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Engine Unit: Reassembly

  1. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Apply seal packing in a continuous bead (diameter: 2.5 mm (0.098 in.)) to the places shown in the illustration.

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the crankcase within 3 minutes of applying the seal packing.
      • Do not start the engine for at least 2 hours after installing the stiffening crankcase.
        Fig 1: Applying Seal Packing
        G05399293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the stiffening crankcase with the 11 bolts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 2: Locating Bolts
      G05399294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt length 

      BOLT LENGTH CHART

      Item Length
      Bolt A 138 mm (5.43 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 70 mm (2.76 in.)
    3. Recheck the torque for bolts 1 and 2.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

    4. Wipe off any excess seal packing with a clean piece of cloth.
  2. INSTALL OIL PUMP ASSEMBLY 
    1. Install the oil pump assembly with the 3 bolts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 3: Locating Bolts And Oil Pump Assembly
      G05399742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove any old packing material from the contact surface.
    2. Apply seal packing in a continuous bead (diameter: 4 mm (0.157 in.)) to the places shown in the illustration.

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.
      • Do not expose the seal to engine oil for 2 hours after installation.
        Fig 4: Applying Seal Packing
        G05399296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.

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

      Fig 5: Locating Bolts And Nuts
      G05399251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

      Fig 6: Locating Oil Pan Drain Plug
      G05399250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL CYLINDER BLOCK WATER DRAIN COCK ASSEMBLY 
    1. Apply adhesive to the threads of the drain cock.

      Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 7: Applying Adhesive To Threads Of Drain Cock
      G04943675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water drain cock as shown in the illustration.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      NOTE:
      • Do not rotate the drain cock more than 1 revolution (360°) after tightening it to the specified torque.
      • Install the water drain cock within 3 minutes after applying the adhesive.
      • Do not start the engine for at least 2 hours after installing the water drain cock.
        • Fig 8: Locating Water Drain Cock Plug
        G05399300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the water drain cock plug to the water drain cock.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

  6. INSTALL VENTILATION VALVE SUB-ASSEMBLY 
    1. Apply adhesive to the threads of the ventilation valve.
      Fig 9: Applying Adhesive To Threads Of Ventilation Valve
      G04974406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the ventilation valve.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      NOTE:
      • Install the crankcase within 3 minutes after applying the adhesive.
      • Do not start the engine for at least 2 hours after installing the ventilation valve.
        Fig 10: Locating Ventilation Valve
        G05399249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CYLINDER HEAD GASKET 
    1. Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
      NOTE:
      • Remove any oil from the contact surface.
      • Pay attention to the mounting orientation of the cylinder head gasket.
      • Do not damage the cylinder gasket when installing the cylinder head onto the cylinder block.
        Fig 11: Identifying Cylinder Head Gasket Lot No. Stamp
        G05398914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    HINT:

    The cylinder head bolts are tightened in 2 successive steps.

    1. Apply a light coat of engine oil to the threads of the cylinder head bolts.
    2. Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with as a 10 mm bi-hexagon wrench in the sequence shown in the illustration.

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

      Fig 12: Locating Cylinder Head Bolts And Tightening Sequence
      G05398915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mark the front of the cylinder head bolt with paint.
    4. Retighten the cylinder head bolts by additional 90° and one more additional 45° as shown in the illustration.
      5. Fig 13: Identifying Cylinder Head Bolt Tightening Direction
      G05398916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check that the paint mark is now at a 135° angle from the front.
  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the lash adjuster free of dirt and foreign objects.
    • Only use clean engine oil.
    1. Place the lash adjuster into a container filled with engine oil.
    2. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

      SST 09276-75010 

      Fig 14: Checking Lash Adjuster
      G04974656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Squeeze the SST and lash adjuster together to move the plunger up and down 5 or 6 times.
    4. Check the movement of the plunger and bleed the air.

      OK: Plunger moves up and down. 

      NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.
    5. After bleeding the air, remove the SST. Then, try to press the plunger quickly and firmly with a finger.

