БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

INSTALL STUD BOLT
1. Install the stud bolts as shown in the illustration.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8.1 ft.*lbf, for stud bolt A }
  
  4.5 N*m { 46 kgf*cm, 40 in.*lbf, for stud bolt B }
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf, for stud bolt C }

INSTALL STRAIGHT PIN

Using a plastic-faced hammer, tap into the straight pin.

Standard protrusion
Pin A 22.5 to 23.5 mm (0.886 to 0.925 in.)
Pin B 10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin C 8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin D 5.5 to 6.5 mm (0.217 to 0.256 in.)

INSTALL TIGHT PLUG
1. Apply adhesive around tight plugs.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Using SST, tap in the tight plugs as shown in the illustration.
  
  SST
  
  09950-60010 ( 09951-00350 )
  
  09950-70010 ( 09951-07150 )
  
  Standard depth
  
  0.2 to 1.2 mm (0.008 to 0.047 in.)
INSTALL OIL JET
1. Using a screwdriver and hammer, tap in a oil jet.
INSTALL TAPER SCREW PLUG
1. Apply adhesive to 2 or 3 threads of the taper screw plug end.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the taper screw plug.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  Note
  
  Install the taper screw plug within 3 minutes after applying adhesive.
  
  Do not expose the taper screw plug to coolant within 1 hour of the installation.
INSTALL OIL NOZZLE
1. Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL PISTON PIN HOLE SNAP RING
1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.
  
  Tech Tips
  
  Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
INSTALL PISTON
1. Gradually heat the piston to about 80°C (176°F).
2. Coat the piston pin with engine oil.
3. Align the front marks of the piston and connecting rod, and push in the piston pin with thumb.
INSTALL PISTON PIN HOLE SNAP RING
1. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.
  
  Tech Tips
  
  Be sure that end of gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
INSTALL PISTON RING SET
1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings.
  
  Note
  
  Install the No. 2 compression ring with the painted mark facing right side.
3. Position the piston rings so that the ring ends are as shown.
INSTALL CONNECTING ROD BEARING
1. Align the bearing claw with the groove of the connecting rod or connecting cap.
  
  Note
  
  Clean the backside of the bearing and the bearing surface of the connecting rod and let not stick the oils and fats.
INSTALL CRANKSHAFT BEARING
Tech Tips

Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.
1. Clean each main journal and bearing.
2. Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.
  
  Note
  
  Do not apply engine oil to the bearing and its contact surface.
3. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.
  
  Note
  
  Do not apply engine oil to the bearing and its contact surface.
  
  Tech Tips
  
  A number is marked on each main bearing cap to indicate the installation position.
INSTALL CRANKSHAFT
1. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.
2. Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block.
  1. Push the crankshaft toward the front (rear) side.
  2. Install the 2 upper thrust washers with the oil grooves facing outward.
3. Install the 2 lower thrust washers on the No. 2 bearing cap with the grooves facing outward.
4. Examine the front marks and numbers and install the bearing caps on the cylinder block.
5. Apply a light coat of engine oil on the threads and under the head of bearing cap bolts.
6. Temporarily install the 8 main bearing cap bolts to the inside positions.
7. Insert the main bearing cap with hand until the clearance between the main bearing cap and the cylinder block will become less than 6mm (0.23 in.) by making the 2 internal bearing cap bolts as a guide.
8. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
9. Apply a light coat of engine oil on the threads and under the head of main bearing cap bolts.
10. Install and uniformly tighten the 16 main bearing cap bolts in several passes, in the sequence shown.
  
  Torque:
  
  61 N*m { 622 kgf*cm, 45 ft.*lbf }
11. Mark the front side of the bearing cap bolts with paint.
12. Retighten the bearing cap bolts by 90°C in the sequence shown.
13. Check that the painted mark is now at a 90°angle to the front.
14. Check that the crankshaft turns smoothly.
15. Install and uniformly tighten the 8 main bearing cap bolts in several passes, in the sequence shown.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
INSTALL PISTON WITH CONNECTING ROD
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.
2. Check the position of the piston ring ends.
3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
  Note
  - Clean the backside of the bearing and the bearing surface of the connecting rod cap and let not stick the oils and fats.
  - Match the numbered connecting rod cap with the connecting rod.
4. Check that the protrusion of the connecting rod cap is facing in the correct direction.
5. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
6. Using SST, tighten the bolts in several passes by the specified torque.
  
