CAMSHAFT INSTALLATION


  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.

  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.

  3. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01CC67

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

    3. A01CBY4E01

      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. A01CET3E01

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

    2. A01CFDAE07

      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
      3.5 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.

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

    3. A01CBJ5E01

      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 with a piston at TDC, valve contact 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. A01CGJLE02

      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.

  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.

  7. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01CEZS

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

    3. A01CDHBE01

      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. A01CET3E01

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

    2. A01CC3TE08

      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
      3.5 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.

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

    3. A01CAN1E01

      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 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 with a piston at TDC, valve contact 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. A01CDQKE02

      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. A01CCIVE02

      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 GEARS AND NO. 2 CHAIN (for Bank 2)


    1. A01CGJSE06

      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 assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.

    4. A01CGATE02

      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.

  11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01CGB9E02

      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 GEARS AND NO. 2 CHAIN (for Bank 1)


    1. A01CE0EE09

      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 assembly. install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

    4. A01CFCNE02

      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.

  13. INSTALL IDLE SPROCKET ASSEMBLY


    1. A01CDKEE08
      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 installation position.

      Tech Tips

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

    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. A01CEIEE08
      Text in Illustration
      *a Timing Mark
      *b Mark Plate

      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. A01CB86

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

    3. A01CGDPE09

      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. A01CC2OE10
      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 pulley set bolt.

    6. A01CAZXE14
      Text in Illustration
      *a Center Line
      *b Timing Mark
      *c Sensor Plate

      Turn the crankshaft clockwise to set it to 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. A01CETGE10
      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. A01CB8J

      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.

      • 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.

      A01CDWEE13
      Text in Illustration
      *a Timing Mark - -

      Tech Tips

      For the intake 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.

      A01CATSE06

    3. If the valve timing is misaligned, reinstall the timing chain.

    4. Remove the pulley set bolt.

  18. INSTALL TIMING CHAIN CASE OIL SEAL


    1. A01CBLUE04

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

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

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

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

  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.

      A01CFPLE07
      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.

      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover 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 as shown in the following illustration.

      A01CBQJE05
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover 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 it.

      Seal Packing Chart
      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Diagonal Line Area 6.0 mm (0.236 in.) or more 5.0 mm (0.197 in.)
    3. A01CDV6E01

      Install a new gasket.

    4. A01CF1HE02

      Align the oil pump drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

    5. Type X:


      1. Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

        A01CBB8E08
        Bolt Length
        Item Length
        Bolt A 40 mm (1.57 in.)
        Bolt B 55 mm (2.17 in.)
        Bolt C 25 mm (0.984 in.)

        Note

        Make sure that there is no oil on the bolt threads.

    6. Type Y:


      1. Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

        A01CBB8E08
        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 bolt threads.

    7. Fully tighten the bolts in Area 1 and 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 }
      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 WATER INLET HOUSING


    1. A01CG1UE01

      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. A01CB0VE02

      Install the 2 stud bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A01CEBDE04
      Text in Illustration
      *1 Drain Cock Plug
      *2 Drain Cock Assembly
      *a Bolt
      *b Nut

      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.

    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  { 130 kgf*cm, 9 ft.*lbf }

    8. Install a new gasket to the thermostat.

    9. A01CFVYE01

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

      Tech Tips

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

    10. A01CC5O

      Install the water inlet with the 2 nuts.

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

  21. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01CE9UE01

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

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

    2. Using an 8 mm socket wrench, install the 2 stud bolts.

      Torque:
      Bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A01CEZ2

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

      Torque:
      54 N*m  { 550 kgf*cm, 40 ft.*lbf }

      Note


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

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

  22. INSTALL OIL PAN SUB-ASSEMBLY


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

      A01CEBOE03
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01CDQF

      Install 2 new O-rings.

    3. A01CF9EE05

      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 surfaces.

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

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

    4. A01CGHYE08
      Text in Illustration
      *a Nut

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

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

  23. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01CF79E04

      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. A01CFSLE07
      Text in Illustration
      *a Bolt
      *b 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 }

  24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01CBNSE02

      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. A01CD7KE04

      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 after applying seal packing.

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

    3. A01CC1PE06
      Text in Illustration
      *a 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 }

  25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)


    1. A01CDCAE01

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

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

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

    2. A01CGHZ

      Install 3 new gaskets shown in the illustration.

