Engine Unit: Reassembly

INSTALL STUD BOLT

Fig 1: Installing Stud Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STRAIGHT PIN

Fig 2: Installing Straight Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RING PIN

Fig 3: Installing Ring Pin
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INSTALL PISTON PIN HOLE SNAP RING
1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
Fig 4: Installing Piston Pin Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
INSTALL W/ PIN PISTON SUB-ASSEMBLY
1. Gradually heat the piston to about 80°C (176°F).
  
  Fig 5: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 your thumb until the pin contacts the snap ring.
Fig 6: Aligning Front Marks Of Piston And Connecting Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON PIN HOLE SNAP RING
1. Using a screwdriver, install a new snap ring on the other end of the piston pin hole.
Fig 7: Installing Piston Pin Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Be sure that end 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 the 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings.
  
  Fig 8: Installing Piston Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The compression ring No. 2 is installed with code mark "2A" faced upward as shown in the illustration.
3. Position the piston rings so that the ring ends are arranged as shown in the illustration.
NOTE: Do not align the ring ends.

Fig 9: Positioning The Piston Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD BEARING
1. Align the key of the bearing with the keyway of the connecting rod or connecting cap.
NOTE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.

Fig 10: Installing Connecting Rod Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT BEARING
1. Clean each main journal and the bearing.
  
  Fig 11: Identifying Crankshaft Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Main bearings come in widths of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4 mm (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.
2. Align the key of the bearing with the keyway of the cylinder block, and push in the 4 upper bearings.
  NOTE: Do not apply engine oil to the bearing and its contact surface.
  
  Fig 12: Pushing In Upper Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the key of the bearing with the keyway 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.

Fig 13: Pushing In Lower Bearings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

A number is marked on each main bearing cap to indicate the installation position.
INSTALL CRANKSHAFT THRUST WASHER SET
1. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
  
  Fig 14: Installing Crankshaft Thrust Washer Under No. 2 Journal Position Of Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward.
INSTALL CRANKSHAFT
1. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.
  
  Fig 15: Installing Thrust Washers On No. 2 Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Examine the front marks and numbers and install the bearing caps on the cylinder block.
3. Apply a light coat of engine oil to the threads of the bearing cap bolts.
4. Temporarily install the 8 main bearing cap bolts to the inside positions.
  
  Fig 16: Identifying Front Marks And Numbers On Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the main bearing cap by hand using the inner bolt as a guides. Stop the main bearing cap is about 6 mm (0.23 in.) away from contacting with the block.
  
  Fig 17: Identifying Distance Between Main Bearing Cap And Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
7. Apply a light coat of engine oil on the threads of the main bearing cap bolts.
  
  Fig 18: Taping Bearing Cap For Proper Fitting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using several steps, install and tighten the 16 main bearing cap bolts uniformly in the sequence shown in the illustration (procedure "A").
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 19: Identifying Main Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Mark the front side of the bearing cap bolts with paint.
10. Retighten the bearing cap bolts by 90° in the same sequence as procedure "A".
11. Check that each painted mark is now at 90° angle to the front.
12. Check that the crankshaft turns smoothly.
  
  Fig 20: Identifying Retightening Angle Of Main Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Using several steps, install and tighten the 8 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)

HINT:

Use the short bolt for the marked position (arrow).

Fig 21: Identifying Main Bearing Cap Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON SUB-ASSEMBLY W/ CONNECTING ROD
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the 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: Match the numbered connecting rod cap with the connecting rod.
4. Check that the protrusion of the connecting rod cap is facing the correct direction.
5. Apply a light coat of engine oil on the threads of the connecting rod cap bolts.
  
  Fig 22: Pushing Piston And Connecting Rod Assemblies Into Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the bolts in several steps to the specified torque.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 23: Identifying Protrusion Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Mark the front side of each connecting cap bolt with paint.
  