  SST
  
  09011-38121
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
7. Mark the front side of the each connecting cap bolt with paint.
8. Retighten the cap bolts by 90° as shown.
9. Check that the crankshaft turns smoothly.
INSTALL RING PIN
1. Using a plastic-faced hammer, tap in the new ring pins to the specified protrusion height.
  
  Specified protrusion height
  
  2.7 to 3.3 mm (0.106 to 0.130 in.)

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Standard depth
0.2 to 1.2 mm (0.008 to 0.047 in.)

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

INSTALL STRAIGHT PIN

Using a plastic-faced hammer, tap in the new straight pins to the specified protrusion height.

Specified protrusion height

Item	Specified Condition
A	17.5 to 19.5 mm (0.689 to 0.768 in.)
B	7.5 to 8.5 mm (0.295 to 0.335 in.)
C	7.0 to 9.0 mm (0.276 to 0.354 in.)

INSTALL STUD BOLT
1. Using E5 and E7 "torx" socket wrench, install the stud bolts.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf, for stud bolt A }
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf, for stud bolt B }
INSTALL UNION
1. Apply adhesive to 2 or 3 threads of the bolt end.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Using a 12 mm deep socket wrench, install the unions.
  
  Torque:
  
  15 N*m { 150 kgf*cm, 11 ft.*lbf }
INSTALL TIGHT PLUG
1. Apply adhesive around tight plug.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Using SST, tap in the tight plugs to the specified depth.
  
  SST
  
  09950-60010 ( 09951-00250 )
  
  09950-70010 ( 09951-07150 )
  
  Specified depth
  
  1.5 mm (0.059 in.)
INSTALL WITH HEAD STRAIGHT SCREW PLUG
1. Using a 16 mm hexagon wrench, install a new gasket and straight screw plug.
  
  Torque:
  
  80 N*m { 816 kgf*cm, 59 ft.*lbf }
INSTALL VALVE STEM OIL SEAL
Tech Tips

The intake valve stem oil seal is light brown and the exhaust valve stem oil seal is gray.
1. Apply a light coat of engine oil to the valve guide bush.
2. Using SST, push in a new valve stem oil seal.
  
  SST
  
  09201-41020
INSTALL VALVE SPRING SEAT
INSTALL VALVE
1. Apply the engine oil to the valve as shown in the illustration.
2. Place the cylinder head on the wooden block.
3. Install the valve, inner compression spring and valve spring retainer.
4. Using SST, compress the inner compression spring and place the 2 valve spring retainer locks around the valve stem.
  
  SST
  
  09202-70020 ( 09202-00010 )
5. Using a 5 mm pin punch, lightly tap the valve stem tip to ensure a proper fit.
  
  Note
  
  Be careful not to damage the valve stem tip.
INSTALL VALVE LIFTER
1. Apply the engine oil to the valve stem end and valve lifter, and install its.
2. Check that the valve lifter rotates smoothly by hand.
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
2. Apply a continuous line of the seal packing to the oil seal retainer as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  2 to 3 mm (0.08 to 0.12 in.)
  
  Note
  
  Parts must be assembled within 3 minutes of application. Otherwise the seal packing must be removed and reapplied.
3. Install the oil seal retainer with the 5 bolts and 2 nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL KNOCK SENSOR
1. Install the 2 knock sensors with the 2 bolts as shown in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Connect the knock sensor connectors.
INSTALL NO. 1 WATER OUTLET PIPE
1. Install the water outlet pipe with the bolt and 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL CYLINDER HEAD GASKET
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.
2. Apply a continuous line of the 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
  
  Seal diameter
  
  2.5 to 3 mm (0.098 to 0.118 in.)
  
  Note
  
  Install the cylinder head within 3 minutes after applying seal packing. After installing it, cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
3. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
  Note
  
  Be careful of the installation direction.
  
  Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD
1. Place the RH cylinder head on the cylinder head gasket.
2. Install the 8 cylinder head bolts.
  Tech Tips
  
  The cylinder head bolts are tightened in 2 progressive steps.
  
  If any cylinder head bolt is broken or deformed, replace it.
  1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  2. Install the plate washer to the cylinder head bolt.
  3. Using a 10 mm bi-hexagon wrench, temporarily tighten each bolts in the several passes, as the sequence shown in the illustration, and fully tighten with specified torque.
    
    Torque:
    
    36 N*m { 367 kgf*cm, 27 ft.*lbf }
    
    If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
    
    Note
    
    Do not drop the washers into the cylinder head.
  4. Mark the front side of each cylinder head bolt with paint.
  5. Retighten the cylinder head bolts by 180° in the numerical order shown.
  6. Check that the painted marks are now a 180° angle to the front.
INSTALL NO. 2 CYLINDER HEAD GASKET
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.
2. Apply a continuous line of the 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
  
  Seal diameter
  
  2.5 to 3 mm (0.098 to 0.118 in.)
  
  Note
  
  Install the cylinder head within 3 minutes after applying seal packing. After installing it, cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
3. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
  Note
  
  Be careful of the installation direction.
  
  Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD LH
1. Place the LH cylinder head on the cylinder head gasket.
2. Install the 8 cylinder head bolts.
  Tech Tips
  
  The cylinder head bolts are tightened in 2 progressive steps.
  
  If any cylinder head bolt is broken or deformed, replace it.
  1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  2. Install the plate washer to the cylinder head bolt.
  3. Using a 10 mm bi-hexagon wrench, temporarily tighten each bolts in the several passes, as the sequence shown in the illustration, and fully tighten with specified torque.
    
    Torque:
    
    36 N*m { 367 kgf*cm, 27 ft.*lbf }
    
    If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
    
    Note
    
    Do not drop the washers into the cylinder head.
  4. Mark the front side of each cylinder head bolt with paint.
  5. Retighten the cylinder head bolts by 180°in the numerical order shown.
  6. Check that the painted marks are now a 180° angle to the front.
3. Install the 2 cylinder head bolts.
  1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  2. Install and uniformly tighten the 2 cylinder head bolts, in several passes, in the sequence shown.
    
    Torque:
    
    30 N*m { 306 kgf*cm, 22 ft.*lbf }
INSTALL NO. 1 CAMSHAFT BEARING
1. Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.
  Note
  
  Install the bearing while aligning with the oil hole in the bearing cap.
  
  Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.
INSTALL NO. 2 CAMSHAFT BEARING
1. Install the No. 2 camshaft bearing to the cylinder head.
  
  Note
  
  Clean the backside of the bearing and the bearing surface of the cylinder head and let not stick the oils and fats.
INSTALL CAMSHAFT
Note

As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
1. Set the crankshaft position.
  1. Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position.
    
    Note
    
    Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.
2. Apply new engine oil to the thrust portion and journal of the camshafts.
3. Install the camshaft of the RH bank.
  1. Place the 2 camshafts onto the RH cylinder head with the cam lobes of No. 1 cylinder faced as shown in the illustration.
  2. Install the 8 bearing caps in their proper locations.
  3. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
  4. Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.
    
    Torque:
    
    9.0 N*m { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
    
    24 N*m { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.47 in.) head (A) }
  5. Rotate the camshafts clockwise using hexagonal portion of the each camshaft at 90° angle of the camshaft knock pin on the cylinder head.
4. Install the camshafts of the LH bank.
  1. Place the 2 camshafts onto the LH cylinder head with the cam lobes of No. 2 cylinder faced as shown in the illustration.
  2. Install the 8 bearing caps in their proper locations.
  3. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
  4. Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.
    
    Torque:
    
    9.0 N*m { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
    
    24 N*m { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.47 in.) head (A) }
INSTALL NO. 2 CHAIN TENSIONER
1. While pushing in the tensioner, insert a pin of diameter of 1.0 mm (0.039 in.) into the hole to fix it.
2. Install the No. 2 chain tensioner with the bolt.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (RH BANK)
1. Align the mark links (yellow) with the timing marks (1 dot mark) of camshaft timing gears as shown in the illustration.
2. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts.
3. Temporarily install the 2 camshaft timing gear bolts.
  