      OK: Plunger is very difficult to move. 

      If the result is not as specified, replace the lash adjuster.

    6. Install the lash adjusters.
      NOTE: Install the lash adjuster into its original position.
  10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the lash adjuster tip and valve stem cap end.
    2. Install the valve rocker arms as shown in the illustration.
      3. Fig 15: Identifying Valve Rocker Arm
      G04974791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean the both surfaces of the bearing.
    2. Install the 2 No. 1 camshaft bearings.
    3. Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.

      Dimension (A - B): 0.7 mm (0.0276 in.) or less 

      NOTE: Position the bearing to the center of the bearing cap by measuring dimension A - B.
      Fig 16: Identifying Bearing Cap's Edge Dimension
      G05398919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL OIL CONTROL VALVE FILTER 
    1. Check that there is no foreign matter on the mesh part of the filter.
    2. Install the oil control valve filter.
      NOTE: Do not touch the mesh when installing the oil control valve filter.
      Fig 17: Installing Oil Control Valve Filter
      G05399309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean both surfaces of the bearing.
    2. Install the 2 No. 2 camshaft bearings.
    3. Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.

      Dimension (A): 1.05 to 1.75 mm (0.042 to 0.068 in.) 

      NOTE: Position the bearing to the center of the bearing cap by measuring dimension A.
      Fig 18: Identifying Bearing Cap's Edge Dimension
      G05398920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 2 CAMSHAFT 
    1. Clean the camshaft journals.
    2. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
    3. Install the No. 2 camshaft to the camshaft housing.
      4. Fig 19: Identifying No. 2 Camshaft
      G05399239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL CAMSHAFT 
    1. Clean the camshaft journals.
    2. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
    3. Install the camshaft to the camshaft housing.
      4. Fig 20: Identifying Camshaft
      G05399238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL CAMSHAFT BEARING CAP 
    1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
    2. Check the marks and numbers on the camshaft bearing caps and place them in the proper position and direction.

      HINT:

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

      Fig 21: Identifying Knock Pin Of Camshaft
      G05398923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the 10 bolts in the order shown in the illustration.

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

      Fig 22: Locating Bolts And Tightening Sequence
      G05398924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
      Fig 23: Identifying Valve Rocker Arm
      G04974791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 

      Seal diameter: 3.5 to 4.0 mm (0.138 to 0.158 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the camshaft housing sub-assembly RH within 3 minutes of applying the seal packing.
      • Do not start the engine for at least 2 hours after installing.
        Fig 24: Applying Seal Packing
        G05398926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set the camshaft and No. 2 camshaft as shown in the illustration.
    4. Install the camshaft housing and tighten the 17 bolts in the order shown in the illustration.

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

      NOTE:
      • After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
      • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
      • After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.
        Fig 25: Locating Camshaft Housing Bolts And Tightening Sequence
        G05398927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Check that the knock pin is installed on the camshaft.
    2. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
      NOTE: Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear assembly.
      Fig 26: Identifying Straight Pin And Key Groove
      G05399318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
      NOTE: Do not turn the camshaft timing gear in the retard direction (the right angle).
      Fig 27: Identifying Straight Pin And Key Groove
      G05399319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the clearance between the gear and the camshaft.

      Clearance: 0.1 to 0.4 mm (0.004 to 0.016 in.) 

      Fig 28: Identifying Clearance Between Gear And Camshaft
      G05399320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the flange bolt with the camshaft timing gear fixed in place.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      Fig 29: Locating Flange Bolt
      G05399321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
      Fig 30: Identifying Camshaft Timing Gear Direction
      G05399322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Check that the knock pin is installed on the camshaft.
    2. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
      3. Fig 31: Identifying Key Groove And Straight Pin
      G04974660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
      NOTE: Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle).
    4. Check that there is no clearance between the gear's flange and the camshaft.
    5. Tighten the flange bolt with the camshaft timing exhaust gear fixed.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      Fig 32: Locating Flange Bolt
      G05399324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Check the camshaft timing exhaust gear lock.
      1. Make sure that the camshaft timing exhaust gear is locked.
  20. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
    1. Install the sensor plate with the "F" mark facing forward.
      Fig 33: Identifying No. 1 Crankshaft Position Sensor Plate
      G05399230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

      HINT:

      Tap in the crankshaft timing gear keys until they come in contact with the crankshaft.

