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Reassembly [03/2019 - 11/2022]: Procedure

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  1. INSTALL STIFFENING CRANKCASE RING PIN 
    NOTE:

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

    1. Using a plastic hammer, tap 2 new ring pins into the stiffening crankcase assembly.
      GTY876672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      *b Width
      *c Height

      Standard Ring Pin

      Item Protrusion Height Height Width
      Ring pin 4.0 mm (0.157 in.) 8.0 mm (0.315 in.) 11 mm (0.433 in.)
    2. Using a plastic-faced hammer, tap in 2 new stiffening crankcase ring pins until they are seated.

      Standard Ring Pin

      Item Protrusion Height Height Width
      Stiffening crankcase ring pin 3.0 mm (0.118 in.) 8.0 mm (0.315 in.) 11 mm (0.433 in.)
      GTY434622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      *b Width
      *c Height
  2. INSTALL STUD BOLT 
    NOTE:

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

    1. Using an E6 "TORX" socket wrench, install the stiffening crankcase stud bolts as shown in the illustration.

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

      GTY867723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 9.0 mm (0.354 in.)
      *b 19 mm (0.748 in.)
    2. Using an E5 "TORX" socket wrench, install the 2 water inlet housing stud bolts as shown in the illustration.

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

      GTY769020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 21 mm (0.827 in.)
      *b 9.0 mm (0.354 in.)
      *c 34 mm (1.34 in.)
    3. Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.

      Torque: 9.5 N.m (97 kgf/cm, 84 in.lbf) 

      GTY769444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 13 mm (0.512 in.)
      *b 24 mm (0.945 in.)
      *c 49.5 mm (1.95 in.)
  3. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Apply seal packing as shown in the illustration.
      GTY746809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Diameter

      Area Specified Condition
      Continuous Line 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      (A) 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Application Length (A)

      56 mm (2.20 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 start the engine for at least 2 hours after installing the stiffening crankcase assembly.
    2. Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.
      GTY859611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Bolt Length

      Item Specified Condition
      Bolt (A) 143.7 mm (5.66 in.)
      Bolt (B) 35 mm (1.38 in.)
      Bolt (C) 70 mm (2.76 in.)
    3. Recheck the torque for the bolts (1) and (2).

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

    4. Wipe off any excess seal packing with a clean piece of cloth.
  4. INSTALL OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1 [03/2019 - 09/2022] , or refer to PROCEDURE - Step 1 [09/2022 - 11/2022]

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove any remaining seal packing.
      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Tighten the bolts and nuts within 15 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installation.
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY905004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing Black
      *b 6.0 mm
      *c 3.0 to 4.5 mm

      Seal Packing

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

      Application Specification

      Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing
      (A) - (A) 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.)
      (B) - (B) -
    3. Install the No. 2 oil pan sub-assembly to the stiffening crankcase assembly with the 10 bolts and 2 nuts.

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

      GTY934516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
  6. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and oil pan drain plug to the No. 2 oil pan sub-assembly.

      Torque: 37 N.m (377 kgf/cm, 27 ft.lbf) 

  7. INSTALL REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 1

  8. INSTALL NO. 1 TAPER SCREW PLUG 
    1. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug.

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

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:
      • Install the No. 1 taper screw plug within 3 minutes of applying adhesive.
      • Do not start the engine for at least 1 hour after installing the No. 1 taper screw plug.
  9. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 1

  10. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  12. 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 each part to its original location.

  13. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem caps.
    2. Install the 16 valve stem caps.

      HINT: 

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

  14. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the tips of the valve lash adjuster assemblies and valve stem caps.
      GTY560422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Valve Lash Adjuster Assembly
      *2 No. 1 Valve Rocker Arm Sub-assembly
      *3 Valve Stem Cap
    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
      NOTE:

      Install each part to its original location.

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE:

    It is not necessary to remove a camshaft housing straight pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in 2 new camshaft housing straight pins to the specified protrusion height.

