ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL RING PIN

    Tech Tips

    It is not necessary to remove the ring pins unless they are being replaced.


    1. Camshaft housing sub-assembly side:


      1. B0074FMC01
        *a Protrusion Height

        Using a plastic hammer, tap in 8 new ring pins to the camshaft housing sub-assembly.

        Standard Protrusion Height
        2.7 to 3.3 mm (0.106 to 0.130 in.)

    2. Stiffening crankcase assembly side:


      1. B0075NOC01
        *a Protrusion Height

        Using a plastic hammer, tap in 2 new ring pins to the stiffening crankcase assembly.

        Standard Protrusion Height
        4.3 to 5.3 mm (0.169 to 0.209 in.)

  2. INSTALL STUD BOLT

    Note

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


    1. Camshaft housing sub-assembly side:


      1. B0073UCC02
        *a 20 mm (0.787 in.)
        *b 13 mm (0.512 in.)
        *c 35 mm (1.38 in.)

        Apply adhesive to the threads of the stud bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      2. Using an E8 "TORX" socket wrench, install the stud bolt to the camshaft housing sub-assembly.

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

    2. Stiffening crankcase assembly side:


      1. B00751EC01
        *a 8.5 mm (0.335 in.)
        *b 8.0 mm (0.315 in.)
        *c 18 mm (0.709 in.)

        Using an E5 "TORX" socket wrench, install the stud bolts to the stiffening crankcase assembly.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Timing chain cover assembly side:


      1. B0073E8C01
        *a 16 mm (0.630 in.)
        *b 9.0 mm (0.354 in.)
        *c 27 mm (1.06 in.)

        Using an E6 "TORX" socket wrench, install the stud bolts to the timing chain cover assembly.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  3. SET ENGINE BALANCER ASSEMBLY


    1. B0073HRC04
      *a No. 1 Balance Shaft Driven Gear
      *b No. 2 Balance Shaft Driven Gear
      *c Alignment Mark

      Make sure that the alignment marks on the No. 1 balance shaft driven gear and No. 2 balance shaft driven gear are aligned.

    2. B0075I3C01
      *a No. 1 Balance Shaft Driven Gear
      *b No. 2 Balance Shaft Driven Gear

      If the alignment marks are not aligned, hold the No. 2 balance shaft with a wrench, and rotate the No. 1 balance shaft as shown in the illustration to align the marks.

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. Clean the bolts and bolt holes.

    2. Clean the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.

    3. B0073Y8C01
      *a Seal Packing
      *b 28 mm (1.10 in.)
      *c 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *d 7.0 to 9.0 mm (0.276 to 0.354 in.)

      Apply seal packing to the areas shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Dimension
      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick

      Note


      • Remove any oil from the contact surface.

      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

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

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

    4. B0072OUC01
      *a

      Timing Mark

      (Balance Shaft Housing Side)
      *b

      Timing Mark

      (Balance Shaft Side)
      *c Crankshaft Pulley Set Key Groove

      Align the crankshaft pulley set key groove, timing marks on the balance shaft and balance shaft housing as shown in the illustration, and then place the stiffening crankcase assembly and engine balancer assembly onto the cylinder block sub-assembly.

    5. B0077B4C01
      *a Bolt Type
      *b Tightening Order
      *c Apply Adhesive

      Apply adhesive to the threads of the bolt (D) shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the bolts within 3 minutes of applying adhesive.

    6. Temporarily install the stiffening crankcase assembly to the cylinder block sub-assembly with the 12 bolts.

      Bolt Length
      Item Length Diameter
      Bolt (A) 65 mm (2.56 in.) 8.0 mm (0.315 in.)
      Bolt (B) 85 mm (3.35 in.) 10 mm (0.394 in.)
      Bolt (C) 140 mm (5.51 in.)
      Bolt (D) 125 mm (4.92 in.)

    7. Tighten the 12 bolts in the order shown in the illustration.

      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 }
    8. B0072PE

      Tighten the bolt.

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

  5. INSTALL ENGINE OIL TEMPERATURE SENSOR

    Click here

  6. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. Install the No. 1 oil pan baffle plate to the engine balancer assembly with the 4 bolts.

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

  7. INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. B0073ONC01
      *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 to the stiffening crankcase assembly and engine balancer assembly with the 3 bolts in several steps in the order shown in the illustration.

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

  8. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  9. INSTALL OIL PAN SUB-ASSEMBLY


    1. B007568C01
      *a Seal Packing

      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
      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 of applying seal packing.

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

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

    2. B00751CN01

      Install the oil pan sub-assembly to the stiffening crankcase assembly with the 11 bolts and 2 nuts in several steps in the order shown in the illustration.

