ENGINE UNIT REASSEMBLY


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A0042UDE06
    Text in Illustration
    *a Width
    *b Height
    *c Protrusion Height

    Note

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


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

      Standard Ring Pin
      Item Protrusion Height Height Width
      Ring pin 3.0 mm (0.118 in.) 11 mm (0.433 in.) 8 mm (0.315 in.)

  2. INSTALL STIFFENING CRANKCASE STUD BOLT

    A0044AUE09

    Note

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


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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A0042PYE02

      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
      Area Specified Condition
      Continuous Line 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      A 4.5 to 5.5 mm (0.177 to 0.217 in.)
      Application Length A
      56 mm (2.20 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the crankcase within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

    2. A0040BCE02

      Install the stiffening crankcase assembly with the 11 bolts in the sequence shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Specified Condition
      Bolt A 138 mm (5.43 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 70 mm (2.76 in.)

    3. Recheck the torque for bolts 1 and 2.

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

    4. Wipe off any excess seal packing with a clean piece of cloth.

  4. INSTALL OIL PUMP ASSEMBLY


    1. Install the oil pump assembly with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

    2. A00426EE11
      Text in Illustration
      *1 Seal Packing

      Apply a continuous bead of seal packing (diameter 4.0 mm (0.157 in.)) 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 oil pan within 3 minutes of applying seal packing.

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

    3. Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.

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

  6. INSTALL OIL PAN DRAIN PLUG


    1. A0040MT

      Install a new gasket and the oil pan drain plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  7. INSTALL REAR ENGINE OIL SEAL


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

      Note

      Keep the lip free from foreign matter.

    2. A0041NGE01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

      SST
      09223-15030
      09950-70010   ( 09951-07100 )

      Note


      • Wipe any extra grease off the crankshaft.

      • Do not tap the oil seal at an angle.

  8. INSTALL NO. 1 TAPER SCREW PLUG


    1. A0042SME01

      Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note


      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the plug.

    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (B).

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the plug.

  9. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. A0042Q0E08
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the threads of the ventilation valve sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Install the ventilation valve sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the ventilation valve sub-assembly.

    2. A0043BH

      Install the ventilation valve sub-assembly.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  10. INSTALL CYLINDER HEAD GASKET


    1. A0040FWE05
      Text in Illustration
      *1 Cylinder Block
      A00407B Engine Front

      Apply seal packing (Diameter 4.0 mm (0.157 in.)) to the cylinder block as shown in the illustration.

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

      Note

      Remove any oil from the cylinder block.

    2. A0041LXE02
      Text in Illustration
      *a Lot No.
      A00407B Engine Front

      Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.

      Note

      Install the cylinder head gasket within 3 minutes after applying seal packing.

    3. A00402SE01
      Text in Illustration
      *1 Cylinder Head Gasket
      A00407B Engine Front

      Apply seal packing (Diameter 4.0 mm (0.157 in.)) to the new cylinder head gasket as shown in the illustration.

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

      Note


      • Remove any oil from the cylinder head gasket and cylinder head sub-assembly.

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

    4. A00435CE02
      Text in Illustration
      *a Before wiping off:
      *b After wiping off:

      After tightening the cylinder head bolts, wipe off the seal packing material seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly.

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 3 progressive steps.


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

      Note


      • Make sure that no oil is on the mounting surface of the cylinder head sub-assembly.

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

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

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

    4. A0040ZAE02

      Step 1:


      1. 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:
        49 N*m  { 500 kgf*cm, 36 ft.*lbf }

        Note

        Do not drop the plate washers into the cylinder head.

    5. A003ZZSE06
      Text in Illustration
      *a Paint Mark
      A00438M Engine Front

      Step 2:


      1. 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.