      Standard Straight Pin

      Item Protrusion Height Height Width
      Camshaft housing straight pin 6.5 to 7.5 mm (0.256 to 0.295 in.) 14 mm (0.551 in.) 6.0 mm (0.236 in.)
      GTY448012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      *b Height
      *c Width
  16. INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY 

    Refer to PROCEDURE - Step 1 [03/2019 - 09/2022] , or refer to PROCEDURE - Step 1 [09/2022 - 11/2022]

  17. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  18. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Fit the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.
      GTY873104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Straight Pin
      *b Pin Hole
      NOTE:

      Do not forcibly push in the camshaft timing exhaust gear assembly. This may cause the straight pin tip to damage the installation surface of the camshaft timing exhaust gear assembly.

    2. Lightly press the camshaft timing exhaust gear assembly against the camshaft and turn the camshaft timing exhaust gear assembly. Push further at the position where the pin enters the hole.
      NOTE:

      Be sure not to turn the camshaft timing exhaust gear assembly in the retard direction (clockwise).

    3. GTY437254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Flange
      *b Gap
      *c No Gap

      Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

    4. Tighten the bolt with the camshaft timing exhaust gear assembly secured in place.
      GTY429315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 54 N.m (551 kgf/cm, 40 ft.lbf) 

    5. Check the camshaft timing exhaust gear assembly lock.
      1. Make sure that the camshaft timing exhaust gear assembly is locked.

        HINT: 

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

        Refer to INITIALIZATION [01/2019 - 11/2022]

  19. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned as shown in the illustration.
      GTY849259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Straight Pin
      *b Key Groove
      NOTE:

      Do not forcibly push in the camshaft timing gear assembly. This may cause the straight pin tip to damage the installation surface of the camshaft timing gear assembly.

    2. Turn the camshaft timing gear assembly as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
      GTY913621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Straight Pin
      *c Key Groove
      NOTE:

      Do not turn the camshaft timing gear assembly in the retard direction (clockwise).

    3. GTY437253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *a Flange
      *b Clearance
      *c No Clearance

      Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

    4. Tighten the bolt with the camshaft timing gear assembly secured in place.
      GTY429316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 54 N.m (551 kgf/cm, 40 ft.lbf) 

    5. Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and is locked in the most retarded position.
      GTY856966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lock

      HINT: 

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

      Refer to INITIALIZATION [01/2019 - 11/2022]

  20. INSTALL CRANKSHAFT TIMING GEAR KEY 
    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.

  21. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
    1. Install the No. 1 crankshaft position sensor plate to the crankshaft with the "F" mark facing forward.
      GTY449127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 2 CHAIN SUB-ASSEMBLY 
    1. Temporarily install the crankshaft pulley set bolt to the crankshaft.
    2. Set the crankshaft timing gear keys as shown in the illustration.
      GTY871159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
    3. Turn the oil pump drive shaft so that the flat face is facing upward.
    4. Remove the crankshaft pulley set bolt from the crankshaft.
    5. Align the mark plates (yellow) with the timing mark of the oil pump drive gear and oil pump drive shaft gear as shown in the illustration.
      GTY495281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *a Mark Plate (Yellow)
      *b Timing Mark
      Front of Engine

      HINT: 

      Make sure the mark plates (yellow) of the No. 2 chain sub-assembly are facing away from the engine assembly.

    6. With the No. 2 chain sub-assembly placed around the oil pump drive gear and oil pump drive shaft gear, install the oil pump drive gear to the crankshaft and temporarily install the oil pump drive shaft gear to the oil pump drive shaft.
    7. Temporarily install the oil pump drive shaft gear nut.
    8. Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

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

    9. Temporarily install the crankshaft pulley with the crankshaft pulley set bolt.
      GTY892677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using SST, hold the crankshaft pulley. Then tighten the oil pump drive shaft gear nut.
      • SST: 09213-54015 
        1. 91551-00850
      • SST: 09330-00021 

      Torque: 28 N.m (286 kgf/cm, 21 ft.lbf) 

    11. Remove SST, the crankshaft pulley set bolt and crankshaft pulley.
  23. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket to the crankshaft as shown in the illustration.
      GTY447302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front of Engine
  24. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

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

  25. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily install the crankshaft pulley set bolt.
    2. Turn the crankshaft counterclockwise to position the timing gear key to the top.
      GTY906196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Gear Key
    3. Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are aligned as shown in the illustration.
      GTY901188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
    4. Remove the crankshaft pulley set bolt.
  26. INSTALL CHAIN SUB-ASSEMBLY 
    1. Align the mark plates (orange) with the timing marks as shown in the illustration and install the chain sub-assembly.
      GTY438537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Orange) *b Timing Mark

      HINT: 

      • Be sure to position the mark plate at the front of the engine.
      • The mark plate on the camshaft side is colored orange.
      • Do not pass the chain sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
      • Pass the chain sub-assembly through the No. 1 chain vibration damper.
    2. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark, and then install the chain sub-assembly.
    3. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

      HINT: 

      To tension the chain sub-assembly, slowly turn the camshaft timing gear assembly clockwise to prevent the chain sub-assembly from being misaligned.

