LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (A25A-FKS) - Service Information (5 Of 6) >> Engine Unit >> Reassembly [08/2020 - 11/2024] >> Procedure

Reassembly [08/2020 - 11/2024]: Procedure

  1. INSTALL STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.

    1. No. 2 timing chain cover assembly side:
      1. Using a plastic-faced hammer, tap in 4 new straight pins to the No. 2 timing chain cover assembly.
        GTY759904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion Height - -

        Standard Protrusion Height

        Straight Pin (A) 

        3.0 to 5.0 mm (0.118 to 0.197 in.)

        Straight Pin (B) 

        5.0 to 7.0 mm (0.197 to 0.276 in.)

    2. Timing chain cover assembly side:
      1. Using a plastic-faced hammer, tap in a new straight pin to the timing chain cover assembly.
        GTY753849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion Height

        Standard Protrusion Height

        18.9 to 19.5 mm (0.744 to 0.768 in.)

  2. INSTALL RING PIN 
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.

    1. Camshaft housing sub-assembly side:
      1. Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing sub-assembly.
        GTY772163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion Height

        Standard Protrusion Height

        3.7 to 4.3 mm (0.146 to 0.169 in.)

    2. Stiffening crankcase assembly side:
      1. Using a plastic-faced hammer, tap in 6 new ring pins to the stiffening crankcase assembly.
        GTY742469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion Height

        Standard Protrusion Height

        Ring Pin (A) 

        3.5 to 4.5 mm (0.138 to 0.177 in.)

        Ring Pin (B) 

        4.3 to 5.3 mm (0.169 to 0.209 in.)

    3. Timing chain cover assembly side:
      1. Using a plastic-faced hammer, tap in a new ring pin to the timing chain cover assembly.

        Standard Protrusion Height

        3.0 to 5.0 mm (0.118 to 0.197 in.)

        GTY756575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion Height
  3. INSTALL STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.

    1. Stiffening crankcase assembly side:
      1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the stiffening crankcase assembly.

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

        GTY750673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 9.0 mm (0.354 in.)
        *b 19 mm (0.748 in.)
    2. Timing chain cover assembly side:
      1. Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

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

        GTY747203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 21 mm (0.827 in.)
        *b 9.0 mm (0.354 in.)
        *c 34 mm (1.34 in.)
  4. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the stiffening crankcase assembly with the bolt.

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

      GTY757876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon socket wrench, install the 3 straight screw plugs and 3 new gaskets to the stiffening crankcase assembly.

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

      GTY756539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL ENGINE BALANCER ASSEMBLY 
    1. Install the engine balancer assembly to the stiffening crankcase assembly with the 2 bolts.
      GTY756851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Rotate the crankshaft clockwise so that the crankshaft timing gear key is at the position 270° from the bottom as shown in the illustration.
      GTY762549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
      *a 270°
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY770663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing

      Seal Packing

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

      Standard Seal Packing Dimension

      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after the installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
      • Do not start the engine for at least 2 hours after installation.
      • After installation, if the seal packing has seeped out, wipe it off.
    3. Check that the rear cutouts are as shown in the illustration.
      GTY746179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cutout
    4. Clean the bolts and bolt holes.
    5. Temporarily install the stiffening crankcase assembly with the 11 bolts.

      Bolt Length

      Item Length
      Bolt (A) 40 mm (1.57 in.)
      Bolt (B) 90 mm (3.54 in.)
      Bolt (C) 170 mm (6.69 in.)
      GTY745144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Type
    6. Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.
      GTY743872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tightening Order

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  8. INSTALL OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 3

  9. INSTALL OIL PUMP BRACKET 
    1. Install the oil pump bracket with the 2 bolts as shown in the illustration.

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

      GTY762510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
  10. INSTALL ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 1

  11. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new oil strainer gasket.
    2. Using an 8 mm socket wrench, install the oil strainer sub-assembly and oil strainer gasket with the bolt.
      GTY756848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  12. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY748652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      *b 4.5 mm (0.177 in.)
      *c 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Seal Packing

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

      Standard Seal Packing Diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
      • Do not add engine oil for at least 2 hours after the installation.
    2. Install the No. 2 oil pan sub-assembly with the 11 bolts and 2 nuts in several steps in the order shown in the illustration.
      GTY770834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut

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

  13. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug to the No. 2 oil pan sub-assembly.