  Fig 24: Tightening Connecting Rod Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Retighten the cap bolts by 90° as shown in the illustration.
9. Check that the crankshaft turns smoothly.
Fig 25: Identifying Retightening Angle Of Connecting Rod Cap Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK W/ HEAD STRAIGHT SCREW NO. 1 PLUG
1. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

Fig 26: Installing No 1 Screw Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK W/ HEAD STRAIGHT SCREW NO. 2 PLUG
1. Using a socket hexagon wrench 10 mm, install a new gasket and the screw plug.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

Fig 27: Installing No 2 Screw Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK W/ HEAD STRAIGHT SCREW NO. 3 PLUG
1. Using a socket hexagon wrench 10, install a new gasket and the screw plug.
Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
INSTALL WATER SEAL PLATE
1. Remove any old seal packing from the contact surface.
  
  Fig 28: Installing No 3 Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 in.) as shown in the illustration.
  Seal packing:
  
  Part No.08826-00100 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the seal plate within 3 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
3. Install the seal plate with the 2 nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

Fig 29: Applying Seal Packing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive to 2 or 3 threads of the drain cock end.
  Adhesive:
  
  Part No.08833-00070, THREE BOND 1324 or equivalent
2. After applying the specified torque, rotate the drain cock clockwise as shown in the illustration.
Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
NOTE:
- Install the drain cock within 3 minutes after applying adhesive.
- Do not expose the seal to coolant within 1 hour after installing.
- Do not rotate the drain cock more than 1 revolution (360°) after tightening the drain cock to the specified torque.
- Do not loosen the drain cock after setting it correctly.
Fig 30: Rotating Drain Cock Clockwise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG TUBE GASKET
1. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
  SST 09950-60010 (09951-00430), 09950-70010 (09951-07100)
2. Return the ventilation plate tab to its original position.
3. Apply a light coat of MP grease to the gasket lip.
Fig 31: Installing Spark Plug Tube Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE REAR OIL SEAL
1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
  SST 09223-15030, 09950-70010 (09951-07100)
  NOTE:
  - Be careful not to tap the oil seal at an angle.
  - Keep the lip free of foreign objects.
2. Apply MP grease to the oil seal lip.
Fig 32: Installing Engine Rear Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Remove any old packing material from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 2 to 3 mm(0.08 to 0.12 in.) as shown in the illustration.
  Seal packing:
  
  Part No. 08826-00080 or equivalent
  NOTE:
  - Remove any oil from contact surface.
  - Install the oil pump within 3 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
3. Install the oil seal retainer with the 6 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Fig 33: Applying Continuous Bead Of Seal Packing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PUMP SEAL
1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
  SST 09223-00010
  NOTE:
  - Be careful not to tap the oil seal at an angle.
  - Keep the lip free of foreign objects.
2. Apply MP grease to the oil seal lip.
Fig 34: Installing Oil Pump Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PUMP ASSEMBLY
1. Remove any old packing material from the contact surface.
2. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.
3. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.) as shown in the illustration.
  
  Fig 35: Installing O-Ring Into Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing:
  
  Part No.08826-00080 or equivalent
  NOTE:
  - Remove any oil from contact surface.
  - Apply seal packing to the inner side of the bolt holes.
  - Install the oil pump within 3 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
  Fig 36: Applying Continuous Bead Of Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.
  
  Fig 37: Aligning Key Of Oil Pump Drive Gear With Keyway Located On Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: Bolt A

8.0 N*m (82 kgf*cm, 71 in.*lbf) Bolt B

20 N*m (199 kgf*cm, 14 ft.*lbf) Bolt C

43 N*m (439 kgf*cm, 32 ft.*lbf)

Fig 38: Installing Oil Pump Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf)
INSTALL OIL PAN BAFFLE PLATE Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
INSTALL OIL PAN SUB-ASSEMBLY
1. Remove any old seal packing from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 in.) as shown in the illustration.
  Seal packing:
  
  Part No.08826-00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Apply seal packing to the outer side of the bolt holes in the region "X".
  - Apply seal packing to the inner side of the bolt holes in the region "Y".
  - Install the oil pan within 3 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
3. Install the oil pan No. 1 with the 15 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
Torque: 10 mm head