  Note
  
  Do not push camshaft timing gear assembly to the camshaft forcibly when installing it.
4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
  
  Torque:
  
  100 N*m { 1,020 kgf*cm, 74 ft.*lbf }
5. Remove the pin from the No. 2 chain tensioner.
INSTALL NO. 3 CHAIN TENSIONER
1. While pushing in the tensioner, insert a pin of diameter of 1.0 mm (0.039 in.) into the hole to hold it.
2. Install the No. 3 chain tensioner with the bolt.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (LH BANK)
1. Align the mark links (yellow) with the timing marks (1 dot mark and 2 dot mark) of camshaft timing gears as shown in the illustration.
2. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the LH camshafts.
3. Temporarily install the 2 camshaft timing gear bolts.
  
  Note
  
  Do not push camshaft timing gear assembly to the camshaft forcibly when installing it.
4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
  
  Torque:
  
  100 N*m { 1,020 kgf*cm, 74 ft.*lbf }
5. Remove the pin from the No. 3 chain tensioner.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the No. 1 chain vibration damper with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL CAMSHAFT TIMING SPROCKET
1. Align the timing gear set key with the key groove of the timing gear.
2. Install the timing gear onto the crankshaft, facing the gear side inward.
INSTALL CHAIN TENSIONER SLIPPER
INSTALL NO. 1 CHAIN TENSIONER
1. While rotating the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
2. While rotating the stopper plate of the tensioner counterclockwise, insert a bar of diameter of 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.
3. Install the chain tensioner with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL CHAIN
1. Set the No. 1 cylinder to TDC/compression.
  1. Align the timing marks of the camshaft timing gears and bearing caps.
  2. Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.
2. Align the mark link (yellow) with the timing mark of the crankshaft timing gear.
3. Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.
INSTALL NO .2 CHAIN VIBRATION DAMPER
1. Install the 2 No. 2 chain vibration dampers.
INSTALL NO. 1 IDLE GEAR
1. Apply a light coat of engine oil to rotating surface of the No. 1 idle gear shaft.
2. Temporarily install the No. 1 idle gear shaft and idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.
  
  Note
  
  Be careful of the idle gear direction.
3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
  
  Torque:
  
  60 N*m { 612 kgf*cm, 44 ft.*lbf }
4. Remove the bar from the chain tensioner.

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Specified depth
1.5 mm (0.059 in.)

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter
2 to 3 mm (0.08 to 0.12 in.)

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter
2.5 to 3 mm (0.098 to 0.118 in.)

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter
2.5 to 3 mm (0.098 to 0.118 in.)

INSTALL TIMING CHAIN COVER

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
Install a new O-ring to the LH cylinder head as shown in the illustration.
Apply a continuous bead of the seal packing to 4 locations as shown in the illustration.

Seal packing

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter

3 to 4 mm (0.12 to 0.16 in.)

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Apply a continuous bead of the seal packing to the timing chain cover as shown in the illustration.

Seal packing
Water pump part: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Other part: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter
3 to 4 mm (0.12 to 0.16 in.)

Note

Install the timing chain cover within 3 minutes after applying seal packing. After installing it, timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
Do not apply seal packing to the "A" position.

Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft timing gear, and slide the timing chain cover.
Install the timing chain cover with the 15 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:

23 N*m { 235 kgf*cm, 17 ft.*lbf }
Note
- Pay attention not to wrap the chain and slipper over the timing chain cover seal line.
- After installing the timing chain cover, must install the water pump within 15 minutes.
Tech Tips

Each bolt length in indicated in the illustration.

A: 25 mm (0.98 in.)

B: 55 mm (2.17 in.)

INSTALL WATER PUMP
1. Install a new gasket and the water pump with the 17 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf, for 12 mm (0.49 in.) head }
INSTALL NO. 1 OIL PAN
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.
2. Install the 4 stud bolts.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
3. Install a new O-ring to the oil pump.
4. Apply a continuous line of the seal packing to the oil pan as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3 to 4 mm (0.12 to 0.16 in.)
  
