The cylinder head set bolts are tightened in 3 progressive steps.
Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
Place the cylinder head sub-assembly on the cylinder block sub-assembly.
Note:
Remove any oil from 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 cylinder head gasket with the bottom of the cylinder head sub-assembly.
Install the 10 cylinder head set plate washers to the 10 cylinder head set bolts.
Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
Step 1:
Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.
32 N*m
326 kgf*cm
24 ft.*lbf
Note:
Do not drop the cylinder head set plate washers for the cylinder head set bolts into the cylinder head sub-assembly.
Step 2:
*a
Paint Mark
*b
90°
Front of Engine
Mark each cylinder head set bolt head with paint as shown in the illustration.
Tighten the cylinder head set bolts 90° in the order shown in step 1.
Step 3:
Tighten the cylinder head set bolts another 90° in the order shown in step 1.
Check that the paint marks are now at a 180° angle to the front.
Note:
Do not add engine oil for at least 2 hours after installing the cylinder head sub-assembly.
*1
Cylinder Head Sub-assembly
*2
Cylinder Block Sub-assembly
*3
Cylinder Head Gasket
*a
Direction to wipe off
*b
Before Wiping Off
*c
After Wiping Off
*d
After Wiping by Cloth
*e
Seal Packing
*f
Chamfer of Cylinder Head Sub-assembly
*g
Chamfer of Cylinder Block Sub-assembly
After tightening the cylinder head set bolts, wipe off any seal packing that seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly.
Note:
Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.
Be sure to avoid clogging the bolt holes when wiping off the seal packing.
Using a cloth, wipe off any seal packing from the chamfers of the cylinder head sub-assembly and cylinder block sub-assembly.
Note:
Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.
Be sure to avoid clogging the bolt holes when wiping off the seal packing.
Do not wipe off the seal packing to the extent that the end of the cylinder head gasket is exposed.
Do not leave any seal packing on the chamfers of the cylinder block sub-assembly or cylinder head sub-assembly.
INSTALL VALVE STEM CAP
Apply a light coat of engine oil to the valve stem ends.
Install the 16 valve stem caps to the cylinder head sub-assembly.
Note:
Install the same parts to their original positions.
Do not drop the valve stem caps into the cylinder head sub-assembly.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
Inspect the 16 valve lash adjuster assemblies before installing them.
Set the camshaft and No. 2 camshaft as shown in the illustration.
Install the 5 camshaft bearing caps to the camshaft housing sub-assembly.
Install and uniformly tighten the 22 bolts in the order shown in the illustration.
Bolt (A)
16 N*m
163 kgf*cm
12 ft.*lbf
except Bolt (A)
28 N*m
286 kgf*cm
21 ft.*lbf
Note:
After installing the camshaft housing sub-assembly, make sure that the cam lobes are positioned as shown in the illustration.
If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly, clean the installation surfaces, and reapply seal packing.
If the camshaft housing sub-assembly is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
After installing the camshaft housing sub-assembly, wipe off any seal packing that seeped out from between the camshaft housing sub-assembly and the cylinder head sub-assembly.
INSTALL WATER OUTLET GASKET
Install the water outlet gasket to the water outlet.
INSTALL WATER OUTLET
Install the water outlet to the cylinder head sub-assembly with the 3 bolts.
Engage the wire harness clamp and install the No. 5 engine wire to the water outlet.
Connect the engine coolant temperature sensor connector.
INSTALL NO. 7 WATER BY-PASS HOSE
Install the No. 7 water by-pass hose to the water outlet and slide the clip to secure it.
INSTALL WATER VALVE
Install the water valve to the No. 7 water by-pass hose and slide the clip to secure it.
Connect the water valve to the camshaft housing sub-assembly with the bolt.
21 N*m
214 kgf*cm
15 ft.*lbf
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
*a
Identification Mark
Note:
There are several different types of camshaft timing gear bolt. Make sure to check the identification mark to determine the tightening torque.
Table 1. Identification Mark
Item
Identification Mark
Type A
B
Type B
G
*a
Knock Pin
*b
Knock Pin Hole
Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.