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

    4. A01CC28E01

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

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

  26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A01CF8SE01

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

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

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

    2. A01CDD3

      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. A01CFJ6E04

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

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

  27. INSTALL CRANKSHAFT PULLEY


    1. A01CBG4

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

    2. A01CDROE02

      Using SST, install the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      250 N*m  { 2550 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.

    2. A01CEVKE09
      Text in Illustration
      *a Oil Pipe Union

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

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

    4. Tighten the oil pipe union (on the cylinder head cover 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.

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

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

  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. A01CDJBE07
      Text in Illustration
      *a Oil Check Valve Bolt

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

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

    4. Tighten the oil pipe union (on the cylinder head cover 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.

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

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

    6. Install the bolt (A) to the cylinder head sub-assembly.

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

  30. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01CFZ2E01

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

    2. A01CCPN

      Install the crank position sensor with the bolt.

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

    3. Connect the crank position sensor connector.

  31. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A01CC91

      Install the bolt and No. 1 vacuum switching valve.

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

  32. INSTALL RADIO SETTING CONDENSER


    1. A01CC4WE01

      Install the 2 bolts and 2 radio setting condensers.

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

  33. INSTALL WATER PUMP PULLEY


    1. A01CDHLE01

      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 }

  34. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01CBCC

      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  { 550 kgf*cm, 40 ft.*lbf }

  35. INSTALL NO. 2 TIMING GEAR COVER


    1. A01CE4J

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

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

  36. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01CF37E01

      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 }

  37. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01CC2TE01

      Install a new gasket as shown in the illustration.

    2. A01CFVHE01

      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 }

  38. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01CEJM

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

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

  39. INSTALL NO. 2 MANIFOLD STAY


    1. A01CG7AE01

      Install the No. 2 manifold stay by tightening the bolt and nut in the order shown in the illustration.

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

  40. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01CDBV

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

    2. A01CFQT

      Install the engine oil level dipstick guide with the bolt.

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

  41. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01CCFV

      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 No. 1 engine oil level dipstick guide.

    4. A01CAP2

      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.

  42. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01CB49E01

      Install a new gasket as shown in the illustration.

    2. A01CCLIE01

      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 }

  43. INSTALL INTAKE MANIFOLD

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Part
    Intake Manifold and Cylinder Head Sub-assembly RH
    Intake Manifold and Cylinder Head Sub-assembly LH

    1. A01CE9B

      Set a new gasket on each cylinder head.

      Note


      • Align the port holes of the gasket and cylinder head.

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

    2. Set the intake manifold on the cylinder heads.

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

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

  44. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A01CATG

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

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

  45. INSTALL IGNITION COIL ASSEMBLY


    1. A01CDMG

      Install the 6 ignition coils with the 6 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01CC6A

      Connect the 6 ignition coil connectors.

    3. A01CCMX

      Connect the 3 wire harness clamps.

  46. INSTALL THROTTLE BODY BRACKET


    1. A01CBKB

      Install the throttle body bracket with the bolt.

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

  47. INSTALL NO. 1 SURGE TANK STAY


    1. A01CEYF

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

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

  48. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    NOTICE
    DO NOT apply oil to the bolts listed below:
    Tightening Part
    Surge Tank and Intake Manifold
    No. 1 Surge Tank Stay and Surge Tank
    Throttle Body Bracket and Surge Tank

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

    2. A01CFH3

      Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
    3. A01CG8R

      Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01CFDY

      Connect the connector to the intake air control valve assembly.

    5. A01CD28

      Connect the 2 water by-pass hoses to the throttle body assembly.

    6. A01CBUZ

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

    7. A01CEHY

      Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.

    8. A01CF6M

      Connect the ventilation hose.

    9. Connect the union to connector tube hose.

  49. INSTALL ENGINE HANGER


    1. A01CBMWE12

      Install the 2 engine hangers with the 4 bolts as shown in the illustration.

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

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

  50. REMOVE ENGINE FROM ENGINE STAND

  51. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01CAM5E01

      Using SST, hold the crankshaft pulley.

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

    2. Clean the 8 bolts and 8 bolt holes.

    3. A01CDPS

      Install the front drive plate spacer.

      Tech Tips

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

    4. A01CEPYE01

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

    5. A01CDZZE05

      Apply adhesive to 2 or 3 threads of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A01CDNYE01

      In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      83 N*m  { 847 kgf*cm, 61 ft.*lbf }

  52. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Tech Tips

    See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle" Click here.