Engine Unit: Reassembly

1. Apply adhesive to the end 2 or 3 threads of the drain union and install the water drain cock within 3 minutes of applying the adhesive.
2. After applying the specified torque, rotate the drain union clockwise until its drain port faces downward.

   Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

   NOTE:

   • Do not add coolant within 1 hour of installation.
   • Do not rotate the drain union more than 360° in step (b), and never loosen it after setting the union correctly.
     Fig 1: Identifying Cylinder Bolt Angle

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 2: Identifying Straight Pin Dimension

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a plastic-faced hammer, tap in the straight pin.

   Standard protrusion: Pin A: 

   8.5 to 9.5 mm (0.335 to 0.374 in.) 

   Pin B: 8.5 to 9.5 mm (0.335 to 0.374 in.) 

   Pin C: 18.5 to 19.5 mm (0.728 to 0.768 in.) 

   Pin D: 11.5 to 12.5 mm (0.453 to 0.492 in.) 

1. Using a plastic-faced hammer, tap in a new ring pin.

   Standard protrusion: 3.5 to 4.5 mm (0.138 to 0.177 in.) 

Fig 3: Identifying Oil Pump Set Ring Pin Dimension (1 Of 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 4: Identifying Oil Pump Set Ring Pin Dimension (2 Of 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using "Torx" socket wrench E5, install the 7 stud bolts.

   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (for Stud bolt A, B and D) 11 N*m (112 kgf*cm, 8.1 ft.*lbf) (for Stud bolt C) 

   NOTE: The lower threads of the bolt are installed into the cylinder block.

1. Align the crankshaft bearing (upper) with the oil hole of the cylinder block and install the bearing.
   NOTE: Do not apply engine oil to the bearing or its contact surface.
   Fig 5: Aligning Crankshaft Bearing With Oil Hole Of Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the crankshaft bearing (lower) with the bearing cap and install the crankshaft bearing cap.
   NOTE:

   • Install the bearing cap so that the gap between A and B is less than 0.7 mm (0.028 in.).
   • Do not apply engine oil to the bearing or its contact surface.
     Fig 6: Identifying Crankshaft Bearing Cap

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.
2. Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.
   Fig 7: Installing Crankshaft Thrust Washer Upper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Examine the front marks and numbers and install the bearing caps onto the cylinder block.
2. Apply a light coat of engine oil to the threads of the bearing cap bolts.
   Fig 8: Identifying Bearing Cap Onto Cylinder Block Marks And Numbers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration (*1).

   SST 09011-38121 

   Torque: 22 N*m (224 kgf*cm, 16 ft.lbf) 

   NOTE: Check that the crankshaft turns smoothly.
   Fig 9: Identifying Crankshaft Bearing Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the front of the bearing cap bolts with paint.
5. Retighten the bearing cap bolts by 90° in the same sequence as step (*1).
6. Check that the painted mark is now at a 90° angle from the front.
   Fig 10: Identifying Mark Front Of Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the piston pin and pin holes in the piston with engine oil.
2. Align the cavity of the piston with the protruding portion on the connecting rod.
   Fig 11: Identifying Piston Pin Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, press in the piston pin.

   SST 09221-25026 (09221-00021, 09221-00030, 09221-00090, 09221-00150, 09221-00100) 

   NOTE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to the original locations when reassembled.
   Fig 12: Identifying Connecting Rod And Piston Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the bearing claw with the groove of the connecting rod or connecting cap.
   NOTE: Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oil.
   Fig 13: Installing Connecting Rod Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

When reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly.

1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings.
   Fig 14: Installing Piston Ring Set

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown.

1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
2. Check the position of the piston ring ends.
   Fig 15: Positioning Piston Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark on the piston facing forward.
   NOTE:

   • Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oil.
   • Match the numbered connecting rod cap with the connecting rod.
     Fig 16: Identifying Front Mark On Piston

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Make sure that the connecting rod and its cap are in the correct combination and that the front mark of the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod.
5. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.
   Fig 17: Identifying Front Mark Of Connecting Rod

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, tighten the bolts in several steps to the specified torque.

