CAUTION / NOTICE / HINT
Tech Tips
Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly or engine coolant temperature sensor.
PROCEDURE
INSTALL RING PIN
Note
It is not necessary to remove a ring pin unless it is being replaced.
*a | Protrusion Height |
Install 2 new ring pins to the stiffening crankcase assembly.
Standard protrusion |
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3 mm (0.118 in.) |
Tech Tips
Standard protrusion may vary, but 3 mm is typical.
INSTALL STUD BOLT
Note
If a stud bolt is deformed or the threads are damaged, replace it.
for Stiffening crankcase assembly:
*1 | 9.0 mm (0.354 in.) |
*2 | 19 mm (0.748 in.) |
Using an E5 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
for Water inlet housing:
*1 | 15 mm (0.591 in.) |
*2 | 34 mm (1.34 in.) |
*3 | 12 mm (0.472 in.) |
Using an E5 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
INSTALL STIFFENING CRANKCASE ASSEMBLY
*1 | 2.0 to 3.0 mm |
*2 | 4.5 to 5.5 mm |
Apply seal packing in a continuous line as shown in the illustration.
Seal packing |
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Toyota Genuine Seal Packing Black, Three bond 1207B or equivalent |
Standard Seal Diameter | ||||||
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|
Application Length A |
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56 mm (2.20 in.) |
Note
Remove any oil from the contact surfaces.
Install the stiffening crankcase 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 installing the stiffening crankcase assembly.
Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.
Bolt Length | ||||||||
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|
Recheck the torque for bolts 1 and 2.
Wipe off any excess seal packing with a clean piece of cloth.
INSTALL REAR ENGINE OIL SEAL
INSTALL OIL PUMP ASSEMBLY
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
INSTALL OIL PAN DRAIN PLUG
Install a new gasket and the oil pan drain plug.
INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)
INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY
INSTALL VALVE LASH ADJUSTER ASSEMBLY
Note
Keep the valve lash adjuster assembly free of dirt and foreign matter.
Only use clean engine oil.
Place the valve lash adjuster assembly into a container filled with engine oil.
*a | Correct |
*b | Incorrect |
*c | Taper Part |
*d | Low Pressure Chamber |
*e | High Pressure Chamber |
*f | Plunger |
*g | Check Ball |
Insert the SST tip into the valve lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.
Check the movement of the plunger and bleed it.
OK |
---|
Plunger moves up and down. |
Note
When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.
After bleeding, remove SST. Then, try to press the plunger quickly and firmly with a finger.
OK |
---|
Plunger is very difficult to move. |
If the result is not as specified, replace the valve lash adjuster assembly.
Install the valve lash adjuster assemblies.
Note
Install each valve lash adjuster assembly to the same place it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
Apply engine oil to each valve lash adjuster assembly tip and valve stem cap end.
*1 | Valve Rocker Arm |
*2 | Valve Lash Adjuster |
*3 | Valve Stem |
*4 | Valve Stem Cap |
Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.
INSTALL NO. 1 CAMSHAFT BEARING
INSTALL OIL CONTROL VALVE FILTER
Check that no foreign matter is on the mesh part of the oil control valve filter.
Install the oil control valve filter.
Note
Do not touch the mesh when installing the oil control valve filter.
INSTALL NO. 2 CAMSHAFT BEARING
Clean both surfaces of the 2 No. 2 camshaft bearings.
Note
Do not apply engine oil to the No. 2 camshaft bearings or the contact surfaces.
Install the 2 No. 2 camshaft bearings to the camshaft housing sub-assembly.
*1 | Vernier Caliper |
Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the No. 2 camshaft bearing edge.
Dimension (A) |
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1.05 to 1.75 mm (0.0413 to 0.0689 in.) |
Note
Position the No. 2 camshaft bearings to the center of the camshaft bearing cap by measuring dimension A.
INSTALL NO. 2 CAMSHAFT
Clean the camshaft journals.
Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
Install the No. 2 camshaft to the camshaft housing sub-assembly.
INSTALL CAMSHAFT
Clean the camshaft journals.
Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.
Install the camshaft to the camshaft housing sub-assembly.
INSTALL CAMSHAFT BEARING CAP
Apply engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
*1 | Straight Pin |
*2 | Camshaft |
*3 | No. 2 Camshaft |
Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
Tech Tips
Make sure that the straight pin of each camshaft is positioned as shown in the illustration.
