Reassembly [09/2015 - ]: Procedure

INSTALL RING PIN

NOTE:

It is not necessary to remove the ring pin unless it is being replaced.

for Camshaft Housing Sub-assembly Side:

Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing sub-assembly.

Standard protrusion height

2.7 to 3.3 mm (0.106 to 0.130 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Protrusion Height

for Stiffening Crankcase Sub-assembly Side:

Using a plastic-faced hammer, tap in 2 new ring pins to the stiffening crankcase sub-assembly.

Standard protrusion height

4.3 to 5.3 mm (0.169 to 0.209 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Protrusion Height

INSTALL STUD BOLT

NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

for Camshaft Housing Sub-assembly Side:

Apply adhesive to camshaft housing sub-assembly side threads of the stud bolt.

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	20 mm (0.787 in.)
*b	13 mm (0.512 in.)
*c	35 mm (1.38 in.)

Using an E8 "TORX" socket wrench, install the stud bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

for Transverse Engine Mounting Bracket Side:

Install the stud bolt.

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	34 mm (1.34 in.)
*b	25 mm (0.984 in.)
*c	76 mm (2.99 in.)

for Stiffening Crankcase Sub-assembly Side:

Using an E5 and E8 "TORX" socket wrench, install the stud bolts.

for stud bolt A

Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf)

for stud bolt B

Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Front Side	*b	Lower Side
*c	20 mm (0.787 in.)	*d	13 mm (0.512 in.)
*e	35 mm (1.38 in.)	*f	8.5 mm (0.335 in.)
*g	8.0 mm (0.315 in.)	*h	18 mm (0.709 in.)

INSTALL ENGINE BALANCER ASSEMBLY

Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Balance Shaft Damper Cover
*2	Balance Shaft Driven Gear
*a	Alignment Mark

If the alignment marks are not aligned, realign them.

Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Balance Shaft Damper Cover
*2	Balance Shaft Driven Gear
*a	Alignment Mark

Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.

Install the engine balancer assembly to the stiffening crankcase sub-assembly with the 4 bolts and tighten the bolts in the sequence shown in the illustration.

for bolt A

Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

for bolt B

Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)

Bolt Length

Item	Specified Condition
Bolt A	55 mm (2.17 in.)
Bolt B	45 mm (1.77 in.)

Fig 1: Engine Balancer Assembly Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Bolt Type
*b	Tightening Order

INSTALL STIFFENING CRANKCASE ASSEMBLY

Rotate the crankshaft clockwise so that the crankshaft pulley set key is at the position 90° from the bottom as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Crankshaft Pulley Set Key

Clean the stiffening crankcase assembly and cylinder block sub-assembly.

Apply seal packing to the areas as shown in the illustration.

Seal packing

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

Standard Seal Dimension

Area	Specified Condition
Continuous Line	2.5 to 3.5 mm (0.0984 to 0.138 in.)
Dashed Line	7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick

Application length A

28 mm (1.10 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Seal Packing
*b	28 mm (1.10 in.)
*c	2.5 to 3.5 mm (0.0984 to 0.138 in.)
*d	7.0 to 9.0 mm (0.276 to 0.354 in.)

NOTE:

Remove any oil from the contact surface.
Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
Do not add engine oil within 2 hours of installation.
Do not start the engine for at least 2 hours after the installation.

Check that the rear cutouts are as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Cutout

Clean the bolts and their installation holes.

NOTE:

Check that there is no oil in the installation holes indicated in the illustration. Remove if there is any oil.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive to the threaded portion of bolt A shown in the illustration.

Adhesive

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Fig 2: Stiffening Crankcase Assembly Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Bolt Type
*b	Tightening Order

NOTE:

Install the bolt within 3 minutes of applying adhesive.

Temporarily install the stiffening crankcase assembly with the 11 bolts.

Bolt Length

Item	Specified Condition
Bolt A	65 mm (2.56 in.)
Bolt B	35 mm (1.38 in.)
Bolt C	125 mm (4.92 in.)
Bolt D	165 mm (6.50 in.)

Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase assembly.
for bolt A

Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)

except bolt A

Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

INSTALL ENGINE OIL TEMPERATURE SENSOR
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL NO. 1 OIL PAN BAFFLE PLATE
1. Install the No. 1 oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the sequence shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 3: No. 1 Oil Pan Baffle Plate Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Apply a light coat of engine oil to a new gasket.
2. Align the protrusion of the gasket with the cutout of the oil strainer sub-assembly and install the gasket to the oil strainer sub-assembly.
  
  Fig 4: Oil Strainer Sub-Assembly Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  *a Protrusion
3. Install the oil strainer sub-assembly with the 3 bolts in several steps in the sequence shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL ENGINE OIL LEVEL SENSOR
Refer to PROCEDURE - Step 1 [10/2014 - ]

INSTALL OIL PAN SUB-ASSEMBLY

Apply seal packing in a continuous line as shown in the illustration.

Seal packing

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

Standard seal diameter

2.5 to 3.5 mm (0.0984 to 0.138 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Seal Packing

NOTE:

Remove any oil from the contact surface.
Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
Do not add engine oil within 2 hours of installation.
Do not start the engine for at least 2 hours after the installation.

Install the oil pan sub-assembly with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Fig 5: Oil Pan Sub-Assembly Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OIL PAN DRAIN PLUG
1. Install a new gasket and the oil pan drain plug.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
INSTALL OIL COOLER ASSEMBLY
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL OIL FILTER BRACKET CLIP
1. Install the oil filter bracket clip to the stiffening crankcase assembly.
INSTALL OIL FILTER CAP ASSEMBLY
Refer to PROCEDURE - Step 3 [10/2014 - 05/2018] , or refer to PROCEDURE - Step 3 [05/2018 - ]
INSTALL REAR ENGINE OIL SEAL
Refer to PROCEDURE - Step 1 [10/2014 - ]

INSTALL CYLINDER BLOCK WATER JACKET SPACER

Install the cylinder block water jacket spacer to the cylinder block sub-assembly shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Engine Front Side
*b	Protrusion

NOTE:

Make sure that the protrusion of the cylinder block water jacket spacer is facing up when installing it.

INSTALL CYLINDER HEAD GASKET
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL CYLINDER HEAD SUB-ASSEMBLY
Refer to PROCEDURE - Step 2 [10/2014 - ]
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the 16 valve stem caps to the cylinder head sub-assembly.
  NOTE:
  - Install the valve stem cap at the same place it was removed from.
  - Do not drop the valve stem caps into the cylinder head sub-assembly.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the valve lash adjuster assembly free from dirt and foreign objects.
- Only use clean engine oil.
- If the valve lash adjuster assembly is tilted after bleeding, oil will leak. Make sure to bleed the valve lash adjuster assembly again.
1. Bleed the valve lash adjuster assembly.
  See step 2
2. If the plunger moves, bleed the valve lash adjuster assembly again.
3. Place the valve lash adjuster assembly into a container full of new engine oil, and then fill the low pressure chamber with engine oil.
4. Apply engine oil to the outer surface of the valve lash adjuster body and the tip of the plunger, and then install the valve lash adjuster assembly while turning it.
  NOTE:
  Install the valve lash adjuster assembly into the same place it was removed from.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Lash Adjuster Assembly
*3	Valve Stem Cap

Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
NOTE:
Install the No. 1 valve rocker arm sub-assemblies at the same place it was removed from.

INSTALL NO. 1 CAMSHAFT BEARING

Clean the No. 1 camshaft bearing.
NOTE:
Do not apply engine oil to the No. 1 camshaft bearing or contact surfaces.

Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Vernier Caliper

Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.
Standard dimension

A - B or B - A = 0 to 0.7 mm (0 to 0.0276 in.)

INSTALL NO. 2 CAMSHAFT BEARING

Clean the No. 2 camshaft bearing.
NOTE:
Do not apply engine oil to the No. 2 camshaft bearing or contact surfaces.

Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Vernier Caliper

Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.
Standard distance

A=1.15 to 1.85 mm (0.0453 to 0.0728 in.)

INSTALL OIL CONTROL VALVE FILTER
1. Check that there is no foreign matter on the mesh section.
2. Install the oil control valve filter to the No. 1 camshaft bearing cap.
  NOTE:
  Do not touch the mesh section on the oil control valve filter.
INSTALL NO. 2 CAMSHAFT
HINT:

Perform "Inspection After Repair" after replacing the No. 2 camshaft.

Refer to INITIALIZATION [10/2014 - 05/2019] , or refer to INITIALIZATION [05/2019 - ]
1. Clean the No. 2 camshaft journals and camshaft housing sub-assembly.
2. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.
3. Set the No. 2 camshaft to the camshaft housing sub-assembly.
INSTALL CAMSHAFT
HINT:

Perform "Inspection After Repair" after replacing the camshaft.

Refer to INITIALIZATION [10/2014 - 05/2019] , or refer to INITIALIZATION [05/2019 - ]
1. Clean the camshaft journals and camshaft housing sub-assembly.
2. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.
3. Set the camshaft to the camshaft housing sub-assembly.
INSTALL CAMSHAFT BEARING CAP
1. Clean the camshaft bearing caps.
2. Apply a light coat of engine oil to the camshaft journals and camshaft bearing caps.
3. Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.
4. Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 6: Camshaft Bearing Cap Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  After installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap, make sure that the camshaft and No. 2 camshaft rotate smoothly.
INSTALL NO. 3 WATER BY-PASS PIPE
1. Install a new gasket and the No. 3 water by-pass pipe with the 3 bolts in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 7: No. 3 Water By-Pass Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Make sure the claws of the gasket face the No. 3 water by-pass pipe.
2. Connect the No. 6 water by-pass hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Lash Adjuster Assembly
*3	Valve Stem Cap

Apply seal packing to the areas as shown in the illustration.

Seal packing

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

Standard seal diameter

3.0 to 4.0 mm (0.118 to 0.158 in.)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Seal Packing

NOTE:

Remove any oil from the contact surface.
Check the bolts and bolt holes and clean them.
Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
Do not add engine oil within 2 hours of installation.
Do not start the engine for at least 2 hours after the installation.

Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Approximately 17°
*b	Approximately 2°
*c	Knock Pin

Install the camshaft housing sub-assembly, and then install the 22 bearing cap bolts in the order shown in the illustration.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)

Fig 8: 22 Bearing Cap Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:
If the bolts have been loosened during the installation, apply seal packing black to the camshaft housing sub-assembly again.

INSTALL OIL PIPE SUB-ASSEMBLY
1. Install the oil pipe sub-assembly with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

NOTE:

There are different types of camshaft timing gear bolts. Make sure to check the identification mark to determine the tightening torque.

IDENTIFICATION MARK:

Item	Identification Mark
for Type A	A
for Type B	C

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Identification Mark

HINT:

Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

Refer to INITIALIZATION [10/2014 - 05/2019] , or refer to INITIALIZATION [05/2019 - ]

Align the knock pin of the camshaft with the knock pin hole of the camshaft timing gear assembly and attach the camshaft timing gear assembly to the camshaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Knock Pin Hole
*b	Knock Pin

NOTE:

Do not forcefully press the camshaft timing gear assembly. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly, leading to poor sealing.

Check that there is no clearance between the camshaft timing gear assembly and portion A of the camshaft indicated in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Camshaft Timing Gear Assembly
*a	Incorrect
*b	Correct
*c	Portion A of Camshaft
*d	No Clearance

Apply engine oil to the areas of the camshaft timing gear bolt indicated in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily install the camshaft timing gear bolt.
HINT:

When temporarily installing the camshaft timing gear bolt, make sure that it is screwed in approximately 2 threads.