      Fig 34: Identifying Crankshaft Timing Gear Keys
      G05399326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 2 CHAIN SUB-ASSEMBLY 
    1. Set the crankshaft key as shown in the illustration.
      2. Fig 35: Locating Crankshaft Key
      G05399327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the drive shaft so that the cutout faces right.
    3. Align the yellow mark links with the timing marks of each gear as shown in the illustration.
      4. Fig 36: Identifying Yellow Mark Links And Timing Marks
      G05399328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the gears onto the crankshaft and oil pump shaft with the chain on the gears.
    5. Temporarily tighten the oil pump drive shaft gear with the nut.
    6. Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

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

      Fig 37: Identifying Bolt, Chain Tensioner Plate And Spring
      G05399228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
      Fig 38: Turning Crankshaft 90° Clockwise
      G05399226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

      Fig 39: Inserting Bar Into Adjusting Hole Of Oil Pump Drive Shaft Gear
      G05399227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Install the crankshaft timing gear or sprocket.
      Fig 40: Locating Crankshaft Timing Gear Or Sprocket
      G05399225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 41: Locating No. 1 Chain Vibration Damper And Bolts
      G05399333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL CHAIN SUB-ASSEMBLY 
    1. Check the No. 1 cylinder TDC/compression.
      1. Temporarily tighten the crankshaft pulley bolt.
      2. Turn the crankshaft counterclockwise until the timing gear key is facing up.
        3. Fig 42: Identifying Timing Gear Key
        G05399334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the crankshaft pulley bolt.
      4. Check the timing mark on each camshaft timing gear.
        Fig 43: Identifying Timing Mark On Camshaft Timing Gear
        G05399335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

      HINT:

      • Be sure to position the mark plate at the front of the engine.
      • The mark plate on the camshaft side is colored orange.
      • Do not pass the chain around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
      • Pass the chain through the No. 1 vibration damper.
        Fig 44: Identifying Mark Plate And Timing Mark
        G05399336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place the chain on the crankshaft without passing it around the shaft.
      Fig 45: Identifying Chain On Crankshaft
      G05399337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark.

      HINT:

      • Be sure to position the mark plate at the front of the engine.
      • The mark plate on the camshaft side is colored orange.
        • Fig 46: Holding Hexagonal Portion Of Camshaft With Wrench
        G05399338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

      HINT:

      When tensioning the chain, turn the camshaft timing gear assembly clockwise slowly to prevent the chain from being misaligned.

    6. Align the mark plate (yellow) and timing mark and install the chain to the crankshaft timing gear.

      HINT:

      The mark plate on the crankshaft side is colored yellow.

      Fig 47: Identifying Mark Plate (Yellow) And Timing Mark (1 Of 2)
      G05399339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Recheck each timing mark at TDC/compression.
      Fig 48: Identifying Mark Plate (Yellow) And Timing Mark (2 Of 2)
      G05399340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
      Fig 49: Identifying Chain Tensioner Slipper
      G05399222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the No. 2 chain vibration damper with the 2 bolts.

