ENGINE UNIT REASSEMBLY


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A00DUNOE05

    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 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

    A00DTZRE05

    Note

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


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

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

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A00DQA7E02

      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 after applying seal packing.

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

    2. A00DT3GE02

      Install the stiffening crankcase 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. A00DUXT

      Install the oil pump with the 3 bolts.

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

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00DQ9GE05

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

      Application Specification
      Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing
      A - A 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.)
      B - B -
      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 and tighten the bolts within 10 minutes after applying seal packing.

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

    3. A00DRAC

      Install the No. 2 oil pan with the 10 bolts and 2 nuts.

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

  6. INSTALL OIL PAN DRAIN PLUG


    1. A00DTL8

      Install a new gasket and the drain plug.

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

  7. INSTALL ENGINE REAR OIL SEAL


    1. A00DQ3RE02

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

      Note


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

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

    2. Using SST and a hammer, tap in the oil seal until its surface is flush with the edges of the cylinder block and crankcase.

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

      Note


      • Wipe off any extra grease from the crankshaft.

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

  8. INSTALL NO. 1 TAPER SCREW PLUG


    1. A00DU9FE01

      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  { 438 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. A00D3DME09
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota genuine adhesive 1324, three bond 1324 or equivalent
    2. A00D3X5

      Using a 22 mm ball joint lock nut wrench, install the ventilation valve sub-assembly.

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

      Note

      Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench Click here.

  10. INSTALL CYLINDER HEAD GASKET


    1. A00DT8RE01

      Apply seal packing to the cylinder block as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal packing diameter
      4.0 mm (0.157 in.)
      Application Specification
      Area Seal Packing Application Length Distance from Edge of Cylinder Block to Center of Seal Packing
      A - 2.0 to 4.0 mm (0.0787 to 0.157 in.)
      B 10 to 15 mm (0.394 to 0.591 in.) -

      Note

      Remove any oil from the cylinder block.

    2. A00DU4VE04

      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. A00DT6YE01

      Apply seal packing to the cylinder head gasket as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal packing diameter
      4.0 mm (0.157 in.)
      Application Specification
      Area Seal Packing Application Length Distance from Edge of Cylinder Head Gasket to Center of Seal Packing
      A - 2.0 to 4.0 mm (0.0787 to 0.157 in.)
      B 10 to 15 mm (0.394 to 0.591 in.) -

      Note


      • Remove any oil from the cylinder head gasket and cylinder head.

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

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 3 progressive steps.


    1. Place the cylinder head on the cylinder block.

      Note


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

      • Place the cylinder head on the cylinder block 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. A00DUDJE02

      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. A00DUO4E01

      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.

    8. A00DRV9E03

      After tightening the cylinder head bolts, wipe off the seal packing material that has seeped out from between the contact surfaces of the cylinder head and cylinder block.

  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. A00DQ7XE07
      Text in Illustration
      *1 Lash Adjuster
      *2 Valve Rocker Arm
      *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

    A00DU6VE01

    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 Ring 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 CAMSHAFT HOUSING STUD BOLT

    Note

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

    A00DSWEE01

    1. Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.

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

  17. INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY


    1. A00DS7XE01
      Text in Illustration
      *1 Protrusion

      Install a new O-ring to the continuously variable valve lift controller.

      Note


      • Align the protrusion of the O-ring with the protrusion of the continuously variable valve lift controller.

      • Make sure that the O-ring is not protruding from the groove in the continuously variable valve lift controller.

    2. A00DR3B

      Install the control actuator clip to the control actuator connector.

      Tech Tips

      When the continuously variable valve lift controller is new, a control actuator connector is attached to it. Remove the control actuator connector before performing these procedures.

      Note

      Be sure to insert the protrusions of the control actuator clip into the holes in the control actuator connector.

    3. A00DS1K

      Install the control actuator connector to the valve rocker shaft and rotate the control actuator connector as shown in the illustration.

    4. Insert the continuously variable valve lift controller into the camshaft housing.

    5. A00DR2P

      Install the continuously variable valve lift controller to the camshaft housing with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      Do not let the O-ring become jammed between parts.

    6. A00DRP1

      Using a screwdriver, slide the control actuator clip from the control actuator connector.

    7. Slide only the upper part of the control actuator clip as the straight pin may fall if the control actuator clip is completely removed.

    8. A00DU28E01
      Text in Illustration
      *1 Rocker Shaft
      *2 Clip
      *3 Straight Pin Hole
      *4 Connector
      *5 Controller Shaft

      Using a screwdriver, lightly pry the control actuator connector and align the hole in the control actuator connector with the hole in the continuously variable valve lift controller.

      Note


      • Do not forcefully pry the control actuator connector.

      • Do not damage the camshaft housing or camshaft bearing cap.

    9. A00DU7D

      Insert the straight pin into the control actuator connector.

      Note

      Do not use a tool to insert the straight pin. Insert the straight pin by hand.

      Tech Tips

      If the straight pin is difficult to insert, insert the straight pin while lightly prying the control actuator connector.

