Item Part No.
      No. 1 Engine Hanger 12281-31120
      No. 2 Engine Hanger 12282-31100
      Bolt 91671-10825
      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

    2. Attach an engine sling device and hang the engine with a chain block.

  51. REMOVE ENGINE STAND

  52. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021

    2. Clean the 8 bolts and 8 bolt holes.

    3. A01G9KL

      Install the front drive plate spacer.

      Tech Tips

      Align the pin of the front drive plate spacer with the pin hole of the crankshaft.

    4. A01G7HUE03
      Text in Illustration
      *1 Drive Plate
      *2 Rear Spacer
      A01G8AH Transaxle Side

      Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft.

    5. A01G9NCE12
      Text in Illustration
      *1 Adhesive

      Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A01G6I0E01

      Install and uniformly tighten the 8 bolts in several steps in the sequence shown in the illustration.

      Torque:
      83 N*m  { 846 kgf*cm, 61 ft.*lbf }

      Note

      Do not start the engine for at least an hour after installing the drive plate and ring gear sub-assembly.

  53. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Click here