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Home >> Toyota >> 2022 >> Corolla Cross L, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (M20A-FKS) - Service Information (4 Of 4) >> Engine Unit >> Reassembly [09/2021 - 11/2023] >> Procedure

Reassembly [09/2021 - 11/2023]: Procedure

  1. INSTALL STRAIGHT PIN 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.
    1. GTY1030191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a plastic hammer, tap in 4 new straight pins to the No. 2 timing chain cover assembly.

        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. INSTALL RING PIN 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.
    1. GTY1029487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height - -
      1. Using a plastic hammer, tap in 4 new ring pins to the stiffening crankcase assembly.

        Standard Protrusion Height

        3.5 to 4.5 mm (0.138 to 0.177 in.)

      2. Using a plastic hammer, tap in 10 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

        Standard Protrusion Height

        3.2 to 4.3 mm (0.126 to 0.169 in.)

  3. INSTALL STUD BOLT 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.
    1. GTY1029926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 9 mm (0.354 in.) *b 19 mm (0.748 in.)
      *c 21 mm (0.827 in.) *d 9 mm (0.354 in.)
      *e 34 mm (1.339 in.)    
      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) 

      2. 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) 

  4. INSTALL WIRE HARNESS CLAMP BRACKET 

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

  5. INSTALL STRAIGHT SCREW PLUG 
    1. GTY1029464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 10 mm hexagon socket wrench, install the straight screw plug and a new gasket to the stiffening crankcase assembly.

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

  6. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Fig 1: Stiffening Crankcase Assembly Tightening Sequence
      GTY1030458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing *b Bolt Type
      *c Tightening Order - -
      1. 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 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.).
      2. Temporarily install the stiffening crankcase assembly with the 10 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.)
      3. Tighten the 10 bolts in the order shown in the illustration to install the stiffening crankcase assembly.

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

  7. INSTALL OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. INSTALL ENGINE OIL LEVEL SENSOR 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  9. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. GTY1029691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

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

  10. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Fig 2: Oil Pan Sub-Assembly Tightening Sequence
      GTY1030551Courtesy 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.) *d Nut
      1. 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

        2.5 to 3.5 mm (0.0984 to 0.138 in.)

        NOTE:
        • Remove any oil from the contact surfaces.
        • Install the 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.).
      2. Install the oil pan sub-assembly with the 10 bolts and 2 nuts in several steps in the order shown in the illustration.

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

  11. INSTALL OIL PAN DRAIN PLUG 

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

  12. INSTALL OIL FILTER UNION 
    1. GTY1029641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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) 

  13. INSTALL OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 [09/2021 - 11/2022] , or refer to PROCEDURE - Step 4 [11/2022 - 11/2023]

  14. INSTALL REAR ENGINE OIL SEAL 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  15. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
  16. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1

  17. INSTALL CYLINDER HEAD SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 HINT: 
    The cylinder head set bolts are tightened in 3 progressive steps.
    1. Fig 3: Cylinder Head Sub-Assembly Tightening Sequence
      GTY1029510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark - -
      Front of Engine - -
      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 6 plate washers to the 10 cylinder head set bolts.

        Bolt Length

        Item Length
        Bolt (A) 129.1 to 130.9 mm (5.08 to 5.15 in.)
        Bolt (B) 139.1 to 140.9 mm (5.48 to 5.55 in.)
      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.

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

        NOTE:

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

      5. 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 [09/2021 - 11/2023]

  18. INSTALL WATER SEAL PLATE 
    1. GTY1030655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, install the water seal plate and a new gasket to the cylinder head sub-assembly with the 2 bolts.

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

  19. INSTALL VALVE STEM CAP 
    1. GTY1029096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  20. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. GTY1030096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 the same parts in the same combination to their original locations.

  21. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. GTY1029082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap - -
      1. Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.
      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.

