Engine Unit: Reassembly

1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.
   Fig 4: Installing Snap Ring On Piston Pin Hole

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2. Gradually heat the piston to about 60°C (140°F).
   Fig 5: Heating Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the piston pin with engine oil.
4. The piston's front mark and the connecting rod's outside mark should face the same direction, as shown in the illustration.
   NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "3L" and the RH piston is marked with "3R".
5. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
   Fig 6: Identifying Piston'S Front Mark Installation Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check the fit between the piston and piston pin.
   1. Try to move the piston back and forth on the piston pin.
   Fig 7: Checking Fitting Between Piston And Piston Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
   Fig 8: Identifying Snap Ring On Piston Pin Hole

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8. Install the oil ring expander and 2 side rails by hand.
9. Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

   Code mark 

   PISTON RING CODE MARK REFERENCE
   
   

   Piston Ring	Code Mark
   No. 1	1R
   No. 2	2R

   Fig 9: Installing Oil Ring Expander And 2 Side Rails By Hand

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 10: Identifying Piston Rings Installing Positions

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   Position the piston rings so that the ring ends are as shown in the illustration.

   NOTE: Do not align the ring ends.

1. Align the bearing claw with the groove of the connecting rod or connecting cap.
2. Install the bearings in the connecting rod and connecting rod cap.

Fig 11: Installing Bearings In Connecting Rod And Connecting Rod Cap

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HINT:

• Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions.
• Upper bearings have an oil groove and oil holes; lower bearings do not.

Fig 12: Identifying Crankshaft Bearing Installation Position

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1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
   Fig 13: Aligning Bearing Claw With Claw Groove Of Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

   HINT:

   A number is marked on each bearing cap to indicate the installation position.

Fig 14: Aligning Bearing Claw With Claw Groove Of Crankshaft Bearing Cap

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1. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
   Fig 15: Installing Thrust Washers Under No 3 Journal Position Of Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.

Fig 16: Installing Thrust Washers On No 3 Bearing Cap With Grooves

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1. Place the crankshaft on the cylinder block.
   Fig 17: Identifying Crankshaft Bearing Installation Position

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2. Install the 5 crankshaft bearing cap in their proper locations.

   HINT:

   Place the bearing caps level and let them return to their original positions by their own weight.

   NOTE: Do not install the bearing cap by tapping it.
   Fig 18: Identifying Crankshaft Bearing Cap In Proper Installation Position

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3. Install the crankshaft bearing cap bolts.

   HINT:

   If any one of the bearing cap bolts is broken or deformed, replace it.

   1. Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts.
   2. Install and uniformly tighten the 20 crankshaft bearing cap bolts in several passes in the sequence shown in the illustration.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      If any of the bearing cap bolts cannot meet the torque specification, replace the bearing cap bolt.

      Fig 19: Identifying Tightening Sequence Of Crankshaft Bearing Cap Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Mark the front of the crankshaft bearing cap bolt's head with paint.
   4. Retighten the crankshaft bearing cap bolts by 90° as shown in the illustration.
   5. Check that the painted mark is now at a 90° angle to the front.
      Fig 20: Retightening Crankshaft Bearing Cap Bolts By 90°

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   6. Install a new seal washer to the crankshaft bearing cap bolt.
   7. Install and uniformly tighten the 10 crankshaft bearing cap bolts.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

4. Check that the crankshaft turns smoothly.
5. Check the crankshaft thrust clearance.

Fig 21: Identifying Crankshaft Bearing Cap Bolts

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1. 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: The shape of the piston varies for the LH and RH banks. The LH piston is marked with "3L" and the RH piston is marked with "3R".
   Fig 22: Installing Piston And Connecting Rod

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2. Place the connecting rod cap on the connecting rod.
   1. Match the numbered connecting rod cap with the connecting rod.
   2. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.
      Fig 23: Aligning Pin Groove Of Connecting Rod Cap With Pins Of Connecting Rod

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Check that the outside mark of the connecting rod cap is facing in correct direction.
   Fig 24: Identifying Outside Mark On Connecting Rod Cap

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3. Install the connecting rod cap bolts.

   HINT:

   If any one of the connecting rod cap bolts is broken or deformed, replace it.

   1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
   2. Install and alternately tighten the 2 connecting rod cap bolts in several passes.

      Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) 

      If any of the connecting rod cap bolts cannot meet the torque specification, replace the connecting rod cap bolts.

      Fig 25: Tightening Connecting Rod Cap Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Mark the front of the connecting cap bolt with paint.
   4. Retighten the cap bolts 90° as shown in the illustration.
   5. Check that the painted mark is now at a 90° angle to the front.
4. Check that the crankshaft turns smoothly.
5. Check the connecting rod thrust clearance.

