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. A019KBOE02
      Text in Illustration
      *1 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. A019OZ4E03
      Text in Illustration
      *1 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. A019PCJE03
        Text in Illustration
        *1 Alignment Mark
        *2 Driven Gear
        *3 Damper Cover

        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. A019M05E01

      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.

    A019PFAE06
    Text in Illustration
    *a Front Side *b Lower Side

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

      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 }

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A019M82E02
      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. A019P2RE04
      Text in Illustration
      *1 Stiffening Crankcase
      *2 Cylinder Block

      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.)

      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. A019MT0E02
      Text in Illustration
      *1 Cutout

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

    4. Clean the bolts and their installation holes.

    5. A019NXQE03
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 3 threads or more of the end of bolt A.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A019O7RE01

      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 bolt A before installing it.

    7. A019O7RE02

      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. A019M3WE01

      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. A019O6HE03
      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:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  7. INSTALL OIL PAN SUB-ASSEMBLY


    1. A019K7VE01

      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. A019OKGE01

      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, its threads and its O-ring groove.

    2. A019MCTE04
      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.

    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. A019OX6E02
      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. Apply a small amount of engine oil to a new drain plug 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. A019N6IE04
      Text in Illustration
      *1 O-ring

      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. A019JRJE01

      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. A019LYA

      Install the water jacket spacer to the cylinder block.

  11. INSTALL CYLINDER HEAD GASKET


    1. A019K48E06
      Text in Illustration
      *1 Cylinder Head Gasket
      *2 Cylinder Block
      *a Front
      *b Lot No.
      *c Seal Packing
      *d 20mm or more

      Clean the cylinder block and cylinder head 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.) thick

      Tech Tips

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

      Note


      • Remove any oil from the contact surface.

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

    3. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp 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 on the cylinder block.

      Note


      • Ensure 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. Step 1:


      1. A019LECE02

        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 washer for the cylinder head bolt into the cylinder head.

    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. A019MCOE05
        Text in Illustration
        *a Paint Mark
        A019JLH Front

        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.

    7. Step 4:


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

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

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

  13. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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


    1. A019NQKE02
      Text in Illustration
      *1 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.)

  14. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    Note

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


    1. A019KHUE02
      Text in Illustration
      *1 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.)

  15. INSTALL CAMSHAFT HOUSING STUD BOLT

    Note

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


    1. A019PITE03

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

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

  16. INSTALL NO. 1 CAMSHAFT BEARING


    1. A019MF0E02
      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.)

  17. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. Install the camshaft bearing to the camshaft housing.

    3. A019OHCE02
      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.)

  18. INSTALL OIL CONTROL VALVE FILTER


    1. A019L6WE01

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

  19. 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 journals, camshaft housing sub-assembly and camshaft bearing caps.

    3. Install the No. 1 camshaft and No. 2 camshaft to the camshaft housing sub-assembly.

  20. INSTALL CAMSHAFT BEARING CAP


    1. A019P8TE01

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    2. A019M63E02

      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 No. 1 camshaft and No. 2 camshaft rotate smoothly after installing the camshaft bearing caps.

  21. 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.

  22. INSTALL VALVE LASH ADJUSTER ASSEMBLY


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

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

      Note

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

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


    1. A019LK7E04
      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.

  24. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A019P87E04
      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. A019OCYE01
      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. A019LBUE05
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

      Position the knock pin of the No. 1 camshaft and No. 2 camshaft as shown in the illustration.

    4. A019ORRE02

      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 if off.

  25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A019L3SE06
      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" procedure).

    2. A019KVLE07
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

      Align and fit the knock pin of the No. 1 camshaft with the knock pin hole of the camshaft timing gear assembly.

    3. A019KYDE16
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance

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

    4. A019KLGE02
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 1 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.

  26. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A019OQ7E07
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

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

    2. A019KYDE16
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance

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

    3. A019KJSE02
      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.

  27. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A019P8LE01

      Install the crankshaft timing sprocket to the crankshaft.

  28. ADD ENGINE OIL


    1. A019MQF

      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.

  29. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. A019MG2E02

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

    3. A019O9RE05
      Text in Illustration
      *a Approximately 7°
      *b Approximately 32°
      *c Timing Mark

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

      Tech Tips

      "A" is not a timing mark.

