Partial Engine ASSY (3MZ-FE): Overhaul

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE SPARK PLUG
REMOVE OIL FILLER CAP SUB-ASSY
REMOVE OIL FILLER CAP GASKET
REMOVE CYLINDER HEAD COVER SUB-ASSY LH
REMOVE CYLINDER HEAD COVER GASKET NO. 2
REMOVE CYLINDER HEAD COVER SUB-ASSY
REMOVE CYLINDER HEAD COVER GASKET
REMOVE VENTILATION VALVE SUB-ASSY
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
REMOVE VVT SENSOR
1. Remove both the camshaft oil control valves.
2. Remove the O-ring from each camshaft oil control valve.
REMOVE OIL LEVEL GAGE SUB-ASSY
REMOVE OIL LEVEL GAGE GUIDE
REMOVE CRANKSHAFT PULLEY
1. Using SST, loosen the pulley bolt.
  SST 09213-54015 (91651-60855), 09330-00021
  
  Fig 1: Loosening Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and the pulley bolt, remove the pulley.
  SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)
  
  NOTE: Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.
  
  Fig 2: Removing Pulley Using SST And Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING BELT NO. 1 COVER
REMOVE TIMING BELT NO. 2 COVER
REMOVE ENGINE MOUNTING BRACKET RH
REMOVE TIMING BELT GUIDE NO. 2
REMOVE TIMING BELT
1. Set the No. 1 cylinder to the TDC/compression.
  1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
  2. Turn the crankshaft clockwise, then align the timing mark of the crankshaft timing pulley with the oil pump body.
    
    Fig 3: Locating Timing Belt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Check that the timing marks of the camshaft timing pulleys and the timing belt No. 3 cover are aligned. If not, turn the crankshaft by 1 revolution (360°).
  4. Remove the crankshaft pulley bolt.
    
    Fig 4: Checking Timing Marks Of Camshaft Timing Pulleys
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.
  1. If the installation marks have disappeared, put new installation marks on the timing belt before removing.
    
    Fig 5: Checking Insulation Mark On Timing Belt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the No. 1 cylinder to approximately 60° BTDC/compression.
  1. Turn the crankshaft counterclockwise by approximately 60°.
    NOTE: If the timing belt is disengaged, having the crankshaft pulley set at the wrong angle can cause contact of the piston head with the valve head when removing the camshaft timing pulley and camshaft, which causes damage. So always set the crankshaft pulley at the correct angle.
4. Remove the timing belt tensioner.
  NOTE: Do not reinstall the tensioner with its plunger extended.
  
  Fig 6: Setting No. 1 Cylinder To Approximately 60 deg.
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the timing belt in this order.
  
  Fig 7: Timing Belt Removing Sequence Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 8: Identifying Timing Belt Removing Sequence Diagram
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING BELT IDLER SUB-ASSY NO. 1
1. Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
REMOVE TIMING BELT IDLER SUB-ASSY NO. 2
REMOVE CRANKSHAFT POSITION SENSOR
REMOVE CAMSHAFT TIMING PULLEY
1. Using SST, remove the bolt and RH timing pulley.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Fig 9: Removing Bolt And RH Timing Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the bolt and LH timing pulley.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  HINT:
  
  Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.
  
  Fig 10: Removing Bolt And LH Timing Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING BELT NO. 3 COVER
REMOVE TIMING BELT IDLER BRACKET
REMOVE CRANKSHAFT TIMING PULLEY
1. Remove the bolt and timing belt plate.
2. Install the pulley bolt to the crankshaft.
3. Using SST, remove the crankshaft timing pulley.
  SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)
  NOTE:
  - Do not scratch the sensor part of the crankshaft timing pulley.
  - Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.
    
    Fig 11: Removing Crankshaft Timing Pulley Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER PUMP ASSY
1. Remove the 3 bolts and 3 nuts, then remove the water pump and gasket.
REMOVE CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being removed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
  
  Fig 12: Locating Water Pump Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 13: Aligning Timing Marks Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Secure the exhaust camshaft sub gear to the main gear with a service bolt.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  Recommended service bolt
  
  Fig 14: Recommended Service Bolt Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
  
  Fig 15: Securing Exhaust Camshaft Sub Gear To Main Gear With Service Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and camshaft.
  NOTE:
  - Do not pry out the camshaft.
  - Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
    
    Fig 16: Identifying Bolt Loosening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CAMSHAFT
1. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 2 camshaft.
  
