ENGINE UNIT REASSEMBLY


  1. INSTALL STIFFENING CRANKCASE RING PIN

    Note

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


    1. A01EZ3HE03
      Text in Illustration
      *a Protrusion Height

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

      Standard protrusion height
      4.3 to 5.3 mm (0.169 to 0.209 in.)

  2. INSTALL ENGINE BALANCER ASSEMBLY


    1. A01EWB9E06
      Text in Illustration
      *a Alignment Mark

      Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

      If the alignment marks are not aligned, realign them.


      1. A01EXCGE07
        Text in Illustration
        *1 Driven Gear
        *2 Damper Cover
        *a Alignment Mark

        Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the shaft in place.

      2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.

    2. A01EU30E01

      Install the engine balancer to the stiffening crankcase with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.

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

  3. INSTALL STIFFENING CRANKCASE STUD BOLT

    Note

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


    1. Using an E5 and E8 "TORX" socket wrench, install the stud bolts.

      A01ETITE06
      Torque:
      for Stud Bolt A
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      for Stud Bolt B
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      Text in Illustration
      *a Front Side *b Lower Side

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01EXYWE02
      Text in Illustration
      *1 Key

      Rotate the crankshaft clockwise so that the crankshaft key is at the position 90° from the bottom as shown in the illustration.

    2. A01ETCAE01

      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 Dimension
      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick
      Application Length A
      28 mm (1.10 in.)
      Text in Illustration
      A01EV1N Stiffening Crankcase
      A01ETD0 Cylinder Block

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

      • Do not apply oil for at least 4 hours after the installation.

    3. A01EWTSE03
      Text in Illustration
      *a Cutout

      Check that the rear cutout parts are as shown in the illustration.

    4. Clean the bolts and their installation holes.

    5. A01EW5ME03
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 3 or more threads of the ends of bolts A.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01EYQ4E01

      Temporarily install the stiffening crankcase with the 11 bolts.

      Bolt Length
      Item Length
      Bolt A 65 mm (2.56 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 125 mm (4.92 in.)
      Bolt D 165 mm (6.50 in.)

      Tech Tips

      Apply adhesive to bolts A before installation.

    7. A01EYQ4E02

      Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase

      Torque:
      for Bolt A
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      except Bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  5. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01EYXRE01

      Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.

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

  6. INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. A01EVTEE03
      Text in Illustration
      *a Protrusion

      Align the protrusion of the gasket with the cutout of the oil strainer, and install the gasket to the oil strainer.

    3. Install the oil strainer with the 3 bolts in several steps, in the sequence shown in the illustration.

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

  7. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01EW5BE01

      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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      • Do not apply oil for at least 4 hours after the installation.

    2. A01EWEME04
      Text in Illustration
      *1 Nut

      Install the oil pan with the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

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

      Tech Tips

      Bolt A and nut A are tightened twice.

  8. INSTALL OIL FILTER CAP ASSEMBLY


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

    2. A01EUPGE07
      Text in Illustration
      *1 Oil Filter Element
      *2 Oil Filter Cap
      *3 O-ring

      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 into the oil filter cap.

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

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

      Note

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

    6. A01ESW9E02
      Text in Illustration
      *a No Clearance

      Using SST, tighten the oil filter cap.

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

      Note

      Make sure that the oil filter is installed securely as shown in the illustration.

    7. A01ET2AE04
      Text in Illustration
      *1 O-ring

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

      Note

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

    8. Install the oil filter drain plug.

      Torque:
      13 N*m  { 127 kgf*cm, 10 ft.*lbf }

      Note

      Be careful that the O-ring does not get caught between any surrounding parts.

  9. INSTALL REAR ENGINE OIL SEAL


    1. 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. A01ETPCE01

      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   ( 09951-07150 )

      Note


      • Keep the lip of the oil seal free from foreign matter.

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

  10. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01EVFA

      Install the water jacket spacer to the cylinder block.

  11. INSTALL CYLINDER HEAD GASKET


    1. A01EX2OE01
      Text in Illustration
      *1 Cylinder Head Gasket
      *2 Cylinder Block Sub-assembly
      *a Lot No.
      *b 3.0 mm or more
      *c 20 mm or more
      A01EUL1 Seal Packing
      A01ETOA Front

      Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

    2. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Dimension
      3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) or thicker

      Tech Tips

      Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block sub-assembly.

      Note


      • Remove any oil from the contact surfaces.

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

    3. Place the new cylinder head gasket on the cylinder block sub-assembly surface with the Lot No. stamp facing upward.

      Note

      Pay attention to the installation direction.