    6. Step 3:


      1. Tighten the cylinder head bolts another 45° in the sequence shown in step 1.

    7. Check that the paint mark is now at a 135° angle to the front.

  12. INSTALL VALVE STEM CAP


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

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

      Note

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

  13. INSTALL VALVE LASH ADJUSTER ASSEMBLY


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

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

      Note

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

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


    1. A0040XQE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A0040H3E02
    Text in Illustration
    *a Width
    *b Height
    *c Protrusion Height

    Note

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


    1. Using a plastic-faced hammer, tap in a new straight pin to the specified protrusion height.

      Standard Straight Pin
      Item Protrusion Height Height Width
      Straight pin 6.5 to 7.5 mm (0.256 to 0.295 in.) 14 mm (0.551 in.) 6.0 mm (0.236 in.)

  16. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean both surfaces of the bearings.

    2. Install the 2 No. 1 camshaft bearings.

    3. A0041CUE01
      Text in Illustration
      *1 Vernier Caliper

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

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

      Note

      Position the bearings to the center of the bearing cap by measuring dimensions A and B.

  17. INSTALL OIL CONTROL VALVE FILTER


    1. A004251

      Check that no foreign matter is on the mesh part of the oil control valve filter.

    2. Install the oil control valve filter.

      Note

      Do not touch the mesh when installing the oil control valve filter.

  18. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean both surfaces of the bearings.

    2. Install the 2 No. 2 camshaft bearings.

    3. A004431E01
      Text in Illustration
      *1 Vernier Caliper

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

      Standard dimension (A)
      1.05 to 1.75 mm (0.0413 to 0.0689 in.)

      Note

      Position the bearings to the center of the bearing cap by measuring dimension A.

  19. INSTALL NO. 2 CAMSHAFT


    1. Clean the camshaft journals.

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

    3. A0040J0

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

  20. INSTALL CAMSHAFT


    1. Clean the camshaft journals.

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

    3. A0041E8

      Install the camshaft to the camshaft housing sub-assembly.

  21. INSTALL CAMSHAFT BEARING CAP


    1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. A00401OE01
      Text in Illustration
      *1 Knock Pin
      *2 Camshaft

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

    3. A0042NJE01

      Tighten the 10 bolts in the order shown in the illustration.

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

  22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A0040ADE01
      Text in Illustration
      *1 Valve Stem Cap
      *2 Valve Rocker Arm
      *3 Valve Lash Adjuster

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

    2. A004144E01

      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
      Area Specified Condition
      Continuous line 3.5 to 4.5 mm (0.138 to 0.177 in.)
      A 8.0 mm (0.315 in.)
      B 7.0 mm (0.276 in.)
      Application Length A and B
      15 mm (0.591 in.)

      Note


      • Remove any oil from the contact surfaces.

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

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

    3. A0042Q5E01

      Set the camshaft and No. 2 camshaft as shown in the illustration.

    4. Install the camshaft housing sub-assembly with the 17 bolts and tighten them in the order shown in the illustration.

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

      Note


      • After installing the camshaft housing sub-assembly, make sure that the cam lobes are positioned as shown in the illustration.

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

      • If the camshaft housing sub-assembly is removed because any of the bolts is loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

      • After installing the camshaft housing sub-assembly, wipe off any seal packing that seeped out from between the housing and cylinder head sub-assembly.

  23. INSTALL CAMSHAFT TIMING SPROCKET


    1. A004460

      Tighten the flange bolt with the camshaft timing sprocket secured in place.

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

  24. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A0041TEE04
      Text in Illustration
      *1 Straight Pin
      *2 Key Groove

      Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned as shown in the illustration.

      Note

      Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.

    2. A00422NE03
      Text in Illustration
      *1 Straight Pin
      *2 Key Groove

      Turn the camshaft timing gear assembly as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

      Note

      Do not turn the camshaft timing gear assembly in the retard direction (clockwise).

    3. A004458E03
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Flange
      *a Clearance
      *b No Clearance

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

    4. A0043D9

      Tighten the flange bolt with the camshaft timing gear secured in place.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
    5. A0041DZE02
      Text in Illustration
      *a Lock

      Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and is locked in the most retarded position.