Fig 26: Retightening Cap Bolts 90°

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing (FIPG) material.
2. Apply seal packing to the seal plate as shown in the illustration.

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal width: 

   2 to 3 mm (0.08 to 0.12 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the seal plate within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
3. Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.

   Torque: 14 N*m (142 kgf*cm, 10 ft.*lbf) 

Fig 27: Applying Seal Packing To Seal Plate

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1. Apply seal packing to 2 or 3 threads.

   Seal packing: 

   Part No. 08826-00100 or equivalent 

   Fig 28: Applying Seal Packing To Threads

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the RH and LH drain cocks.

   Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

   HINT:

   After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

Fig 29: Identifying RH And LH Drain Cocks

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1. Place a new oil seal into the timing tube.
   NOTE: Be careful of the installation direction.

Fig 30: Identifying Camshaft Setting Oil Seal

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1. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
2. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.

   SST 09960-10010 (09962-01000, 09963-00500) 

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

   NOTE: Be careful not to damage the timing tube.
   Fig 31: Aligning Timing Tube Knock Pin With Knock Pin Groove Of Drive Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mount the hexagon wrench head portion of the camshaft in a vise.
   NOTE: Be careful not to damage the camshaft.
   Fig 32: Identifying Hexagonal Portion Of Camshaft In Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
5. Using a 10 mm hexagon wrench, install the bolt.

   Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 

6. Install the seal washer and screw plug.

   Torque: 15 N*m (152 kgf*cm, 11 ft.*lbf) 

Fig 33: Tightening Camshaft Bolt

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1. Install the bolt washer (1), sub gear (2) and wave washer (3).

   HINT:

   Attach the pins on the gears to the gear bolt washer ends.

   Fig 34: Identifying Bolt Washer, Sub Gear And Wave Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using snap ring pliers, install the snap ring.
   Fig 35: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mount the hexagon wrench head portion of the camshaft in a vise.
   NOTE: Be careful not to damage the camshaft.
   Fig 36: Removing Camshaft Sub Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt.

   SST 09960-10010 (09962-01000, 09963-00500) 

5. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.

1. Remove any oil packing (FIPG) material.
   Fig 37: Aligning Holes Of Driven Main Gear And Sub Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to the oil seal retainer as shown in the illustration.

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal width: 

   3 to 4 mm (0.12 to 0.16 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil seal within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
   Fig 38: Applying Seal Packing To Oil Seal Retainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new O-ring to the cylinder block.
4. Install the oil seal retainer with the 7 bolts.
   Fig 39: Identifying Oil Seal Retainer With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install a new gasket and the water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt 

   18 N*m (184 kgf*cm, 13 ft.*lbf) for stud bolt and nut 

   HINT:

   Use the bolts that are 30 mm (1.18 in.) in length.

Fig 41: Locating Water Pump Bolts

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1. Place a new cylinder head gasket on the cylinder block.

   HINT:

   The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3R" mark is on the RH bank's gasket.

   NOTE: Be careful of the installation direction.
2. Place the cylinder head on the cylinder head gasket.
   Fig 42: Identifying Cylinder Head Gasket In Position On Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cylinder head bolts.

   HINT:

   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 place washer to the cylinder head bolt.
      Fig 43: Identifying Installing Sequence Of Cylinder Head Bolt (RH)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.

      Torque: 59 N*m (602 kgf*cm, 44 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 plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
      Fig 44: Identifying Portion A (RH Bank)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Mark the front of the cylinder head bolt's head with paint.
   5. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
   6. Check that the painted mark is now at a 90° angle to the front.

Fig 45: Retightening Cylinder Head Bolts By 90°

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place a new cylinder head gasket on the cylinder block.

   HINT:

   The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3L" mark is on the LH bank's gasket.

   NOTE: Be careful of the installation direction.
2. Place the cylinder head on the cylinder head gasket.
   Fig 46: Placing Cylinder Head Gasket In Position On Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cylinder head bolts.

   HINT:

   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 place washer to the cylinder head bolt.
      Fig 47: Identifying Cylinder Head Bolts Tightening Sequence

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.

      Torque: 59 N*m (602 kgf*cm, 44 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 plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
      Fig 48: Identifying Portion A (LH Bank)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Mark the front of the cylinder head bolt's head with paint.
   5. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
   6. Check that the painted mark is now at a 90° angle to the front.