  Fig 17: Identifying No. 2 Camshaft Bolt Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not pry out the camshaft.
  - Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
2. Remove the oil seal from the No. 2 camshaft.
REMOVE NO. 3 CAMSHAFT SUB-ASSY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being removed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Align the timing marks (1 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
  
  Fig 18: Aligning Timing Marks Of Camshaft Drive
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Secure the exhaust camshaft sub gear to the main gear with a service bolt.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  Recommended service bolt
  
  Fig 19: Recommended Service Bolt Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
  
  Fig 20: Securing Exhaust Camshaft Sub Gear To Main Gear With Service Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 3 camshaft.
  NOTE:
  - Do not pry out the camshaft.
  - Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
    
    Fig 21: Identifying Bearing Cap Bolts Loosening sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 4 CAMSHAFT SUB-ASSY
1. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and No. 4 camshaft.
  NOTE:
  - Do not pry out the camshaft.
  - Be careful not to damage the contact surface of the cylinder head that receives the shaft thrust.
2. Remove the oil seal from the No. 4 camshaft.
  
  Fig 22: Identifying No. 4 Camshaft Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING GEAR ASSY
1. Clamp the camshaft in a vise on the hexagonal lobe.
2. Check that the VVT-i will not turn.
  
  Fig 23: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Cover all the oil ports with vinyl tape except the port on the advance angle side (nearest to the convex portion) shown in the illustration.
4. Using the air gun, apply about 100 kPa (1 kgf/cm² , 14 psi) of air pressure to the port on the advance angle side.
  NOTE: Some oil spraying will occur. Be prepared to catch the spray with a shop rag.
  
  HINT:
  
  This operation releases the lock pin for the most retard angle lock.
5. Under the condition above, turn the VVT-i to the advance angle side (the direction of the white arrow in the illustration) by hand.
  Standard: Must turn
  
  HINT:
  
  Depending on the air pressure, the VVT-i will turn to the advance angle side without applying force by hand. Also, if the pressure can be hardly applied because of the air leakage from the port, the lock pin might not be released easily.
  
  Fig 24: Locating Convex Portion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check that the VVT-i moves freely within about 30° range. Avoid moving the VVT-i unit to the most retard angle position as the lock pin will engage again.
  Standard: Smooth movable range is about 30°
7. Turn the VVT-i by hand, then lock it at the most retard angle position.
REMOVE CAMSHAFT TIMING GEAR ASSY
NOTE: Do not remove or install the camshaft timing gear (VVT-i) unless you are replacing the VVT-i or camshaft.
1. Clamp the camshaft in a vise on the hexagonal lobe.
  NOTE: Be careful not to damage the camshaft.
  
  Fig 25: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.
  NOTE:
  - Remove it with the lock pin engaged and locked at the most retard angle position.
  - The lock nut has LH threads.
  - Never use any tools other than the socket wrench. Other tools will deform the cam angle rotor.
3. Remove the camshaft VVT-i.
  NOTE: Never remove the 3 bolts on the gear.
  
  If it is difficult to remove VVT-i, tap it lightly using a plastic-faced hammer, then remove it.
  
  Fig 26: Removing Lock Nut Using Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT SUB GEAR
1. Clamp the camshaft in a vise on the hexagonal lobe.
  NOTE: Be careful not to damage the camshaft.
  
  Fig 27: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, turn the sub gear counterclockwise, then remove the service bolt.
  SST 09960-10010 (09962-01000, 09963-00500)
  
  Fig 28: Turning Sub Gear Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using snap ring pliers, remove the snap ring.
4. Remove the wave washer, camshaft sub gear and camshaft gear bolt washer.
  HINT:
  
  Arrange the camshaft sub gears and gear bolt washers (RH and LH sides) so that they can be returned to the original locations when reassembling.
  
  Fig 29: Removing Snap Ring Using Snap Ring Plier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE HANGER NO. 2
REMOVE CYLINDER HEAD COVER REAR
REMOVE OIL CONTROL VALVE FILTER
1. Remove the plug, gasket and valve filter.
  
  Fig 30: Locating Bolt (Oil Control Valve Filter)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD SUB-ASSY
1. Using a socket hexagon wrench 8, remove the hexagon bolt.
  