  25. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A0043BT

      Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

      Tech Tips

      Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

  26. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00436C

      Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.

  27. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley bolt.

    2. A0043JO

      Turn the crankshaft counterclockwise to position the timing gear key at the 9 o'clock position.

    3. Turn the drive shaft so that the cutout faces the 12 o'clock position.

    4. A0040YOE02
      Text in Illustration
      *1 Front
      *2 Mark Plate (Yellow)
      *3 Timing Mark
      *4 Oil Pump Drive Gear
      *5 Oil Pump Drive Shaft Gear

      Align the yellow mark links with the timing marks of each gear as shown in the illustration.

      Tech Tips

      Be sure to position the mark plates at the front of the engine.

    5. Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.

    6. Temporarily tighten the oil pump drive shaft gear with the nut.

    7. Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

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

    8. Temporarily tighten the crankshaft pulley with the bolt.

    9. A0041IGE01

      Using SST, install the oil pump drive shaft gear nut while holding the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    10. Remove the crankshaft pulley and crankshaft pulley bolt.

  28. INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the crankshaft timing sprocket.

  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A0040YK

      Install the No. 1 chain vibration damper with the 2 bolts.

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

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A0043LGE01
      Text in Illustration
      *1 Timing Gear Key

      Temporarily install the crankshaft pulley bolt.

    2. Turn the crankshaft to position the timing gear key to the top.

    3. A004491E01
      Text in Illustration
      *1 Timing Mark (Rectangle)
      *2 Timing Mark
      *3 Mark (Circle)

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

      Tech Tips

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

    4. Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain sub-assembly.

    5. Remove the crankshaft pulley bolt.

  31. INSTALL CHAIN SUB-ASSEMBLY


    1. A0040T6E01
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark (Rectangle)
      *3 Mark (Circle)
      *a Place the Chain on the Sprocket
      *b Pass the Chain through the Damper

      Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain sub-assembly.

      Tech Tips


      • There are 3 marks on the camshaft timing sprocket. Make sure to align the mark plate with the timing mark (rectangle).

      • Be sure to position the mark plate at the front of the engine.

      • The mark plate on the camshaft side is colored orange.

      • Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.

      • Pass the chain through the No. 1 vibration damper.

    2. A00418P

      Place the chain on the crankshaft without passing it around the shaft.

    3. A0041VGE04
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark
      *a Tension the Chain

      Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark, and then install the chain.

    4. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

      Tech Tips

      To tension the chain, slowly turn the camshaft timing gear assembly clockwise to prevent the chain from being misaligned.

    5. A0040YVE06
      Text in Illustration
      *1 Mark Plate (Yellow or Pink)
      *2 Timing Mark

      Align the mark plate (yellow or pink) and timing mark and install the chain to the crankshaft timing gear.

      Tech Tips

      The mark plate on the crankshaft side is colored yellow or pink.

  32. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Check each timing mark at TDC/compression.

      A00423CE01
      Text in Illustration
      *1 Timing Mark *2 Mark Plate (Orange)
      *3 Mark Plate (Yellow or Pink) *4 Timing Mark (Rectangle)
      *5 Mark (Circle) - -

      Tech Tips

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

  33. INSTALL CHAIN TENSIONER SLIPPER


    1. A0043NG

      Install the chain tensioner slipper to the cylinder block sub-assembly.

  34. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. A00417J

      Install the No. 2 chain vibration damper with the 2 bolts.

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

  35. INSTALL WATER INLET SUB-ASSEMBLY STUD BOLT

    Note

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


    1. A003ZZGE01

      Using an E5 "TORX" socket wrench, install the 2 water inlet sub-assembly stud bolts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  36. INSTALL WATER INLET SUB-ASSEMBLY


    1. A00423H

      Install a new gasket and the water inlet sub-assembly with the bolt and 2 nuts.

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

  37. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A0040I2E01

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

      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.

      Tech Tips

      Tap in the oil seal so that it is positioned within 1.0 mm (0.0394 in.) from the edge of the timing chain case.