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

  10. 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 }

  11. INSTALL OIL COOLER ASSEMBLY

    Click here

  12. INSTALL OIL FILTER BRACKET CLIP


    1. Install the oil filter bracket clip to the stiffening crankcase assembly.

  13. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  14. INSTALL REAR ENGINE OIL SEAL

    Click here

  15. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. B00751GC01
      *a Front of Engine
      *b Protrusion

      Install the cylinder block water jacket spacer to the cylinder block sub-assembly as shown in the illustration.

      Note

      Make sure that the protrusion of the cylinder block water jacket spacer is facing upward when installing it.

  16. INSTALL CYLINDER HEAD GASKET

    Click here

  17. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  18. INSTALL VALVE STEM CAP


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

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

      Note


      • Install the valve stem caps to the same place they were removed from.

      • Be careful not to drop the valve stem caps into the cylinder head sub-assembly.

  19. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster assembly free from dirt and foreign matter.

    • Only use clean engine oil.

    • If the valve lash adjuster assembly is tilted after bleeding, oil will leak. If the valve lash adjuster assembly is tilted, bleed the valve lash adjuster assembly again.


    1. Bleed the valve lash adjuster assembly.

      Click here

    2. If the plunger moves, bleed the valve lash adjuster assembly again.

    3. Place the valve lash adjuster assembly into a container filled with engine oil, and then fill the low pressure chamber with engine oil.

    4. Apply engine oil to the outer surface of the valve lash adjuster body and the tip of the plunger, and then install the valve lash adjuster assembly while turning it.

      Note

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

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


    1. B0072V0C43
      *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.

      Note

      Install the No. 1 valve rocker arm sub-assemblies to the same place they were removed from.

  21. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

      Note


      • Do not allow coolant to come into contact with the No. 1 camshaft bearing inner surface.

      • If any coolant comes into contact with the No. 1 camshaft bearing inner surface, replace the No. 1 camshaft bearing with a new one.

    2. B0075COC02
      *a Vernier Caliper

      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.

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)

  22. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

      Note


      • Do not allow coolant to come into contact with the No. 2 camshaft bearing inner surface.

      • If any coolant comes into contact with the No. 2 camshaft bearing inner surface, replace the No. 2 camshaft bearing with a new one.

    2. B0075QEC02
      *a Vernier Caliper

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

    3. 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.)

  23. INSTALL OIL CONTROL VALVE FILTER


    1. Check that there is no foreign matter on the mesh.

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

      Note

      Do not touch the mesh of the oil control valve filter.

  24. INSTALL NO. 2 CAMSHAFT

    Tech Tips

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



    1. Clean the No. 2 camshaft journals and camshaft housing sub-assembly.

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

    3. Place the No. 2 camshaft onto the camshaft housing sub-assembly.

  25. INSTALL CAMSHAFT

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft.



    1. Clean the camshaft journals and camshaft housing sub-assembly.

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

    3. Place the camshaft onto the camshaft housing sub-assembly.

  26. INSTALL CAMSHAFT BEARING CAP


    1. Clean the camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft bearing caps.

    3. Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap onto the camshaft housing sub-assembly.

    4. B00746YN05

      Uniformly tighten the 11 bolts in several steps in the order shown in the illustration.

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

      Note

      After installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap, make sure that the camshaft and No. 2 camshaft rotate smoothly.

  27. INSTALL NO. 3 WATER BY-PASS PIPE


    1. B0076H3N01

      Install a new gasket and the No. 3 water by-pass pipe to the cylinder head sub-assembly with the 3 bolts in the order shown in the illustration.

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

      Tech Tips

      Make sure the claws of the gasket are facing the No. 3 water by-pass pipe.

  28. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B0072S8C01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
      *a Incorrect
      *b Correct

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

    2. B00760XC02
      *a Seal Packing

      Apply seal packing to the areas 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.

      • Check and clean the bolts and bolt holes.

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

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

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

    3. B0075T8C02
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin

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

    4. B00753BN02

      Install the camshaft housing sub-assembly, and then tighten the 22 bearing cap bolts in the order shown in the illustration.

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

      Note

      If the bolts have been loosened during the installation, apply seal packing to the camshaft housing sub-assembly again.

  29. INSTALL OIL PIPE SUB-ASSEMBLY


    1. Install the oil pipe sub-assembly to the No. 4 camshaft bearing cap with the bolt.

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

  30. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Note

    There are several different types of camshaft timing gear bolt. Make sure to check the identification mark to determine the tightening torque.

    Identification Mark
    Item Identification Mark
    Type A A
    Type B C
    B00734QC01
    *a Identification Mark

    Tech Tips

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



    1. B0075A9C02
      *a Knock Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

    2. B0077UMC02
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Portion A of Camshaft
      *d No Gap

      Check that there is no gap between the camshaft timing gear assembly and portion A of the camshaft shown in the illustration.

