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Reassembly [10/2022 - ]: Procedure

  1. INSTALL STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.
    1. GTY1079193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a plastic hammer, tap in 2 new straight pins to the No. 2 timing chain cover assembly.

        Standard Protrusion Height

        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. GTY1079824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a plastic 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.)

      2. Using a plastic hammer, tap in 5 new ring pins to the stiffening crankcase assembly.

        Standard Protrusion Height

        Ring Pin (A) 

        3.5 to 4.5 mm (0.138 to 0.177 in.)

        Ring Pin (B) 

        4.3 to 5.3 mm (0.169 to 0.209 in.)

  3. INSTALL STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.
    1. GTY1077229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 9 mm (0.354 in.) *b 19 mm (0.748 in.)
      *c 22.5 mm (0.886 in.) *d 20 mm (0.787 in.)
      *e 46 mm (1.81 in.) - -
      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) 

      2. Using an E10 "TORX" socket wrench, install the 3 stud bolts to the cylinder block sub-assembly.

        Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf) 

      3. Using an E6 "TORX" socket wrench, install the stud bolt to the cylinder head cover sub-assembly.

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

  4. INSTALL STRAIGHT SCREW PLUG 
    1. GTY1077523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 10 mm hexagon socket wrench, install the 3 straight screw plugs and 3 new gaskets to the stiffening crankcase assembly.

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

  5. INSTALL OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  6. INSTALL ENGINE BALANCER ASSEMBLY 
    1. GTY1076852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. GTY1077127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Crankshaft Timing Gear Key *b 270°
      *c Seal Packing (A) *d Seal Packing (B)
      *e Timing Mark *f Hole
      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.
      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
        Seal Packing (A) 2.5 to 3.5 mm (0.0984 to 0.138 in.)
        Seal Packing (B) 4.5 to 5.5 mm (0.177 to 0.217 in.)
        NOTE:
        • Remove any oil from the contact surfaces.
        • Install the stiffening crankcase 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 the installation.
        • Make sure that the diameter at the start and end of each line of seal packing is 3 to 7 mm (0.118 to 0.276 in.).
        • Do not start the engine for at least 2 hours after installation.
        • After installation, if the seal packing has seeped out, wipe it off within 10 minutes.
      3. Check that the hole and timing mark are as shown in the illustration.
    2. Fig 1: Stiffening Crankcase Assembly Bolts Tightening Sequence
      GTY1077053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Clean the bolts and bolt holes.
      2. Temporarily install the stiffening crankcase assembly with the 11 bolts.

        Bolt Length

        Item Length
        Bolt (A) 70 mm (2.76 in.)
        Bolt (B) 90 mm (3.54 in.)
        Bolt (C) 170 mm (6.69 in.)
      3. Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.

        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. GTY1076549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 with the bolt.

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

  10. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. GTY1077160Courtesy 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.) *d Nut
      1. Clean and degrease the contact surfaces of the stiffening crankcase assembly and No. 2 oil pan sub-assembly.
      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

        2.5 to 3.5 mm (0.0984 to 0.138 in.)

        NOTE:
        • Install the No. 2 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.
        • 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 3 to 7 mm (0.118 to 0.276 in.).
      3. Install the No. 2 oil pan sub-assembly with the 13 bolts and 2 nuts in several steps in the order shown in the illustration.

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

  11. INSTALL OIL PAN DRAIN PLUG 

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

  12. INSTALL OIL FILTER UNION 
    1. GTY1076470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 12 mm straight hexagon wrench, install the oil filter union to the stiffening crankcase assembly.

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

  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 HEAD GASKET 
    Refer to PROCEDURE - Step 1
  16. INSTALL CYLINDER HEAD SUB-ASSEMBLY 
    1. Fig 2: Cylinder Head Sub-Assembly Tightening Sequence
      GTY1254310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Plate Washer - -
      *a Paint Mark *b 1st: Turn 90°
      *c 2nd: Turn 90° - -
      Front of Engine - -
      1. Place the cylinder head sub-assembly on the cylinder block sub-assembly.
        NOTE:
        • The cylinder head set bolts are tightened in 3 progressive steps.
        • Inspect and clean the bolt and bolt hole.
        • Ensure that the contact surface of the cylinder head sub-assembly is free of oil.
        • Do not allow oil to adhere to the bottom of the cylinder head sub-assembly.
      2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
      3. Temporarily install the cylinder head sub-assembly with the 6 plate washers and 10 cylinder head set bolts.