  Fig 31: Locating Bolt (Cylinder Head Sub-Assy)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
  NOTE:
  - Be careful not to drop the washers into the cylinder head.
  - Head warpage or cracking could result from removing the bolts in an incorrect order.
    
    Fig 32: Identifying Cylinder Head Bolts Loosening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD GASKET
REMOVE CYLINDER HEAD LH
1. Using a socket hexagon wrench 8, remove the hexagon bolt.
  
  Fig 33: Locating Bolt (Cylinder Head LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
  NOTE:
  - Be careful not to drop the washers into the cylinder head.
  - Head warpage or cracking could result from removing the bolts in an incorrect order.
    
    Fig 34: Identifying Bolt Loosening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD GASKET NO. 2
REMOVE WATER INLET HOUSING
1. Remove the 8 bolts and 2 nuts, then remove the water in-let housing.
  
  Fig 35: Identifying Water Inlet Housing Bolt Removing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER SUB-ASSY
1. Using SST, remove the oil filter.
  SST 09228-07501
2. Using a socket hexagon wrench 12, remove the oil filter union.
  
  Fig 36: Removing Oil Filter Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN DRAIN PLUG
REMOVE OIL PAN SUB-ASSY NO. 2
1. Remove the 10 bolts and 2 nuts.
  
  Fig 37: Locating Oil Pan Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, then cut off the sealer and remove the oil pan No. 2.
  SST 09032-00100
  NOTE:
  - Be careful not to damage the contact surface of the oil pan No. 1 where the oil pan No. 2 is mounted.
  - Do not damage the flange portion of the oil pan No. 2 when removing.
REMOVE OIL STRAINER SUB-ASSY
1. Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
  
  Fig 38: Cutting Sealer And Removing Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 39: Identifying Oil Pan Bolt Removing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN SUB-ASSY
1. Loosen and remove the 15 bolts and 2 nuts uniformly.
2. Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan.
  NOTE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.
  
  Fig 40: Removing Oil Pan Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN BAFFLE PLATE
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
2. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and bearing cap.
  
  Fig 41: Removing Oil Seal Retainer Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL
1. Using a screwdriver and hammer, tap out the oil seal.
  
  Fig 42: Tapping Out Oil Seal Using Screwdriver And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PUMP ASSY
1. Remove the 9 bolts.
2. Using a screwdriver, remove the oil pump by prying between the oil pump and bearing cap.
3. Remove the O-ring.
  
  Fig 43: Locating Oil Pump Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PUMP SEAL
1. Using a screwdriver, pry out the oil seal.
  
  Fig 44: Prying Out Oil Seal Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPARK PLUG TUBE GASKET
1. Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.
  NOTE: Be careful not to damage the baffle plate of the cylinder head cover.
  
  Fig 45: Removing Spark Plug Tube Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver and hammer, tap out the gasket.
3. Using needle-nose pliers, pry out the gasket.
  NOTE: Be careful not to damage the cylinder head cover.
  
  Fig 46: Prying Out Gasket Using Plier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TIMING BELT
NOTE:
- Do not bend, twist or turn the timing belt inside out.
- Do not allow contact of the timing belt with oil, water or steam.
- Do not use the timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.
Check the belt for any defects as shown in the illustrations. Also, check these points below.
1. If the belt tears in a short time:
  - Check if the belt is installed properly.
  - Check if the timing cover gasket is damaged and if it is installed properly.
2. If the belt teeth are cracked or damaged, check if either camshaft is locked.
3. If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.
  
  Fig 47: Inspecting Timing Belt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. If there is wear or damage on only one side of the belt, check the belt guide and alignment of each pulley.
5. If there is noticeable wear on the belt teeth:
  - Check the timing cover for damage.
  - Check that the gasket has been installed correctly.
  - Check for foreign objects on the pulley teeth.
    If there is any doubt about the belt condition, replace the timing belt.
    
    Fig 48: Inspecting Camshaft For Runout
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT
1. Inspect the camshaft for runout.
  1. Place the camshaft on V-blocks.
  2. Using a dial indicator, measure the runout at the center journal.
    Maximum circle runout: 0.06 mm (0.0024 in.)
    
    If the runout is greater than maximum, replace the camshaft.
    