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

      Fig 50: Locating Bolts And No. 2 Chain Vibration Damper
      G05399221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL NO. 1 GENERATOR BRACKET 
    1. Install the No. 1 generator bracket with the 4 bolts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 51: Locating Bolts And Generator Bracket
      G05399220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL WATER INLET HOUSING 
    1. Install a new gasket and the water inlet housing with the 3 bolts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 52: Locating Bolts, Gasket And Water Inlet Housing
      G05399219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
      Fig 53: Identifying Old Packing (FIPG) Material
      G05399345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 3 new O-rings.
      Fig 54: Locating O-Rings
      G05399216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply seal packing as shown in the illustration.
      Fig 55: Applying Seal Packing
      G05399347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Seal diameter: 3.0 mm (0.118 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the chain cover within 3 minutes of applying the seal packing.
      • Do not start the engine for at least 2 hours after installing.
    4. Apply seal packing in a continuous line to the timing chain cover, as shown in the following illustration.
      Fig 56: Applying Seal Packing To Timing Chain Cover
      G05399348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
      • Install the chain cover within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.
      • Do not start the engine for at least 2 hours after installation.

      Apply seal packing as follows 

      SEAL PACKING DIAMETER CHART

      Area Seal Packing Diameter Application Position from Inside Seal Line Seal packing
      Continuous Line Area 3.0 mm (0.118 in.) 2.5 mm (0.098 in.) Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Dashed Line Area 4.0 mm (0.156 in.) 3.0 mm (0.118 in.) Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent
    5. Install a new gasket.
      NOTE: Remove any oil from the contact surface.
      Fig 57: Identifying Gasket
      G05399218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install 2 new O-rings.
      Fig 58: Locating O-Rings
      G05399213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the timing chain cover with the 19 bolts as shown in the illustration.
      Fig 59: Locating Timing Chain Cover Bolts
      G05399351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A and C 

      26 N*m (260 kgf*cm, 19* ft.*lbf) 

      Bolt B and D 

      51 N*m (520 kgf*cm, 38 ft.*lbf) 

      Bolt E 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      NOTE:
      • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
      • Install the chain cover 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.
      • Tighten bolt D through the engine mounting bracket, pressing it against the timing chain or belt cover sub-assembly.
      • Tighten bolt C through the oil filter bracket, pressing it against the timing chain or belt cover sub-assembly.

      Bolt length 

      BOLT LENGTH CHART

      Item Length
      Bolt A and C 35 mm (1.38 in.)
      Bolt B 55 mm (2.16 in.)
      Bolt D 80 mm (3.15 in.)
      Bolt E 40 mm (1.57 in.)
    8. Install the water pump with the 3 bolts.

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

      Fig 60: Locating Bolts And Water Pump Assembly
      G05399217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL THERMOSTAT 
    1. Install a new gasket onto the thermostat.
    2. Install the thermostat with the jiggle valve facing upward.

      HINT:

      The jiggle valve may be set within 10° on either side, as shown in the illustration.

      Fig 61: Identifying Jiggle Valve Facing Upward
      G05399657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL WATER INLET 
    1. Install the water inlet with the 2 nuts.

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

      Fig 62: Locating Water Inlet And Nuts
      G05399209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL CRANKSHAFT PULLEY 
    1. Align the pin hole in the crankshaft pulley with the pin position and install the crankshaft pulley.
    2. Provisionally install the bolt.
    3. Using SST, tighten the bolt while holding the crankshaft pulley.

      SST 09213-58013 (91651 -60855), 09330-00021 

      Torque: 190 N*m (1940 kgf*cm, 140 ft.*lbf) 

      NOTE: Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the timing chain or belt cover sub-assembly.
      Fig 63: Tightening Bolt
      G05399055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

      Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 64: Applying Adhesive To 2 Or 3 Threads Of Oil Pressure Switch
      G05009178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 24 mm deep socket wrench, install the oil pressure switch.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

      NOTE:
      • Install the oil pressure switch within 3 minutes of applying the adhesive.
      • Do not start the engine within 1 hour of installation.
        Fig 65: Locating Engine Oil Pressure Switch Assembly
        G05399203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL ENGINE WATER TEMPERATURE SENSOR 
    1. Install a new gasket to the engine water temperature sensor.
      2. Fig 66: Identifying Engine Water Temperature Sensor
      G05399206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine water temperature sensor.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

  36. INSTALL KNOCK SENSOR 
    1. Install the knock sensor with the bolt.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      NOTE: Make sure that the knock sensor is in the correct position.
      Fig 67: Locating Knock Sensor And Bolt
      G05399359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL NO. 1 TAPER SCREW PLUG 
    1. Apply adhesive to 2 or 3 threads of the plug, and install the plug.