        Bolt Length

        Item Length
        Bolt (A) 139.1 to 140.9 mm (5.48 to 5.55 in.)
        Bolt (B) 149.1 to 150.9 mm (5.87 to 5.94 in.)
        NOTE:

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

      4. Step 1:

        1. Using a 12 mm socket wrench, uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.

        Torque: 90 N.m (918 kgf/cm, 66 ft.lbf) 

      5. Step 2:

        1. Mark each cylinder head set bolt head with paint as shown in the illustration.

        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.

    2. Perform "Inspection After Repair" after replacing the cylinder head sub-assembly.

      Refer to INITIALIZATION [10/2022 - ]

  17. INSTALL VALVE STEM CAP 
    1. GTY1077487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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:

        Do not drop the valve stem caps into the cylinder head sub-assembly.

  18. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. GTY1077838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct *b Incorrect
      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.
  19. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. GTY1076977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap - -
      1. Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.
      2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
  20. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 4
  21. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 5
  22. INSTALL CAMSHAFT BEARING CAP 
    1. Fig 3: Camshaft Bearing Cap Tightening Sequence
      GTY1076411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check the number of the camshaft bearing caps and temporarily set the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap, No. 4 camshaft bearing cap and No. 5 camshaft bearing cap.
      2. Uniformly tighten the 8 bolts in the order shown in the illustration.

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

        NOTE:

        After installing the camshaft bearing caps, make sure that the intake camshaft sub-assembly and exhaust camshaft sub-assembly rotate smoothly.

  23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. GTY1076900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly - -
      *a Correct *b Incorrect
      *c Seal Packing *d 28° to 58°
      *e 19° *f 15°
      *g No. 1 Cylinder Cam Nose - -
      1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      2. Make sure the installation surface of the camshaft housing sub-assembly is clean and degreased.
      3. 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.)

        NOTE:
        • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
        • Make sure that the diameter at the start and end of each line of seal packing is 3 to 7 mm (0.118 to 0.276 in.).
        • After installation, if the seal packing has seeped out, wipe it off within 10 minutes.
      4. Position the intake camshaft sub-assembly and exhaust camshaft sub-assembly as shown in the illustration.
    2. Fig 4: Camshaft Housing Sub-Assembly Bolts Tightening Sequence
      GTY1077105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Clean and inspect the bolts and bolt holes.
      2. Temporarily install the camshaft housing sub-assembly with the 18 bolts.
        NOTE:

        If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly, clean the installation surfaces, and reapply seal packing.

      3. Tighten the 18 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.
  24. INSTALL FUEL PUMP LIFTER GUIDE 
    1. GTY1076511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, install the fuel pump lifter guide to the No. 5 camshaft bearing cap with the 2 bolts.

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

  25. INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY 
  26. INSTALL TIMING CHAIN COVER ASSEMBLY 
    1. GTY1077005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Chain Cover Assembly Side *b Engine Assembly Side
      1. Clean the contact surfaces of the timing chain cover assembly, cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, crankshaft bearing cap and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
    2. GTY1077166Courtesy 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 355.2 mm (1.17 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.) *h 17 mm (0.669 in.)
      *i 67.4 mm (2.65 in.) - -
      Seal Packing - -
      1. Apply seal packing to the timing chain cover assembly as shown in the illustration.

        Seal Packing

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

        NOTE:
        • Install the 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 3 to 7 mm (0.118 to 0.276 in.).
    3. GTY1076686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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.

      2. Tighten the 20 bolts in the order shown in the illustration.

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

  27. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. GTY1077130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin *b Knock Pin Hole
      *c Hold - -
      1. Align and fit the knock pin of the intake camshaft sub-assembly to the knock pin hole of the camshaft timing gear assembly.
      2. Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.
        NOTE:
        • Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly, fuel injector tube and spark plug tube with the wrench.
        • Do not disassemble the camshaft timing gear assembly.
      3. Temporarily install the intake camshaft timing gear bolt assembly to the camshaft timing gear assembly.
        NOTE:
        • If the intake camshaft timing gear bolt assembly has been struck or dropped, replace it.
        • Make sure to fit the protrusion of the intake camshaft timing gear bolt assembly into the cutout of the camshaft timing gear assembly.
      4. Using a 5 mm hexagon socket wrench, install the camshaft timing gear assembly and intake camshaft timing gear bolt assembly with the 3 bolts.

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

      5. Pull the intake camshaft timing gear bolt assembly to confirm that is installed securely.
    2. Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

      Refer to INITIALIZATION [10/2022 - ]

  28. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. GTY1077316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin *b Knock Pin Hole
      *c Hold - -
      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.
      2. Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.
        NOTE:
        • Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly, fuel injector tube and spark plug tube with the wrench.
        • Do not disassemble the camshaft timing exhaust gear assembly.
      3. Temporarily install the exhaust camshaft timing gear bolt assembly to the camshaft timing exhaust gear assembly.
        NOTE:
        • If the exhaust camshaft timing gear bolt assembly has been struck or dropped, replace it.
        • Make sure to fit the protrusion of the exhaust camshaft timing gear bolt assembly into the cutout of the camshaft timing exhaust gear assembly.
      4. Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly and exhaust camshaft timing gear bolt assembly with the 3 bolts.