    Fig 49: Measuring Cam Lobe Height Using Micrometer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the cam lobes.
  1. Using a micrometer, measure the cam lobe height.
    Standard cam lobe height:
    
    43.132 to 43.232 mm (1.6981 to 1.7020 in.) for intake
    
    43.010 to 43.110 mm (1.6933 to 1.6972 in.) for exhaust
    
    Minimum cam lobe height:
    
    42.98 mm (1.6921 in.) for intake
    
    42.86 mm (1.6874 in.) for exhaust
    
    If the cam lobe height is less than minimum, replace the camshaft.
3. Inspect the camshaft journals.
  1. Using a micrometer, measure the journal diameter.
    Journal diameter:
    
    26.959 to 26.975 mm (1.0614 to 1.0620 in.)
    
    If the journal diameter is not as specified, check the oil clearance.
    
    Fig 50: Measuring Journal Diameter Using Micrometer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD SET BOLT
1. Using vernier calipers, measure the tension portion diameter of the bolt.
  Standard outside diameter:
  
  8.95 to 9.05 mm (0.3524 to 0.3563 in.)
  
  Minimum outside diameter: 8.75 mm (0.3445 in.)
  
  If the diameter is less than minimum, replace the bolt.
  
  Fig 51: Identifying Tension Portion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG TUBE GASKET
1. Using SST and a hammer, tap in the new gasket until its surface is flush with the upper edge of the cylinder head cover.
  SST 09950-60010 (09951-00430), 09950-70010 (09951-07100)
  
  Fig 52: Taping In Gasket Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Return the ventilation plate tab to its original position.
3. Apply a light coat of multi-purpose grease to the gasket lip.
INSTALL ENGINE REAR OIL SEAL
1. Using SST and a hammer, tap in the new oil seal until its surface is flush with the rear oil seal retainer edge.
  SST 09223-15030, 09950-70010 (09951-07100)
  
  Fig 53: Installing Engine Rear Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to tap the oil seal at an angle.
  - Keep the lip free of foreign objects.
2. Apply multi-purpose grease to the oil seal lip.
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Remove any old packing material from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 54: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil seal retainer within 3 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
3. Install the oil seal retainer with the 6 bolts. Tighten the bolts uniformly in several steps.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL OIL PUMP SEAL
1. Using SST and a hammer, tap in the new oil seal until its surface is flush with the oil pump body edge.
  SST 09223-00010
  
  Fig 55: Installing Oil Pump Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to tap the oil seal at an angle.
  - Keep the lip free of foreign objects.
2. Apply multi-purpose grease to the oil seal lip.
INSTALL OIL PUMP ASSY
1. Remove any old packing material from the contact surface.
2. Apply a light coat of engine oil to a new O-ring, then place it on the cylinder block.
  
  Fig 56: Locating O Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  NOTE:
  - Remove any oil from contact surface.
  - Apply seal packing to the inner side of the volt holes.
  - Install the oil pump within 3 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
    
    Fig 57: Identifying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the key of the oil pump drive gear with the keyway located on the crankshaft, then slide the oil pump into place.
  
  Fig 58: Aligning Key Of Oil Pump Drive Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
  
  Fig 59: Identifying Oil Pump Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque:
  
  8.0 N.m (82 kgf.cm, 71 in.lbf) for bolt A
  
  20 N.m (199 kgf.cm, 14 ft.lbf) for bolt B
  
  43 N.m (439 kgf.cm, 32 ft.lbf) for bolt C
INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL OIL PAN SUB-ASSY
1. Remove any old seal packing from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Apply seal packing to the outer side of the bolt holes in the region "X".
  - Apply seal packing to the inner side of the bolt holes in the region "Y".
  - Install the oil pan within 3 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
3. Install the oil pan with the 15 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
  Torque:
  
  8.0 N.m (82 kgf.cm, 71 in.lbf) for 10 mm head
  
  20 N.m (199 kgf.cm, 14 ft.lbf) for 12 mm head
  
  Fig 60: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL STRAINER SUB-ASSY
1. Install a new gasket and the oil strainer with the bolt and 2 nuts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL OIL PAN SUB-ASSY NO. 2
1. Remove any old seal packing from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 61: Identifying Seal Width
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Apply seal packing to the inner side of the bolt holes.
  - Install the oil pan within 3 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
3. Install the oil pan No. 2 with the 10 bolts and 2 nuts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL OIL PAN DRAIN PLUG
1. Install the drain plug with a new gasket.
  Torque: 45 N.m (459 kgf.cm, 33 ft.lbf)
INSTALL WATER INLET HOUSING
1. Remove any old packing material from the contact surface.
  
