LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2024 >> Corolla LE >> Repair and Diagnosis >> External Pages >> Different car >> Section 266 (Engine Mechanical System - Service Information (3 Of 3)) >> Engine Unit >> Reassembly [09/2022 - ] >> Procedure

Reassembly [09/2022 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota GR Corolla, 2024 Toyota GR Corolla, and 2023 Toyota GR Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL RING PIN 
    NOTE:

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

    1. Using a plastic hammer, tap in a new ring pin to the oil pan sub-assembly.
      GTY1019997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard Protrusion Height

      3.0 to 5.0 mm (0.118 to 0.197 in.)

    2. Using a plastic hammer, tap in a new ring pin to the camshaft position sensor holder.

      Standard Protrusion Height

      3.5 to 4.5 mm (0.138 to 0.177 in.)

      GTY1019590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
  2. INSTALL STUD BOLT 
    NOTE:

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

    1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the oil pan sub-assembly.

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

      GTY1020041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 9 mm (0.354 in.)
      *b 19 mm (0.748 in.)
    2. GTY1019285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 16 mm (0.630 in.)
      *b 9 mm (0.354 in.)
      *c 27 mm (1.063 in.)

      Using an E6 "TORX" socket wrench, install the 2 stud bolts to the No. 2 camshaft bearing cap.

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

    3. Using an E6 "TORX" socket wrench, install the stud bolt to the outlet water sub-assembly.
      GTY1105051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 16 mm (0.630 in.)
      *b 9 mm (0.354 in.)
      *c 27 mm (1.063 in.)

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

  3. INSPECT BALANCESHAFT BACKLASH 

    See step  10

  4. INSTALL REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 1 [09/2022 - 09/2024] , or refer to PROCEDURE - Step 1 [09/2024 - ]

  5. INSTALL BALANCESHAFT HOUSING SPACER 
    1. Install the balanceshaft housing spacer to the crankshaft bearing cap.
      GTY1019741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL ENGINE BALANCER ASSEMBLY 
    1. Install a new o-ring to the crankshaft bearing cap.
      GTY1019756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine balancer assembly to the crankshaft bearing cap with the 4 bolts.
      GTY1019311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      1st 

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

      2nd 

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

  7. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new oil strainer gasket.
    2. Install the oil strainer sub-assembly and oil strainer gasket to the stiffening crankcase assembly with the 2 bolts.

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

      GTY1019313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY1020135Courtesy 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 oil pan sub-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 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. Install the 2 new o-ring to the crankshaft bearing cap.
      GTY1019321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the oil pan sub-assembly with the 13 bolts.

      Bolt Length

      Item Length
      Bolt (A) 70 mm (2.76 in.)
      Bolt (B) 30 mm (1.18 in.)
      GTY1020101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Type
    4. Tighten the 13 bolts in the order shown in the illustration to install the oil pan sub-assembly.
      Fig 1: Oil Pan Sub-Assembly Bolts Tightening Sequence
      GTY1020103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tightening Order

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

  9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    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

      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.).
      GTY1020409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
    2. Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts in several steps in the order shown in the illustration.
      Fig 2: No. 2 Oil Pan Sub-Assembly Bolts And Nuts Tightening Sequence
      GTY1020381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  10. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new oil pan drain gasket and the oil pan drain plug to the oil pan sub-assembly.

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

  11. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY 
    1. Install 2 new gaskets and the oil filter bracket sub-assembly to the oil pan sub-assembly with the 3 bolts.

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

  12. INSTALL OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  13. INSTALL OIL FILTER UNION 
    1. Using a 12 mm hexagon socket wrench, install the oil filter union to the oil filter bracket sub-assembly.

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

      GTY1252419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  15. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1

  16. 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. Install the 8 plate washers to the 8 cylinder head set bolts.
    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
    4. Install the 8 cylinder head set bolts and 3 bolts to the cylinder head sub-assembly.
      GTY1019502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front of Engine

      Bolt Diameter

      Item Diameter
      Bolt (A) 11 mm (0.433 in.)
      Bolt (B) 12 mm (0.472 in.)
    5. Step 1:
      1. Using a 12 mm socket wrench, install and uniformly tighten the 8 cylinder head set bolts in several steps in the order shown in the illustration.
        Fig 3: Cylinder Head Set Bolts Tightening Sequence
        GTY1019920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Front of Engine
        NOTE:

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

        Bolt (A) 

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

        Bolt (B) 

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

    6. Step 2:
      1. Mark each cylinder head set bolt head with paint as shown in the illustration.
        GTY741015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        Front of Engine
      2. Tighten the cylinder head set bolts 90° in the order shown in step 1.
    7. 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 [09/2022 - ]

    8. Install the 3 bolts in the order shown in the illustration.
      Fig 4: Cylinder Head Sub-Assembly Bolts Tightening Sequence
      GTY1020224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

  17. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem cap ends.
    2. Install the 12 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.
      GTY1020023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Inspect the 12 valve lash adjuster assemblies before installing them.