    2. Apply MP grease to the lip of the oil seal.

  38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head and cylinder block.

      A004466
      Text in Illustration
      A00413R Clean and degrease - -
    2. A00447T

      Install 3 new O-rings.

    3. Apply seal packing as shown in the illustration.

      A004060E01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the timing chain cover sub-assembly within 3 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.

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

      Note


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

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

      A0042TNE02
      Seal Packing
      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Application Specification
      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.0 mm (0.0984 to 0.118 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -
      A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      B - B 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Opposite edge of seal packing

      5.0 mm (0.197 in.)

      		 - -
      C - C 7.0 to 8.0 mm (0.276 to 0.315 in.)

      Opposite edge of seal packing

      7.5 mm (0.295 in.)

      		 - -
      F 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.5 mm (0.610 in.) 50.4 mm (1.98 in.)
      G 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 143.1 mm (5.63 in.)
      H 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 153.4 mm (6.04 in.)
      I 4.5 to 5.5 mm (0.177 to 0.217 in.) - 16.0 mm (0.630 in.) 385.8 mm (1.27 ft.)
      J 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      K 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 121.9 mm (4.80 in.)
      L 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 147.2 mm (5.80 in.)
      M 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.1 mm (0.201 in.) 173.0 mm (6.81 in.)
      N 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 385.8 mm (1.27 ft.)
      O 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -

      Note


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

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

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

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

    5. Clean the bolt and fitting hole.

    6. Install the timing chain cover sub-assembly.

    7. Temporarily tighten the engine mounting bracket RH with the 3 bolts.

      Note


      • Install the mounting bracket within 10 minutes of installing the timing chain cover sub-assembly.

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

      Bolt Length
      Item Length
      Bolt 80 mm (3.15 in.)

    8. Install 2 new O-rings.

    9. Temporarily tighten the oil filter bracket with the 4 bolts.

      Note


      • Install the oil filter bracket within 10 minutes of installing the timing chain cover sub-assembly.

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

      Bolt Length
      Item Length
      Bolt 35 mm (1.38 in.)

    10. Install the timing chain cover sub-assembly with the 25 bolts and a new gasket as shown in the illustration.

      A004181E03
      Text in Illustration
      *1 Gasket - -
      *a Torque *b Bolt Torque Order
      Torque:
      Bolt A, E, F
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }
      Bolt B, C
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      Bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • Apply adhesive 1324 to the threads of the bolt F.

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

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.

      • Do not add engine oil for at least 2 hours after installing the timing chain cover sub-assembly.

      • Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.

      Bolt Length
      Item Length
      Bolt A, F 35 mm (1.38 in.)
      Bolt B, E 55 mm (2.16 in.)
      Bolt C 80 mm (3.15 in.)
      Bolt D 40 mm (1.57 in.)
    11. A00449WE01

      Using a 8mm deep socket wrench, install the stud bolt to the engine mounting bracket RH.

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

  39. INSTALL CRANKSHAFT PULLEY


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

    2. A0042O6E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the pulley in place and tighten the bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      Torque:
      190 N*m  { 1937 kgf*cm, 140 ft.*lbf }

  40. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00447XE02
      Text in Illustration
      *1 Cam
      *2 Pin
      *3 Hook
      *a Push
      *b Raise
      *c CORRECT
      *d INCORRECT

      Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

      Note

      Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

    2. A0042AS

      Install a new gasket, the bracket and chain tensioner with the 2 nuts.

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

      Note

      If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

    3. A0043ELE01
      Text in Illustration
      *1 Pin
      *2 Hook
      *a Push
      *b Turn
      *c Disconnect

      Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.

    4. A0042Z6E01
      Text in Illustration
      *1 Plunger
      *a Turn
      *b Plunger Extended

      Turn the crankshaft clockwise and check that the plunger is extended.

