ENGINE UNIT REASSEMBLY


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A003VKDE06
    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 ring pins until they stop.

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

  2. INSTALL STIFFENING CRANKCASE STUD BOLT

    A003YXOE09

    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. A003YDTE02

      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. A003VK5E02

      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. Install the oil pump 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. A003XJ5E11
      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 with the 10 bolts and 2 nuts.

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

  6. INSTALL OIL PAN DRAIN PLUG


    1. A003Z4J

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

      Note

      Keep the lip free from foreign matter.

    2. A003Y1PE03

      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 of the crankshaft.

      • Do not tap the oil seal at an angle.

  8. INSTALL NO. 1 TAPER SCREW PLUG


    1. A003ZSBE01

      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. A003XLKE08
      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. A003YYA

      Install the ventilation valve sub-assembly.

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

  10. INSTALL CYLINDER HEAD GASKET


    1. A003XVZE14
      Text in Illustration
      *1 Cylinder Block
      A003ZV9 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. A003VRKE02
      Text in Illustration
      *a Lot No.
      A003ZV9 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 of applying seal packing.

    3. A003YGYE03
      Text in Illustration
      *1 Cylinder Head Gasket
      A003ZV9 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.

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

    4. A003XSZE02
      Text in Illustration
      *a Before wiping off
      *b After wiping off

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

  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. A003XVFE02

      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. A003Z1HE06
      Text in Illustration
      *a Paint Mark
      A003YYF 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. A003YX4E06
      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

    A003WGYE02
    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. A003YPVE01
      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. A003XPJ

      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. A003XZNE01
      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. Install the No. 2 camshaft to the camshaft housing.

  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. Install the camshaft to the camshaft housing.

  21. INSTALL CAMSHAFT BEARING CAP


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

    2. A003Z0NE01
      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. A003XOOE01

      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. A003XT3E01
      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. A003V55E01

      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 of applying seal packing.

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

    3. A003Z81E01

      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 is 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 is 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.

  23. INSTALL CAMSHAFT TIMING SPROCKET


    1. 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. A003VA3E04
      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. A003VKOE03
      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. A003YL3E03
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Flange
      *a Clearance
      *b No Clearance

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

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

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
    5. A003X7TE02
      Text in Illustration
      *a Lock

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

  25. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A003YXH

      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. A003V61

      Install the 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. A003WD7

      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. A003XIGE02
      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. A003YZ8E02

      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 bolt.

  28. INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the crankshaft timing sprocket.

  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. Install the 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. A003VC4E01
      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. A003V4DE01
      Text in Illustration
      *1 Timing Mark (Rectangle)
      *2 Timing Mark
      *3 Mark (Circle)

      Check that the timing marks on the camshaft timing gear 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. Remove the crankshaft pulley bolt.

  31. INSTALL CHAIN SUB-ASSEMBLY


    1. A003YQ2E01
      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.

      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. A003Y6X

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

    3. A003XHFE04
      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 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 clockwise.

      Tech Tips

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

    5. A003WSJE06
      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.

  32. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Check each timing mark at TDC/compression.

      A003ZKCE01
      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. Install the chain tensioner slipper to the cylinder block.

  34. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

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

  35. INSTALL INLET WATER SUB-ASSEMBLY STUD BOLT

    Note

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


    1. A003YFQE01

      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 }

  36. INSTALL INLET WATER SUB-ASSEMBLY


    1. A003ZEU

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

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

  37. 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, cylinder head and cylinder block.

      A003XSHE02
      Text in Illustration
      *a Clean and degrease - -
    2. A003XNX

      Install 3 new O-rings.

    3. Apply seal packing as shown in the illustration.

      A003XFTE01
      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 chain cover 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 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 chain cover 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.

      A003ZDGE02
      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 within 3 minutes and tighten the bolts within 10 minutes of 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.

    5. Clean the bolt and fitting hole.

    6. Install the timing chain cover.

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

      Note


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

      • 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 chain cover.

      • 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 with the 25 bolts and seal washer as shown in the illustration.

      A003WHME03
      Text in Illustration
      *1 Seal Washer - -
      *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 chain cover 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 chain cover.

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

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

  38. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A003VX3E01

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

      SST
      09223-22010

      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.

  39. INSTALL CRANKSHAFT PULLEY


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

    2. Install the crankshaft pulley to the crankshaft.

    3. A003WI4E02
      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. A003WT3E02
      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. A003YIX

      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. A003YPPE02
      Text in Illustration
      *1 Pin
      *2 Hook
      *a Push
      *b Turn
      *c Disconnect

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

    4. A003XL9E02
      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. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

    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. A003Z03

      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 cap.

      Note

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

    6. A003W47E05
      Text in Illustration
      *1 Oil Filter Bracket Clip
      *a No Clearance

      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, check for gaps between the installation surfaces.

      • 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. A003ZM8E04

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

      Text in Illustration
      A003YGT Part to Cut Off
    2. A003W17E02
      Text in Illustration
      *1 Plug Tube Gasket without Sealing Part
      *2 New Plug Tube Gasket

      Using a hammer and the plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket 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. A003Z30E01
      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. A003XE0

      Install 2 new gaskets to the camshaft bearing cap.

    2. A003V4N

      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. A003VEM
      Text in Illustration
      *1 Timing Chain Cover
      *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 and the camshaft housing and the center of the cylinder head gasket tab should be within 4.0 mm (0.157 in.).

      A003ZPPE01

  45. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A003ZJUE07
      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. A003WY3

      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. A003YTM

      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. A003YRCE01

      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.

  48. INSTALL CRANKSHAFT POSITION SENSOR


    1. A003Y0J

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

    2. A003ZVS

      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. A003Y19

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

    2. A003X5Y

      Install the camshaft timing oil control valve 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 oil control valve.

  50. INSTALL CAMSHAFT POSITION SENSOR


    1. A003WUBE06

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

    2. A003VZ2

      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. 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. A003YBY

      Install the 3 engine cover joint bolts.

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

  53. INSTALL WIRING HARNESS CLAMP BRACKET


    1. A003XSJ

      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. A003WE4

      Install the gasket to the oil filler cap.

  55. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A003XDW

      Install the oil filler cap.