  12. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 4 progressive steps.


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

      Note


      • Ensure that no oil is on the contact surface of the cylinder head sub-assembly.

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

    2. Install the 10 plate washers to the 10 cylinder head bolts.

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

    4. Step 1:


      1. A01EU6JE02

        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:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

        Note

        Do not drop the plate washers for the cylinder head bolts into the cylinder head sub-assembly.

    5. Step 2:


      1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    6. Step 3:


      1. A01EWXYE02
        Text in Illustration
        *a Paint Mark
        A01EUL1 Front

        Mark each cylinder head bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head bolts by 90° in the sequence shown in step 1.

    7. Step 4:


      1. Tighten the cylinder head bolts by another 90° in the sequence shown in step 1.

      2. Check that the paint marks are now facing rearward.

        Note


        • Do not add engine oil for at least 4 hours after installation.

        • Do not start the engine for at least 4 hours after installation.

        • After installation, if the seal packing has seeped out, wipe it off.

        Tech Tips

        Perform "Inspection After Repair" after replacing the cylinder head sub-assembly Click here.

  13. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

    When installing the camshaft timing gear assembly, release the lock pin and set the camshaft timing gear assembly to the advanced position before installation.


    1. A01EX0RE05
      Text in Illustration
      *a Advanced Position
      *b Retarded Position
      *c Knock Pin Hole
      *d Alignment Mark

      Check the camshaft timing gear assembly position.

      Note


      • If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

      • If the camshaft timing gear assembly rotates to the retarded position, release the lock pin and set the camshaft timing gear assembly to the advanced position.

    2. A01EVVOE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and insert the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    3. A01ET3ZE19
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d Camshaft Flange
      *e No Clearance

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

    4. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    5. A01EVENE10

      Release the lock pin.

      Text in Illustration
      *1 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close
      *e Rubber
      *f Vinyl Tape

      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the camshaft journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.

      3. Open a hole at port (A) shown in the illustration.

      4. A01EVFG

        While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the path with a piece of cloth when applying pressure to keep oil from spraying.

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips


        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      5. Remove the vinyl tape and rubber pieces from the camshaft.

    6. Remove the bolt and camshaft timing gear assembly.

      Note

      Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

  14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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


    1. A01EXNFE03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    Note

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


    1. A01EYYXE03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing.

      Standard protrusion height
      5.0 to 7.0 mm (0.197 to 0.276 in.)

  16. INSTALL CAMSHAFT HOUSING STUD BOLT

    Note

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


    1. A01ETGZE01

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

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

  17. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01EYOQE03
      Text in Illustration
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

    2. Install the camshaft bearing to the No. 1 camshaft bearing cap.

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

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  18. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. Install the camshaft bearing to the camshaft housing.

    3. A01EWCGE04
      Text in Illustration
      *1 Vernier Caliper

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

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  19. INSTALL OIL CONTROL VALVE FILTER


    1. A01EWXX

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

  20. INSTALL CAMSHAFT


    1. Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journal, camshaft housing sub-assembly and camshaft bearing caps.

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

      Tech Tips

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

  21. INSTALL CAMSHAFT BEARING CAP


    1. A01EVOQ

      Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.

    2. A01EXYCE02

      Install the 11 bolts in the order shown in the illustration.

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

      Note

      Make sure that the camshaft and No. 2 camshaft rotate smoothly after installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and No. 3 camshaft bearing caps.

  22. 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 sub-assembly.

      Note

      Do not drop the valve stem caps into the cylinder head sub-assembly.

  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assemblies before installing them Click here.

    2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

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

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


    1. A01EU1CE06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01EWTKE03
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Incorrect
      *b Correct

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

    2. A01EX00E01
      Text in Illustration
      *a Dashed Line
      *b Groove

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

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Apply Seal Packing as Follows
      Area Seal Packing Diameter Application Position
      Continuous Line 3.0 to 4.0 mm (0.118 to 0.157 in.) Distance from edge of camshaft housing sub-assembly to center of seal packing: 3.5 to 4.0 mm (0.138 to 0.157 in.)
      Dashed Line Distance from outside edge of groove to center of seal packing: 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

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

    3. A01ETOTE02
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

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

    4. A01EYLQE02

      Install the camshaft housing sub-assembly, and then install the 20 bolts in the order shown in the illustration.

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

      Note


      • Do not add engine oil for at least 4 hours after the installation.