Fig 49: Retightening Cylinder Head Bolts By 90°

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1. Set the crankshaft position.
   1. Using the crankshaft damper bolt, turn the crankshaft, and set the set key of the crankshaft to 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.
      NOTE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.
2. Apply MP grease to the thrust portion of the camshafts.
   Fig 50: Setting Crankshaft Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the 2 camshafts.
4. Set the timing marks (1 dot mark each) of the camshaft drive and driven main gears at approximately 10° angle.
   Fig 51: Aligning Timing Marks Of Camshaft Drive And Driven Main Gears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply seal packing to the camshaft housing plug.
   1. Remove the old packing (FIPG) material.
   2. Apply seal packing to the housing plug as shown in the illustration.

      Seal packing: 

      Part No. 08826-00080 or equivalent 

   Fig 52: Applying Seal Packing To Housing Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the camshaft housing plug to the cylinder head as shown in the illustration.
7. Install the oil control valve filter to the cylinder head.
   NOTE: Be careful of the installation direction.
   Fig 53: Identifying Camshaft Housing Plug To Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Apply seal packing to the front bearing cap.
   1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
   2. Apply seal packing to the bearing cap as shown in the illustration.

      Seal packing: 

      Part No. 08826-00080 or equivalent 

      Seal width: 

      1.5 to 2.0 mm (0.059 to 0.079 in.) 

      NOTE: Do not apply seal packing to the front bearing cap grooves.
   Fig 54: Applying Seal Packing To Front Bearing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Install the front bearing cap.

   HINT:

   Installing the front bearing cap will determine the thrust portion of the camshaft.

10. Install the other bearing caps in the sequence shown with the arrow mark facing forward.
    Fig 55: Identifying Front Bearing Cap Installing Sequence

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11. Push in the camshaft setting oil seal.
    Fig 56: Pushing Camshaft Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Install new seal washers to the bearing cap bolts (A and B).
13. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (D and E).
    NOTE: Do not apply engine oil under the heads of the bearing cap bolt A, B and C.
    Bolt length:
    94 mm (3.70 in.) for A with seal washer
    72 mm (2.83 in.) for B with seal washer
    25 mm (0.98 in.) for C
    52 mm (2.05 in.) for D
    38 mm (1.50 in.) for E
14. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
    Fig 57: Identifying Installing Sequence Of Bearing Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.

    Torque: 7.5 N*m (76 kgf*cm, 66 ft.*lbf) for bolts 21 and 22 

    Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)for other bolts 

    Fig 58: Identifying Bearing Cap Bolts Tightening Sequence

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16. Remove the service bolt.

Fig 59: Identifying Service Bolt

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1. Check that the set key of the crankshaft is at the position 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.
   NOTE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.
2. Apply MP grease to the thrust portion of the camshafts.
   Fig 60: Checking Set Key Of Crankshaft Position 45°

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the 2 camshafts.
   Fig 61: Aligning Timing Marks Of Camshaft Drive And Driven Main Gears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply seal packing to the camshaft housing plug.
   1. Remove the old packing (FIPG) material.
   2. Apply seal packing to the housing plug as shown in the illustration.

      Seal packing: 

      Part No. 08826-00080 or equivalent 

   Fig 62: Applying Seal Packing To Camshaft Housing Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the camshaft housing plug to the cylinder head as shown in the illustration.
6. Install the oil control valve filter to the cylinder head.
   NOTE: Be careful of the installation direction.
   Fig 63: Installing Camshaft Housing Plug To Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Apply seal packing to the front bearing cap.
   1. Remove any old packing (FIPG) material.
   2. Apply seal packing to the bearing cap as shown in the illustration.

      Seal packing: 

      Part No. 08826-00080 or equivalent 

      Seal width: 

      1.5 to 2.0 mm (0.059 to 0.079 in.) 

      NOTE: Do not apply seal packing to the front bearing cap grooves.
   Fig 64: Applying Seal Packing To Bearing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the front bearing cap.

   HINT:

   Installing the front bearing cap will determine the thrust portion of the camshaft.

9. Install the other bearing cap in the sequence shown with the arrow mark facing forward.
   Fig 65: Identifying Front Bearing Cap

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10. Push in the camshaft setting oil seal.
    Fig 66: Pushing Camshaft Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Install new seal washers to the bearing cap bolts (A and B).
12. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (D and E).
    NOTE: Do not apply engine oil under the heads of the bearing cap bolt A, B and C.
    Bolt length:
    94 mm (3.70 in.) for A with seal washer
    72 mm (2.83 in.) for B with seal washer
    25 mm (0.98 in.) for C
    52 mm (2.05 in.) for D
    38 mm (1.50 in.) for E
13. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
    Fig 67: Identifying Bearing Cap Bolt

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14. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.

    Torque: 7.5 N*m (76 kgf*cm, 66 ft*lbf) for bolts 21 and 22 

    Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) for other bolts 

    Fig 68: Identifying Installing Sequence Of Bearing Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Remove the service bolt.