  22. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 HINT: 
    Perform "Inspection After Repair" after replacing the exhaust camshaft sub-assembly.
    Refer to INITIALIZATION [09/2021 - 11/2023]
    1. GTY1029811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 exhaust camshaft sub-assembly to the camshaft housing sub-assembly.
  23. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 HINT: 
    Perform "Inspection After Repair" after replacing the intake camshaft sub-assembly.
    Refer to INITIALIZATION [09/2021 - 11/2023]
    1. GTY1029751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 intake camshaft sub-assembly to the camshaft housing sub-assembly.
  24. INSTALL CAMSHAFT BEARING CAP 
    1. Fig 4: Camshaft Bearing Cap Tightening Sequence
      GTY1029194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
      2. Install and uniformly tighten the 9 bolts in the order shown in the illustration.

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

      3. Check the torque of each bolt again.
  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Fig 5: Camshaft Housing Sub-Assembly Tightening Sequence
      GTY1030627Courtesy 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
      *c Seal Packing *d 17° to 47°
      *e 42° to 72° *f No. 1 Cylinder Cam Nose
      1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      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.)

        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 intake camshaft sub-assembly and exhaust camshaft sub-assembly as shown in the illustration.
      4. Temporarily install the camshaft housing sub-assembly with the 17 bolts.

        Bolt Length

        Item Length
        Bolt (A) 40 mm (1.57 in.)
        Bolt (B) 65 mm (2.56 in.)
      5. Tighten the 17 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.
        • After installation, if the seal packing has seeped out, wipe it off.
  26. INSTALL FUEL PUMP LIFTER GUIDE 
    1. GTY1029147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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) 

  27. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. GTY1029156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a plastic 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.

  28. INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY 
  29. INSTALL TIMING CHAIN COVER ASSEMBLY 
    1. GTY1030071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Chain Cover Assembly Side *b Engine Assembly Side
      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.
    2. GTY1029465Courtesy 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 344.2 mm (1.13 ft.) *f 4.0 to 6.0 mm (0.157 to 0.236 in.)
      *g 3.0 to 4.0 mm (0.118 to 0.157 in.) - -
      Seal Packing - -
      1. Apply seal packing to the timing chain cover assembly as shown in the illustration.

        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 engine 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. Fig 6: Timing Chain Cover Assembly Bolts Tightening Sequence
      GTY1180776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the timing chain cover assembly with the 20 bolts.

        Bolt Length

        Bolt Length
        (A) 30 mm (1.18 in.)
        (B) 45 mm (1.77 in.)
        NOTE:

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

      2. Tighten the 20 bolts in the order shown in the illustration.

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

  30. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 HINT: 
    Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.
    Refer to INITIALIZATION [09/2021 - 11/2023]
    1. GTY1029102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole *b Knock Pin
      *c Hold - -
      1. Align and fit the knock pin of the exhaust camshaft sub-assembly to the knock pin hole of the camshaft timing exhaust gear assembly.
      2. Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.
        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.
      3. Install the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly).
      4. Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly with the 3 bolts.

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

  31. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. GTY1029187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key - -
      *a 44.2° *b Timing Mark
      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.
      3. Check that the timing marks of the camshaft timing exhaust gear assembly and knock pin are as shown in the illustration.
  32. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

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

  33. INSTALL CHAIN TENSIONER SLIPPER 

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

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 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. GTY1029083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a End of the plunger *b Groove
      *c Oil Hole *d No. 1 Chain Tensioner Slipper
      *e Plunger - -
      1. While slightly pushing in the plunger of the No. 1 chain tensioner assembly, install the chain tensioner slipper.

        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.

        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) 

  35. INSTALL CRANKSHAFT TIMING SPROCKET 
  36. INSTALL CHAIN SUB-ASSEMBLY 
    1. GTY1030369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key - -
      *a Paint Mark (Yellow) *b Timing Mark
      *c Paint Mark (Orange) - -
      Turn - -
      1. Set the crankshaft timing gear key as shown in the illustration.
      2. Remove the crankshaft pulley bolt.
      3. Install the crankshaft timing sprocket and chain sub-assembly.
      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.
      5. Using a wrench and the hexagonal portion of the exhaust camshaft sub-assembly, rotate the exhaust camshaft sub-assembly counterclockwise, align the timing mark of the camshaft timing exhaust gear assembly with the paint mark (orange) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing exhaust gear assembly.
  37. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 HINT: 
    Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.
    Refer to INITIALIZATION [09/2021 - 11/2023]
    1. GTY1029064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Loosen *b Paint Mark (Orange)
      *c Timing Mark *d Knock Pin Hole
      *e Knock Pin *f Hold
      Turn - -
      1. Hold the hexagonal portion of the exhaust camshaft sub-assembly 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.
      2. Align the paint mark (orange) of the chain sub-assembly with the timing mark of the camshaft timing gear assembly and install the chain sub-assembly to the camshaft timing gear assembly.
      3. Align and fit the knock pin of the intake camshaft sub-assembly to the knock pin hole of the camshaft timing gear assembly.
      4. Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.
        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) 