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

  14. INSTALL OIL FILTER UNION 
    1. Using a 12 mm hexagon socket wrench, install the oil filter union to the stiffening crankcase assembly.

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

      GTY772059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 4 [12/2021 - 10/2023] , or refer to PROCEDURE - Step 4 [10/2023 - ]

  16. INSTALL REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 1

  17. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the cylinder block water jacket spacer to the exhaust side of the cylinder block sub-assembly.
      GTY756752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 1 [12/2021 - ]

  19. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    HINT: 

    The cylinder head set bolts are tightened in 3 progressive steps.

    1. Place the cylinder head sub-assembly on the cylinder block sub-assembly.
      NOTE:
      • Ensure that the contact surface of the cylinder head sub-assembly is free of oil.
      • Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the cylinder head gasket with the bottom of the cylinder head sub-assembly.
    2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
    3. Install the 10 plate washers to the 10 cylinder head set bolts.

      Bolt Length

      Item Length
      Bolt (A) 139.1 to 140.9 mm (5.48 to 5.55 in.)
      Bolt (B) 149.1 to 150.9 mm (5.87 to 5.94 in.)
      GTY760826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front of Engine
    4. Step 1:
      1. Using a 12 mm socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.
        GTY760827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Front of Engine

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

        NOTE:

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

    5. GTY773764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 90°
      *c 90°
      Front of Engine

      Step 2:

      1. Mark each cylinder head set bolt head with paint as shown in the illustration.
      2. Tighten the cylinder head set bolts 90° in the order shown in step 1.
    6. Step 3:
      1. Tighten the cylinder head set bolts another 90° in the order shown in step 1.
      2. Check that the paint marks are now facing rearward.

        HINT: 

        Perform inspection after repair after replacing the cylinder head sub-assembly.

        Refer to INITIALIZATION [08/2020 - 12/2021] , or refer to INITIALIZATION [12/2021 - ]

  20. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) 
    1. Using an 8 mm socket wrench, install the water by-pass pipe sub-assembly and a new gasket to the cylinder head sub-assembly with the 2 bolts.

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

      GTY920686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL NO. 3 STRAIGHT SCREW PLUG (w/o Oil Cooler) 
    1. Apply adhesive to the No. 3 straight screw plug.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      Install the No. 3 straight screw plug within 3 minutes of applying adhesive.

    2. Using a 14 mm straight hexagon wrench, install the No. 3 straight screw plug to the cylinder head sub-assembly.

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

      GTY947186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 2 CAMSHAFT 

    HINT: 

    Perform inspection after repair after replacing the No. 2 camshaft.

    Refer to INITIALIZATION [08/2020 - 12/2021] , or refer to INITIALIZATION [12/2021 - ]

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

    HINT: 

    Perform inspection after repair after replacing the camshaft.

    Refer to INITIALIZATION [08/2020 - 12/2021] , or refer to INITIALIZATION [12/2021 - ]

    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 to the camshaft housing sub-assembly.
  24. INSTALL CAMSHAFT BEARING CAP 
    1. Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap in their correct locations.
      GTY753788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Uniformly tighten the 8 bolts in the order shown in the illustration.

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

      GTY772240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the torque of each bolt again.
  25. 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:
      • Install the same parts in the same combination to their original locations.
      • Do not drop the valve stem caps into the cylinder head sub-assembly.
      GTY757626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Inspect the 16 valve lash adjuster assemblies before installing them.

      See step  2

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

      Install the same parts in the same combination to their original locations.

