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Reassembly [10/2018 - ]: Procedure

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  1. INSTALL STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.

    1. Using a plastic hammer, tap in 4 new straight pins to the No. 2 timing chain cover assembly.
      GTY783139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -

      Standard Protrusion Height

      Straight Pin (A) 

      3.0 to 5.0 mm (0.118 to 0.197 in.)

      Straight Pin (B) 

      5.0 to 7.0 mm (0.197 to 0.276 in.)

  2. INSTALL RING PIN 
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.

    1. Using a plastic hammer, tap in 6 new ring pins to the stiffening crankcase assembly.
      GTY776190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard Protrusion Height

      3.5 to 4.5 mm (0.138 to 0.177 in.)

  3. INSTALL STUD BOLT 
    NOTE:

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

    1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the stiffening crankcase assembly.

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

      GTY795294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 9 mm (0.354 in.)
      *b 19 mm (0.748 in.)
    2. Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

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

      GTY790769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 21 mm (0.827 in.)
      *b 9 mm (0.354 in.)
      *c 34 mm (1.34 in.)
    3. Using an E8 "TORX" socket wrench, install the stud bolt to the cylinder head sub-assembly.

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

      GTY808568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 14 mm (0.551 in.)
      *b 13 mm (0.512 in.)
      *c 27 mm (1.063 in.)
  4. INSTALL STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon socket wrench, install the straight screw plug and a new gasket to the stiffening crankcase assembly.

      Torque: 44 N.m (449 kgf/cm, 32 ft.lbf) 

      GTY820693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 4

  6. INSTALL ENGINE BALANCER ASSEMBLY 
    1. Install the engine balancer assembly to stiffening crankcase assembly with the 2 bolts.

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

      GTY837281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Rotate the crankshaft clockwise so that the crankshaft timing gear key is at the position 270° from the bottom as shown in the illustration.
      GTY809957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
      *a 270°
    2. 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 Packing Dimension

      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after the installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
      GTY834982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
    3. Check that the rear cutouts are as shown in the illustration.
      GTY746179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cutout
    4. Clean the bolts and bolt holes.
    5. Temporarily install the stiffening crankcase assembly with the 11 bolts

      Bolt Length

      Item Length
      Bolt (A) 40 mm (1.57 in.)
      Bolt (B) 90 mm (3.54 in.)
      Bolt (C) 170 mm (6.69 in.)
      GTY779468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Type
    6. Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.
      Fig 1: Stiffening Crankcase Assembly Bolt Tightening Sequence
      GTY779469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tightening Order

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

  8. INSTALL ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 1

  9. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new oil strainer gasket.
    2. Using an 8 mm socket wrench, install the oil strainer sub-assembly and oil strainer gasket to the stiffening crankcase assembly with the bolt.
      GTY820709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  10. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY826879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      *b 4.5 mm (0.177 in.)
      *c 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Seal Packing

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

      Standard Seal Packing Diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
    2. Install the oil pan sub-assembly with the 12 bolts and 2 nuts in several steps in the order shown in the illustration.
      Fig 2: Oil Pan Sub-Assembly Nut/Bolt Installation Sequence
      GTY836882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut

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

  11. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug to the oil pan sub-assembly.

      Torque: 40 N.m (408 kgf/cm, 30 ft.lbf) 

  12. INSTALL OIL FILTER UNION 
    1. Using a 12 mm hexagon socket wrench, install the oil filter union to the stiffening crankcase assembly.

      Torque: 29.5 N.m (301 kgf/cm, 22 ft.lbf) 

      GTY820701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  14. INSTALL REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 1

  15. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the cylinder block water jacket spacer to the exhaust side of the cylinder block sub-assembly.
      GTY809301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1

  17. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    HINT: 

    The cylinder head set bolts are tightened in 3 progressive steps.

    1. Place the cylinder head sub-assembly on the cylinder block sub-assembly.
      NOTE:
      • Ensure that the contact surface of the cylinder head sub-assembly is free of oil.
      • Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the cylinder head gasket with the bottom of the cylinder head sub-assembly.
    2. Install the 10 plate washers to the 10 cylinder head set bolts.

      Bolt Length

      Item Length
      Bolt (A) 129.1 to 130.9 mm (5.08 to 5.15 in.)
      Bolt (B) 139.1 to 140.9 mm (5.48 to 5.55 in.)
      GTY760826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front of Engine
    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
    4. Step 1:
      1. Using a 12 mm socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.
        Fig 3: Cylinder Head Set Bolt Tightening Sequence
        GTY760827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Front of Engine

        Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

        NOTE:

        Be careful not to drop the plate washers into the cylinder head sub-assembly.

