ENGINE UNIT REASSEMBLY


  1. INSTALL STIFFENING CRANKCASE RING PIN

    Note

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


    1. A01G8POE03
      Text in Illustration
      *a Protrusion Height

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

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

  2. INSTALL ENGINE BALANCER ASSEMBLY


    1. A01G7C3E06
      Text in Illustration
      *a 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, align them.


      1. A01G9MNE07
        Text in Illustration
        *1 Driven Gear
        *2 Damper Cover
        *a Alignment Mark

        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. A01G8COE01

      Install the engine balancer assembly to the stiffening crankcase assembly 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 stiffening crankcase stud bolt is deformed or the threads are damaged, replace it.


    1. Using an E5 and E8 "TORX" socket wrench, install the stiffening crankcase stud bolts.

      A01G48XE06
      Torque:
      for Stud Bolt A
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      for Stud Bolt B
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      Text in Illustration
      *a Front Side *b Lower Side

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01G8JKE02
      Text in Illustration
      *1 Crankshaft Pulley Key

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

    2. A01G67FE01

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

      Text in Illustration
      A01G6PZ Stiffening Crankcase Assembly
      A01G6ZK cylinder block sub-assembly
      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 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

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

    3. A01G7UGE03
      Text in Illustration
      *a Cutout

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

    4. Clean the bolts and their installation holes.

    5. A01G67VE03
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 3 or more threads of the ends of the bolts A.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01G6I7E01

      Temporarily install the stiffening crankcase assembly with the 11 bolts.

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

      Tech Tips

      Apply adhesive to the bolts A before installation.

    7. A01G6I7E02

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

      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. A01G5PGE01

      Install the No. 1 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. A01G8DME03
      Text in Illustration
      *a Protrusion

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

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

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

  7. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01G6AHE01

      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 surface.

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

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

    2. A01G6V5E04
      Text in Illustration
      *1 Nut

      Install the oil pan sub-assembly 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

      The bolt A and the nut A are tightened twice.

  8. INSTALL OIL PAN DRAIN PLUG


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

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

  9. INSTALL OIL FILTER CAP ASSEMBLY


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

    2. A01G6EFE01
      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 into the oil filter cap assembly.

    4. Remove all dirt and foreign matter from the installation surface and the inside of the oil filter cap assembly on the engine side.

    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. A01G5J8E01
      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. A01G4J7E04
      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.

  10. INSTALL REAR ENGINE OIL SEAL


    1. Using a height adjustable attachment and plate lift attachment, place the engine assembly on a flat level surface.

      Note


      • Using a height adjustable attachment and plate lift attachment, place the engine assembly horizontally.

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments onto the oil pan sub-assembly of the engine assembly.

      • Using an engine sling device and engine lift, secure the engine assembly before service.

    2. Apply MP grease to the lip of a new rear engine oil seal.

      Note


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

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

    3. A01G93AE01

      Using SST and a hammer, tap in the rear engine oil seal until its surface is flush with the edges of the cylinder block sub-assembly and stiffening crankcase assembly.

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

      Note


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

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

  11. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01G4CN

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

  12. INSTALL CYLINDER HEAD GASKET


    1. A01G604E01
      Text in Illustration
      *1 Cylinder Head Gasket
      *2 Cylinder Block Sub-assembly
      *a Lot No.
      *b 3.0 mm or more
      *c 20 mm or more
      A01G8AH Seal Packing
      A01G47H Front

      Clean the cylinder block sub-assembly and cylinder head sub-assembly 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.) or thicker

      Tech Tips

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

      Note


      • Remove any oil from the contact surfaces.

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

    3. Place the new cylinder head gasket on the cylinder block sub-assembly surface with the Lot No. stamp facing upward.

      Note

      Pay attention to the installation direction.

  13. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 4 progressive steps.


    1. Place the cylinder head sub-assembly on the cylinder block sub-assembly.

      Note


      • Ensure that no oil is on the contact surface of the cylinder head sub-assembly.

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

    2. Install the 10 plate washers to the 10 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. A01G9SEE02

        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 washers for the cylinder head bolts into the cylinder head sub-assembly.

    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. A01G57JE02
        Text in Illustration
        *a Paint Mark
        A01G8AH Front

        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 paint marks are now facing rearward.

        Note


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

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

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

        Tech Tips

        Perform "Inspection After Repair" after replacing the cylinder head sub-assembly Click here.

  14. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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


    1. A01G9ENE05
      Text in Illustration
      *a Advance Position
      *b Retard Position
      *c Knock Pin Hole
      *d Alignment Mark

      Check the camshaft timing gear assembly position.