   SST 09205-16010 

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

   Fig 18: Tightening Bolts With Specified Torque

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Mark the front of the connecting cap bolts with paint.
8. Retighten the cap bolts by 90° as shown.
9. Check that the crankshaft turns smoothly.

Fig 19: Identifying Mark Front Of Bearing Cap Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using "Torx" socket wrench E5, install the 4 stud bolts.

   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

   Fig 20: Identifying Stud Bolt Dimension

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing material from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 2.0 mm to 3.0 mm (0.079 to 0.118 in.)) to the oil pan mating surface as 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 oil pan within 3 minutes of applying the seal packing.
   • Do not expose the seal to engine oil for at least within 2 hours after the installation.
     Fig 21: Identifying Oil Pan Sub-Assembly Dimension

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install 2 new O-rings onto the cylinder block.
4. Using several steps, install and tighten the 13 bolts uniformly in the sequence shown in the illustration.

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

   HINT:

   Each bolt length is as follows:

   Bolt A 49 mm (1.93 in.)

   Bolt B 88 mm (3.47 in.)

   Bolt C 144 mm (5.67 in.)

Fig 22: Identifying Bolts Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket and the oil strainer with the 2 nuts and the bolt.

   Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) 

1. Remove any old packing material from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan mating surface as 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 oil pan within 3 minutes of applying the seal packing.
   • Do not expose the seal to engine oil for at least 2 hours after the installation.
   • Do not start the engine for at least 2 hours after the installation.
     Fig 23: Identifying Seal Packing Area

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install oil pan No. 2 with the 9 bolts and the 2 nuts.

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

4. Install the drain plug with a new gasket.

   Torque: 38 N*m (382 kgf*cm, 28 ft.*lbf) 

1. Using a 12 mm hexagon wrench, install the oil filter union.

   Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

Fig 24: Identifying Oil Filter Union

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of a new oil filter.
3. Gently screw the oil filter into place, and tighten it until the gasket comes into contact with the seat.
4. Using SST, tighten it an additional 3/4 turn.

   SST 09228-06501 

   HINT:

   When using a torque wrench, tighten it to the specified torque.

   Torque: 13 N*m (133 kgf*cm, 9.5 ft.*lbf) 

   Fig 25: Removing Oil Filter With SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
   • Place the cylinder head on the cylinder head gently in order not to damage the gasket.
     Fig 26: Identifying Cylinder Head Gasket Lot No. Stamp

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 an 8 mm bi-hexagon wrench in the sequence shown in the illustration.

   Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

3. Mark the front of the cylinder head bolt with paint.
   Fig 27: Identifying Cylinder Head Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Retighten the cylinder head bolts by 90° and then an additional 90° as shown in the illustration.
5. Check that the paint mark is now at a 180° angle from the front.
   Fig 28: Identifying Paint Mark Angle From Front

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as 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 oil pump assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
     Fig 29: Identifying Cylinder Head Gasket Dimension

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply MP grease to a new oil seal lip.
   NOTE: Keep the seal lip free of foreign matter.
2. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

   SST 09223-56010 

   NOTE:

   • Do not tap the oil seal at an angle.
   • Wipe any extra grease off the crankshaft.

Fig 30: Tapping Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Put the camshaft timing gear assembly and camshaft together with the straight pin of the groove.
2. Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits into the groove, push to ensure a good fit.
   NOTE: Do not turn the camshaft timing gear in the retard direction (clockwise).
   Fig 31: Identifying Camshaft Together With Straight Pin Of Groove

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that there is no clearance between the gear fringe and the camshaft.
4. Tighten the flange bolt with the camshaft timing gear fixed.

   Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

   NOTE:

   • Do not lock the camshaft timing gear assembly when tightening the bolt.
   • Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position.
   • Tightening the bolts with the lock pin locked could cause breakage of the lock pin.
5. Check that the camshaft timing gear assembly moves smoothly in the retard direction (clockwise) and is locked in the most retarded position.

1. Apply a light coat of engine oil to the camshaft journals.
2. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
3. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.