8.0 N*m (82 kgf*cm, 71 in.*lbf)

12 mm head

20 N*m (199 kgf*cm, 14 ft.*lbf)
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Install a new gasket and the oil strainer with the bolt and 2 nuts.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 39: Applying Continuous Bead Of Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN SUB-ASSEMBLY NO. 2
1. Remove any old seal packing from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 in.) as shown in the illustration.
  Seal packing:
  
  Part No.08826-00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Apply seal packing to the inner side of the bolt holes.
  - Install the oil pan within 3 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
3. Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Fig 40: Applying Continuous Bead Of Seal Packing On Oil Pan
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN DRAIN PLUG
1. Install the drain plug with a new gasket.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
INSTALL WATER INLET HOUSING
1. Remove any old packing material from the contact surface.
  
  Fig 41: Applying Continuous Bead Of Seal Packing On Water Inlet Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 in.) as shown in the illustration.
  Seal packing:
  
  Part No.08826-00100 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the water inlet housing within 3 minutes after applying seal packing.
  - Do not expose the seal to coolant within 2 hours after installing.
3. Install the water inlet housing with the 8 bolts and 2 nuts. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Fig 42: Identifying Water Inlet Housing Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD GASKET
1. Place a new cylinder head gasket on the cylinder block with the R mark upward.
NOTE:
- Remove any oil from the contact surface.
- Be careful of the installing orientation.
- Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
Fig 43: Placing New Cylinder Head Gasket On Cylinder Block With R Mark Upward
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY
NOTE: The cylinder head bolts are tightened in 2 successive steps.
1. Apply a light coat of engine oil to the threads of the cylinder head bolts.
2. Install the plate washers to the cylinder head bolts.
3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration (procedure "B").
  Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf)
  
  Fig 44: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
5. Retighten the cylinder head bolts by 90° in the same sequence as procedure "B".
6. Check that each painted mark is now at a 90° angle to the front.
  
  Fig 45: View Of 90 Degree Turn Using Paint Mark Reference
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf)

Fig 46: Identifying Hexagon Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD GASKET NO. 2
1. Place a new cylinder head gasket on the cylinder block with the L mark upward.
NOTE:
- Remove any oil from the contact surface.
- Be careful of the installing orientation.
- Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
Fig 47: Placing New Cylinder Head Gasket On Cylinder Block With L Mark Upward
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD LH
1. Apply a light coat of engine oil on the threads of the cylinder head bolts.
2. Install the plate washers to the cylinder head bolts.
3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration (procedure "C").
  Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf)
  
  Fig 48: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
5. Retighten the cylinder head bolts by 90° in the same sequence as procedure "C".
6. Check that each painted mark is now at a 90° angle to the front.
  
  Fig 49: View Of 90 Degree Turn Using Paint Mark Reference
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf)

Fig 50: Identifying Hexagon Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL CONTROL VALVE FILTER
1. Check that no foreign object is on the mesh part of the filter.
2. Assemble the valve filter and the plug.
3. Install the plug with a new gasket.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)

Fig 51: Installing Oil Control Valve Filter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER REAR
1. Install the rear cover and a new gasket.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT SUB GEAR
1. Clamp the camshaft in a vise on the hexagonal lobe.
  NOTE: Be careful not to damage the camshaft.
  
  Fig 52: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshaft gear bolt washer and the camshaft sub-gear.
  HINT:
  
  Attach the pins on the gears to the gear bolt washer ends.
3. Install the wave washer.
  
  Fig 53: Installing Camshaft Gear Bolt Washer And Camshaft Sub-Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using snap ring pliers, install the snap ring.
  
  Fig 54: Removing/Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
  SST 09960-10010 (09962-01000, 09963-00500)
6. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

NOTE: Be careful not to damage the camshaft journals.

Fig 55: Installing Service Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installation of the service bolt.
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
1. Align the alignment pin with the alignment pin groove and install VVT-i on the camshaft.
  NOTE: Install it with the lock-pin engaged and locked at the most retard angle position.
  