Use a wrench to hold the hexagonal portion of the camshaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Hold
	Turn

Tighten the camshaft timing gear bolt.
Type A

Torque: 120 N*m (1224 kgf*cm, 89 ft.*lbf)

Type B

Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
NOTE:
- Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
- Do not disassemble the camshaft timing gear assembly.

INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

Refer to INITIALIZATION [10/2014 - 05/2019] , or refer to INITIALIZATION [05/2019 - ]

Align the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear assembly and attach the camshaft timing exhaust gear assembly to the No. 2 camshaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Knock Pin Hole
*b	Knock Pin

NOTE:

Do not forcefully press the camshaft timing exhaust gear assembly. Otherwise, the tip of knock pin of the No. 2 camshaft may damage the seal surface of the camshaft timing exhaust gear assembly, leading to poor sealing.

Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Camshaft Timing Exhaust Gear Assembly
*a	Incorrect
*b	Correct
*c	No. 2 Camshaft Flange
*d	No Clearance

Use a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)

*a	Hold
	Turn

NOTE:

Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
Do not disassemble the camshaft timing exhaust gear assembly.

INSTALL CRANKSHAFT TIMING SPROCKET
1. Install the crankshaft timing sprocket to the crankshaft.

ADD ENGINE OIL

Add 50 cc (3.1 cu.in.) of engine oil into the oil hole shown in the illustration.

NOTE:

Oil must be added if the valve lash adjuster assemblies were removed.
Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.

INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Temporarily install the No. 1 chain vibration damper with the 2 bolts.
  
  Fig 9: No. 1 Chain Vibration Damper Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 2 bolts in the order shown in the illustration.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

INSTALL CHAIN SUB-ASSEMBLY

Temporarily install the crankshaft pulley set bolt.

Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley set key as shown in the illustration.

*1	Crankshaft Pulley Set Key

Check that the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.

*a	Timing Mark
*b	Approximately 7°
*c	Approximately 32°

Place the chain sub-assembly onto the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.
HINT:
- Make sure the mark plate of the chain sub-assembly faces away front of the engine.
- It is not necessary to install the chain sub-assembly to teeth of the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

Align the mark plate (orange) of the chain sub-assembly with the timing mark of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

*a	Mark Plate (Orange)
*b	Timing Mark

Align the mark plate (yellow) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.

*a	Mark Plate (Yellow)
*b	Timing Mark

Tie a string above the crankshaft timing sprocket so that the chain sub-assembly in secure.

Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear assembly with the mark plate (orange) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.

*a	Mark Plate (Orange)
*b	Timing Mark

HINT:

Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.

NOTE:

Make sure the chain sub-assembly is secure.

INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Install a new gasket and the No. 1 chain tensioner assembly with the bolt and nut.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Remove the pin from the stopper plate.
INSTALL TIMING CHAIN GUIDE
1. Install the timing chain guide with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
SET NO. 1 CYLINDER TO TDC/COMPRESSION
See step 35
INSTALL TIMING CHAIN COVER PLATE
1. Install a new gasket and the timing chain cover plate with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL TIMING CHAIN COVER ASSEMBLY
Refer to PROCEDURE - Step 1 [09/2015 - ]
INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
Refer to PROCEDURE - Step 2 [09/2015 - ]
INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
Refer to PROCEDURE - Step 1 [10/2014 - ]

INSTALL SPARK PLUG TUBE GASKET

NOTE:

Be sure not to disconnect the PCV hose or the No. 4 PCV hose from the cylinder head cover sub-assembly.

Install the 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

*1	Spark Plug Tube Gasket
*2	Cylinder Head Cover Sub-assembly
*a	No Clearance

NOTE:

Do not install the spark plug tube gasket at an angle.
Keep the lip free from foreign matter.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Refer to PROCEDURE - Step 10 [09/2015 - ]

INSTALL CRANKSHAFT PULLEY ASSEMBLY

Align the crankshaft pulley set key with the crankshaft pulley set key groove of the crankshaft pulley assembly.

Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley set bolt.

SST: 09213-54015
SST: 09330-00021

Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf)

*a	Hold
	Turn

HINT:

Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

INSTALL NO. 1 PCV CASE

Apply seal packing to a new No. 1 PCV case in the areas indicated in the illustration.

Seal packing

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

Standard seal diameter

2.5 to 3.5 mm (0.0984 to 0.138 in.)

*a	Seal Packing

NOTE:

Do not reuse the No. 1 PCV case
Remove any oil from the contact surface.
Install the No. 1 PCV case within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not add engine oil within 2 hours of installation.
Do not start the engine for at least 2 hours after the installation.

HINT:

Make sure to apply seal packing so that there are no gaps in the areas indicated by A in the illustration.

Install the No. 1 PCV case, and then install the 6 bolts and 2 nuts in the order shown in the illustration.

Fig 10: No. 1 PCV Case Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSTALL PCV VALVE SUB-ASSEMBLY
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL CRANKSHAFT POSITION SENSOR
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL KNOCK SENSOR
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL SPARK PLUG
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL THERMOSTAT (for Cylinder Block)
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL WATER INLET HOUSING
Refer to PROCEDURE - Step 2 [10/2014 - ]
INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY
Refer to PROCEDURE - Step 1 [10/2014 - ]

INSTALL NO. 4 WATER BY-PASS PIPE

Install a new gasket and the No. 4 water by-pass pipe with the 2 nuts and bolt in the order shown in the illustration.

Fig 11: No. 4 Water By-Pass Pipe Tightening Sequence

*a	Bolt
*b	Nut

for nut

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

for bolt

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

Connect the No. 4 water by-pass hose to the oil cooler assembly, and slide the clamp to secure the hose.

INSTALL NO. 1 WATER BY-PASS PIPE
Refer to PROCEDURE - Step 4 [10/2014 - ]
INSTALL NO. 4 EXHAUST MANIFOLD HEAT INSULATOR
Refer to PROCEDURE - Step 5 [10/2014 - ]
INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR
Refer to PROCEDURE - Step 6 [10/2014 - ]
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Refer to PROCEDURE - Step 7 [10/2014 - ]
INSTALL VACUUM PUMP ASSEMBLY
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL FUEL INJECTOR SEAL (for Direct Injection)
Refer to PROCEDURE - Step 1 [09/2015 - ]
INSTALL FUEL INJECTOR SET (for Direct Injection)
Refer to PROCEDURE - Step 2 [09/2015 - ]
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection)
Refer to PROCEDURE - Step 3 [09/2015 - ]
INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)
Refer to PROCEDURE - Step 1 [10/2014 - ]
INSTALL FUEL DELIVERY PIPE (for Port Injection)
Refer to PROCEDURE - Step 2 [10/2014 - ]
SET FUEL PUMP ASSEMBLY (for High Pressure)
Refer to PROCEDURE - Step 1 [09/2015 - 09/2017] , or refer to PROCEDURE - Step 1 [09/2017 - ]
TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)
Refer to PROCEDURE - Step 2 [09/2015 - 09/2017] , or refer to PROCEDURE - Step 2 [09/2017 - ]
INSTALL FUEL PUMP ASSEMBLY (for High Pressure)
Refer to PROCEDURE - Step 3 [09/2015 - 09/2017] , or refer to PROCEDURE - Step 3 [09/2017 - ]
TIGHTEN NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)
Refer to PROCEDURE - Step 4 [09/2015 - 09/2017] , or refer to PROCEDURE - Step 4 [09/2017 - ]
INSTALL BRACKET
Refer to PROCEDURE - Step 6 [09/2015 - 09/2017] , or refer to PROCEDURE - Step 6 [09/2017 - ]
INSTALL FUEL PUMP PROTECTOR
Refer to PROCEDURE - Step 7 [09/2015 - 09/2017] , or refer to PROCEDURE - Step 7 [09/2017 - ]