  Fig 62: Identifying Seal Packing Width
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 in.)) as shown in the illustration.
  Seal packing: Part No. 08826-00100 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the water inlet housing within 3 minutes after applying seal packing.
  - Do not expose the seal packing to coolant within 2 hours after installing.
3. Install the water inlet housing with the 8 bolts and 2 nuts. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 63: Identifying Water Inlet Housing Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD GASKET
1. Place a new cylinder head gasket on the cylinder block with the R mark upward.
  
  Fig 64: Identifying Cylinder Head Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Be careful of the installing orientation.
  - Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
INSTALL CYLINDER HEAD SUB-ASSY
NOTE: 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. Install the plate washers to the cylinder head bolts.
3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
  Torque: 54 N.m (550 kgf.cm, 40 ft.lbf)
  
  Fig 65: Installing And Tightening Cylinder Head Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
5. Retighen the cylinder head bolts by 90° in the same sequence as step (c).
6. Check that each painted mark is now at a 90° angle to the front.
  
  Fig 66: Identifying Painted Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a socket hexagon wrench 8, install the hexagon bolt.
  Torque: 19 N.m (189 kgf.cm, 14 ft.lbf)
  
  Fig 67: Installing Hexagon Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD GASKET NO. 2
1. Place a new cylinder head gasket on the cylinder block with the L mark upward.
  
  Fig 68: Installing Cylinder Head Gasket No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Be careful of the installing orientation.
  - Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
INSTALL CYLINDER HEAD LH
NOTE: 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. Install the plate washers to the cylinder head bolts.
  
  Fig 69: Installing And Tightening Cylinder Head Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
  Torque: 54 N.m (550 kgf.cm, 40 ft.lbf)
  
  Fig 70: Identifying Painted Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
5. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
6. Check that each painted mark is now at a 90° angle to the front.
  
  Fig 71: Installing Hexagon Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a socket hexagon wrench 8, install the hexagon bolt.
  Torque: 19 N.m (189 kgf.cm, 14 ft.lbf)
INSTALL OIL CONTROL VALVE FILTER
1. Check that no foreign object is on the mesh part of the filter.
2. Assemble the valve filter and plug.
3. Install the plug with a new gasket.
  Torque: 45 N.m (459 kgf.cm, 33 ft.lbf)
  
  Fig 72: Locating Oil Control Valve Filter Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER REAR
1. Install the rear cover and a new gasket.
  Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
INSTALL CAMSHAFT SUB GEAR
1. Clamp the camshaft in a vise on the hexagonal lobe.
  NOTE: Be careful not to damage the camshaft.
  
  Fig 73: Clamping Camshaft In Vise On Hexagonal Lobe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshaft gear bolt washer and camshaft sub gear.
  HINT:
  
  Attach the pins on the gears to the gear bolt washer ends.
3. Install the wave washer.
  
  Fig 74: Identifying Camshaft Gear Bolt Washer And Camshaft Sub Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using snap ring pliers, install the snap ring.
  
  Fig 75: Installing Snap Ring Using Snap Ring Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, then temporarily install a service bolt.
  SST 09960-10010 (09962-01000, 09963-00500)
  
  Fig 76: Aligning Holes Of Camshaft Main Gear Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Align the gear teeth of the main gear and sub gear, then tighten the service bolt.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  NOTE: Be careful not to damage the camshaft journals.
  
  HINT:
  
  When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt.
INSTALL CAMSHAFT TIMING GEAR ASSY
1. Align the alignment pin with the alignment pin groove, then install the VVT-i into the camshaft.
  
  Fig 77: Aligning Alignment Pin With Alignment Pin Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Install it with the lock pin engaged and locked at the most retard angle position.
2. Apply engine oil to the nut, mounting surface of the VVT-i and screw threads.
  NOTE:
  1. Be sure to apply the oil, otherwise the specified torque cannot be
  2. New nuts must be used when replacing the VVT-i unit.
3. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
  Torque: 150 N.m (1,530 kgf.cm, 111 ft.lbf
  NOTE:
  - The lock nut has LH threads.
  - Never use any tools other than the socket wrench. Other tools will deform the cam angle rotor.
INSTALL NO. 2 CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
  
  Fig 78: Installing And Tighten Lock Nut Using Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the No. 2 camshaft at a 90° angle of the timing mark (2 dot marks) on the cylinder head.
3. Apply multi-purpose grease to a new oil seal lip.
  