  Fig 56: Aligning Alignment Pin With Alignment Pin Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply engine oil to the nut, the mounting surface of VVT-i and the screw threads.
  NOTE:
  - Be sure to apply the oil, otherwise the specified torque cannot be obtained.
  - New nuts must be used when replacing the VVT-i unit.
3. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
Torque: 150 N*m (1,530 kgf*cm, 111 ft.*lbf)
NOTE:
- The lock nut has LH threads.
- Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.
Fig 57: Tightening Lock Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CAMSHAFT
NOTE: Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Place the No. 2 camshaft at a 90° angle of the timing mark (2-dot marks) on the cylinder head.
3. Apply MP grease to a new oil seal lip.
  
  Fig 58: Placing No 2 Camshaft At 90° Angle Of Timing Mark (2-Dot Marks) On Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil seal to the camshaft.
  NOTE:
  - Do not turn over the oil seal lip.
  - Insert the oil seal until it stops.
5. Remove any old packing material from the contact surface.
  
  Fig 59: Installing Oil Seal To Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply seal packing to the No. 1 bearing cap as shown in the illustration.
  Seal packing:
  
  Part No.08826-00080 or equivalent
  NOTE:
  - Install the No. 1 bearing cap within 5 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
  Fig 60: Locating Seal Packing On No. 1 Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the 5 bearing caps in their proper locations.
  
  Fig 61: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Apply a light coat of engine oil to the threads of the bearing cap bolts.
9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
INSTALL CAMSHAFT
NOTE: Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
  
  Fig 62: Identifying Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the timing marks (2-dot marks) of the camshaft drive gear with the mark on the driven gears.
3. Place the camshaft on the cylinder head.
  
  Fig 63: Aligning Timing Marks (2-Dot Marks) Of Camshaft Drive Gear With Mark On Driven Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 5 bearing caps in their proper locations.
5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 64: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
7. Remove the service bolt.
Fig 65: Identifying Bearing Cap Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
NOTE: Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Place the No. 4 camshaft at a 90° angle of the timing mark (1-dot mark) on the cylinder head.
3. Apply MP grease to a new oil seal lip.
  
  Fig 66: Placing No 4 Camshaft At 90° Angle Of Timing Mark (1-Dot Mark) On Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil seal to the camshaft.
  NOTE:
  - Do not turn over the oil seal lip.
  - Insert the oil seal until it stops.
5. Remove any old packing material from the contact surface.
  
  Fig 67: Installing Oil Seal To Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply seal packing to the No. 1 bearing cap as shown in the illustration.
  Seal packing:
  
  Part No.08826-00080 or equivalent
  NOTE:
  - Install the No. 1 bearing cap within 5 minutes after applying seal packing.
  - Do not expose the seal to engine oil within 2 hours after installing.
  Fig 68: Locating Seal Packing On No. 1 Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the 5 bearing caps in their proper locations.
8. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 69: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
NOTE: Since 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
  
  Fig 70: Identifying Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the timing marks (1-dot mark) of the camshaft drive gear with the mark on the driven gear.
3. Place the camshaft on the cylinder head.
  
  Fig 71: Aligning Timing Marks (1-Dot Mark) Of Camshaft Drive Gear With Mark On Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 5 bearing caps in their proper locations.
5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 72: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
7. Remove the service bolt.
  
  Fig 73: Identifying Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING PULLEY
1. Align the keyway of the timing pulley with the key located on the crankshaft and slide the timing pulley into place.
  NOTE: Do not scratch the sensor area of the crankshaft timing pulley.
2. Install the timing belt plate with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Fig 74: Aligning Keyway Of Timing Pulley With Key Located On Crankshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket and the water pump with the 3 bolts and 3 nuts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
INSTALL OIL LEVEL GAGE GUIDE
1. Apply a light coat of engine oil to a new O-ring and install it to the level gage guide.
2. Install the level gage guide.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Fig 75: Installing Water Pump Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER SUB-ASSEMBLY
1. Using a socket hexagon wrench 12, install the oil filter union.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
2. Check and clean the oil filter installation surface.
3. Apply clean engine oil to the gasket of a new oil filter.
4. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
5. Using SST, tighten it an additional 3/4 turn.
SST 09228-07501