      Note

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

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

    2. A01G9DKE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

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

    3. A01G959E19
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d Camshaft Flange
      *e No Clearance

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

    4. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear assembly 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. A01G8JRE10

      Release the lock pin.

      Text in Illustration
      *1 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close
      *e Rubber
      *f Vinyl Tape

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

      2. Cover the 4 oil paths of the camshaft 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. A01G4AY

        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 path with a piece of cloth when applying pressure to keep oil from spraying.

        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 turn in the advance direction without assistance by hand.

        • 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 assembly.

      Note

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

  15. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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


    1. A01G76UE03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, tap in 10 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

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

  16. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    Note

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


    1. A01G9I9E03
      Text in Illustration
      *a Protrusion Height

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

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

  17. INSTALL CAMSHAFT HOUSING STUD BOLT

    Note

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


    1. A01G6SLE01

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

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

  18. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01G5ZWE02
      Text in Illustration
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

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

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

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

  19. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

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

    3. A01G6F4E05
      Text in Illustration
      *1 Vernier Caliper

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

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

  20. INSTALL OIL CONTROL VALVE FILTER


    1. A01G5I2

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

  21. INSTALL CAMSHAFT


    1. Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

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

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

      Tech Tips

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

  22. INSTALL CAMSHAFT BEARING CAP


    1. A01G8A9

      Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.

    2. A01G59JE02

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

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

      Note

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

  23. 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 sub-assembly.

      Note

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

  24. INSTALL VALVE LASH ADJUSTER ASSEMBLY


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

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

      Note

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

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


    1. A01G546E06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

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

  26. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01G4D4E03
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Incorrect
      *b Correct

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

    2. A01G56WE01
      Text in Illustration
      *a Dashed Line
      *b Groove

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

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Apply Seal Packing as Follows
      Area Seal Packing Diameter Application Position
      Continuous Line 3.0 to 4.0 mm (0.118 to 0.157 in.) Distance from edge of camshaft housing sub-assembly to center of seal packing: 3.5 to 4.0 mm (0.138 to 0.157 in.)
      Dashed Line Distance from outside edge of groove to center of seal packing: 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

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

    3. A01G65ZE02
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

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

    4. A01G84FE02

      Install the camshaft housing sub-assembly, and then install the 20 bolts in the order shown in the illustration.

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

      Note


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

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

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

  27. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01G83WE04
      Text in Illustration
      *a Knock Pin Hole
      *b Alignment Mark

      Check the camshaft timing gear assembly position.

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

    2. A01G9DKE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

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

    3. A01G959E19
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d Camshaft Flange
      *e No Clearance

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

    4. A01G8IIE01
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

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

      Note


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

      • Do not disassemble the camshaft timing gear assembly.

      Tech Tips

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

  28. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01G8E6E04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

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

    2. A01G959E19
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d No. 2 Camshaft Flange
      *e No Clearance

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

    3. A01G7F5E01
      Text in Illustration
      *a Hold
      *b Turn

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

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

      Note


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

      • Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

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

  29. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01G8CS

      Install the crankshaft timing sprocket to the crankshaft.

  30. ADD ENGINE OIL


    1. A01G9UK

      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 valve lash adjuster assemblies were removed.

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

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01G46ZE02

      Temporarily install the crankshaft pulley bolt.

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

    3. A01G62JE02
      Text in Illustration
      *a Approximately 7°
      *b Approximately 32°
      *c Timing Mark

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

      Tech Tips

      "A" is not a timing mark.

  32. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01G9DHE01

      Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.

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

  33. INSTALL CHAIN SUB-ASSEMBLY


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

      Tech Tips


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

      • It is not necessary to install the chain sub-assembly to the teeth of the camshaft timing exhaust gear assembly, camshaft timing gear assembly and crankshaft timing sprocket.

    2. A01G9NKE03
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

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

    3. A01G5YKE04
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

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

    4. A01G6MN

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

    5. A01G7L9E03
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

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

      Tech Tips

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

    6. A01G6TC

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

      Note

      Make sure the chain sub-assembly is secure.

  34. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  35. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

    2. Remove the pin from the stopper plate.

  36. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01G4FEE10
      Text in Illustration
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

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

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

      Tech Tips

      "A" is not a timing mark.

    4. Remove the crankshaft pulley bolt.

  38. INSTALL TIMING CHAIN COVER PLATE


    1. A01G57G

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

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

  39. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. A01G6VF

      Using a 14 mm hexagon wrench, install a new gasket and the timing chain cover tight plug.

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

  40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01G6FE

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

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

    3. A01G4C4E02
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft Timing Sprocket

      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.