Note:
Do not forcibly push in the camshaft timing exhaust gear assembly. This may cause the knock pin tip to damage the installation surface of the camshaft timing exhaust gear assembly.
Tip:
Fit the No. 2 camshaft and camshaft timing exhaust gear assembly together by pushing camshaft timing exhaust gear assembly lightly against the No. 2 camshaft and rotating it to the left (counterclockwise).
*1
Camshaft Timing Exhaust Gear Assembly
*2
No. 2 Camshaft Flange
*a
No Gap
Check that there is no gap between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.
Apply engine oil to the areas of the camshaft timing gear bolt (for exhaust side) shown in the illustration.
Tighten the camshaft timing gear bolt (for exhaust side) while holding the camshaft timing exhaust gear assembly.
Type A
120 N*m
1224 kgf*cm
89 ft.*lbf
Type B
95 N*m
969 kgf*cm
70 ft.*lbf
Note:
If the camshaft timing gear bolt (for exhaust side) has been struck or dropped, replace it.
Do not use an impact wrench.
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
*a
Identification Mark
Note:
There are several different types of camshaft timing gear bolt. Make sure to check the identification mark to determine the tightening torque.
Table 2. Identification Mark
Item
Identification Mark
Type A
A
Type B
C
*a
Knock Pin
*b
Knock Pin Hole
Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.
Note:
Do not forcibly push in the camshaft timing gear assembly. This may cause the knock pin tip to damage the installation surface of the camshaft timing gear assembly.
Tip:
Fit the camshaft and camshaft timing gear assembly together by pushing camshaft timing gear assembly lightly against the camshaft and rotating it to the left (counterclockwise).
*1
Camshaft Timing Gear Assembly
*2
Camshaft Flange
*a
No Gap
Check that there is no gap between the camshaft timing gear assembly and camshaft flange.
Apply engine oil to the areas of the camshaft timing gear bolt (for intake side) shown in the illustration.
Tighten the camshaft timing gear bolt (for intake side) while holding the camshaft timing gear assembly.
Type A
120 N*m
1224 kgf*cm
89 ft.*lbf
Type B
95 N*m
969 kgf*cm
70 ft.*lbf
Note:
If the camshaft timing gear bolt (for intake side) has been struck or dropped, replace it.
Do not use an impact wrench.
INSTALL NO. 2 CHAIN SUB-ASSEMBLY
Temporarily install the crankshaft pulley set bolt to the crankshaft.
*a
Crankshaft Timing Gear Key
Set the crankshaft timing gear keys as shown in the illustration.
Turn the oil pump drive shaft so that the flat face upward.
Remove the crankshaft pulley set bolt from the crankshaft.
*1
Oil Pump Drive Gear
*2
Oil Pump Drive Shaft Gear
*a
Mark Plate (Gold)
*b
Timing Mark
*c
Crankshaft Timing Gear Key Groove
Front of Engine
Align the mark plates (gold) with the timing mark of the oil pump drive gear and oil pump drive shaft gear as shown in the illustration.
Tip:
Make sure the mark plates (gold) of the No. 2 chain sub-assembly are facing away from the engine assembly.
With the No. 2 chain sub-assembly placed around the oil pump drive gear and oil pump drive shaft gear, install the oil pump drive gear to the crankshaft and temporarily install the oil pump drive shaft gear to the oil pump drive shaft.
Temporarily install the oil pump drive shaft gear nut.
*1
Chain Tensioner Plate
*2
Chain Damper Spring
*a
Bolt
Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.
10 N*m
102 kgf*cm
7 ft.*lbf
Temporarily install the crankshaft pulley to the crankshaft with the crankshaft pulley set bolt.
Using SST, hold the crankshaft pulley. Then tighten the oil pump drive shaft gear nut.
09213-70011
09213-70020
09330-00021
28 N*m
286 kgf*cm
21 ft.*lbf
Remove SST, the crankshaft pulley set bolt and crankshaft pulley.
INSTALL CRANKSHAFT TIMING SPROCKET
Front of Engine
Install the crankshaft timing sprocket to the crankshaft.
SET NO. 1 CYLINDER TO TDC/COMPRESSION
Temporarily install the crankshaft pulley set bolt to the crankshaft.