Fig 76: Tightening Oil Filter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT IDLER BRACKET
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)

INSTALL TIMING BELT NO. 3 COVER

Visually check for cracks and breaks on the gasket of the timing belt cover.
HINT:

If a trace of water is found in the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.
If the timing belt cover gasket is needed to repair, follow the procedure below.
1. Repair the cracks and breaks by applying the seal packing to the damaged area.
Seal packing:

Part No.08826-00080 or equivalent

NOTE: When applying the seal packing, apply it as wide and high as the gasket.

If the timing belt cover gasket is needed to replace, follow the procedure below.

Using a screwdriver and gasket scraper, remove the remaining gasket.
NOTE: Be careful not to damage the timing belt cover.

Fig 77: Applying Seal Packing To Damaged Area
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.

NOTE:

Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform.

GASKET LENGTH SPECIFICATION

Gasket	D	E	F	G
Length	335 mm (13.19 in.)	180 mm (7.09 in.)	133 mm (5.24 in.)	72 mm (2.83 in.)

Fig 78: Affixing Gasket Along Groove Of Timing Belt Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If there is a gap on the joint of the gasket, apply seal packing to close the gap.

Seal packing:

Part No.08826-00080 or equivalent

NOTE: When applying the seal packing, apply it as wide and high as the gasket.

Install the timing belt cover with the 6 bolts.

Torque: 8.5 N*m (87 kgf*cm, 76 in.*lbf)

Fig 79: Installing Timing Belt Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CAMSHAFT TIMING PULLEY
1. Pay attention to the orientation of the belt guide, install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporally.
  
  Fig 80: Identifying Camshaft Timing Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Face the belt guide of the RH timing pulley toward front of the engine.
  - Face the belt guide of the LH timing pulley toward rear of the engine.
2. Using SST, tighten the RH pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000) Torque: 125 N*m (1,275 kgf*cm, 92 ft.*lbf)
  
  Fig 81: Tightening RH Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000) Torque: 125 N*m (1,275 kgf*cm, 92 ft.*lbf)
INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2
1. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 1
1. Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt.
Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)

INSTALL TIMING BELT

Remove any oil or water on the pulleys, and keep them clean.
NOTE:
- If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
- Wipe only the pulleys; do not use any cleaning agent.
Inspect the idler pulleys.

Fig 82: Tightening LH Pulley Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Check that the idler pulley turns smoothly.
2. Visually check the seal portion of the idler pulley for oil leakage.
Inspect the water pump.
1. Turn the pulley, and check that the water pump bearing moves smoothly and does not make noise.
2. Visually check the drain hole for coolant leakage.
Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
Turn the crankshaft counterclockwise by approximately 60°.
NOTE: To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.

Fig 83: Turning Crankshaft Counterclockwise By Approximately 60°
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, turn the crankshaft pulley, and align the timing marks of the timing pulley with the No. 3 timing belt cover.
SST 09960-10010 (09962-01000, 09963-01000)

Fig 84: Aligning Timing Marks Of Timing Pulley With No 3 Timing Belt Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.

Fig 85: Aligning Timing Mark Of Crankshaft Timing Pulley With Oil Pump Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Face the front mark on the timing belt forward.
Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.

Fig 86: Aligning Installation Mark On Timing Belt With Timing Mark Of Crankshaft Timing Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the timing belt in this order.

TIMING BELT INSTALLATION SEQUENCE

1st	Crankshaft timing pulley
2nd	Water pump pulley
3rd	LH camshaft timing pulley
4th	No.2 idler pulley
5th	RH camshaft timing pulley
6th	No.1 idler pulley

Fig 87: Identifying Timing Belt Installation Order

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
1. Set the timing belt tensioner upright on the press.
2. Slowly press in the push rod.
  NOTE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.
3. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
4. Release the press.
5. Temporarily install the tensioner with the 2 bolts.
  Alternately tighten the 2 bolts.
  
  Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
  
  NOTE: Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause failure of its operation.
6. Remove the 1.5 mm hexagon wrench from the tensioner.
  
  Fig 88: Pressing In Push Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Turn the crankshaft 2 revolutions slowly, and align the timing mark of the crankshaft timing pulley with the oil pump body.
  NOTE: Always turn the crankshaft clockwise.
  
  Fig 89: Aligning Timing Mark Of Crankshaft Timing Pulley With Oil Pump Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it.
9. Remove the crankshaft pulley bolt.
Fig 90: Aligning Timing Marks Of RH And LH Timing Pulleys With Timing Marks Of No 3 Timing Belt Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT GUIDE NO. 2
1. Install the timing belt guide with the cup side facing toward the engine front.
INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
INSTALL TIMING BELT NO. 2 COVER
1. Visually check for cracks and breaks on the gasket of the timing belt cover.
  If there is a trace that water is entering at the visual check, replace the timing belt cover.
2. Install the timing belt cover.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)

Fig 91: Installing Timing Belt Guide
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT NO. 1 COVER
1. Visually check for cracks and breaks on the gasket of the timing belt cover.
  If a trace of water is found in the visual check, replace the timing belt cover.
2. Install the timing belt cover.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
INSTALL CRANKSHAFT PULLEY
1. Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
2. Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021

Torque: 220 N*m (2,250 kgf*cm, 162 ft.*lbf)
INSTALL VVT SENSOR
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Fig 92: Installing Crankshaft Pulley Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE HANGER NO. 2
1. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)
INSPECT VALVE CLEARANCE
1. Turn the crankshaft pulley, and align the timing notch with the timing mark "0" of the No. 1 timing belt cover.
2. Check that the valve lifters on the No. 1 cylinder (IN and EX) are both loose.
  If not, turn the crankshaft 1 revolution (360°) and align the mark as above.
  
  Fig 93: Aligning Timing Notch With Timing Mark "0" Of No 1 Timing Belt Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the valves indicated in the illustration on the left.
  1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
    Valve clearance (Cold):
    
    Intake:
    
    0.15 to 0.25 mm (0.0059 to 0.0098 in.)
    
    Exhaust:
    
    0.25 to 0.35 mm (0.0098 to 0.0138 in.)
  2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
  Fig 94: Identifying Valves For Measuring Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
  1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
    Valve clearance (Cold):
    
    Intake:
    
    0.15 to 0.25 mm (0.0059 to 0.0098 in.)
    
    Exhaust:
    
    0.25 to 0.35 mm (0.0098 to 0.0138 in.)
  2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
  Fig 95: Identifying Valves For Measuring Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
  Valve clearance (Cold):
  
  Intake:
  
  0.15 to 0.25 mm (0.0059 to 0.0098 in.)
  
  Exhaust:
  
  0.25 to 0.35 mm (0.0098 to 0.0138 in.)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
Fig 96: Identifying Valves For Measuring Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST VALVE CLEARANCE

Turn the camshaft so that the cam lobe faces upward.
Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.

Fig 97: Turning Valve Lifter With Screwdriver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter.

Remove SST (A).

SST 09248-55040 (09248-05410, 09248-05420)

HINT:

Apply SST (B) at a slight angle on the side marked with "9" or "7" at the position shown in the illustration.
When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side at a slight angle.

SST SPECIFICATION

SST (A)	09248-05410
SST (B)	09248-05420

Fig 98: Pressing Down Valve Lifter And Placing SST (B) Between Camshaft And Valve Lifter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a screwdriver and magnetic finger, remove the adjusting shim.

Fig 99: Removing Adjusting Shim
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a micrometer, measure the thickness of the removed shim.

Calculate the thickness of a new shim so the valve clearance comes within the specified value.

SHIM THICKNESS REFERENCE

A	Thickness of new shim
B	Thickness of used shim
C	Measured valve clearance

Specified value (Cold):

Intake A = B + (C - 0.20 mm (0.0079 in.)

Exhaust A = B + (C - 0.30 mm (0.0118 in.)