    10. Using a screwdriver, install the control actuator clip to the control actuator connector.

      Note

      Insert the protrusion of the control actuator clip into the hole in the control actuator connector.

  18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A00DSIEE01
      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. A00DQY2E01

      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 within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

    3. A00DPTVE01

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

    4. Install the camshaft housing 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, make sure that the cam lobes are positioned as shown in the illustration.

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

      • If the camshaft housing 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.

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

  19. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A00DRHSE05
      Text in Illustration
      *1 Straight Pin
      *2 Pin Hole

      Put the camshaft timing exhaust gear and camshaft together by aligning the pin hole and straight pin.

      Note

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

    2. Lightly press the gear against the camshaft and turn the gear. Push further at the position where the pin enters the hole.

      Note

      Be sure not to turn the camshaft timing exhaust gear in the retard direction (clockwise).

    3. A00DTR9E01

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

    4. A00DUTB

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

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

    5. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear is locked.

  20. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A00DPLNE02
      Text in Illustration
      *1 Straight Pin
      *2 Key Groove

      Put the camshaft timing gear 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. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear.

    2. A00DTCOE02
      Text in Illustration
      *1 Straight Pin
      *2 Key Groove

      Turn the camshaft timing gear 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 in the retard direction (clockwise).

    3. A00DTR9E01

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

    4. A00DSZU

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

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
    5. A00DQ5OE01
      Text in Illustration
      *1 Lock

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

  21. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A00DTKE

      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.

  22. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00DSQH

      Install the crankshaft position sensor plate with the "F" mark facing forward.

  23. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. A00DS3T

      Temporarily install the crankshaft pulley bolt.

    2. Set the crankshaft key as shown in the illustration.

    3. Turn the drive shaft so that the cutout faces upward.

    4. Remove the crankshaft pulley bolt.

    5. A00DQ1SE01

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

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

    7. Temporarily install the oil pump drive shaft gear with the nut.

    8. A00DRMW

      Install the damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. A00DRCSE01

      Temporarily install the crankshaft pulley with the pulley bolt.

    10. Using SST, hold the crankshaft. Then tighten the drive shaft gear nut.

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

    11. Remove SST, the crankshaft pulley bolt and crankshaft pulley.

  24. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A00DQQJE01

      Install the crankshaft timing sprocket as shown in the illustration.

  25. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A00DS1L

      Install the chain vibration damper with the 2 bolts.

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

  26. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A00DS2FE02
      Text in Illustration
      *1 Timing Gear Key

      Temporarily install the crankshaft pulley bolt.

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

    3. A00DSWBE02
      Text in Illustration
      *1 Timing Mark

      Check that the timing marks on the camshaft timing gears are aligned as shown in the illustration.

    4. Remove the crankshaft pulley bolt.

  27. INSTALL CHAIN SUB-ASSEMBLY


    1. A00DTG8E01
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark

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

      Tech Tips


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

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

      Tech Tips

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

    4. A00DTBOE03
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (Pink)

      Align the mark plates (pink) and timing marks and install the chain to the crankshaft timing gear.

      Tech Tips

      The mark plates on the crankshaft side are colored pink.

  28. INSTALL CHAIN TENSIONER SLIPPER


    1. A00DS61

      Install the chain tensioner slipper to the cylinder block.

  29. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Check each timing mark at TDC/compression.

      A00DRWME02
      Text in Illustration
      *1 Timing Mark *2 Mark Plate (Orange)
      *3 Mark Plate (Pink) -

  30. INSTALL NO. 1 GENERATOR BRACKET


    1. A00DSK8

      Install the generator bracket with the 4 bolts.

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

  31. INSTALL WATER INLET HOUSING STUD BOLT

    A00DQYHE03

    Note

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


    1. Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration.

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

  32. INSTALL WATER INLET HOUSING


    1. A00DS4N

      Install a new gasket and the water inlet housing with the 3 bolts.

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

  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A00DU13E03

      Install a new gasket.

      Note

      Remove any oil from the contact surface.

    2. A00DQKR

      Install the water pump with the 3 bolts.

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

    3. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, camshaft housing, stiffening crankcase and cylinder block.

      A00DTT9E03
    4. A00DQMC

      Install 3 new O-rings.

    5. Apply seal packing as shown in the illustration.

      A00DTFGE03
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

    6. Apply seal packing to the timing chain cover in a continuous line as shown in the following illustration.

      A00DPROE01
      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 3.0 mm (0.0984 to 0.118 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 oil-free cloth before applying seal packing.

      • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

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

    7. Clean the bolts and their installation holes.

    8. Install the timing chain cover.

    9. A00DRLH

      Temporarily install the engine mounting bracket with the 3 bolts.

      Note


      • Install the mounting bracket within 10 minutes after installing the timing chain cover.

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

    10. A00DPKQ

      Install 2 new O-rings.

    11. A00DUZI

      Temporarily install the oil filter bracket with the 4 bolts.

      Note


      • Install the oil filter bracket within 10 minutes after installing the timing chain cover.