      See step  2

    2. Install the 12 valve lash adjuster assemblies to the cylinder head sub-assembly.
      NOTE:

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

      GTY1104054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for intake side *B for exhaust side
      GTY1020509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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 12 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.

  20. INSTALL NO. 1 CAMSHAFT BEARING CAP 
    1. Install the No. 1 camshaft bearing cap to the cylinder head sub-assembly.
  21. INSTALL NO. 5 CAMSHAFT BEARING CAP 
    1. Install the No. 5 camshaft bearing cap to the cylinder head sub-assembly.
  22. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY 

    HINT: 

    Perform inspection after repair after replacing the exhaust camshaft sub-assembly.

    Refer to INITIALIZATION [09/2022 - ]

    1. Clean the camshaft journals and cylinder head sub-assembly.
    2. Apply a light coat of engine oil to the camshaft journals and cylinder head sub-assembly.
    3. Install the exhaust camshaft sub-assembly to the cylinder head sub-assembly.
  23. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY 

    HINT: 

    Perform inspection after repair after replacing the intake camshaft sub-assembly.

    Refer to INITIALIZATION [09/2022 - ]

    1. Clean the camshaft journals and cylinder head sub-assembly.
    2. Apply a light coat of engine oil to the camshaft journals, cylinder head sub-assembly.
    3. Install the intake camshaft sub-assembly to the cylinder head sub-assembly.
  24. INSTALL CAMSHAFT BEARING CAP 
    1. Set the No. 2 camshaft bearing cap, 6 No. 4 camshaft bearing caps and No. 6 camshaft bearing cap.
      GTY1104497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 camshaft bearing cap
      *2 No. 4 camshaft bearing cap
      *3 No. 6 camshaft bearing cap

      Installation Position of Camshaft Bearing Cap

      Installation Position Inscribed No.
      Intake No. 1 cylinder I2
      Intake No. 2 cylinder I3
      Intake No. 3 cylinder I4
      Exhaust No. 1 cylinder E2
      Exhaust No. 2 cylinder E3
      Exhaust No. 3 cylinder E4
    2. Temporarily install and uniformly tighten the 18 bolts.

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

      GTY1105847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt Length

      Item Length
      Bolt (A) 65 mm (2.56 in.)
      Bolt (B) 40 mm (1.57 in.)
      Bolt (C) 55 mm (2.17 in.)
    3. Tighten the 18 bolts in the order shown in the illustration.
      Fig 5: Camshaft Bearing Cap Bolts Tightening Sequence
      GTY1105846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  25. TEMPORARILY TIGHTEN CAMSHAFT POSITION SENSOR HOLDER 
    1. Temporarily tighten the camshaft position sensor holder with the bolt.
  26. INSTALL FUEL PUMP LIFTER HOUSING 
    1. Install the fuel pump lifter housing with the 4 bolts in the order shown in the illustration.

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

      Fig 6: Fuel Pump Lifter Housing Bolts Tightening Sequence
      GTY1107032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FUEL PUMP LIFTER GUIDE 
    1. Install the fuel pump lifter guide with the 2 bolts.

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

  28. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    HINT: 

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

    Refer to INITIALIZATION [09/2022 - ]

    1. Align and fit the knock pin of the intake camshaft sub-assembly to the knock pin hole of the camshaft timing gear assembly.
      GTY1019575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    2. Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.
      GTY1019986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      NOTE:
      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
    3. Using a 5 mm hexagon socket wrench, install the camshaft timing gear assembly and the camshaft timing valve assembly with the 3 bolts.

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

  29. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    HINT: 

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

    Refer to INITIALIZATION [09/2022 - ]

    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.
      GTY1019602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
    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. Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly and the camshaft timing valve assembly with the 3 bolts.

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

      GTY1019350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. 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.

      GTY1019359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Install the crankshaft timing gear or sprocket to the crankshaft.
  32. SET VALVE TIMING 
    1. Temporarily install the crankshaft pulley bolt.
    2. Rotate the crankshaft 117.11° counterclockwise to position the crankshaft timing gear key as shown in the illustration.
      GTY1019426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
      *a 117.11°
    3. Check that the timing marks of the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.
      GTY1019783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
  33. 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) 

  34. INSTALL CHAIN SUB-ASSEMBLY 
    1. Remove the crankshaft pulley bolt.
    2. Align the paint marks (pink) of the chain sub-assembly with the timing marks of the camshaft timing gear assembly, camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing gear assembly and camshaft timing exhaust gear assembly.
      GTY1020435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (Pink)
      *b Timing Mark
    3. Align the paint marks (yellow) of the chain sub-assembly with the timing mark of the crankshaft timing gear or sprocket and install the chain sub-assembly to the crankshaft timing gear or sprocket.
      GTY1020262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (Yellow)
      *b Timing Mark
  35. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper with the bolt.