    4. Align the mark plate (yellow or pink) and timing mark and install the chain sub-assembly to the crankshaft timing sprocket.
      GTY904093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Yellow or pink)
      *b Timing Mark

      HINT: 

      The mark plate on the crankshaft side is colored yellow or pink.

  27. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper to the cylinder block sub-assembly.
  28. CHECK NO. 1 CYLINDER IS TDC/COMPRESSION 
    1. Check each timing mark at TDC/compression.
      GTY441589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b Mark Plate (Orange)
      *c Mark Plate (Yellow) - -
  29. INSTALL NO. 1 GENERATOR BRACKET 
    1. Install the No. 1 generator bracket to the cylinder block sub-assembly with the 4 bolts.

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

  30. INSTALL WATER INLET HOUSING 
    1. Install a new gasket and water inlet housing to the timing chain cover sub-assembly with the 3 bolts.

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

  31. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Install a new gasket to the timing chain cover sub-assembly.
      NOTE:

      Remove any oil from the contact surface.

    2. Install the engine water pump assembly to the timing chain cover sub-assembly with the 3 bolts.

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

    3. Remove any remaining seal packing material.
    4. Clean the contact surfaces of the timing chain cover sub-assembly, camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
      GTY757880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Assembly Side *b Timing Chain Cover Sub-assembly Side
      Clean and degrease - -
    5. Install 2 new O-rings to the cylinder head sub-assembly.
    6. Install a new O-ring to the cylinder block sub-assembly.
    7. Apply seal packing to the engine unit as shown in the illustration.
      GTY756475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Diameter

      5.0 mm (0.197 in.)

      NOTE:

      Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

    8. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.
      GTY751839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2.5 mm (0.10 in.) *b 2.5 to 3.5 mm (0.10 to 0.14 in.)
      *c 5.0 mm (0.20 in.) *d 4.5 to 5.5 mm (0.18 to 0.22 in.)
      *e 7.5 mm (0.30 in.) *f 7.0 to 8.0 mm (0.28 to 0.31 in.)

      Seal Packing

      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Application Specification

      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.5 mm (0.0984 to 0.138 in.) Center of seal packing
      2.5 mm (0.0984 in.)      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.) Center of seal packing
      3.0 mm (0.118 in.)      		 - -
      (A) - (A) 2.5 to 3.5 mm (0.0984 to 0.138 in.) Center of seal packing
      2.5 mm (0.0984 in.)      		 - -
      (B) - (B) 4.5 to 5.5 mm (0.177 to 0.217 in.) Opposite edge of seal packing
      5.0 mm (0.197 in.)      		 - -
      (C) - (C) 7.0 to 8.0 mm (0.276 to 0.315 in.) Opposite edge of seal packing
      7.5 mm (0.295 in.)      		 - -
      (F) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.8 mm (0.622 in.) 50.1 mm (1.97 in.)
      (G) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 155.1 mm (6.11 in.)
      (H) 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 165.4 mm (6.51 in.)
      (I) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (15.7 in.)
      (J) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      (K) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 133.9 mm (5.27 in.)
      (L) 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 159.2 mm (6.27 in.)
      (M) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.0 mm (0.197 in.) 185.0 mm (7.28 in.)
      (N) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (15.7 in.)
      (O) 4.0 mm (0.157 in.) Center of seal packing
      3.0 mm (0.118 in.)      		 - -
      NOTE:

      Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

    9. Clean the bolts and their installation holes.
    10. Apply adhesive to 5 and a half threads or more of the end of the bolt (C).
      GTY596378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    11. Temporarily install the timing chain cover sub-assembly with the 19 bolts and a new seal washer.