   Torque: 13 N*m (129 kgf*cm, 9.4ft.*lbf) 

   NOTE: Tighten each bolt uniformly while keeping the camshaft level.
   Fig 32: Identifying Camshaft Journals Front Marks And Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clamp the camshaft in a vice.
2. Align the knock pin hole in the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket.

   Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

   NOTE: Do not damage the camshaft.

Fig 33: Aligning Knock Pin Hole In Camshaft Timing Sprocket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of engine oil to the camshaft journals.
2. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
3. Examine the front marks and numbers on camshaft bearing caps No. 1 and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.

   Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 2 23 N*m (235 kgf*cm, 17 ft.*lbf) for bearing cap No. 1 

   NOTE: Tighten each bolt uniformly while keeping the camshaft level.
   Fig 34: Identifying Front Marks And Numbers Of Camshaft Bearing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply engine oil to the O-ring.
   NOTE: If the O-ring is damaged, replace the camshaft position sensor.
2. Install the camshaft position sensor with the bolt.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   Fig 35: Locating Camshaft Position Sensor And Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Make sure that all the timing marks are in the positions (TDC) shown in the illustration.

   HINT:

   The positions of the timing marks may differ from the predetermined positions due to the force of the valve spring.

   Fig 36: Identifying Timing Marks On Chain Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the timing mark of the crankshaft in a position between 40 and 140°ATDC, as illustrated.
   Fig 37: Identifying Timing Mark Of Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the camshaft timing gear and the camshaft timing sprocket in the positions (20°ATDC) shown in the illustration.
4. Set the crankshaft in the position (20°ATDC) shown in the illustration.
   Fig 38: Identifying Camshaft Timing Gear And Camshaft Timing Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install chain vibration damper No. 1 with the 2 bolts.

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

   Fig 39: Identifying Chain Vibration Damper With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Align the timing marks of the camshaft with the mark plates of the timing chain and install the timing chain.

   HINT:

   Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench.

   Fig 40: Identifying Timing Marks Of Camshaft With Mark Plates Of Timing Chain

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the chain tensioner slipper.
   Fig 41: Identifying Chain Tensioner Slipper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install chain tensioner assembly No. 1 with the 2 bolts.

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

2. Remove the bar from chain tensioner assembly No. 1.
   Fig 42: Locating Chain Tensioner Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

   SST 09950-60010 (09951-00250, 09951-00380, 09952-06010), 09950-70010 (09951-07100) 

   NOTE:

   • Do not tap the oil seal at an angle.
   • Keep the seal lip free of foreign matter.
2. Apply MP grease to the oil seal lip.
   Fig 43: Tapping Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 new O-rings in the 2 locations shown in the illustration.
   Fig 44: Locating O-Rings From Cylinder Block And Oil Pan Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration.
   Fig 45: Identifying Seal Packing Dimension Of Oil Pump Assembly, Cylinder Head And Cylinder Block Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing: 

   Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Other part Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pump assembly within 3 minutes and tighten the bolts and nut within 15 minutes of applying the seal packing.
   • Do not expose the seal to engine oil for at least 2 hours after the installation.
3. Align the keyway of the oil pump rotor with the rectangular portion of the crankshaft, and slide the oil pump into place.
   Fig 46: Aligning Keyway Of Oil Pump Rotor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil pump assembly with the 15 bolts and nut. Tighten the bolts and nut uniformly in several steps.

   Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for bolt A 11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt B 11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt C 24 N*m (245 kgf*cm, 18 ft/lbf) for nut D 24 N*m (245 kgf*cm, 18 ft.lbf) for bolt E 

   NOTE: Install the mounting bracket and water pump within 15 minutes of installing the oil pump assembly.

   HINT:

   Each bolt length is as follows.

   A: 30 mm (1.181 in.)

   B: 35 mm (1.378 in.)

   C: 20 mm (0.787 in.)

   E: 20 to 14 mm (0.787 to 0.551 in.) Double ended bolt

   Fig 47: Locating Oil Pump Assembly With Bolts And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the water pump and a new gasket with the 3 bolts and 2 nuts.

   Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) 

   Fig 48: Locating Water Pump Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the transverse engine mounting bracket with the 4 bolts.

   Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 

1. Align the pin hole in the crankshaft damper with the pin position and install the crankshaft damper sub-assembly.
2. Provisionally install the bolt.
   Fig 49: Locating Transverse Engine Mounting Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using 2 SSTs, tighten the bolt while holding the crankshaft damper sub-assembly.

   SST 09213-14010 (91651-60865), 09330-00021 

   Torque: 128 N*m (1305 kgf*cm, 95 ft.*lbf) 

   NOTE: Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.
   Fig 50: Loosening Bolt While Holding Crankshaft Damper Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the pump pulley with the 3 bolts.

   SST 09960-10010 (09962-01000, 09963-00700) 

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

   Fig 51: Locating Pump Pulley And SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the No. 1 cylinder to TDC/compression.
   1. Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump.
      Fig 52: Identifying Timing Notch

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward, as shown in the illustration.

      HINT:

      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

      Fig 53: Identifying Timing Marks

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the valves indicated in the illustration.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (cold): 

      for intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) 

      for exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) 

   2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
      Fig 54: Identifying Valve Lifter And Camshaft

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the crankshaft 1 complete revolution (360°) and align its timing notch with timing mark "0" of the oil pump.
4. Check the valves indicated in the illustration.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (cold): 

      for Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) 

      for Exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) 

   2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
      Fig 55: Identifying Valve Lifter

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 56: Identifying Matchmark Of Timing Chain Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the No. 1 cylinder to TDC/compression.
   1. Turn the crankshaft damper, and align its timing notch with timing mark "0" of the oil pump.
      Fig 57: Identifying Timing Notch

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward as shown in the illustration.

      HINT:

      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

      Fig 58: Identifying Timing Marks On Camshaft Timing Sprocket And Camshaft Timing Gear

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Put paint marks on the chain in the places where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.
   Fig 59: Identifying Paint Marks And Timing Marks Of Camshaft Timing Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using an 8 mm hexagon wrench, remove the screw plug.
   Fig 60: Locating Screw Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.
   Fig 61: Identifying Stopper Plate Of Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a wrench, rotate the No. 2 camshaft clockwise to push in the plunger of the chain tensioner.
   Fig 62: Pushing In Plunger Of Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and insert a 3 mm (0.12 in.) diameter bar into the holes to hold the stopper plate.

   HINT:

   • Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
   • Hold the bar with tape so that it does not come out.
     Fig 63: Rotating Camshaft Right And Left

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a wrench, hold the hexagonal lobe of No. 2 camshaft and remove the flange bolt.
   Fig 64: Locating Fringe Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2.
   NOTE: Loosen each bolt uniformly while keeping the camshaft level.
   Fig 65: Identifying Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the flange bolt and remove the camshaft timing sprocket.
   Fig 66: Identifying Fringe Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Remove the No. 2 camshaft.
    Fig 67: Identifying Camshaft

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2.
    NOTE: Loosen the bolts uniformly while keeping the camshaft level.
    Fig 68: Identifying Bearing Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly.
    Fig 69: Identifying Camshaft And Camshaft Timing Gear Assembly

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Tie the chain with a piece of string as shown in the illustration.
14. Remove the valve lifters.
    Fig 70: Identifying Tie Chain With Piece Of String

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Using a micrometer, measure the thickness of the removed lifter.
16. Calculate the thickness of the new lifter so that the valve clearance comes to within the specified values.
    LIFTER SPECIFICATIONS
    
    

    A	Thickness of new lifter
    B	Thickness of used lifter
    C	Measured valve clearance

    Valve clearance: 

    Intake A = B + (C - 0.20 mm (0.008 in.)) 

    Exhaust A = B + (C - 0.30 mm (0.012 in.)) 

    Fig 71: Measuring Thickness Of Removed Lifter

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Select a new lifter with a thickness as close to the calculated values as possible.