  Note
  
  Install the oil pan within 3 minutes after applying seal packing. After installing it, oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
5. Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf, for bolt A, B and nut }
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf, for bolt C }
  
  Tech Tips
  
  Each bolt length in indicated in the illustration.
  
  A: 25 mm (0.98 in.)
  
  B: 40 mm (1.57 in.)
  
  C: 14 mm (0.55 in.)
  
  Note
  
  The bolts indicated by starts in the illustration are precoated parts. When reusing them, apply adhesive to 2 or 3 threads before installation.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
INSTALL OIL STRAINER
1. Install a new gasket and the oil strainer with the 2 nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL NO. 2 OIL PAN
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 2 oil pan and oil pan.
2. Apply a continuous line of the seal packing as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3 to 4 mm (0.12 to 0.16 in.)
  
  Note
  
  Install the oil pan No. 2 within 3 minutes after applying seal packing. After installing it, No. 2 oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
3. Install the No. 2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL OIL PAN DRAIN PLUG
1. Install the drain plug with a new gasket.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
INSTALL CRANKSHAFT PULLEY
1. Using SST, install the pulley set bolt.
  
  SST
  
  09213-54015 ( 91651-60855 )
  
  09330-00021
  
  Torque:
  
  250 N*m { 2,549 kgf*cm, 184 ft.*lbf }
SET NO. 1 CYLINDER TO TDC/COMPRESSION
1. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.
2. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.
  
  If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.
INSPECT VALVE CLEARANCE
INSTALL CYLINDER HEAD COVER RH
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
2. Install the gasket to the cylinder head cover.
3. Apply a continuous bead of the seal packing to the cylinder head and timing chain cover as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  2 to 3 mm (0.08 to 0.12 in.)
  
  Note
  
  Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
4. Install the seal washers to the bolts.
5. Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf, for bolt A }
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf, for bolt B }
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf, for nut }
INSTALL CYLINDER HEAD COVER LH
1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
2. Apply adhesive on the threads of the ventilation valve.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
3. Install the ventilation valve to the cylinder head cover.
  
  Torque:
  
  27 N*m { 275 kgf*cm, 20 ft.*lbf }
4. Install the gasket to the cylinder head cover.
5. Apply a continuous bead of the seal packing to the cylinder head and timing chain cover as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  2 to 3 mm (0.08 to 0.12 in.)
  
  Note
  
  Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
6. Install the seal washers to the bolts.
7. Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf, for bolt A }
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf, for bolt B }
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf, for nut }
INSTALL OIL CONTROL VALVE FILTER
1. Check that no foreign objects on the mesh part of the 2 filters.
2. Install 2 new gaskets to each new plug.
3. Insert the filters to the plugs.
4. Apply adhesive to 2 or 3 threads of the plugs.
  
  Adhesive
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
5. Install the plugs to each cylinder head.
  
  Torque:
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf }
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the crankshaft position sensor with the bolt.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL VVT SENSOR
1. Apply a light coat of engine oil to the O-ring of each VVT sensor.
2. Install the 2 VVT sensors with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL CYLINDER BLOCK WATER DRAIN COCK
1. Apply adhesive to 2 or 3 threads of the cylinder block water drain cock end.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. After applying the specified torque, rotate the cylinder block water drain cock clockwise as shown in the illustration.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  Note
  
  Do not rotate the cylinder block water drain cock more than 1 revolution (360°) after tightening the cylinder block water drain cock with the specified torque.
  
  Do not loosen the cylinder block water drain cock after setting it correctly.
INSTALL OIL DIPSTICK GUIDE
1. Install a new O-ring to the oil level gauge guide.
2. Apply a light coat of engine oil to the O-ring.
3. Push in the oil level gauge guide end into the guide hole of the oil pan.
4. Install the oil dipstick gauge guide with the bolt.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL NO. 2 ENGINE HANGER
1. Install the engine hanger with the 2 bolts.
  
  Torque:
  
  33 N*m { 336 kgf*cm, 24 ft.*lbf }
INSTALL NO.1 ENGINE HANGER
1. Install the engine hanger with the 2 bolts.
  
  Torque:
  
  33 N*m { 336 kgf*cm, 24 ft.*lbf }