  41. INSTALL OIL FILTER CAP ASSEMBLY


    1. Clean the oil filter cap threads and O-ring groove.

    2. A0042J9E01
      Text in Illustration
      *1 O-ring
      *a CORRECT
      *b INCORRECT

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

      Note


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

      • Do not twist the O-ring.

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

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

    5. A004122

      Reapply a small amount of engine oil to the O-ring of the oil filter cap assembly. Align the cutout in the oil filter cap threads 90° to the grooves in the oil filter bracket and temporarily tighten the oil filter cap assembly.

      Note

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

    6. A00407ME01
      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.

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

      Note


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

      • Do not remove the oil filter bracket clip when installing the oil filter cap assembly.

      • Do not cross thread the oil filter cap assembly.

  42. INSTALL SPARK PLUG TUBE GASKET


    1. A0041JL

      Using a cutter knife, cut off the seal part of the removed gasket.

      Text in Illustration
      A0040ED Part to Cut Off
    2. A0041P1E03
      Text in Illustration
      *a Plug Tube Gasket without Sealing Part
      *b New Plug Tube Gasket

      Using a hammer and the plug tube gasket which has had the sealing part cut off, uniformly tap in a 4 new plug tube gaskets all the way.

      Note


      • Keep the lip free of foreign matter.

      • Do not tap in the plug tube gasket.

      Tech Tips

      If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

    3. Return the claws of the ventilation baffle plate to their original positions.

  43. INSTALL CYLINDER HEAD COVER GASKET


    1. A0043KOE01
      Text in Illustration
      *1 Cylinder Head Cover
      *2 Cylinder Head Cover Gasket

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

      Note


      • Remove any oil from the contact surfaces.

      • Misalignment between the center of the cylinder head cover rib and the center of the cylinder head gasket tab should be within 4.0 mm (0.157 in.).

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A0042NG

      Install 2 new gaskets to the camshaft bearing cap.

    2. A0043F2

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard diameter
      4.0 mm (0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

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

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

    3. A004075
      Text in Illustration
      *1 Timing Chain Cover Sub-assembly
      *2 Camshaft Housing
      *3 Cylinder Head Cover Gasket

      Install the cylinder head cover with a new seal washer and the 13 bolts.

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

      Note

      Misalignment between the contact surfaces of the timing chain cover sub-assembly and the camshaft housing and the center of the cylinder head gasket tab should be within 4.0 mm (0.157 in.).

      A0043P3E01

  45. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A0040HIE07
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note


      • Install the oil pressure switch within 3 minutes after applying adhesive.

      • Do not start the engine within 1 hour after installation.

    2. A0043G2

      Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  46. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A00430J

      Install a new gasket and the engine coolant temperature sensor.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  47. INSTALL KNOCK SENSOR


    1. A00449XE01

      Install the knock sensor with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Make sure that the knock sensor is in the correct position.

  48. INSTALL CRANKSHAFT POSITION SENSOR


    1. A0040PM

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

    2. A0041OC

      Install the crankshaft position sensor with the bolt.

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

  49. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A0040GM

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

    2. A00400W

      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 oil control valve (connecting surface with cylinder head cover).

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

  50. INSTALL CAMSHAFT POSITION SENSOR


    1. A00428NE06

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

    2. A00436Z

      Install the camshaft position sensor with the bolt.

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

      Note

      Make sure that the O-ring is not cracked or jammed when installing the sensor.

  51. INSTALL SPARK PLUG


    1. A00443L

      Using a 14 mm spark plug wrench, install the 4 spark plugs.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  52. INSTALL ENGINE COVER JOINT BOLT


    1. A0040AM

      Install the 3 engine cover joint bolts.

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

  53. INSTALL WIRING HARNESS CLAMP BRACKET


    1. A0043US

      Install the wiring harness clamp bracket with the bolt.

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

  54. INSTALL OIL FILLER CAP GASKET


    1. A0043WP

      Install the oil filler cap gasket to the oil filler cap sub-assembly.

  55. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A0041KW

      Install the oil filler cap sub-assembly.