      GTY757627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.
      GTY774599Courtesy 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.
      NOTE:

      Install the same parts in the same combination to their original locations.

  28. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY767156Courtesy 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.

      Seal Packing

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

      Standard Seal Packing Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      GTY765042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      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.
      • Do not start the engine for at least 2 hours after installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
    3. Position the camshaft and No. 2 camshaft as shown in the illustration.
      GTY751224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 28° to 58°
      *b 43° to 73°
    4. Temporarily install the camshaft housing sub-assembly with the 18 bolts.

      Bolt Length

      Item Length
      Bolt (A) 40 mm (1.57 in.)
      Bolt (B) 65 mm (2.56 in.)
      GTY746159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the camshaft housing sub-assembly, and then tighten the 18 bolts in several steps in the order shown in the illustration.

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

      NOTE:
      • Do not add engine oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
      GTY746160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL FUEL PUMP LIFTER GUIDE 
    1. Using an 8 mm socket wrench, install the fuel pump lifter guide to the No. 4 camshaft bearing cap with the 2 bolts.

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

      GTY760310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

      HINT: 

      Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

      GTY562563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY 
    1. Install the oil nozzle valve sub-assembly to the cylinder block sub-assembly.
      GTY757325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL TIMING CHAIN COVER ASSEMBLY 
    1. Clean the contact surfaces of the timing chain cover assembly, cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
      GTY769425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Chain Cover Assembly Side *b Engine Assembly Side
    2. Apply seal packing in a continuous line to the timing chain cover assembly as shown in the illustration.
      GTY768352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2.5 to 3.5 mm (0.0984 to 0.138 in.) *b 2.0 to 6.0 mm (0.0787 to 0.236 in.)
      *c 10 mm (0.394 in.) *d 20 mm (0.787 in.)
      *e 4.0 to 6.0 mm (0.157 to 0.236 in.) *f 3.0 to 4.0 mm (0.118 to 0.157 in.)
      *g 8.0 to 10 mm (0.315 to 0.394 in.) *h 30 mm (1.18 in.)
      Seal Packing - -

      Seal Packing

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

      NOTE:
      • Clean the surfaces with non-residue solvent before applying seal packing.
      • Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not add oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
    3. Temporarily install the timing chain cover assembly with the 19 bolts.

      Bolt Length

      Bolt Length Thread Diameter
      (A) 30 mm (1.18 in.) 12 mm (0.472 in.)
      (B) 45 mm (1.77 in.) 12 mm (0.472 in.)
      NOTE:

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

      GTY757211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 19 bolts in the order shown in the illustration.
      GTY757212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  33. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    HINT: 

    Perform inspection after repair after replacing the camshaft timing exhaust gear assembly.

    Refer to INITIALIZATION [08/2020 - 12/2021] , or refer to INITIALIZATION [12/2021 - ]

    1. Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.
      GTY752289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    2. Using a wrench, hold the hexagonal portion of the No. 2 camshaft.
      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.
      GTY996009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly with the 3 bolts and install the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly).

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

  34. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. Temporarily install the crankshaft pulley bolt.
    2. Rotate the crankshaft 44.2° counterclockwise to position the crankshaft timing gear key as shown in the illustration.
      GTY752882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
      *a 44.2°
    3. Check that the timing marks of the camshaft timing exhaust gear assembly and knock pin are as shown in the illustration.
      GTY799858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
  35. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

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

      GTY756909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper with the bolt.

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

      GTY807235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    HINT: 

    After replacing or removing and installing the No. 1 chain tensioner assembly, an abnormal noise may occur at start up until the oil in the line has had time to replenish.

    1. While slightly pushing in the plunger of the No. 1 chain tensioner assembly, install the chain tensioner slipper.
      GTY780479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a End of the plunger
      *b Groove
      *c Oil Hole
      *d No. 1 Chain Tensioner Slipper
      *e Plunger

      HINT: 

      • Make sure that the end of the plunger is correctly seated in the groove of the No. 1 chain tensioner slipper.
      • Make sure that the oil hole of the plunger is facing up.
    2. Using an 8 mm socket wrench, install the bolt.
      GTY806424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the No. 1 chain tensioner assembly with the nut.