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

      5. Pull the exhaust camshaft timing gear bolt assembly to confirm that is installed securely.
    2. Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

      Refer to INITIALIZATION [10/2022 - ]

  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

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

  30. INSTALL CHAIN SUB-ASSEMBLY 
    1. GTY1076780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cutout *b Timing Mark
      *c Mark Plate (Yellow) *d Mark Plate (Orange)
      Turn - -
      1. Align the mark plate (yellow) and timing mark and install the chain sub-assembly to the crankshaft timing gear or sprocket as shown in the illustration.
        NOTE:

        Make sure to install with the mark plate (yellow) facing the front side of the engine.

      2. Install the crankshaft timing gear or sprocket and chain sub-assembly to the crankshaft.
      3. Temporarily install the crankshaft pulley bolt.
      4. Rotate the crankshaft to align the timing mark of the crankshaft timing gear or sprocket and mark plate (yellow) of the chain sub-assembly with the cutout as shown in the illustration.
      5. Align the mark plate (orange) and timing mark as shown in the illustration and install the chain sub-assembly to the camshaft timing gear assembly.
        NOTE:

        Make sure to install with the mark plate (orange) facing the front side of the engine.

        HINT: 

        Place the chain sub-assembly on top of the camshaft timing exhaust gear assembly without installing it to the camshaft timing exhaust gear assembly.

      6. Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly, rotate the camshaft timing gear assembly counterclockwise and align the mark plate (orange) with the timing mark as shown in the illustration, and install the chain sub-assembly to the camshaft timing exhaust gear assembly.
        NOTE:
        • Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly, fuel injector tube and spark plug tube with the wrench.
        • Make sure to install with the mark plate (orange) facing the front side of the engine.
  31. INSTALL CHAIN TENSIONER SLIPPER 

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

  32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. GTY1077266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin - -
      1. Using an 8 mm socket wrench, install the No. 1 chain tensioner assembly with the 2 bolts.

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

      2. Remove the pin from the No. 1 chain tensioner assembly.
    2. GTY1078265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Crankshaft Timing Gear Key *b Timing Mark
      1. Rotate the crankshaft 2 times and when the crankshaft timing gear key is vertical, check that the camshaft timing gear assembly and camshaft timing exhaust gear assembly is as shown in the illustration.
      2. Remove the crankshaft pulley bolt.
  33. INSTALL NO. 2 CHAIN VIBRATION DAMPER 

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

  34. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. GTY1076972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pump Drive Sprocket *2 Oil Pump Drive Shaft Sprocket
      *3 Chain Damper Spring *4 Oil Pump Assembly
      *5 Chain Tensioner Plate - -
      *a Mark Plate (Yellow) *b Mark Plate (Orange)
      *c Timing Mark *d Crankshaft Timing Gear Key
      1. Set the crankshaft timing gear key as shown in the illustration.
      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.
      4. With the oil pump drive chain sub-assembly placed around the oil pump drive sprocket and oil pump drive shaft sprocket, temporarily 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. Temporarily install the oil pump drive shaft sprocket with the bolt.
      6. Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate.
      7. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
      8. Using SST, hold the crankshaft pulley assembly and tighten the bolt.
        • SST: 09213-54015 
          1. 91651-60855
        • SST: 09330-00021 

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

      9. Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.
  35. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    Refer to PROCEDURE - Step 34
  36. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. GTY1076250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 2 Timing Chain Cover Assembly Side *b Timing Chain Cover Assembly Side
      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.
    2. GTY1254061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Seal Packing - -
      1. Apply seal packing 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:
        • 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 3 to 7 mm (0.118 to 0.276 in.).
      2. Temporarily install the No. 2 timing chain cover assembly to the timing chain cover assembly with the 19 bolts.
        NOTE:

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

      3. Tighten the 19 bolts in the order shown in the illustration.

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

      4. Temporarily install the engine mounting bracket RH to the No. 2 timing chain cover assembly with the 3 bolts.
      5. Tighten the 3 bolts.

        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.

  37. INSTALL STRAIGHT SCREW PLUG 
    1. GTY1077108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply adhesive to the straight screw plug.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      2. Using a 10 mm hexagon socket wrench, install the straight screw plug to the No. 2 timing chain cover assembly.

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

        NOTE:

        Do not add engine oil for at least 1 hour after installation.