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

      NOTE:
      • Install the plug within 3 minutes of applying the adhesive.
      • Do not start the engine within 1 hour of installation.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 68: Locating No. 1 Taper Screw Plug
      G05399204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Apply a light coat of engine oil to the O-ring of the sensor.
      Fig 69: Identifying O-Ring Of Sensor
      G05399361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the crankshaft position sensor with the bolt.

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

      Fig 70: Locating Bolt And Crankshaft Position Sensor
      G05399202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Release the ratchet pawl, then fully push in the plunger and hook the hook on the pin so that the plunger is in the position shown in the illustration.
      NOTE: Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.
      Fig 71: Checking No. 1 Chain Tensioner Assembly
      G05399363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket, bracket and the No. 1 chain tensioner with the 2 nuts.

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

      NOTE: If the hook releases the plunger while the chain tensioner is being installed, set the hook again.
      Fig 72: Locating Gasket, Bracket And No. 1 Chain Tensioner
      G05399364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.
      Fig 73: Turning Crankshaft Counterclockwise
      G05399365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the crankshaft clockwise, then check that the plunger is extended.
      Fig 74: Turning Crankshaft Clockwise
      G05399366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL OIL FILTER SUB-ASSEMBLY 
    1. Clean the inside of the oil filter cap, threads and Coring groove.
    2. Apply a small amount of engine oil to a new O-ring and install it onto the oil filter cap.
      3. Fig 75: Identifying Oil Filter Element And O-Ring
      G05399716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set a new oil filter element into the oil filter cap.
    4. Remove any dirt or foreign matter from the installation surface of the engine.
    5. Apply a small amount of engine oil to the O-ring again and install the oil filter cap.
    6. Using SST, tighten the oil filter cap.

      SST 09228-06501 

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      NOTE:
      • Make sure that the oil filter is installed securely as shown in the illustration.
      • Be careful that the O-ring does not get caught between the parts.
        Fig 76: Tightening Oil Filter Cap
        G05399718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL CYLINDER HEAD COVER GASKET 
    1. Install the gasket to the cylinder head cover.
      NOTE: Remove any oil from the contact surface.
      Fig 77: Installing Gasket To Cylinder Head Cover
      G05399197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install 3 new gaskets onto the No. 1 camshaft bearing cap.
      Fig 78: Locating Gaskets
      G05399196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing as shown the illustration.

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover 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 the installation.
        Fig 79: Locating Seal Packing Area
        G05399371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cylinder head cover with a new seal washer and the 13 bolts.

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

      Fig 80: Locating Bolts, Seal Washer And Cylinder Head Cover
      G05399195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Apply a light coat of engine oil to 2 new O-rings, then install each of them onto the camshaft timing oil control valve.
      Fig 81: Identifying O-Rings
      G05399373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 camshaft timing oil control valves and bracket with the 2 bolts.

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

      Fig 82: Locating Bolts, O-Rings, Bracket And Oil Control Valves
      G05399194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CAMSHAFT POSITION SENSOR 
    1. Apply a light coat of engine oil to the O-ring of the sensor.
      Fig 83: Identifying O-Ring
      G04973357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 sensors with the 2 bolts.

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

      Fig 84: Locating Bolts And Sensors
      G05399193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL SPARK PLUG 
    1. Using a socket wrench 14 mm, install the 4 spark plugs.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 85: Installing Spark Plugs
      G05399192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL OIL FILLER CAP GASKET 
    1. Install the gasket to the cap.
      Fig 86: Locating Gasket
      G04974253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap.
      Fig 87: Locating Oil Filler Cap
      G05399379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL ENGINE HANGER 
    1. Install the 2 engine hangers with the 2 bolts.

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

      Fig 88: Locating Bolts And Engine Hangers
      G05399189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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