      • Do not start the engine for at least 4 hours after the installation.

      • After installation, if the seal packing has seeped out, wipe it off.

  26. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EVGVE04
      Text in Illustration
      *a Knock Pin Hole
      *b Alignment Mark

      Check the camshaft timing gear assembly position.

      If the camshaft timing gear assembly is not set to the advanced position, release the lock pin and reset the camshaft timing gear assembly (Refer to the "Set Camshaft Timing Gear Assembly" procedures).

    2. A01EVVOE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and insert the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    3. A01ET3ZE19
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d Camshaft Flange
      *e No Clearance

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

    4. A01EYOVE01
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

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

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

      Tech Tips

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

  27. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01EYISE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and insert the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

    2. A01ET3ZE19
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d No. 2 Camshaft Flange
      *e No Clearance

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

    3. A01EWGOE01
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

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

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

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

  28. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01EUIM

      Install the crankshaft timing sprocket to the crankshaft.

  29. ADD ENGINE OIL


    1. A01EV4U

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

      Note


      • Oil must be added if the valve lash adjuster assemblies were removed.

      • Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01EV13E02

      Temporarily install the crankshaft pulley bolt.

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

    3. A01EVE6E02
      Text in Illustration
      *a Approximately 7°
      *b Approximately 32°
      *c Timing Mark

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

      Tech Tips

      "A" is not a timing mark.

  31. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01EUB3E01

      Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.

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

  32. INSTALL CHAIN SUB-ASSEMBLY


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

      Tech Tips


      • Make sure the mark plate of the chain sub-assembly faces away from the engine.

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

    2. A01ETW5E03
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

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

    3. A01EX09E04
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Align the mark plate (pink or gold) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.

    4. A01EV8R

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

    5. A01EX5NE03
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear assembly with the mark plate (yellow or gold) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    6. A01EUKR

      Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.

      Note

      Make sure the chain sub-assembly is secure.

  33. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

    2. Remove the pin from the stopper plate.

  35. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  36. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01ETOLE10
      Text in Illustration
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.

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

      Tech Tips

      "A" is not a timing mark.

    4. Remove the crankshaft pulley bolt.

  37. INSTALL TIMING CHAIN COVER PLATE


    1. A01EX56

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

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

  38. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. A01EWN1

      Using a 14 mm hexagon wrench, install a new gasket and the plug.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01ETJC

      Apply a light coat of engine oil to 2 new oil pump gaskets and a new oil hole cover gasket.

    2. Install the 2 oil pump gaskets and oil hole cover gasket to the stiffening crankcase assembly.

    3. A01EXUCE02
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft Timing Sprocket

      Align the drive rotor spline and crankshaft timing sprocket as shown in the illustration.

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

      A01EVY3E11
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Apply Seal Packing as Follows
      Area Seal Packing Diameter (Round) Distance from Edge of Cover to Center of Seal Packing Seal Packing Application Length
      Seal Packing Dimension (Flat)
      Dashed Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) -
      -
      A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) -
      -
      B - B 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 28 mm (1.10 in.)
      7.0 mm (0.276 in.) or wider and 3.0 mm (0.118 in.) or thicker
      C - C 7.0 mm (0.276 in.) 5.0 mm (0.197 in.) 25 mm (0.984 in.)
      13.0 mm (0.512 in.) or wider and 3.0 mm (0.118 in.) or thicker
      D - D 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 26 mm (1.02 in.)
      7.0 mm (0.276 in.) or wider and 3.0 mm (0.118 in.) or thicker
      E 2.5 to 3.5 mm (0.0984 to 0.138 in.) 3.0 mm (0.118 in.) -
      -

      Note


      • Clean the surfaces with non-residue solvent 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 RH within 10 minutes.

      • Do not add engine oil for at least 4 hours after installation.

      • Do not start the engine for at least 4 hours after installation.

    5. Temporarily install the timing chain cover sub-assembly with the 17 bolts and 2 nuts.

      A01ETHUE04
      Text in Illustration
      *1 Nut - -
      *a Torque *b Tightening Order
      Bolt Length
      Item Length Thread Diameter
      Bolt A 30 mm (1.18 in.) 8 mm (0.315 in.)
      Bolt B 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt C 45 mm (1.77 in.) 8 mm (0.315 in.)

      Note

      Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

    6. Tighten the 17 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

      Torque:
      Bolt A, C and Nut
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }
      Bolt B
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  40. INSTALL ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket RH with the 3 bolts.