      A01G96DE05
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Apply Seal Packing as Follows
      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 0.0138 in.) 2.5 mm (0.0984 in.) -
      -
      A - A 2.5 to 3.5 mm (0.0984 to 0.0138 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 0.0138 in.) 3.0 mm (0.118 in.) -
      -

      Note


      • 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 add oil for at least 2 hours after installation.

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

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

      A01G8SBE01
      Text in Illustration
      *1 Nut - -
      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 oil is found on any bolt, clean it before installation.

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

      Torque:
      for bolt A, C and Nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  41. INSTALL ENGINE MOUNTING BRACKET RH


    1. A01G81RE01

      Install the engine mounting bracket RH with 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.

  42. INSTALL TIMING CHAIN COVER OIL SEAL


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

      Note


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

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

    2. A01G7NXE01

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

      SST
      09223-22010

      Note


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

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

  43. INSTALL SPARK PLUG TUBE GASKET


    1. A01G8YV

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

      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 sub-assembly.

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01G8SQ

      Apply a light coat of engine oil to 3 new camshaft bearing cap oil hole gaskets.

    2. Install the 3 camshaft bearing cap oil hole gaskets.

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

      Note

      Remove any oil from the contact surface.

    4. A01G7Q8E03
      Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover Sub-assembly
      *3 Camshaft Housing Sub-assembly

      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 surface.

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

    5. A01G8SME01

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

    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 2 hours after the installation.

  45. INSTALL CRANKSHAFT PULLEY


    1. A01G473E13
      Text in Illustration
      *a Hold
      *b Turn

      Align the crankshaft pulley 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)

  46. INSTALL CRANKSHAFT POSITION SENSOR


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

    2. A01G4DLE07
      Text in Illustration
      *1 O-ring

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

    3. A01G7LYE06
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt.

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

    4. Install the crankshaft position sensor with the bolt.

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

      Note

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

    5. Connect the crankshaft position sensor connector.

  47. INSTALL WATER INLET HOUSING


    1. A01G5X3

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

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

  48. INSTALL ENGINE WATER PUMP ASSEMBLY


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

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

  49. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01G6NB

      Install the V-ribbed belt tensioner assembly 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. A01G5EYE06
      Text in Illustration
      *1 Jiggle valve
      *a 10°

      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. 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. A01G7OR

      Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.

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

  53. INSTALL SEPARATOR CASE


    1. A01G7WX

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

    2. Install the gasket to the separator case.

    3. Install the separator case to the ventilation case sub-assembly with the 2 bolts.

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

  54. INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. A01G4N3E01

      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 surface.

      • Install the ventilation case sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01G4DZE02

      Install the ventilation case sub-assembly, 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

      The bolt A is tightened twice.

  55. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly.

      Adhesive
      Toyota genuine adhesive 1324, three bond 1324 or equivalent

    2. Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly to the ventilation case sub-assembly.

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

    3. Connect the No. 2 ventilation hose to the ventilation valve sub-assembly.

  56. INSTALL CAMSHAFT POSITION SENSOR


    1. Camshaft position sensor (for Intake Side)


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

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

        Note

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

      3. A01G7LYE06
        Text in Illustration
        *1 Adhesive

        Apply adhesive to 2 or 3 threads of the bolt.

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

      4. Install the camshaft position sensor with the bolt.

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

      5. Connect the camshaft position sensor connector.

    2. Camshaft position sensor (for Exhaust Side)


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

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

        Note

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

      3. A01G7LYE06
        Text in Illustration
        *1 Adhesive

        Apply adhesive to 2 or 3 threads of the bolt.

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

      4. Install the camshaft position sensor with the bolt.

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

      5. Connect the camshaft position sensor connector.

  57. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. Camshaft timing oil control valve assembly (for exhaust side)


      1. A01G4UFE06
        Text in Illustration
        *1 New O-ring

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

      2. Install the camshaft timing oil control valve assembly 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 camshaft timing oil control valve assembly (connecting surface with cylinder head cover).

        • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft timing oil control valve assembly.

      3. Connect the camshaft timing oil control valve assembly connector.

    2. Camshaft timing oil control valve assembly (for intake side)


      1. A01G4UFE06
        Text in Illustration
        *1 New O-ring

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

      2. Install the camshaft timing oil control valve assembly 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 camshaft timing oil control valve assembly (connecting surface with cylinder head cover).

        • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft timing oil control valve assembly.

      3. Connect the camshaft timing oil control valve assembly connector.

  58. INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

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

  59. INSTALL SPARK PLUG


    1. Install the 4 spark plugs.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing a spark plug Click here.

  60. INSTALL ENGINE COVER JOINT


    1. A01G5JQ

      Install the 3 engine cover joints.

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