Tighten the 10 bolts in the order shown in the illustration.
INSTALL NO. 1 TAPER SCREW PLUG
Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug.
Adhesive |
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Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Note
Install the No. 1 taper screw plug within 3 minutes of applying adhesive.
Do not start the engine for at least 1 hour after installing the No. 1 taper screw plug.
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
*1 | Valve Rocker Arm |
*2 | Lash Adjuster |
*3 | Valve Stem |
*4 | Valve Stem Cap |
Make sure that the valve rocker arm is installed as shown in the illustration.
*1 | 7.0 mm |
*2 | 8.0 mm |
*3 | 3.5 to 4.5 mm |
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 | ||||||||
---|---|---|---|---|---|---|---|---|
|
Application Length A and B |
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15 mm (0.591 in.) |
Note
Remove any oil from the contact surfaces.
Install the camshaft housing sub-assembly 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.
Set the camshaft and No. 2 camshaft as shown in the illustration.
Install the camshaft housing sub-assembly and tighten the 17 bolts in the order shown in the illustration.
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 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
Check that the straight pin is installed on the No. 2 camshaft.
*a | Straight Pin |
*b | Key Groove |
Put the camshaft timing exhaust gear assembly and No. 2 camshaft together by aligning the key groove and straight pin.
Lightly press the camshaft timing exhaust gear assembly against the No. 2 camshaft, and turn the camshaft timing exhaust gear assembly. Push further at the position where the pin enters the groove.
Note
Be sure not to turn the camshaft timing exhaust gear assembly in the retard direction (clockwise).
Check that there is no clearance between the gear and the No. 2 camshaft flange.
Tighten the flange bolt while holding the hexagonal portion of the No. 2 camshaft.
Check the lock of the camshaft timing exhaust gear assembly.
Make sure that the camshaft timing exhaust gear assembly is locked.
Tech Tips
Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
Check that the straight pin is installed on the camshaft.
*a | Straight Pin |
*b | Key Groove |
Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
Note
Do not forcibly push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.
*a | Straight Pin |
*b | Key Groove |
Turn the camshaft timing gear assembly 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 assembly assembly in the retard direction (clockwise).
*1 | Camshaft Timing Gear Assembly |
*a | Clearance |
*b | No clearance |
*c | Flange |
Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.
Tighten the flange bolt while holding the hexagonal portion of the camshaft.
*a | Lock |
Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and is locked in the most retarded position.
Tech Tips
Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.
INSTALL CRANKSHAFT TIMING GEAR KEY
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.
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.
INSTALL NO. 2 CHAIN SUB-ASSEMBLY
INSTALL CRANKSHAFT TIMING SPROCKET
INSTALL NO. 1 CHAIN VIBRATION DAMPER
Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.
INSTALL CHAIN SUB-ASSEMBLY
Check that the No. 1 cylinder is at TDC/compression.
Temporarily tighten the crankshaft pulley bolt.
*1 | Timing Gear Key |
Turn the crankshaft counterclockwise to position the timing gear key to the top.
Remove the crankshaft pulley bolt.
*a | Timing Mark |
Check that the timing marks on each camshaft timing gear assembly are aligned as shown in the illustration.
*a | Place the Chain Sub-assembly on the Sprocket |
*b | Pass the Chain Sub-assembly through the Damper |
*c | Mark Plate (Orange) |
*d | Timing Mark |
Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain sub-assembly.
Tech Tips
Be sure to position the mark plate at the front of the engine.
The mark plate on the camshaft side is colored orange.
Do not pass the chain sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
Pass the chain sub-assembly through the No. 1 vibration damper.
Place the chain sub-assembly on the crankshaft without passing it around the shaft.
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plates (orange) and timing mark.
Tech Tips
Be sure to position the mark plates at the front of the engine.
The mark plates on the camshaft side are colored orange.
*a | Turn | *b | Tension the Chain Sub-assembly |
*c | Mark Plate (Orange) | *d | Timing Mark |
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.
Tech Tips
To tension the chain sub-assembly, slowly turn the camshaft timing gear assembly clockwise to prevent the chain sub-assembly from being misaligned.
