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Installation [12/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT CYLINDER HEAD BOLT 

    Refer to PROCEDURE - Step 17

  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  3. INSTALL CYLINDER HEAD GASKET 
    1. Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
      GTY450591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Gasket
      *2 Cylinder Block Sub-assembly
      *a Lot No.
      *b 3.0 mm or more
      *c 20 mm or more
      Seal Packing
      Front
    2. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

      Seal Packing

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

      Standard Seal Dimension

      3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) or thicker

      HINT: 

      Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block sub-assembly.

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
    3. Place the new cylinder head gasket on the cylinder block sub-assembly with the Lot No. stamp facing upward.
      NOTE:

      Pay attention to the installation direction.

  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    HINT: 

    The cylinder head bolts are tightened in 4 progressive steps.

    1. Place the cylinder head sub-assembly on the cylinder block sub-assembly.
      NOTE:
      • Ensure that no oil is on the contact surface of the cylinder head sub-assembly.
      • Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the gasket with the bottom of the cylinder head sub-assembly.
    2. Install the 10 plate washers to the 10 cylinder head bolts.
    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
    4. Step 1:
      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the order shown in the illustration.

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

        Fig 1: Cylinder Head Bolts Tightening Sequence
        GTY432599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Do not drop the plate washers for the cylinder head bolts into the cylinder head sub-assembly.

    5. Step 2:
      1. Check that the cylinder head bolts are tightened to the specified torque.

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

    6. Step 3:
      1. Mark each cylinder head bolt head with paint as shown in the illustration.
        GTY451643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        Front
      2. Tighten the cylinder head bolts by 90° in the order shown in step 1.
    7. Step 4:
      1. Tighten the cylinder head bolts by another 90° in the order shown in step 1.
      2. Check that the paint marks are now facing rearward.
        NOTE:
        • Do not apply oil for at least 2 hours after installation.
        • Do not start the engine for at least 2 hours after installation.
        • After installation, if the seal packing has seeped out, wipe it off.

        HINT: 

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

        Refer to INITIALIZATION [12/2013 - ]

  5. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem cap ends.
    2. Install the 16 valve stem caps to the cylinder head sub-assembly.
      NOTE:

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

  6. SET CAMSHAFT TIMING GEAR ASSEMBLY 

    HINT: 

    When installing the camshaft timing gear assembly, release the lock pin and set the camshaft timing gear assembly to the advanced position before installation.

    1. Check the camshaft timing gear assembly position.
      GTY439329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Advanced Position
      *b Retarded Position
      *c Knock Pin Hole
      *d Alignment Mark
      NOTE:
      • If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.
      • If the camshaft timing gear assembly has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear assembly to the most advanced position before tightening the bolt of the camshaft timing gear assembly.
    2. Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.
      GTY442566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Pin Hole
    3. Check that there is no gap between the camshaft timing gear assembly and camshaft flange.
      GTY443874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap
    4. Secure the camshaft in place by hand, and then install the bolt of the camshaft timing gear assembly by hand.
      NOTE:

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    5. Release the lock pin.
      GTY450134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retard Side Path *b Advance Side Path
      *c Open *d Close
      *e Rubber Piece *f Vinyl Tape
      *g Knock Pin - -
      1. Clean the camshaft journal with non-residue solvent.
      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        HINT: 

        There are 4 oil paths in the grooves of the camshaft. Plug 3 of the paths with rubber pieces.

      3. Make a hole at the port (A) shown in the illustration.
      4. While applying approximately 200 kPa (2.0 kgf/ cm2 , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).
        GTY383765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        WARNING:

        Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

        NOTE:

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        HINT: 

        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.
        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
      5. Remove the vinyl tape and rubber pieces from the camshaft.
    6. Remove the bolt and camshaft timing gear assembly.
      NOTE:

      Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

  7. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Inspect the 16 valve lash adjuster assemblies before installing them.

      Refer to PROCEDURE - Step 2

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

      Install each valve lash adjuster assembly to the same place it was removed from.

  8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.
      GTY438545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
  9. INSTALL NO. 2 CAMSHAFT BEARING 

    Refer to PROCEDURE - Step 20 , or refer to PROCEDURE - Step 20

  10. INSTALL NO. 1 CAMSHAFT BEARING 

    Refer to PROCEDURE - Step 19 , or refer to PROCEDURE - Step 19

  11. INSTALL OIL CONTROL VALVE FILTER 

    Refer to PROCEDURE - Step 21 , or refer to PROCEDURE - Step 21

  12. INSTALL CAMSHAFT 
    1. Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
    2. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
    3. Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly.

      HINT: 

      Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft.

      Refer to INITIALIZATION [12/2013 - ]

  13. INSTALL CAMSHAFT BEARING CAP 
    1. Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.
      GTY449022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 11 bolts in the order shown in the illustration.
      Fig 2: Camshaft Bearing Caps Bolt Tightening Sequence
      GTY437446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      Make sure that the camshaft and No. 2 camshaft rotate smoothly after installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps.