Fig 100: Checking Thickness Of Removed Shim

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a new shim with a thickness as close as possible to the calculated values.

Fig 101: Adjusting Shim Selection Chart (Intake Valve)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 102: Adjusting Shim Selection Chart (Exhaust Valve)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUSTING SHIM SELECTION EXAMPLE

EXAMPLE (Intake):

Measured valve clearance = 0.45 mm (0.0177 in.)

0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.)

(Measured - Specification = Excess clearance)

Used shim measurement = 2.80 mm (0.1102 in.)

0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.)

(Excess clearance + Used shim = Ideal new shim)

Closest new shim = 3.05 mm (0.1201 in.)

Select No.12 shim

HINT:

Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
Refer to NEW SHIM THICKNESS TABLE .
New lifter thickness mm (in.)

NEW LIFTER THICKNESS SPECIFICATION

Lifter No.	Thickness	Lifter No.	Thickness	Lifter No.	Thickness
12	5.12 (0.2016)	32	5.32 (0.2094)	52	5.52 (0.2173)
14	5.14 (0.2024)	34	5.34 (0.2102)	54	5.54 (0.2181)

Intake valve clearance (Cold):

0.15 to 0.25 mm (0.0059 to 0.0098 in.)

EXAMPLE:

The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No. 12 shim.

New shim thickness mm (in.)

NEW SHIM THICKNESS SPECIFICATION

Shim No.	Thickness	Shim No.	Thickness
1	2.500 (0.0984)	10	2.950 (0.1161)
2	2.550 (0.1004)	11	3.000 (0.1181)
3	2.600 (0.1024)	12	3.050 (0.1201)
4	2.650 (0.1043)	13	3.100 (0.1220)
5	2.700 (0.1063)	14	3.150 (0.1240)
6	2.750 (0.1083)	15	3.200 (0.1260)
7	2.800 (0.1102)	16	3.250 (0.1280)
8	2.850 (0.1122)	17	3.300 (0.1299)
9	2.900 (0.1142)	-	-

HINT:

New shims have the thickness in millimeters imprinted on the face.

Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.0098 to 0.0138 in.)

EXAMPLE:

The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.).

Replace the 2.800 mm (0.1102 in.) shim with a new No.10 shim.

New shim thickness mm (in.)

NEW SHIM THICKNESS SPECIFICATION

Shim No.	Thickness	Shim No.	Thickness
1	2.500 (0.0984)	10	2.950 (0.1161)
2	2.550 (0.1004)	11	3.000 (0.1181)
3	2.600 (0.1024)	12	3.050 (0.1201)
4	2.650 (0.1043)	13	3.100 (0.1220)
5	2.700 (0.1063)	14	3.150 (0.1240)
6	2.750 (0.1083)	15	3.200 (0.1260)
7	2.800 (0.1102)	16	3.250 (0.1280)
8	2.850 (0.1122)	17	3.300 (0.1299)
9	2.900 (0.1142)	-	-

HINT:

New shims have the thickness in millimeters imprinted on the face.

Place a new adjusting shim on the valve lifter with imprinted number facing down.
Press down the valve lifter with SST (A), and remove SST (B).
SST 09248-55040 (09248-05410, 09248-05420)
Recheck the valve clearance.

Fig 103: Pressing Down Valve Lifter With SST (A) And Removing SST (B)

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the gasket to the cylinder head as shown in the illustration.
2. Apply seal packing to the cylinder head as shown in the illustration.
  Seal packing:
  
  Part No.08826-00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
3. Install the cylinder head cover with the 9 bolts.
Tighten the bolts uniformly in several steps.

Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf)

Fig 104: Applying Seal Packing To Cylinder Head
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Install the gasket to the cylinder head cover.
2. Apply seal packing to the cylinder head as shown in the illustration.
  Seal packing:
  
  Part No.08826-00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
3. Install the cylinder head cover with the 9 bolts.
Tighten the bolts uniformly in several steps.

Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf)

Fig 105: Applying Seal Packing To Cylinder Head
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG
1. Install the spark plug.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)