*a | Timing Mark |
*b | Mark Plate (Yellow) |
Align the mark plates (yellow) and timing marks and install the chain sub-assembly to the crankshaft timing gear.
Tech Tips
The mark plates on the crankshaft side are colored yellow.
Recheck each timing mark at TDC/compression.
*a | Timing Mark | *b | Mark Plate (Orange) |
*c | Mark Plate (Yellow) | - | - |
INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper to the cylinder block sub-assembly.
INSTALL NO. 2 CHAIN VIBRATION DAMPER
Install the No. 2 chain vibration damper with the 2 bolts.
INSTALL NO. 1 GENERATOR BRACKET
Install the No. 1 generator bracket with the 4 bolts.
INSTALL WATER INLET HOUSING
Install a new gasket and water inlet housing with the 3 bolts.
INSTALL TIMING CHAIN COVER OIL SEAL
Using SST, tap in a new timing chain cover oil seal until its surface is flush with the timing gear case edge.
Apply a light coat of MP grease to the lip of the timing chain cover oil seal.
Note
Keep the lip free of foreign matter.
Do not tap in the timing chain cover oil seal at an angle.
Make sure that the timing chain cover oil seal edge does not stick out of the timing chain cover sub-assembly.
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
INSTALL CRANKSHAFT PULLEY
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
*a | Correct |
*b | Incorrect |
*c | Push |
*d | Raise |
*e | Cam |
*f | Hook |
*g | Pin |
Release the ratchet pawl, 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.
Install a new gasket, the bracket and No. 1 chain tensioner assembly with the 2 nuts.
Note
If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, engage the hook again.
*a | Turn |
*b | Disconnect |
*c | Hook |
*d | Pin |
Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.
*a | Turn |
*b | Push |
*c | Plunger |
Turn the crankshaft clockwise, then check that the plunger is extended.
INSTALL OIL FILTER CAP ASSEMBLY
INSTALL SPARK PLUG TUBE GASKET
*a | Plug Tube Gasket without Sealing Part |
*b | New Plug Tube Gasket |
*c | Claw |
Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.
Note
Keep the lip free of foreign matter.
Do not tap in the oil seal at an angle.
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.
Return the claws of the ventilation baffle plate to their original positions.
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.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Install 3 new gaskets to the camshaft bearing cap.
Apply seal packing 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 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 installing the cylinder head cover sub-assembly.
Install the cylinder head cover sub-assembly to the camshaft housing sub-assembly with a new seal washer and the 13 bolts.
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
*a | 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 of applying adhesive.
Do not start the engine within 1 hour after installation.
Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Install a new gasket to the engine coolant temperature sensor.
Install the engine coolant temperature sensor.
Tech Tips
Perform "Inspection After Repair" after replacing the engine coolant temperature sensor.
INSTALL KNOCK CONTROL SENSOR
Install the knock control sensor with the bolt.
Note
Make sure that the knock control sensor is in the correct position.
INSTALL CRANKSHAFT POSITION SENSOR
*1 | O-ring |
Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.
Install the crankshaft position sensor with the bolt.
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
*1 | O-ring |
Apply a light coat of engine oil to 2 new O-rings and install them to the camshaft timing oil control valve assemblies.
*1 | Bracket |
Install the 2 camshaft timing oil control valves and bracket to the cylinder head cover sub-assembly with the 2 bolts.
Note
Do not allow foreign matter to contact the oil seal face of the camshaft oil control valve assembly (surface that contacts cylinder head cover sub-assembly).
Be careful that the O-ring is not cracked or moved out of place when installing the camshaft oil control valve assembly.
INSTALL CAMSHAFT POSITION SENSOR
*1 | O-ring |
Apply a light coat of engine oil to the O-ring of the camshaft position sensor.
Install the 2 camshaft position sensors to the cylinder head cover sub-assembly with the 2 bolts.
Note
Make sure that the O-rings are not cracked or jammed when installing the camshaft position sensors.
INSTALL SPARK PLUG
INSTALL ENGINE COVER JOINT
Install the 2 engine cover joints to the cylinder head cover sub-assembly.
INSTALL OIL FILLER CAP GASKET
Install the oil filler cap gasket to the oil filler cap sub-assembly.
INSTALL OIL FILLER CAP SUB-ASSEMBLY
Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.