    HINT:

    Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

    Fig 72: Lifter Reference Chart (1 Of 2)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Intake valve clearance (cold): 0.15 to 0.25 mm (0.006 to 0.010 in.) 

    EXAMPLE: 

    A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter. 

    New Shim Thickness 

    SHIM THICKNESS SPECIFICATIONS
    
    

    Shim No.	Thickness	Shim No.	Thickness	Shim No.	Thickness
    06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)
    08	5.080 (0.2000)	32	5.320 (0.2094)	56	5.560 (0.2189)
    10	5.100 (0.2008)	34	5.340 (0.2102)	58	5.580 (0.2197)
    12	5.120 (0.2016)	36	5.360 (0.2110)	60	5.600 (0.2205)
    14	5.140 (0.2024)	38	5.380 (0.2118)	62	5.620 (0.2213)
    16	5.160 (0.2031)	40	5.400 (0.2126)	64	5.640 (0.2220)
    18	5.180 (0.2039)	42	5.420 (0.2134)	66	5.660 (0.2228)
    20	5.200 (0.2047)	44	5.440 (0.2142)	68	5.680 (0.2236)
    22	5.220 (0.2055)	46	5.460(0.2150)	70	5.700 (0.2244)
    24	5.240 (0.2063)	48	5.480 (0.2157)	72	5.720 (0.2252)
    26	5.260 (0.2071)	50	5.500(0.2165)	74	5.740 (0.2260)
    28	5.280 (0.2079)	52	5.520(0.2173)

    Fig 73: Lifter Reference Chart (2 Of 2)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Exhaust valve clearance (cold): 0.25 to 0.35 mm (0.010 to 0.014 in.) 

    EXAMPLE: 

    A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter. 

    New Shim Thickness 

    SHIM THICKNESS SPECIFICATIONS
    
    

    Shim No.	Thickness	Shim No.	Thickness	Shim No.	Thickness
    06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)
    08	5.080 (0.2000)	32	5.320 (0.2094)	56	5.560 (0.2189)
    10	5.100 (0.2008)	34	5.340 (0.2102)	58	5.580 (0.2197)
    12	5.120(0.2016)	36	5.360 (0.2110)	60	5.600 (0.2205)
    14	5.140 (0.2024)	38	5.380 (0.2118)	62	5.620 (0.2213)
    16	5.160 (0.2031)	40	5.400 (0.2126)	64	5.640 (0.2220)
    18	5.180 (0.2039)	42	5.420 (0.2134)	66	5.660 (0.2228)
    20	5.200 (0.2047)	44	5.440 (0.2142)	68	5.680 (0.2236)
    22	5.220 (0.2055)	46	5.460(0.2150)	70	5.700 (0.2244)
    24	5.240 (0.2063)	48	5.480(0.2157)	72	5.720 (0.2252)
    26	5.260 (0.2071)	50	5.500(0.2165)	74	5.740 (0.2260)
    28	5.280 (0.2079)	52	5.520 (0.2173)

18. Install the selected valve lifter.
19. Apply a light coat of engine oil to the camshaft and camshaft journals.
20. Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned, as shown in the illustration.
    Fig 74: Identifying Chain Onto Camshaft Timing Gear With Paint Mark And Timing Mark

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. Examine the front marks and the numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration. Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf)
    NOTE: Tighten the bolts uniformly while keeping the camshaft level.
    Fig 75: Identifying Numbers On Camshaft Bearing Cap

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. Install camshaft No. 2.
    Fig 76: Identifying Camshaft

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. Hold the chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the chain.
24. Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft.
    Fig 77: Identifying Timing Mark On Camshaft Timing Sprocket With Paint Mark

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. Provisionally install the flange bolt.
    Fig 78: Identifying Fringe Bolt

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. Examine the front marks and the numbers of camshaft bearing cap No. 1 and camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.