    5. Step 2:
      1. Mark each cylinder head set bolt head with paint as shown in the illustration.
        GTY741015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        Front of Engine
      2. Tighten the cylinder head set bolts 90° in the order shown in step 1.
    6. Step 3:
      1. Tighten the cylinder head set bolts another 90° in the order shown in step 1.
      2. Check that the paint marks are now facing rearward.

        HINT: 

        Perform inspection after repair after replacing the cylinder head sub-assembly.

        Refer to INITIALIZATION [10/2018 - 08/2021] , or refer to INITIALIZATION [08/2021 - ]

  18. INSTALL WATER SEAL PLATE 
    1. Using an 8 mm socket wrench, install the water seal plate and a new water seal plate gasket to the cylinder head sub assembly with the 2 bolts.

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

      GTY820702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem cap ends.
    2. Install the 16 valve stem caps to the cylinder head sub-assembly.
      NOTE:
      • Install the same parts in the same combination to their original locations.
      • Do not drop the valve stem caps into the cylinder head sub-assembly.
      GTY757626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Inspect the 16 valve lash adjuster assemblies before installing them.

      See step  2

    2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.
      NOTE:

      Install the same parts in the same combination to their original locations.

      GTY757627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.
      GTY774599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
      NOTE:

      Install the same parts in the same combination to their original locations.

  22. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.

    1. Using a plastic hammer, tap in 10 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.
      GTY781266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard Protrusion Height

      3.2 to 4.3 mm (0.126 to 0.169 in.)

  23. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY 

    HINT: 

    Perform inspection after repair after replacing the exhaust camshaft sub-assembly.

    Refer to INITIALIZATION [10/2018 - 08/2021] , or refer to INITIALIZATION [08/2021 - ]

    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. Install the exhaust camshaft sub-assembly to the camshaft housing sub-assembly.
  24. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY 

    HINT: 

    Perform inspection after repair after replacing the intake camshaft sub-assembly.

    Refer to INITIALIZATION [10/2018 - 08/2021] , or refer to INITIALIZATION [08/2021 - ]

    1. Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
    2. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
    3. Install the intake camshaft sub-assembly to the camshaft housing sub-assembly.
  25. INSTALL CAMSHAFT BEARING CAP 
    1. Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap in their correct locations.
      GTY806518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Uniformly tighten the 9 bolts in the order shown in the illustration.

      Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

      Fig 4: Camshaft Bearing Cap Bolt Tightening Sequence
      GTY800898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the torque of each bolt again.
  26. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY767156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Incorrect
      *b Correct
    2. 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 Packing Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      GTY823336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
    3. Position the intake camshaft sub-assembly and exhaust camshaft sub-assembly as shown in the illustration.
      GTY751224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 17° to 47°
      *b 42° to 72°
    4. Temporarily install the camshaft housing sub-assembly with the 17 bolts.

      Bolt Length

      Item Length
      Bolt (A) 40 mm (1.57 in.)
      Bolt (B) 65 mm (2.56 in.)
      Fig 5: Camshaft Housing Sub-Assembly Bolts Tightening Sequence
      GTY817022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the camshaft housing sub-assembly, and then tighten the 17 bolts in several steps in the order shown in the illustration.

      Torque: 28.5 N.m (291 kgf/cm, 21 ft.lbf) 

      NOTE:
      • Do not add engine oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
      • After installation, if the seal packing has seeped out, wipe it off.
      Fig 6: Camshaft Housing Sub-Assembly Bolts Tightening Sequence
      GTY817021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FUEL PUMP LIFTER GUIDE 
    1. Using an 8 mm socket wrench, install the fuel pump lifter guide to the No. 4 camshaft bearing cap with the 2 bolts.

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

      GTY833240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Using a plastic hammer, tap in the 2 crankshaft timing gear keys.

      HINT: 

      Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

      GTY562563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY 
    1. Install the oil nozzle valve sub-assembly to the cylinder block sub-assembly.
      GTY809232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL TIMING CHAIN COVER ASSEMBLY 
    1. Clean the contact surfaces of the timing chain cover assembly, cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
      GTY808315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Chain Cover Assembly Side *b Engine Assembly Side
    2. Apply seal packing in a continuous line to the timing chain cover assembly as shown in the illustration.
      GTY785645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2.5 to 3.5 mm (0.0984 to 0.138 in.) *b 2.0 to 6.0 mm (0.0787 to 0.236 in.)
      *c 10 mm (0.394 in.) *d 20 mm (0.787 in.)
      *e 344.2 mm (1.13 ft.) *f 4.0 to 6.0 mm (0.157 to 0.236 in.)
      *g 3.0 to 4.0 mm (0.118 to 0.157 in.) - -
      Seal Packing - -

      Seal Packing

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

      NOTE:
      • Clean the surfaces with non-residue solvent before applying seal packing.
      • Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not add oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
    3. Temporarily install the timing chain cover assembly with the 20 bolts.