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

  38. INSTALL CHAIN SUB-ASSEMBLY 
    1. Set the crankshaft timing gear key as shown in the illustration.
      GTY769677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
    2. Remove the crankshaft pulley bolt.
    3. Install the crankshaft timing sprocket and chain sub-assembly.
      GTY756912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the paint mark (yellow) 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.
      GTY763681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (Yellow)
      *b Timing Mark
    5. Using the hexagonal portion of the No. 2 camshaft, rotate the No. 2 camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing exhaust gear assembly with the paint mark (pink) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing exhaust gear assembly.
      GTY787591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (Pink)
      *b Timing Mark
      Turn
  39. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    HINT: 

    Perform inspection after repair after replacing the camshaft timing gear assembly.

    Refer to INITIALIZATION [08/2020 - 12/2021] , or refer to INITIALIZATION [12/2021 - ]

    1. Hold the hexagonal portion of the No. 2 camshaft with a wrench and turn the camshaft timing exhaust gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and crankshaft timing sprocket as shown in the illustration.
      GTY822014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Loosen
    2. Align the paint mark (pink) of the chain sub-assembly and the timing mark of the camshaft timing gear assembly.
      GTY773818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (Pink)
      *b Timing Mark
    3. Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.
      GTY744117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    4. Using a wrench, hold the hexagonal portion of the camshaft.
      GTY793348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.
      • Do not disassemble the camshaft timing gear assembly.
    5. Using a 10 mm bi-hexagonal wrench, install the camshaft timing gear assembly with the bolt.

      Torque: 86 N*m (877 kgf*cm, 63 ft.*lbf) 

  40. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. Set the crankshaft timing gear key as shown in the illustration.
      GTY747200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pump Drive Sprocket *2 Oil Pump Drive Shaft Sprocket
      *3 Crankshaft Timing Gear Key *4 Oil Pump Sub-assembly
      *a Mark Plate *b Timing Mark
    2. Turn the oil pump drive shaft so that the flat face is facing upward.
    3. Align the mark plates with the timing marks of the oil pump drive sprocket and oil pump drive shaft sprocket as shown in the illustration.

      HINT: 

      Make sure the mark plates of the oil pump drive chain sub-assembly are facing away from the engine assembly.

    4. With the oil pump drive chain sub-assembly placed around the oil pump drive sprocket and oil pump drive shaft sprocket, install the oil pump drive sprocket to the crankshaft and temporarily install the oil pump drive shaft sprocket to the oil pump drive shaft.
    5. Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate.
      GTY774573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring
    6. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
    7. Using SST, hold the crankshaft pulley assembly and tighten the bolt.
      GTY746147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-54015 
      • SST: 09330-00021 

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

    8. Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.
  41. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 

    Refer to PROCEDURE - Step 31

  42. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. Clean the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
      GTY752716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 2 Timing Chain Cover Assembly Side *b Timing Chain Cover Assembly Side
    2. Apply seal packing in a continuous line to the No. 2 timing chain cover assembly as shown in the illustration.

      Seal Packing

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

      Standard Seal Packing Diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      NOTE:
      • Clean the surfaces with non-residue solvent before applying seal packing.
      • Install the No. 2 timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not add oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
      • Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).
      GTY745094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Seal Packing
    3. Temporarily install the No. 2 timing chain cover assembly to the timing chain cover assembly with the 20 bolts.
      NOTE:

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

      GTY749870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 20 bolts in the order shown in the illustration.

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

    5. Temporarily install the engine mounting insulator RH to the engine mounting bracket RH with the 3 bolts.
    6. Install the engine mounting bracket RH with the 3 bolts in the order shown in the illustration.
      GTY763668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      NOTE:

      After applying seal packing to the No. 2 timing chain cover assembly, install the engine mounting bracket RH within 10 minutes.