  Fig 79: Placing Camshaft At 90deg
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil seal to the camshaft.
  NOTE:
  - Do not turn over the oil seal lip.
  - Insert the oil seal until it stops.
5. Remove any old packing material from the contact surface.
  
  Fig 80: Installing Oil Seal To Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply seal packing to the bearing cap No. 1 as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  NOTE:
  - Install the bearing cap No. 1 within 5 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
    
    Fig 81: Identifying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the 5 bearing caps in their proper locations.
8. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 82: Installing Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)
  
  Fig 83: Tightening Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Align the timing marks (2 dot marks) of the camshaft drive and driven gears.
3. Place the camshaft on the cylinder head.
  
  Fig 84: Aligning Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 5 bearing caps in their proper locations.
5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 85: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)
7. Remove the service bolt.
INSTALL NO.4 CAMSHAFT SUB-ASSY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
  
  Fig 86: Identifying Tightening Sequence for Cam Shaft Sub Assy.
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the No. 4 camshaft at a 90° angle of the timing mark (1 dot marks) on the cylinder head.
3. Apply multi-purpose grease to a new oil seal lip.
  
  Fig 87: Placing Camshaft At 90deg
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil seal to the camshaft.
  NOTE:
  - Do not turn over the oil seal lip.
  - Insert the oil seal until it stops.
5. Remove any old packing material from the contact surface.
  
  Fig 88: Installing Oil Seal To Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply seal packing to the bearing cap No. 1 as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  NOTE:
  - Install the bearing cap No. 1 within 5 minutes after applying seal packing.
  - Do not expose the seal packing to engine oil within 2 hours after installing.
    
    Fig 89: Identifying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the 5 bearing caps in their proper locations.
8. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 90: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)
  
  Fig 91: Identifying Bearing Cap Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 CAMSHAFT SUB-ASSY
NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
1. Apply new engine oil to the thrust portion and journal of the camshaft.
2. Align the timing marks (1 dot marks) of the camshaft drive and driven gears.
3. Place the camshaft on the cylinder head.
  
  Fig 92: Aligning Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 5 bearing caps in their proper locations.
5. Apply a light coat of engine oil to the threads of the bearing cap bolts.
  
  Fig 93: Installing Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
  Torque: 16 N.m (163 kgf.cm, 12 ft.lbf)
7. Remove the service bolt.
  
  Fig 94: Identifying Tightening Sequence Of Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING PULLEY
1. Align the keyway of the timing pulley with the key located on the crankshaft, then slide the timing pulley into place.
  NOTE: Do not scratch the sensor area of the crankshaft timing pulley.
2. Install the timing belt plate with the bolt.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 95: Installing Crankshaft Timing Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER PUMP ASSY
1. Install a new gasket and the water pump with the 3 bolts and 3 nuts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 96: Locating Water Pump Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL LEVEL GAGE GUIDE
1. Apply a light coat of engine oil to a new O-ring, then install it to the level gage guide.
2. Install the level gage guide.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL OIL FILTER SUB-ASSY
1. Using a socket hexagon wrench 12, install the oil filter union.
  Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
2. Check and clean the oil filter installation surface.
3. Apply clean engine oil to the gasket of a new oil filter.
4. Lightly screw the oil filter into place, then tighten it until the gasket contact the seat.
5. Using SST, tighten it by an additional 3/4 turn.
  SST 09228-078501
  
  Fig 97: Tightening Oil Filter Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT IDLER BRACKET
Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
INSTALL TIMING BELT NO. 3 COVER
1. Visually check for cracks and breaks on the gasket of the timing belt cover.
  HINT:
  
  If there is a trace of water intrusion when checking visually, repair the gasket with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) or longer.
2. If the timing belt cover gasket is needed to repair, follow the procedure below.
  1. Repair the cracks and breaks by applying seal packing to the damaged area.
    Seal packing: Part No. 08826-00080 or equivalent
    
    Fig 98: Identifying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: When applying the seal packing, apply it as wide and high as the gasket.
3. If the timing belt cover gasket is needed to replace, follow the procedure below.
  1. Using a screwdriver and gasket scraper, remove the remaining gasket.
    NOTE: Be careful not to damage the timing belt cover.
  2. Remove the backing paper from a new gasket, then affix the gasket along the groove of the timing belt cover as shown in the illustration.
    NOTE:
    Affix the gasket in the center of the groove.
    