    Torque: 13 N*m (129 kgf*cm, 9.4 ft.*lbf) for bearing cap No. 2 23 N*m (235 kgf*cm, 17 ft.*lbf) for bearing cap No. 1 

    NOTE: Tighten the bolts uniformly while keeping the camshaft level.
    Fig 79: Identifying Front Marks And Numbers Of Camshaft Bearing Cap

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. (aa) Using a wrench, hold the hexagonal lobe of camshaft No. 2, and install the flange bolt.

   Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

   SST 09023-38400 

2. (ab) Remove the bar from the timing chain tensioner.
   Fig 80: Installing Flange Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. (ac) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump.
4. (ad) Check that all the pairs of timing marks are aligned.
   Fig 81: Identifying Timing Notch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. (ae) Apply adhesive to the end 2 or 3 threads of the screw plug.

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

   Fig 82: Identifying Paint Marks And Timing Marks Of Camshaft Timing Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. (af) Using an 8 mm hexagon wrench, install the screw plug.

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

   Fig 83: Locating Screw Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of engine oil to a new O-ring, and install it onto the camshaft timing oil control valve.
2. Install the camshaft timing oil control valve with the bolt.

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

   NOTE: Do not twist the O-ring.
   Fig 84: Locating Camshaft Timing Oil Control Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each fuel injector.
2. Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the CD-ring of the fuel injector.
   Fig 85: Identifying O-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. While turning the fuel injector left and right, install it onto the fuel delivery pipe.
   NOTE:

   • Do not twist the O-ring.
   • After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring with a new one.
     Fig 86: Turning Fuel Injector

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 4 new injector vibration insulators onto the cylinder head.
   Fig 87: Locating Injector Vibration Insulators

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 delivery pipe No. 1 spacers onto the cylinder head.
   NOTE: Install delivery pipe No. 1 spacer in the correct direction.
   Fig 88: Locating Delivery Pipe No. 1 Spacers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Provisionally install the fuel delivery pipe sub-assembly and 4 fuel injectors with the 3 bolts.
   NOTE:

   • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
   • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub-assembly.
     Fig 89: Locating Fuel Delivery Pipe Sub-Assembly

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 3 bolts to the specified torque.

   Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A 9.0 N*m (92 kgf*cm, 80 in/lbf) for bolt B 

   Fig 90: Locating Fuel Delivery Pipe Sub-Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the gasket onto the cylinder head cover.
2. Apply seal packing to the cylinder head, as shown in the illustration.

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

   Fig 91: Identifying Seal Packing Applying To Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover sub-assembly within 3 minutes of applying the seal packing.
   • Do not start engine for at least 2 hours after the installation.
3. Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.
4. Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.

   Torque: 10 N*m (102 kgf*cm, 7.0 ft.*lbf) 

   Fig 92: Identifying Cylinder Head Cover Sub-Assembly Bolts And Nuts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the ventilation valve onto the cylinder head cover.

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

1. Apply engine oil to a new O-ring.
2. Install the oil level gauge guide with the bolt.

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

   Fig 93: Identifying Ventilation Valve From Cylinder Head Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.
   NOTE: If the O-ring is damaged, replace the crankshaft position sensor.
2. Install the crankshaft position sensor with the bolt.

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

1. Install the oil filler cap gasket onto the oil filler cap.

1. Install the oil filler cap onto the cylinder head cover.

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°either side as shown in the illustration.

   Fig 94: Identifying Jiggle Valve Angle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the water inlet with the 2 nuts.

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

1. Provisionally install the engine coolant temperature sensor through a new gasket.
   Fig 95: Locating Engine Coolant Temperature Sensor Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, tighten the engine coolant temperature sensor.

   SST 09817-33190 

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

   Fig 96: Identifying Engine Coolant Temperature Sensor With SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply adhesive to the end 2 or 3 threads of the oil pressure switch.

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

   Fig 97: Applying Adhesive To Threads Of Oil Pressure Switch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 24 mm deep socket wrench, install the oil pressure switch.
   Fig 98: Locating Oil Pressure Switch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install the knock sensor with the nut as shown in the illustration.

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

   Fig 99: Identifying Knock Sensor Installation Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a spark plug wrench, install the spark plugs.

   Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

   Fig 100: Identifying Spark Plugs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002