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY440214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Incorrect
      *b Correct
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY428677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Dashed Line
      *b Groove

      Seal Packing

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

      APPLY SEAL PACKING AS FOLLOWS

      Area Seal Packing Diameter Application Position
      Continuous Line 3.0 to 4.0 mm (0.118 to 0.157 in.) Distance from edge of camshaft housing sub-assembly to center of seal packing: 3.5 to 4.0 mm (0.138 to 0.157 in.)
      Dashed Line Distance from outside edge of groove to center of seal packing: 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
    3. Position the knock pins of the camshaft and No. 2 camshaft as shown in the illustration.
      GTY436552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin
    4. Install the camshaft housing sub-assembly, and then install the 20 bolts in the order shown in the illustration.
      Fig 3: Camshaft Housing Bolts Tightening Sequence
      GTY424985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Do not apply oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
      • After installation, if the seal packing has seeped out, wipe it off.
  15. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Check the camshaft timing gear assembly position.
      GTY425343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Alignment Mark

      If the camshaft timing gear assembly is not set to the advanced position, release the lock pin and reset the camshaft timing gear assembly. (Refer to the "Set Camshaft Timing Gear Assembly" procedures.)

    2. Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.
      GTY454467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Pin Hole
    3. Check that there is no gap between the camshaft timing gear assembly and camshaft flange.
      GTY443875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap
    4. Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.
      GTY454044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      NOTE:
      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing gear assembly.

      HINT: 

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

      Refer to INITIALIZATION [12/2013 - ]

  16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Align and fit the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
      GTY439572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Pin Hole
    2. Check that there is no gap between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.
      GTY454744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 No. 2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap
    3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.
      GTY432077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      NOTE:
      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing exhaust gear assembly.

      HINT: 

      Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

      Refer to INITIALIZATION [12/2013 - ]

  17. ADD ENGINE OIL 
    1. Add 50 cc (3.1 cu.in.) of engine oil into the oil hole shown in the illustration.
      GTY195141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Engine oil must be added if the lash adjusters were removed.
      • Make sure that the low pressure chamber and oil paths of the lash adjusters are full of engine oil.
  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily install the crankshaft pulley bolt.
      GTY442306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.
    3. Check that the timing marks of the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.
      GTY430415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Approximately 7°
      *b Approximately 32°
      *c Timing Mark

      HINT: 

      "A" is not a timing mark.

  19. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.
      Fig 4: No. 1 Chain Vibration Damper Bolts Tightening Sequence
      GTY432521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  20. INSTALL CHAIN SUB-ASSEMBLY 
    1. Place the chain sub-assembly onto the camshaft timing exhaust gear assembly and camshaft timing gear assembly and crankshaft timing sprocket.

      HINT: 

      • Make sure the mark plate of the chain sub-assembly faces away from the engine.
      • It is not necessary to install the chain sub-assembly to the teeth of the gears and sprocket.
    2. Align the mark plate (yellow or gold) of the chain sub-assembly with the timing mark of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.
      GTY444523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate
      *b Timing Mark
    3. Align the mark plate (pink or gold) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.
      GTY447996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate
      *b Timing Mark
    4. Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.
      GTY195062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a wrench, hold the hexagonal portion of the camshaft and rotate the camshaft counterclockwise to align the timing mark of the camshaft timing gear assembly with the mark plate (yellow or gold) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.
      GTY454031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate
      *b Timing Mark

      HINT: 

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    6. Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.
      GTY184269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure the chain sub-assembly is secure.

  21. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper with the bolt.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

    2. Remove the pin from the stopper plate.
  23. INSTALL TIMING CHAIN GUIDE 
    1. Install the timing chain guide with the bolt.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  24. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily install the crankshaft pulley bolt.
      GTY435968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -
    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.
    3. Check that the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.

      HINT: 

      "A" is not a timing mark.

  25. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 1

  26. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 2

  27. CONNECT UNION TO VACUUM TUBE HOSE 

    Refer to PROCEDURE - Step 5

  28. CONNECT NO. 2 VENTILATION HOSE 

    Refer to PROCEDURE - Step 6

  29. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) 

    Refer to PROCEDURE - Step 7

  30. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 3

  31. INSTALL EXHAUST MANIFOLD 

    Refer to PROCEDURE - Step 3 , or refer to PROCEDURE - Step 3

  32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4 , or refer to PROCEDURE - Step 4

  33. INSTALL NO. 2 MANIFOLD STAY 

    Refer to PROCEDURE - Step 5 , or refer to PROCEDURE - Step 5

  34. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 6 , or refer to PROCEDURE - Step 6

  35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 

    Refer to INSTALLATION [12/2013 - 11/2015] , or refer to INSTALLATION [11/2015 - ]

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