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

  36. INSTALL DAMPER PLATE SPACER 
    1. Install the 2 damper plate spacers to the No. 2 camshaft bearing cap.
  37. INSTALL TIMING CHAIN GUIDE 
    1. Install the timing chain guide with the 2 nuts.

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

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

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

    2. Remove the pin.
  39. SET VALVE TIMING 

    Refer to PROCEDURE - Step 23

  40. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 2 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 2 [11/2022 - 09/2024] , or refer to PROCEDURE - Step 2 [09/2024 - ]

  41. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 1 [11/2022 - 09/2024] , or refer to PROCEDURE - Step 1 [09/2024 - ]

  42. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. Align the engine name plate with the plate attachment standard location and install it.
      GTY1251509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plate Attachment Standard Location
      *b Engine Name Plate

      HINT: 

      Perform this procedure only when replacement of the No. 2 timing chain cover assembly is necessary.

    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY1020451Courtesy 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 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 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.).
    3. Apply adhesive to 2 or 3 threads at the end of each of the 2 bolts (B).
      GTY445334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Temporarily tighten the No. 2 timing chain cover assembly with the 8 bolts.
      GTY1020222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Type
    5. Tighten the 8 bolts in the order shown in the illustration.
      Fig 7: No. 2 Timing Chain Cover Assembly Bolts Tightening Sequence
      GTY1019665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tightening Order

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

    6. 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) 

      NOTE:

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

      GTY1019886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL NO. 1 VACUUM PUMP BRACKET 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY1250881Courtesy 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 3.0 to 4.0 mm (0.118 to 0.157 in.)
      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the No. 1 vacuum pump bracket 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 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. Install the No. 1 vacuum pump bracket with the 2 bolts.

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

    3. Wipe off any excess seal packing.
      GTY1251245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL SPARK PLUG TUBE GASKET 
    1. Install 3 new spark plug tube gaskets to the cylinder head cover sub-assembly.
  45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install 2 new camshaft bearing cap oil hole gaskets to the No. 2 camshaft bearing cap and fuel pump lifter housing.
      NOTE:

      Remove any oil from the contact surfaces.

      GTY1020350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 5 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.
      GTY1108665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
      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. Apply adhesive to 2 or 3 threads at the end of each of the bolt (D).
      GTY445334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Install the 2 camshaft position sensors (for exhaust side and for intake side) and cylinder head cover sub-assembly with the 19 bolts (A, B, C, D, E) in the order shown in the illustration.
      Fig 8: Cylinder Head Cover Sub-Assembly Bolts Tightening Sequence
      GTY1181161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt Length

      Bolt Length Thread Diameter
      (A), (D) 23.5 mm (0.925 in.) 6 mm (0.236 in.)
      (B) 45 mm (1.77 in.) 5.22 mm (0.206 in.)
      (C) 30 mm (1.18 in.) 5.22 mm (0.206 in.)
      (E) 80 mm (3.15 in.) 5.22 mm (0.206 in.)

      Torque: 10 N*m (102 kgf*cm, 7 ft.*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.
  46. INSTALL OUTLET WATER SUB-ASSEMBLY 
    1. Install the outlet water sub-assembly and a new outlet water gasket to the cylinder head sub-assembly with the 2 nuts.

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

  47. INSTALL CRANKSHAFT PULLEY ASSEMBLY 
    1. Align the crankshaft timing gear key with the key groove of the crankshaft pulley assembly.
      GTY1019291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    2. Using SST, hold the crankshaft pulley assembly and install the a new crankshaft pulley set bolt.
      • SST: 09213-54015 
      • SST: 09330-00021 

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

    3. Mark each crankshaft pulley set bolt with paint as shown in the illustration.
      GTY1019720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      Front of Engine
    4. Tighten the crankshaft pulley set bolt 90°.
  48. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 1

  50. INSTALL CRANK POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  51. INSTALL OIL FILLER CAP GASKET 
    1. Install a new oil filler cap gasket to the oil filler cap assembly.
  52. INSTALL OIL FILLER CAP ASSEMBLY 
    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
  53. INSTALL WATER INLET WITH WATER PUMP HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  54. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  55. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side) 

    Refer to PROCEDURE - Step 2

  56. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side) 

    Refer to PROCEDURE - Step 3

  57. INSTALL OIL PRESSURE AND TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  58. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

scientia non olet · About LEMON Manuals