*a
Crankshaft Timing Gear Key
Turn the crankshaft clockwise until the crankshaft timing gear key is facing upward.
*a
Timing Mark
Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are aligned as shown in the illustration.
Remove the crankshaft pulley set bolt from the crankshaft.
Install a new water pump gasket to the engine water pump assembly.
Tip:
Be sure to clean the contact surfaces.
Temporarily install the engine water pump assembly to the timing chain cover assembly with the 4 bolts.
Remove any remaining seal packing.
Clean the contact surfaces of the timing chain cover assembly, camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
*a
Engine Side
*b
Timing Chain Cover Assembly Side
Clean
-
-
Apply seal packing to the engine unit as shown in the illustration.
Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard Seal Packing Diameter
5.0 mm (0.197 in.)
Note:
Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
*a
Seal Packing
*b
Thickness: 2.5 to 3.5 mm (0.0984 to 0.138 in.) Width: 6.0 to 8.0 mm (0.236 to 0.315 in.)
*c
Thickness: 2.5 to 3.5 mm (0.0984 to 0.138 in.) Width: 14.0 to 16.0 mm (0.551 to 0.630 in.)
*d
9.1 mm (0.358 in.)
*e
19.9 mm (0.783 in.)
*f
7.9 mm (0.311 in.)
*g
8.3 mm (0.327 in.)
*h
20.0 mm (0.787 in.)
*i
8.1 mm (0.319 in.)
Apply seal packing to the timing chain cover assembly as shown in the illustration.
Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard Seal Packing Diameter
2.5 to 3.5 mm (0.0984 to 0.138 in.)
Note:
Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
Install the timing chain cover assembly.
Temporarily install the engine mounting bracket RH with the 3 bolts.
Note:
Make sure that there is no oil on the threads of the bolts.
*a
Adhesive
Apply adhesive to the threads of the 2 bolts (B).
Adhesive
Toyota Genuine Adhesive 1324, Three bond 1324 or equivalent
Note:
Make sure that there is no oil on the threads of the bolts.
Tighten the 26 bolts in the order shown in the illustration.
*a
Torque
*b
Bolt Tightening Order
Bolt (A), (B), (D), (E)
21 N*m
214 kgf*cm
15 ft.*lbf
Bolt (C), (F)
43 N*m
438 kgf*cm
32 ft.*lbf
Note:
Tighten the bolts within 10 minutes of applying seal packing.
Do not add engine oil for at least 2 hours after installation.
Do not start the engine for at least 2 hours after installation.
Make sure that there is no oil on the threads of the bolts.
Tip:
Using a 12 mm union nut wrench, tighten the bolt (A).
Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.
INSTALL CYLINDER HEAD COVER GASKET
Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
Note:
Remove any oil from the contact surfaces.
ADD ENGINE OIL
Tip:
Before installing the cylinder head cover sub-assembly, pour engine oil into the oil hole shown in the illustration until the oil hole is filled with engine oil.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Install 3 new gaskets to the locations shown in the illustration.
*a
18.0 mm (0.709 in.)
*b
17.0 mm (0.669 in.)
*c
21.0 mm (0.827 in.)
Apply seal packing as shown in the illustration.
Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard Seal Packing Diameter
2.0 to 3.0 mm (0.0787 to 0.118 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 installation.
*1
Cylinder Head Cover Seal Washer
Install the cylinder head cover sub-assembly to the camshaft housing sub-assembly with the 17 bolts and 2 new cylinder head cover seal washers in the order shown in the illustration.
10 N*m
102 kgf*cm
7 ft.*lbf
Using a 10 mm deep socket wrench, install the cover joint to the cylinder head cover sub-assembly.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL OIL PUMP RELIEF VALVE HOUSING ASSEMBLY
*1
Oil Pump Relief Valve Housing Assembly
*2
Oil Regulator Body Gasket
*a
Bolt
Install a new oil regulator body gasket to the oil pump relief valve housing assembly as shown in the illustration.
Install the oil pump relief valve housing assembly to the cylinder block sub-assembly with the 2 bolts.