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

    12. A00DQ3SE07
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 5 and a half threads or more of the end of bolt E.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the timing chain cover with the 26 bolts and seal washer in the order shown in the illustration.

      A00DQ8WE01
      Torque:
      for bolt A, E
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }
      for bolt B
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt C
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


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

      • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying the seal packing.

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

      Bolt Length
      Item Length Thread Diameter
      Bolt A, E 35 mm (1.38 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt C 80 mm (3.15 in.) 10 mm (0.394 in.)
      Bolt D 40 mm (1.57 in.) 6 mm (0.236 in.)

      Tech Tips

      Apply adhesive to bolt E before installing it.

  34. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A00DR6QE01

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

      Note


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

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

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

      SST
      09223-22010

      Note


      • Wipe off any extra grease from the crankshaft.

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

  35. INSTALL ENGINE MOUNTING BRACKET STUD BOLT

    Note

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

    A00DR74

    1. Install the stud bolt.

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

  36. INSTALL CRANKSHAFT PULLEY


    1. A00DQCVE01
      Text in Illustration
      *1 Hold
      *2 Turn

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

    2. Temporarily install the pulley with the pulley bolt.

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

      SST
      09330-00021
      09213-58014   ( 91551-80840 )
      Torque:
      190 N*m  { 1940 kgf*cm, 140 ft.*lbf }

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00DUQOE01

      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. A00DPIV

      Install a new gasket, the chain tensioner and bracket 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. A00DPZBE01
      Text in Illustration
      *1 Release
      *2 Pin
      *3 Hook
      *4 Turn

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

    4. A00DUECE01
      Text in Illustration
      *1 Plunger
      *2 Plunger Extended
      *3 Turn

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

  38. INSTALL OIL FILTER CAP ASSEMBLY


    1. A00DSFLE02

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

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

      Text in Illustration
      *1 O-Ring

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

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

    5. A00DQMA

      Reapply a small amount of engine oil to the O-ring of the oil filter cap. Align the oil filter cap with the oil filter bracket so that the cutout portion of the cap threads is in a position 90° from the groove in the bracket, and then temporarily install the cap.

      Note

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

    6. A00DUJEE01

      Using SST, tighten the oil filter cap.

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

      Note


      • After tightening the oil filter cap, check for gaps between the installation surfaces.

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

      • Do not cross thread the oil filter cap.

  39. INSTALL SPARK PLUG TUBE GASKET


    1. A00DU3AE01
      Text in Illustration
      *1 Part to Cut Off

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

    2. A00DU33E01
      Text in Illustration
      *1 Plug Tube Gasket without Sealing Part
      *2 New Plug Tube Gasket
      *3 Claw

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

      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.

      Note


      • Keep the lip free of foreign matter.

      • Do not tap in the plug tube gasket at an angle.

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

  40. INSTALL CYLINDER HEAD COVER GASKET


    1. A00DQEY

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

      Note

      Remove any oil from the contact surfaces.

  41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00DSLL

      Install 3 new gaskets to the camshaft bearing cap.

    2. A00DQZZ

      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 after applying seal packing.

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

    3. A00DQSC

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

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

  42. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A00DULSE06
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Do not let adhesive adhere to the oil hole.

    2. A00DUNV

      Using a 22 mm deep socket wrench, install the oil pressure switch.

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

      Note

      Do not start the engine for at least 1 hour after installation.

    3. Connect the oil pressure switch connector.

  43. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A00DU0BE01

      Using SST, install a new gasket engine coolant temperature sensor.

      SST
      09817-33190
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  44. INSTALL KNOCK SENSOR


    1. A00DU7QE01

      Install the knock sensor with the bolt.

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

      Note

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

  45. INSTALL CRANKSHAFT POSITION SENSOR


    1. A00DU4EE04
      Text in Illustration
      *1 O-Ring

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

    2. A00DT8B

      Install the crankshaft position sensor with the bolt.

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

  46. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A00DTTPE04
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of engine oil to 2 new O-rings and install them to the camshaft timing oil control valves.

    2. A00DRTQE02
      Text in Illustration
      *1 Bracket

      Install the 2 camshaft timing oil control valves and bracket with the 2 bolts.

      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 oil control valve.

  47. INSTALL CAMSHAFT POSITION SENSOR


    1. A00DS1IE07
      Text in Illustration
      *1 O-Ring

      Apply a light coat of engine oil to the O-rings of the sensors.

    2. A00DSDV

      Install the 2 camshaft position sensors with the 2 bolts.

      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.

  48. INSTALL SPARK PLUG


    1. A005RUK

      Using a 14 mm spark plug wrench and 100 mm extension bar, install the 4 spark plugs.

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

  49. INSTALL ENGINE COVER JOINT


    1. A00DU0E

      Install the 2 engine cover joints.

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

  50. INSTALL OIL FILLER CAP GASKET


    1. A00DSE3

      Install the gasket to the oil filler cap.

  51. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A00DRBM

      Install the oil filler cap.