    At the corners, try to keep the gasket thickness uniform.
    HINT:
    
    Fig 99: Gasket Dimension Table
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 100: Identifying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. If there is a gap between the ends of the gasket, apply seal packing to close the gap.
    Seal packing: Part No. 08826-00080 or equivalent
    
    NOTE: When applying the seal packing, apply it as wide and high as the gasket.
4. Install the timing belt cover with the 6 bolts.
  Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
INSTALL CAMSHAFT TIMING PULLEY
1. Pay attention to the orientation of the belt guide. Install the camshaft timing pulley with the belt guide properly oriented, then tighten the bolt temporarily.
  HINT:
  - Align the belt guide of the RH timing pulley so it faces the front of the engine as illustrated.
    
    Fig 101: Installing Camshaft Timing Pulley
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Align the belt guide of the LH timing pulley so it faces the rear of the engine as illustrated.
2. Using SST, tighten the RH pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Torque: 125 N.m (1,275 kgf.cm, 92 ft.lbf)
  
  Fig 102: Tightening RH Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, tighten the LH pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Torque: 125 N.m (1,275 kgf.cm, 92 ft.lbf)
  
  Fig 103: Tightening LH Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT IDLER SUB-ASSY NO. 2
Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)
INSTALL TIMING BELT IDLER SUB-ASSY NO. 1
1. Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt.
  Torque: 34 N.m (347 kgf.cm, 25 ft.lbf)
INSTALL TIMING BELT
1. Remove any oil or water on the pulleys, then keep them clean.
  NOTE:
  - If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
  - Only wipe the pulleys; do not use any cleaning agent.
2. Check the idler pulleys.
  1. Check that the idler pulley turns smoothly.
  2. Visually check the seal portion of the idler pulley for oil leakage.
3. Check the water pump.
  1. Turn the pulley, then check that water pump bearing moves smoothly and does not make a noise.
  2. Visually check the drain hole for coolant leakage.
4. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
5. Turn the crankshaft counterclockwise by approximately 60°.
  NOTE: To prevent contact of the piston head with the valve head, set the crankshaft pulley at the 60° BTDC/compression position.
  
  Fig 104: Turning Crankshaft Counterclockwise By 60deg
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, turn the crankshaft pulley, then align the timing marks of the timing pulley with the timing belt No. 3 cover.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Fig 105: Turning Crankshaft Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Turn the crankshaft, then align the timing mark of the crankshaft timing pulley with the oil pump body.
  
  Fig 106: Aligning Timing Mark Of Crankshaft Timing Pulley With Oil Pump Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Align the front mark on the timing belt so it faces forward.
9. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
10. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
  
  Fig 107: Aligning Installation Marks On Timing Belt With Timing Marks Of Camshaft Timing Pulleys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Install the timing belt in this order.
  
  Fig 108: Timing Belt Installation Sequence Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 109: Identifying Timing Belt Installation Sequence Diagram
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT TENSIONER ASSY
1. Set the timing belt tensioner upright on the press.
  
  Fig 110: Aligning Holes Of Push Rod And Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Slowly press in the push rod.
  NOTE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.
3. Align the holes of the push rod and housing, then pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
4. Release the press.
5. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
  Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)
  
  NOTE: Be sure to tighten the bolts uniformly. Installing the tensioner at an angle may cause failure of its proper operation.
6. Remove the 1.5 mm hexagon wrench from the tensioner.
7. Turn the crankshaft 2 revolutions slowly, then align the timing mark of the crankshaft timing pulley with the oil pump body.
  NOTE: Always turn the crankshaft clockwise.
  
  Fig 111: Aligning Timing Mark Of Crankshaft Timing Pulley With Oil Pump Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the timing belt No. 3 cover as shown in the illustration.
  If the marks are not aligned, remove the timing belt and reinstall it.
9. Remove the crankshaft pulley bolt.
  