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

  41. INSTALL TIMING CHAIN COVER OIL SEAL


    1. 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. A01EU8NE01

      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


      • Keep the lip of the oil seal free from foreign matter.

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

  42. INSTALL SPARK PLUG TUBE GASKET


    1. A01ESY8

      Install 4 new plug tube gaskets to the cylinder head cover.

      Note

      After pressing in the spark plug tube gasket, make sure the gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover.

  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01EV5L

      Apply a light coat of engine oil to 3 new gaskets.

    2. Install the 3 gaskets to the camshaft bearing caps.

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

      Note

      Remove any oil from the contact surface.

    4. A01EU0SE03
      Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover
      *3 Camshaft Housing

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application width A
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surface.

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

    5. A01EUREE01

      Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.

    6. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

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

      Note


      • Do not apply oil for at least 4 hours after the installation.

  44. INSTALL CRANKSHAFT PULLEY


    1. A01EUANE15
      Text in Illustration
      *a Hold
      *b Turn

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

    2. Using SST, hold the crankshaft pulley and install the pulley bolt.

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

      Tech Tips

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

  45. INSTALL CRANKSHAFT POSITION SENSOR


    1. Clean and degrease the threads of the bolt for the crankshaft position sensor.

    2. A01EXUJE07
      Text in Illustration
      *1 O-ring

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

    3. A01ET13E06
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt.

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

    4. Install the sensor with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

      Make sure that the O-ring is not cracked or does not jump out of position during installation.

    5. Connect the sensor connector.

  46. INSTALL WATER INLET HOUSING


    1. A01EY4A

      Install a new gasket and the inlet water housing with the 4 bolts and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  47. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. Install a new gasket and the engine water pump with the 7 bolts.

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

  48. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01EWOV

      Install the V-ribbed belt tensioner with the bolt.

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

  49. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A01EUL4E06
      Text in Illustration
      *1 Jiggle valve
      *a 10°

      Install the thermostat with the jiggle valve facing upward.

      Tech Tips

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

  50. INSTALL WATER INLET


    1. Install the water inlet with the 2 nuts.

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

  51. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A01EU05

      Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.

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

  52. INSTALL SEPARATOR CASE


    1. A01EU29

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

    2. Install the gasket to the separator case.

    3. Install the separator case with the 2 bolts.

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

  53. INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. A01ETY7E01

      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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01EW00E02

      Install the ventilation case, and install the 8 bolts and 2 nuts in the order shown in the illustration.

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

      Tech Tips

      Bolt A is tightened twice.

  54. INSTALL VENTILATION VALVE SUB-ASSEMBLY


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

      Adhesive
      Toyota genuine adhesive 1324, three bond 1324 or equivalent

    2. Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly.

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

    3. Connect the No. 2 ventilation hose to the ventilation valve sub-assembly.

  55. INSTALL CAMSHAFT POSITION SENSOR


    1. Camshaft position sensor (for Intake Side)


      1. Clean and degrease the threads of the bolt for the camshaft position sensor.

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

        Note

        Make sure that the O-ring is not cracked or does not jump out of position during installation.

      3. A01ET13E06
        Text in Illustration
        *1 Adhesive

        Apply adhesive to 2 or 3 threads of the bolt.

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

      4. Install the sensor with the bolt.

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

      5. Connect the sensor connector.

    2. Camshaft position sensor (for Exhaust Side)


      1. Clean and degrease the threads of the bolt for the camshaft position sensor.

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

        Note

        Make sure that the O-ring is not cracked or does not jump out of position during installation.

      3. A01ET13E06
        Text in Illustration
        *1 Adhesive

        Apply adhesive to 2 or 3 threads of the bolt.

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

      4. Install the sensor with the bolt.

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

      5. Connect the sensor connector.

  56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. Camshaft timing oil control valve assembly (for exhaust side)


      1. A01EWYWE06
        Text in Illustration
        *1 New O-ring

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

      2. Install the 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 the cylinder head cover).

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

      3. Connect the oil control valve connector.

    2. Camshaft timing oil control valve assembly (for intake side)


      1. A01EWYWE06
        Text in Illustration
        *1 New O-ring

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

      2. Install the 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.

      3. Connect the oil control valve connector.

  57. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new gasket to the oil filler cap.

    2. Install the oil filler cap to the cylinder head.

  58. INSTALL SPARK PLUG


    1. Using a spark plug wrench, install the 4 spark plugs.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the spark plug Click here.

  59. INSTALL ENGINE COVER JOINT


    1. A01ET2O

      Install the 3 joints.

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