1. Install the timing belt plate with the bolt and stud bolt.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. Install the timing belt plate with the 2 bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. Install the timing belt plate with the bolt.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. Install the timing belt plate with the 2 bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

Fig 69: Identifying Service Bolt

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1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward.
3. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

Fig 70: Tightening Pulley Bolts

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1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "L" mark forward.
3. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

Fig 71: Identifying Pulley Bolts

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1. Align the timing pulley set key with the key groove of the pulley.
2. Using SST and a hammer, tap in the timing pulley, facing the flange side inward.

   SST 09223-46011 

1. Install the idler with the bolt.

   Torque: 34.5 N*m (351 kgf*cm, 25 ft.*lbf) 

2. Check that the idler moves smoothly.

Fig 72: Tapping Timing Pulley

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1. Apply adhesive to 2 to 3 threads of the pivot bolt.

   Adhesive: 

   Part No. 08833-00080, THREE BOND 1344, LOCATE 242 or equivalent 

2. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.

   Torque: 34.5 N*m (351 kgf*cm, 25 ft.*lbf) 

3. Check that the idler bracket moves smoothly.

Fig 73: Installing Plate Washer And Idler With Pivot Bolt

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Fig 74: Identifying Timing Marks Of Camshaft Timing Pulleys And Timing Belt Plates

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1. Set the No. 1 cylinder to TDC/compression.
   1. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates aligned.

      HINT:

      Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.

      Camshaft timing pulley of LH bank: 1/2 of a tooth Camshaft timing pulley of RH bank: 1 tooth

      Fig 75: Identifying Make On Timing Belt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
   Fig 76: Turning Crankshaft Of Crankshaft Timing Pulley And Oil Pump Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the timing belt.
   1. Remove any oil or water on each pulley, and keep them clean.
      NOTE: Only wipe the pulleys. Do not use cleaning agents on the pulleys.
   2. Face the front mark (arrow) on the belt forward.
   3. Connect the belt to the crankshaft timing pulley. Align the installation mark of the crankshaft timing pulley.
   4. Connect the belt to the No. 2 idler.
   5. Connect the timing belt to the camshaft timing pulley LH. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
   6. Connect the timing belt to the water pump pulley.
   7. Connect the timing belt to the camshaft timing pulley RH. Align the installation mark on the belt with the timing mark of the camshaft timing pulley.
   8. Connect the timing belt to the No. 1 idler.
   Fig 77: Identifying Timing Mark Of Crankshaft Timing Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the belt tensioner.
   1. Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure.
   2. Align the holes of the push rod and housing. Pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
   3. Release the press.
   4. Install the dust boot to the belt tensioner.
   Fig 78: Aligning Holes Of Push Rod And Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the belt tensioner.
   1. Temporarily install the belt tensioner with the 2 bolts.
   2. Alternately tighten the 2 bolts.

      Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

   3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
   Fig 79: Identifying Belt Tensioner With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the valve timing.
   1. Using the crankshaft damper bolt, slowly turn the crankshaft timing pulley 2 revolutions from TDC to TDC.
      NOTE: Always turn the crankshaft pulley clockwise.
      Fig 80: Turning Crankshaft Pulley

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Check that each pulley aligns with the timing marks as shown in the illustration.

      If the timing marks do not align, remove the belt and reinstall it.

Fig 81: Aligning Timing Marks In Illustration

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the crankshaft position sensor plate as shown in the illustration.
   NOTE: Be careful of the installation direction.

1. Install the gasket to the cover spacer.
   Fig 82: Identifying Sensor Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cover spacer.

1. Install the timing belt cover with the 4 bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. Align the damper set key with the key groove of the crankshaft damper.
2. Using SST and a hammer, tap in the crankshaft damper.

   SST 09223-46011 

   Fig 83: Aligning Damper Set Key With Key Groove Of Crankshaft Damper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, install the damper bolt.
   Fig 84: Tightening Damper Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09213-70011,09330-00021 

   Torque: 245 N*m (2,498 kgf*cm, 181 ft.*lbf) 

1. Install the idler pulley and cover plate with the bolt.

   Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

1. Remove any old packing (FIPG) material.
2. Apply seal packing to the semicircular plug grooves.

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Fig 85: Applying Seal Packing To Semicircular Plug Grooves

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 semicircular plugs to the cylinder heads as shown in the illustration.

Fig 86: Identifying Bolts, Drive Gear And Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing (FIPG) material.
2. Apply seal packing to the cylinder heads as shown in the illustration.
   Fig 87: Applying Seal Packing To Cylinder Heads

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing: 

   Part No. 08826-00080 or equivalent 

3. Install the gasket to the cylinder head cover.
4. Install the seal washer to the bolt.
5. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.

   Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)