      Bolt Length

      Bolt Length
      (A) 30 mm (1.18 in.)
      (B) 45 mm (1.77 in.)
      NOTE:

      Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

      GTY778804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 20 bolts in the order shown in the illustration.
      Fig 7: Timing Chain Cover Assembly Bolts Tightening Sequence
      GTY778805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  31. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    HINT: 

    Perform inspection after repair after replacing the camshaft timing exhaust gear assembly.

    Refer to INITIALIZATION [10/2018 - 08/2021] , or refer to INITIALIZATION [08/2021 - ]

    1. Align and fit the knock pin of the exhaust camshaft sub-assembly to the knock pin hole of the camshaft timing exhaust gear assembly.
      GTY752289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    2. Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.
      NOTE:
      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing exhaust gear assembly.
    3. Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly with the 3 bolts and install the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly).

      Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

      GTY926153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. Temporarily install the crankshaft pulley bolt.
    2. Rotate the crankshaft 44.2° counterclockwise to position the crankshaft timing gear key as shown in the illustration.
      GTY752882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
      *a 44.2°
    3. Check that the timing marks of the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.
      GTY838852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
  33. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

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

      GTY802431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper with the bolt.

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

      GTY926155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    HINT: 

    After replacing or removing and installing the No. 1 chain tensioner assembly, an abnormal noise may occur at start up until the oil in the line has had time to replenish.

    1. While slightly pushing in the plunger of the No. 1 chain tensioner assembly, install the chain tensioner slipper.
      GTY972165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a End of the Plunger
      *b Groove
      *c Oil Hole
      *d No. 1 Chain Tensioner Slipper
      *e Plunger

      HINT: 

      • Make sure that the end of the plunger is correctly seated in the groove of the No. 1 chain tensioner slipper.
      • Make sure that the oil hole of the plunger is facing up.
    2. Install the bolt.
      GTY926163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the No. 1 chain tensioner assembly with the nut.

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

  36. INSTALL CHAIN SUB-ASSEMBLY 
    1. Set the crankshaft timing gear key as shown in the illustration.
      GTY769677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
    2. Remove the crankshaft pulley bolt.
    3. Install the crankshaft timing sprocket and chain sub-assembly.
      GTY802328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the paint mark (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.
      GTY964692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (Yellow)
      *b Timing Mark
    5. Using the hexagonal portion of the exhaust camshaft sub-assembly, rotate the exhaust camshaft sub-assembly counterclockwise with a wrench, align the timing mark of the camshaft timing exhaust gear assembly with the paint mark (orange) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing exhaust gear assembly.
      GTY879339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (Orange)
      *b Timing Mark
      Turn
  37. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    HINT: 

    Perform inspection after repair after replacing the camshaft timing gear assembly.

    Refer to INITIALIZATION [10/2018 - 08/2021] , or refer to INITIALIZATION [08/2021 - ]

    1. Hold the hexagonal portion of the exhaust camshaft sub-assembly with a wrench and turn the camshaft timing exhaust gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and crankshaft timing sprocket as shown in the illustration.
      GTY873749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Loosen
    2. Align the paint mark (orange) of the chain sub-assembly with the timing mark of the camshaft timing gear assembly and install the chain sub-assembly to the camshaft timing gear assembly.
      GTY773818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (Orange)
      *b Timing Mark
    3. Align and fit the knock pin of the intake camshaft sub-assembly to the knock pin hole of the camshaft timing gear assembly.
      GTY744117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    4. Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.
      GTY889768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly or spark plug tube with the wrench.
    5. Using a 10 mm bi-hexagonal wrench, install the camshaft timing gear assembly with the bolt.

      Torque: 86 N.m (877 kgf/cm, 63 ft.lbf) 

  38. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. Set the crankshaft timing gear key as shown in the illustration.
      GTY747200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pump Drive Sprocket *2 Oil Pump Drive Shaft Sprocket
      *3 Crankshaft Timing Gear Key *4 Oil Pump Sub-assembly
      *a Mark Plate *b Timing Mark
    2. Turn the oil pump drive shaft so that the flat face is facing upward.
    3. Align the mark plates with the timing marks of the oil pump drive sprocket and oil pump drive shaft sprocket as shown in the illustration.

      HINT: 

      Make sure the mark plates of the oil pump drive chain sub-assembly are facing away from the engine assembly.