  Fig 112: Checking Timing Marks Of RH and LH Timing Pulleys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING BELT GUIDE NO. 2
1. Install the timing belt guide with the cup side facing the engine front.
  
  Fig 113: Installing Timing Belt Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
INSTALL TIMING BELT NO. 2 COVER
1. Visually check for cracks and breaks on the gasket of the timing belt cover.
  If there is a trace of water intrusion when checking visually, replace the timing belt cover.
2. Install the timing belt cover.
  Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
INSTALL TIMING BELT NO. 1 COVER
1. Visually check for cracks and breaks on the gasket of the timing belt cover.
  If there is a trace of water intrusion when checking visually, replace the timing belt cover.
2. Install the timing belt cover.
  Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
INSTALL CRANKSHAFT PULLEY
1. Align the keyway of the pulley with the key located on the crankshaft, then slide the pulley into place.
2. Using SST, install the pulley bolt.
  SST 09213-54015 (91651-60855), 09330-00021
  
  Torque:220 N.m (2,250 kgf.cm, 162 ft.lbf)
  
  Fig 114: Installing Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VVT SENSOR
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL ENGINE HANGER NO. 2
Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)

Fig 115: Turning Crankshaft Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE CLEARANCE
1. Turn the crankshaft pulley, then align the timing notch with the timing mark "0" of the timing belt No. 1 cover.
2. Check that the valve lifters on the intake side of the No. 1 cylinder are not pushed by the cam.
  If the valve lifters are pushed, turn the crankshaft 1 revolution (360°) and align the marks as above.
3. Inspect the valves indicated in the illustration on the left.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (Cold):
    
    0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
    
    0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
  2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
    
    Fig 116: Inspecting Valves (1 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the crankshaft by 2/3 of a revolution (240°), then inspect the valves indicated in the illustration on the left.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (Cold):
    
    0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
    
    0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
  2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
    
    Fig 117: Inspecting Valves (2 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Turn the crankshaft by 2/3 of a revolution (240°), then inspect the valves indicated in the illustration on the left.
  1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
    Valve clearance (Cold):
    
    0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
    
    0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
  2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
    
    Fig 118: Inspecting Valves (3 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST VALVE CLEARANCE
1. Turn the camshaft so that the cam lobe faces upward.
2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.
  
  Fig 119: Adjusting Valve Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A).
  SST 09248-55040 (09248-05410, 09248-05420)
  
  HINT:
  - Apply SST (B) at a slight angle on the side marked with "9" or "7" at the position shown in the illustration.
  - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent SST (B) from getting stuck, insert it gently from the intake side at a slight angle.
    
    Fig 120: SST Table
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 121: Pressing Down Valve Lifter And Placing SST Between Camshaft And Valve Lifter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a small screwdriver and magnetic finger, remove the adjusting shim.
  
  Fig 122: Removing Adjusting Shim Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a micrometer, measure the thickness of the removed shim.
6. Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
  
  Fig 123: Thickness Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 124: Measuring Thickness Of Shim Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Specified value (Cold):
  
  Intake A = B + (C - 0.20 mm (0.0079 in.))
  
  Exhaust A = B + (C - 0.30 mm (0.0118 in.))
7. Select a new shim with a thickness which is as close to the calculated values as possible.
  
  Fig 125: Calculation Specification
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
  - Refer to New Shim Thickness table on the next 2 pages.
    
    Fig 126: Adjusting Shim selection Chart (Intake)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 127: Adjusting Shim selection Chart (Exhaust)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Place a new adjusting shim on the valve lifter with the imprinted number facing down.
9. Press down the valve lifter with SST (A), then remove SST (B).
  SST 09248-55040 (09248-05410, 09248-05420)
  
  Fig 128: Pressing Down Valve Lifter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Recheck the valve clearance.
INSTALL CYLINDER HEAD COVER SUB-ASSY
1. Install the gasket to the cylinder head cover.
2. Apply seal packing to the cylinder head as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 129: Applying Seal Packing To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
3. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
  Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
INSTALL CYLINDER HEAD COVER SUB-ASSY LH
1. Install the gasket to the cylinder head cover.
2. Apply seal packing to the cylinder head as shown in the illustration.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Fig 130: Applying Seal Packing To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes after applying seal packing.
  - Do not start the engine within 2 hours after installing.
3. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
  Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
INSTALL SPARK PLUG
Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)