  30. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A019LB2E01

      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 }

  31. INSTALL CHAIN SUB-ASSEMBLY


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

      Tech Tips


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

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

    2. A019JY9E05
      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. A019KB7E06
      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. A019KJE

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

    5. A019L2RE03
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Using a wrench, hold the hexagonal portion of the No. 1 camshaft, rotate the No. 1 camshaft counterclockwise, 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 No. 1 camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    6. A019LF0

      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.

  32. INSTALL CHAIN TENSIONER SLIPPER


    1. A019KGH

      Install the chain tensioner slipper with the bolt.

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

  33. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A019LHS

      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.

  34. INSTALL TIMING CHAIN GUIDE


    1. A019KFN

      Install the timing chain guide with the bolt

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

  35. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A019OTDE07
      Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Crankshaft Pulley Key

    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 gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    4. Remove the crankshaft pulley bolt.

  36. INSTALL TIMING CHAIN COVER PLATE


    1. A019PM7

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

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

  37. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. A019O2E

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

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

  38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A019LE0

      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. A019JZME02
      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.

      A019NWCE10
      Text in Illustration
      *a 3.0 mm or more *b 7.0 mm or more
      *c 13.0 mm or more - -
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Seal Packing Application Chart
      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.

      A019LCHE02
      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 order shown in the illustration.

      Torque:
      Bolt A, C, and Nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt B
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  39. INSTALL ENGINE MOUNTING BRACKET RH


    1. A019NXUE01

      Install the engine mounting bracket RH with the 5 bolts in the order shown in the illustration.

      Torque:
      Bolt 1, 2 and 3
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      Bolt 4 and 5
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

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

  40. 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. A019LCPE01

      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.

  41. INSTALL SPARK PLUG TUBE GASKET


    1. A019KXOE03
      Text in Illustration
      *1 Upper Surface
      *2 Inner Lip
      *3 Outer Lip

      Visually check the spark plug tube gasket.

      OK
      Area Specified Condition
      Upper surface No scratches or deformation
      Outer lip No scratches or deformation
      Inner lip No scratches

      If the result is not as specified, replace the spark plug tube gasket.

    2. A019OHZ

      Install the 4 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.

  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A019N3Z

      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. A019N73E04
      Text in Illustration
      *1 Timing Chain Cover
      *2 Cam Shaft Housing
      A019NE4 Seal Packing

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      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. A019JM1E01

      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.

  43. INSTALL CRANKSHAFT PULLEY


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

    2. A019ODLE04
      Text in Illustration
      *a Hold
      *b Turn

      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)

  44. INSTALL CRANKSHAFT POSITION SENSOR


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

    2. A019K2VE07
      Text in Illustration
      *1 O-ring

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

    3. A019MWWE06
      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.

  45. INSTALL INLET WATER HOUSING


    1. A019OMI

      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 }

  46. INSTALL OIL COOLER ASSEMBLY


    1. Clean the oil cooler contact surface on the engine.

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

    3. Install the 3 new gaskets to the oil cooler.

    4. Temporarily install the oil cooler with the union bolt, nut and a new seal washer.

    5. A019KCCE04
      Text in Illustration
      *1 Union Bolt
      *2 Seal Washer
      *3 Nut

      Tighten the bolt and nut in several steps in the sequence shown in the illustration.

      Torque:
      Union Bolt
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
      Nut
      10 N*m  { 102 kgf*cm, 7 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. A019O3V

      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. A019P6ZE04
      Text in Illustration
      *1 Jiggle Valve

      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. A019MPU

      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. A019NWW

      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. A019LB7

      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. A019NTQE01

      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. A019MP9E02

      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.

      Adhesive
      Toyota genuine adhesive 1324, three bond 1324 or equivalent

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

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

    3. Connect the No. 2 ventilation hose to the ventilation valve.

  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. A019MWWE06
        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. A019MWWE06
        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. A019N7SE06
        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. A019K7J

        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. A019N7SE06
        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. A019KDD

        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 }

  59. INSTALL ENGINE COVER JOINT


    1. A019KC7

      Install the 3 joints.

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