    4. With the oil pump drive chain sub-assembly placed around the oil pump drive sprocket and oil pump drive shaft sprocket, install the oil pump drive sprocket to the crankshaft and temporarily install the oil pump drive shaft sprocket to the oil pump drive shaft.
    5. Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate.
      GTY799063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring
    6. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
    7. Using SST, hold the crankshaft pulley assembly and tighten the bolt.
      GTY802020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      • SST: 09213-54015 
      • SST: 09330-00021 

      Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

    8. Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.
  39. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 

    See step  23

  40. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. Clean the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
      GTY788281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 2 Timing Chain Cover Assembly Side *b Timing Chain Cover Assembly Side
    2. Apply seal packing in a continuous line to the No. 2 timing chain cover assembly as shown in the illustration.

      Seal Packing

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

      Standard Seal Packing Diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      NOTE:
      • Clean the surfaces with non-residue solvent before applying seal packing.
      • Install the No. 2 timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
      GTY825081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the No. 2 timing chain cover assembly to the timing chain cover assembly with the 20 bolts.
      NOTE:

      Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

      Fig 8: No. 2 Timing Chain Cover Assembly Bolts Tightening Sequence
      GTY788639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 20 bolts in the order shown in the illustration.

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

    5. Install the engine mounting bracket RH with the 3 bolts in the order shown in the illustration.
      Fig 9: Engine Mounting Bracket (RH) Tightening Sequence
      GTY798673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      After applying seal packing to the No. 2 timing chain cover assembly, install the engine mounting bracket RH within 10 minutes.

  41. INSTALL STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon wrench, install the straight screw plugto the No. 2 timing chain cover assembly.

      Torque: 40 N.m (408 kgf/cm, 30 ft.lbf) 

      GTY809907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1

  43. INSTALL SPARK PLUG TUBE GASKET 
    1. Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.
      GTY825079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install a new camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.
      NOTE:

      Remove any oil from the contact surfaces.

      GTY811822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 7 new cylinder head cover gaskets to the cylinder head cover sub-assembly.
      NOTE:

      Remove any oil from the contact surfaces.

    3. Apply seal packing as shown in the illustration.
      GTY823015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
      *b Mark
      Seal Packing

      Seal Packing

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

      Standard Seal Packing Diameter

      3.0 to 6.0 mm (0.118 to 0.236 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    4. Using an 8 mm socket wrench, install the 2 camshaft position sensors (for Exhaust Side and for Intake Side) with 2 new bolts (B) and cylinder head cover sub-assembly with 4 new bolts (C) and the 12 bolts (A) in the order shown in the illustration.
      Fig 10: Camshaft Position Sensor And Cylinder Head Cover Sub-Assembly Bolt Installation Order
      GTY817073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt Length

      Bolt Length Thread Diameter
      (A) 23.5 mm (0.925 in.) 10 mm (0.394 in.)
      (B), (C) 30 mm (1.18 in.) 8 mm (0.315 in.)

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

      NOTE:
      • If a camshaft position sensor (for Exhaust Side and for Intake Side) has been struck or dropped, replace it.
      • Make sure that the 2 O-rings are not cracked or moved out of place when installing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).
      • Do not start the engine for at least 2 hours after installation.

      HINT: 

      After tightening all bolts, check the tightening torque of the bolts (7) and (8). Retighten them if necessary.

  45. INSTALL OUTLET WATER BY-PASS SUB-ASSEMBLY 
    1. Using an 8 mm socket wrench, install the outlet water by-pass sub-assembly and a new outlet water pipe gasket to the cylinder head sub-assembly with the 3 bolts.

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

      GTY820303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL WATER OUTLET 
    1. Install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 2 bolts.

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

      GTY820682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL CRANKSHAFT PULLEY ASSEMBLY 
    1. Align the crankshaft timing gear key with the key groove of the crankshaft pulley assembly.
      GTY782922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    2. Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley bolt.
      • SST: 09213-54015 
      • SST: 09330-00021 

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

  48. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 1

  49. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  50. INSTALL OIL FILLER CAP GASKET 
    1. Install a new oil filler cap gasket to the oil filler cap sub-assembly.
      GTY652152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL OIL FILLER CAP ASSEMBLY 
    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
      GTY811821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL CAM TIMING CONTROL MOTOR O-RING 

    Refer to PROCEDURE - Step 1

  53. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 

    Refer to PROCEDURE - Step 2

  54. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 2

  55. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  56. INSTALL OIL PRESSURE AND TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  57. INSTALL KNOCK SENSOR 

    Refer to PROCEDURE - Step 1

  58. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

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