  43. INSTALL STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon wrench, install the straight screw plug.

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

      GTY756771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1

  45. INSTALL SPARK PLUG TUBE GASKET 
    1. Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.
      GTY772138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap in the spark plug tube gaskets at an angle.
  46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install a new camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.
      NOTE:

      Remove any oil from the contact surfaces.

      GTY756766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 7 new cylinder head cover gaskets to the cylinder head cover sub-assembly.
      NOTE:

      Remove any oil from the contact surfaces.

    3. Apply seal packing as shown in the illustration.
      GTY750670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
      *b Mark
      Seal Packing

      Seal Packing

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

      Standard Seal Packing Diameter

      3.0 to 6.0 mm (0.118 to 0.236 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    4. Perform this procedure only when reusing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).
      GTY941184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a O-ring Groove
      *b Camshaft Position Sensor Tip
      1. Clean the O-ring groove of the 2 camshaft position sensors (for Exhaust Side and for Intake Side).
        NOTE:

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

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

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

      3. Check if each O-ring is twisted.

        HINT: 

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

        GTY894545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 O-ring
        *a Correct
        *b Incorrect
        *c Seam
    5. Apply a light coat of engine oil to the O-ring of the camshaft position sensor.
    6. Using an 8 mm socket wrench, install the 2 camshaft position sensors (for Exhaust Side and for Intake Side) with 2 new bolts (B) and cylinder head cover sub-assembly with 4 new bolts (C) and the 12 bolts (A) in the order shown in the illustration.
      GTY756092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt Length

      Bolt Length Thread Diameter
      (A) 23.5 mm (0.925 in.) 10 mm (0.394 in.)
      (B), (C) 30 mm (1.18 in.) 8 mm (0.315 in.)

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

      NOTE:
      • If a camshaft position sensor (for Exhaust Side and for Intake Side) has been struck or dropped, replace it.
      • Make sure that the 2 O-rings are not cracked or moved out of place when installing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).
      • Do not start the engine for at least 2 hours after installation.

      HINT: 

      After tightening all bolts, check the tightening torque of the bolts (7) and (8). Retighten them if necessary.

  47. INSTALL OUTLET WATER BY-PASS SUB-ASSEMBLY 
    1. Using an 8 mm socket wrench, install the outlet water by-pass sub-assembly and a new outlet water pipe gasket to the cylinder head sub-assembly with the 3 bolts.

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

      GTY760311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL WATER OUTLET 
    1. Using an 8 mm socket wrench, install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 3 bolts.

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

      GTY760308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL CRANKSHAFT PULLEY ASSEMBLY 
    1. Align the crankshaft timing gear key with the key groove of the crankshaft pulley assembly.
      GTY763927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    2. Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley bolt.
      • SST: 09213-54015 
      • SST: 09330-00021 

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

  50. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  51. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 1

  52. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  53. INSTALL OIL FILLER CAP GASKET 
    1. Install a new oil filler cap gasket to the oil filler cap sub-assembly.
      GTY652152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
      GTY760309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL NO. 2 WATER BY-PASS HOSE (w/ Oil Cooler) 
    1. Install the No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
      GTY904308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL NO. 1 WATER BY-PASS HOSE (w/ Oil Cooler) 
    1. Install the No. 1 water by-pass hose to the cylinder block sub-assembly and slide the clip to secure it.
      GTY940757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) 

    Refer to PROCEDURE - Step 1

  58. INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING) 
    1. Install the engine water pump assembly (water inlet housing) and a new gasket to the cylinder block sub-assembly with the 4 bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  59. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  60. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 

    Refer to PROCEDURE - Step 1

  61. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 1

  62. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  63. INSTALL OIL PRESSURE AND TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  64. INSTALL STRAIGHT SCREW PLUG 
    1. Install the straight screw plug and a new gasket to the cylinder block sub-assembly.

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

  65. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  66. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  67. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

scientia non olet · About LEMON Manuals