      Bolt Length

      Item Length
      Bolt (A), (C) 35 mm (1.38 in.)
      Bolt (B) 55 mm (2.17 in.)
      Bolt (D) 40 mm (1.57 in.)
      NOTE:

      Make sure that there is no oil on the threads of the bolts.

      GTY691002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer
    12. Temporarily install the engine mounting bracket RH to the timing chain cover sub-assembly with the 3 bolts.
      GTY868013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt Length

      Item Length
      Bolt 80 mm (3.15 in.)
      NOTE:

      Make sure that there is no oil on the threads of the bolts.

    13. Install 2 new O-rings to the timing chain cover sub-assembly.
      GTY433986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Temporarily install the oil filter bracket to the timing chain cover sub-assembly with the 4 bolts.

      Bolt Length

      Item Length
      Bolt 35 mm (1.38 in.)
      NOTE:

      Make sure that there is no oil on the threads of the bolts.

      GTY420343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Install the timing chain cover sub-assembly with the 26 bolts and a new seal washer in the order shown in the illustration.
      GTY840925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer - -
      *a Torque *b Bolt Tightening Order

      Bolt (A), (C) 

      Torque: 25.5 N.m (260 kgf/cm, 19 ft.lbf) 

      Bolt (B), (E) 

      Torque: 51 N.m (520 kgf/cm, 38 ft.lbf) 

      Bolt (D) 

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

      NOTE:
      • Install the timing chain cover 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 there is no oil on the threads of the bolts.
  32. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1

  33. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 2

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Raise the cam, then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.
      GTY916267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
      *c Push
      *d Raise
      *e Cam
      *f Hook
      *g Pin
      NOTE:

      Make sure that the cam engages with the first tooth of the plunger to allow the hook to pass over the pin.

    2. Install a new gasket, the bracket and No. 1 chain tensioner assembly with the 2 nuts.
      GTY433768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

      NOTE:

      If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, set the hook again.

    3. Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.
      GTY426413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hook
      *b Disconnect
    4. Turn the crankshaft clockwise and check that the plunger is extended.
      GTY450325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger Extended
      *b Plunger
  35. INSTALL OIL FILTER UNION 
    1. Using a 12 mm hexagon socket wrench, install the oil filter union to the oil filter bracket.

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

  36. INSTALL OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 [03/2019 - 06/2021] , or refer to PROCEDURE - Step 4 [06/2021 - 11/2022]

  37. INSTALL SPARK PLUG TUBE GASKET 
    1. Using a hammer and the spark plug tube gasket which has had the sealing part cut off, uniformly tap in a new spark plug tube gasket all the way.
      GTY874771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
      *b Spark Plug Tube Gasket without Seal Part
      *c New Spark Plug Tube Gasket
      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap the spark plug tube gasket.

      HINT: 

      If a spark plug tube gasket that will be used to install the spark plug tube gasket is deformed, and cannot be positioned on the spark plug tube gasket, correct the deformation using pliers.

    2. Return the 4 claws of the ventilation baffle plate to their original positions.
  38. INSTALL CYLINDER HEAD COVER GASKET 
    1. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
      NOTE:

      Remove any oil from the contact surfaces.

  39. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install 3 new gaskets to the camshaft bearing cap.
      GTY429204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing as shown the illustration.
      GTY429202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Diameter

      4.0 mm (0.157 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 installing the cylinder head cover sub-assembly.
    3. Install the cylinder head cover sub-assembly to the camshaft housing sub-assembly with the 13 bolts and a new seal washer in the order shown in the illustration.
      GTY859453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer

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

  40. INSTALL CYLINDER HEAD COVER SCREEN (w/o Canister Pump Module) 
    1. Apply a light coat of engine oil to the O-ring of the cylinder head cover screen.
    2. Install the cylinder head cover screen to the cylinder head cover sub-assembly with the bolt.

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

  41. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  42. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1 [01/2019 - 09/2022] , or refer to PROCEDURE - Step 1 [09/2022 - 11/2022]

  43. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  44. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  45. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
  46. INSTALL CAMSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  47. INSTALL VALVEMATIC SHAFT SENSOR (CAM POSITION SENSOR) (w/ Canister Pump Module) 

    Refer to PROCEDURE - Step 1

  48. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  49. INSTALL OIL FILLER CAP GASKET 
    1. Install the oil filler cap gasket to the oil filler cap sub-assembly.
  50. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
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