    3. B00777B

      Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.

    4. Temporarily install the camshaft timing gear bolt.

      Tech Tips

      Temporarily install the camshaft timing gear bolt until 2 or 3 threads are screwed into the camshaft.

    5. B0073DLC05
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the camshaft timing gear bolt.

      Torque:
      Type A
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
      Type B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

  31. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tech Tips

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



    1. B0075WNC02
      *a Knock Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.

    2. B0076REC02
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c No. 2 Camshaft Flange
      *d No Gap

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

    3. B0073GXC04
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the camshaft timing gear bolt.

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

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

  32. INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the crankshaft timing sprocket to the crankshaft.

  33. ADD ENGINE OIL


    1. B0075FC

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

      Note


      • Make sure to add oil 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 filled with engine oil.

  34. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. B0073O7N01

      Temporarily install the No. 1 chain vibration damper to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.

    2. Tighten the 2 bolts in the order shown in the illustration.

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

  35. INSTALL CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley set bolt.

    2. B0076S5C01
      *1 Crankshaft Pulley Set Key

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

    3. B007688C01
      *a Timing Mark (Groove)
      *b Approximately 7°
      *c Approximately 32°

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

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

      Tech Tips


      • Make sure the mark plate of the chain sub-assembly is facing away from the front of the engine.

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

    5. B0074QLC02
      *a Mark Plate (Orange)
      *b Timing Mark (Groove)

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

    6. B0076D9C01
      *a Mark Plate (Yellow)
      *b Timing Mark

      Align the mark plate (yellow) 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.

    7. B0075YC

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

    8. B0075RRC01
      *a Mark Plate (Orange)
      *b Timing Mark (Groove)

      Using a wrench, hold the hexagonal portion of the camshaft and rotate the camshaft counterclockwise to align the timing mark (groove) of the camshaft timing gear assembly with the mark plate (orange) 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.

    9. B0073TG

      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.

  36. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper to the cylinder head sub-assembly with the bolt.

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

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new gasket and the No. 1 chain tensioner assembly to the cylinder block sub-assembly with the bolt and nut.

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

    2. Remove the pin from the stopper plate.

  38. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide to the No. 1 camshaft bearing cap with the bolt.

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

  39. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  40. INSTALL TIMING CHAIN COVER PLATE


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

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

  41. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  42. INSTALL WATER OUTLET SUB-ASSEMBLY


    1. Install a new O-ring to the timing chain cover assembly.

    2. Install the water outlet sub-assembly to the timing chain cover assembly with the 2 bolts and nut.

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

    3. Connect the No. 6 water by-pass hose to the water outlet sub-assembly and slide the clamp to secure it.

  43. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  44. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

    Click here

  45. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  46. INSTALL SPARK PLUG TUBE GASKET


    1. B0077JOC03
      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly
      *a No Clearance

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

      Note


      • Do not install the spark plug tube gasket at an angle.

      • Keep the lip of the spark plug tube gasket free from foreign matter.

  47. INSTALL CYLINDER HEAD COVER GASKET


    1. Install a new cylinder head cover gasket and new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly.

  48. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to a new gasket and new camshaft bearing cap oil hole gasket.

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

    3. Install the camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.

    4. B0077V4C02
      *1 Timing Chain Cover Assembly
      *2 Camshaft Housing Sub-assembly
      *a Application Width: 8.0 mm (0.315 in.)
      *b Application Width: 5.0 mm (0.197 in.)
      *c Seal Diameter: 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      B0073AQ Seal Packing

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Diameter
      2.0 to 3.0 mm (0.0787 to 0.118 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.

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

      • Do not start the engine within 2 hours after installation.

    5. Apply a light coat of engine oil to the 2 camshaft position sensors.

    6. Temporarily install the cylinder head cover sub-assembly and 2 camshaft position sensors with the 21 bolts.

    7. B0077A9N01

      Tighten the 21 bolts in the order shown in the illustration.

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

  49. INSTALL CRANKSHAFT PULLEY ASSEMBLY


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

    2. B0073NUC06
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley set bolt.

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

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

  50. INSTALL NO. 1 VENTILATION CASE


    1. B0076E0C02
      *a Seal Packing

      Apply seal packing to a new No. 1 ventilation case as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Diameter
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Do not reuse the No. 1 ventilation case.

      • Remove any oil from the contact surface.

      • Install the No. 1 ventilation case within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

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

      Tech Tips

      Make sure to apply seal packing so that there are no gaps in the areas (A) shown in the illustration.

    2. B00762LN01

      Install the No. 1 ventilation case, and then install the 6 bolts and 2 nuts in the order shown in the illustration.

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

  51. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  52. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  53. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  54. INSTALL KNOCK SENSOR

    Click here

  55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  56. INSTALL SPARK PLUG

    Click here