  38. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. GTY1030199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pump Drive Sprocket *2 Oil Pump Drive Shaft Sprocket
      *3 Crankshaft Timing Gear Key *4 Oil Pump Assembly
      *a Mark Plate *b Timing Mark
      1. Set the crankshaft timing gear key as shown in the illustration.
      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.
  39. INSTALL CHAIN TENSIONER PLATE 
    1. GTY1029626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Chain Tensioner Plate *2 Chain Damper Spring
      1. Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate.
      2. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
      3. Using SST, hold the crankshaft pulley assembly and tighten the bolt.]
        • SST: 09213-54015 
        • SST: 09330-00021 

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

      4. Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.
  40. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 27
  41. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. GTY1027443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 2 Timing Chain Cover Assembly Side *b Timing Chain Cover Assembly Side
      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.
    2. Fig 7: No. 2 Timing Chain Cover Assembly Bolts Tightening Sequence
      GTY1029242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Seal Packing - -
      1. Apply seal packing 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 engine 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.).
      2. 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.

      3. Tighten the 20 bolts in the order shown in the illustration.

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

      4. Install the engine mounting bracket RH with the 3 bolts in the order shown in the illustration.

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

  42. INSTALL STRAIGHT SCREW PLUG 
    1. GTY1029358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply adhesive to the straight screw plug.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      2. Using a 10 mm hexagon wrench, install the straight screw plug.

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

        NOTE:
        • Install the straight screw plug within 3 minutes of applying adhesive.
        • Do not add engine oil for at least 1 hour after installation.
  43. INSTALL ENGINE MOUNTING BRACKET RH 
  44. INSTALL TIMING CHAIN COVER OIL SEAL 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  45. INSTALL SPARK PLUG TUBE GASKET 
    1. GTY1030197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. TEMPORARILY INSTALL CAMSHAFT POSITION SENSOR 
    1. GTY1030542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. GTY1030666Courtesy 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 - -
      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.

      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.

        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.
    2. Fig 8: Cylinder Head Cover Sub-Assembly Tightening Sequence
      GTY1029587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, install the 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.

        Bolt Length

        Bolt Length Width Across Flats
        (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) 

        HINT: 

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

  48. INSTALL WATER OUTLET PIPE GASKET 
  49. INSTALL WATER BY-PASS OUTLET SUB-ASSEMBLY 
    1. GTY1029233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, install the water by-pass outlet sub-assembly and a new water pipe outlet gasket to the cylinder head sub-assembly with the 3 bolts.

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

  50. INSTALL WATER OUTLET GASKET 
  51. INSTALL WATER OUTLET 
    1. GTY1029201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 2 bolts.

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

  52. INSTALL CRANKSHAFT PULLEY ASSEMBLY 
    1. GTY1029477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold *b Turn
      1. Align the crankshaft timing gear key with the key groove of the crankshaft pulley assembly.
      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) 

  53. INSTALL VACUUM PUMP ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  54. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  55. INSTALL CRANKSHAFT POSITION SENSOR 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  56. INSTALL OIL FILLER CAP GASKET 
  57. INSTALL OIL FILLER CAP ASSEMBLY 
  58. INSTALL CAM TIMING CONTROL MOTOR O-RING 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  59. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 2
  60. INSTALL CAM TIMING OIL CONTROL SOLENOID O-RING 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  61. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 2
  62. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  63. INSTALL OIL PRESSURE AND TEMPERATURE SENSOR 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  64. INSTALL KNOCK CONTROL SENSOR 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  65. INSTALL SPARK PLUG 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
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