  38. INSTALL TIMING CHAIN CASE OIL SEAL 
    Refer to PROCEDURE - Step 1
  39. INSTALL INJECTOR HOLDER SUB-ASSEMBLY 
    1. GTY1077198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Plate Washer - -
      1. Install a new gasket to the camshaft housing sub-assembly.
      2. Install the injector holder sub-assembly with the 6 bolts and 2 plate washers in the order shown in the illustration.

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

  40. INSTALL CYLINDER HEAD COVER PLUG (w/ Plug) 
  41. INSTALL SPARK PLUG TUBE GASKET 
    NOTE:
    • Keep the lip free from foreign matter.
    • Do not tap in the spark plug tube gaskets at an angle.
    1. GTY1076612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. GTY1194542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring - -
      *a Seal Packing Diameter: 3.0 to 6.0 mm *b Rib
      *c Seam *d Camshaft Position Sensor Tip
      *e OK *f NG
      Seal Packing - -
      1. Apply a light coat of engine oil to a new gasket.
      2. Install the gasket to the No. 1 camshaft bearing cap.
      3. Install 4 new gaskets to the cylinder head cover sub-assembly.
        NOTE:

        Make sure the rib of the gasket does not protrude from the groove of the cylinder head cover sub-assembly.

      4. Apply seal packing as shown in the illustration.

        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 10 minutes of applying seal packing.
      5. Perform this procedure only when reusing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

        1. Clean each O-ring groove of the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

        NOTE:

        Make sure the O-ring groove is free of foreign matter.

        2. Install 2 new O-rings to the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

        NOTE:

        Set each O-ring on the tip of the 2 camshaft position sensors (for Exhaust Side and for Intake Side) and roll it into the O-ring groove with bare hands to install it.

        3. Check if each O-ring is twisted.

        HINT: 

        Check the entire circumference of the seam of the O-ring for twisting.

      6. Apply a light coat of engine oil to each O-ring of the camshaft position sensors (for Exhaust Side and for Intake Side).
    2. Fig 5: Cylinder Head Cover Sub-Assembly Tightening Sequence
      GTY1076273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the cylinder head cover sub-assembly with the 9 bolts (A) and using an 8 mm socket wrench, install the 2 camshaft position sensors (for Exhaust Side and for Intake Side) with 2 new bolts (B) in the order shown in the illustration.

        Bolt Length

        Bolt Length Width Across Flats
        (A) 23.5 mm (0.925 in.) 10 mm (0.394 in.)
        (B) 30 mm (1.18 in.) 8 mm (0.315 in.)

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

        NOTE:
        • Do not start the engine for at least 2 hours after installation.
        • Do not add engine oil for at least 2 hours after installation.
      2. Install the 12 bolts in the order shown in the illustration.

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

        NOTE:
        • Do not start the engine for at least 2 hours after installation.
        • Do not add engine oil for at least 2 hours after installation.
  43. INSTALL CRANKSHAFT PULLEY ASSEMBLY 
    1. GTY1078856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold - -
      Turn - -
      1. Align the crankshaft timing gear key with the key groove of the crankshaft pulley assembly.
      2. Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley bolt.
        • SST: 09213-54015 
          1. 91651-60855
        • SST: 09330-00021 

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

  44. INSTALL FUEL INJECTOR SEAL 
    Refer to PROCEDURE - Step 1
  45. INSTALL INJECTOR VIBRATION INSULATOR 
    Refer to PROCEDURE - Step 2
  46. INSTALL C-RING 
    Refer to PROCEDURE - Step 3
  47. INSTALL NO. 1 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 4
  48. INSTALL NO. 3 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 5
  49. INSTALL NOZZLE HOLDER CLAMP 
  50. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 7
  51. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 8
  52. INSTALL OIL COOLER PIPE GASKET 
  53. INSTALL OIL COOLER GASKET 
  54. INSTALL OIL COOLER ASSEMBLY 
    Refer to PROCEDURE - Step 3
  55. INSTALL NO. 1 VACUUM PUMP O-RING 
    Refer to PROCEDURE - Step 1
  56. INSTALL VACUUM PUMP ASSEMBLY 
    Refer to PROCEDURE - Step 2
  57. INSTALL OIL FILLER CAP GASKET 
  58. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
  59. INSTALL CAM TIMING OIL CONTROL SOLENOID O-RING 
    Refer to PROCEDURE - Step 1
  60. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side) 
    Refer to PROCEDURE - Step 2
  61. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side) 
    Refer to PROCEDURE - Step 3
  62. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 1
  63. INSTALL ENGINE OIL TEMPERATURE SENSOR 
    Refer to PROCEDURE - Step 1
  64. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY 
    Refer to PROCEDURE - Step 1
  65. INSTALL SPARK PLUG 
    Refer to PROCEDURE - Step 1
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