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Reassembly [01/2019 - 09/2022]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    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.
      GTY568274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      *b 11 mm
      *c 8.0 mm

      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. Apply seal packing as shown in the illustration.

      Seal Packing

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

      Standard Seal Packing 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.
      GTY546402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.

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

      Bolt Length

      Item Specified Condition
      Bolt (A) 138 mm (5.43 in.)
      Bolt (B) 35 mm (1.38 in.)
      Bolt (C) 70 mm (2.76 in.)
      Fig 1: Stiffening Crankcase Assembly Bolts Tightening Sequence
      GTY540619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Recheck the torque for the bolts (1) and (2).

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

    5. Wipe off any excess seal packing with a clean piece of cloth.
  2. INSTALL OIL PUMP ASSEMBLY 
    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.
      GTY565863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      *b 11 mm
      *c 8.0 mm

      Standard Ring Pin

      Item Protrusion Height Height Width
      Ring pin 3.0 mm (0.118 in.) 8.0 mm (0.315 in.) 11 mm (0.433 in.)
    2. Install the oil pump assembly.

      Refer to PROCEDURE - Step 1

  3. INSTALL ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 1

  4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    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 as shown in the illustration.
      GTY583316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 9 mm (0.354 in.)
      *b 19 mm (0.748 in.)

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

    2. 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.
      • Do not add engine oil for at least 2 hours after installing the No. 2 oil pan sub-assembly.
      • Keep the contact surfaces of the stiffening crankcase assembly and No. 2 oil pan sub-assembly free of oil.
    3. Apply seal packing in a continuous line as shown in the illustration.

      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) -
      GTY545986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      *b 6.0 mm
      *c 3.0 to 4.5 mm
    4. 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) 

      GTY576244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
  5. 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) 

      GTY589155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 1

  8. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1

  9. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    HINT: 

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

    1. Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
    2. Place the cylinder head sub-assembly on the cylinder block sub-assembly.
      NOTE:
      • Remove any oil from the contact surface of the cylinder head sub-assembly.
      • Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the gasket with the bottom of the cylinder head sub-assembly.
    3. Install the 10 cylinder head set plate washers to the 10 cylinder head set bolts.
    4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
    5. Step 1:
      1. Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.

        Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

        NOTE:

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

        Fig 2: Cylinder Head Set Bolts Tightening Sequence
        GTY566000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Step 2:
      GTY539058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      Front of Engine
      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.
    7. Step 3:
      1. Tighten the cylinder head set bolts another 45° in the order shown in step 1.
    8. Check that the paint marks are now at a 135° angle.
      NOTE:

      Do not add engine oil for at least 2 hours after installing the cylinder head sub-assembly.

    9. After tightening the cylinder head set bolts, wipe off any seal packing that seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly.
      NOTE:
      • Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.
      • Be sure to avoid clogging the bolt holes when wiping off the seal packing.
      GTY608635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Before Wiping Off
      *b After Wiping Off
  10. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem ends.
    2. Install the 16 valve stem caps to the cylinder head sub-assembly.
      NOTE:
      • Install each part to its original location.
      • Do not drop the valve stem caps into the cylinder head sub-assembly.
      GTY565098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Inspect the 16 valve lash adjuster assemblies before installing them.

      Refer to PROCEDURE - Step 2

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

      Install each part to its original location.

      GTY565072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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.

  13. INSTALL RING PIN 
    NOTE:

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

    1. Using a plastic hammer, tap 10 new ring pins into the camshaft housing sub-assembly.
      GTY562298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      *b 20 mm
      *c 13 mm

      Standard Ring Pin

      Item Protrusion Height Height Width
      Ring pin 3.0 mm (0.118 in.) 13 mm (0.512 in.) 20 mm (0.787 in.)
  14. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean both surfaces of the No. 1 camshaft bearings.
    2. Install the 2 No. 1 camshaft bearings.
    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.
      GTY555552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper

      Standard Dimension (A) - (B)

      0.7 mm (0.0276 in.) or less

      NOTE:

      Position the No. 1 camshaft bearings to the center of the camshaft bearing cap by measuring dimensions (A) and (B).

  15. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean both surfaces of the No. 2 camshaft bearings.
    2. Install the 2 No. 2 camshaft bearings.
    3. Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

      Dimension (A)

      1.05 to 1.75 mm (0.0413 to 0.0689 in.)

      NOTE:

      Position the No. 2 camshaft bearings to the center of the camshaft housing sub-assembly by measuring dimension (A).

      GTY574339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper
  16. INSTALL OIL CONTROL VALVE FILTER 
    1. Check that no foreign matter is on the mesh of the oil control valve filter.
      GTY564310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil control valve filter.
      NOTE:

      Do not touch the mesh when installing the oil control valve filter.

  17. INSTALL NO. 2 CAMSHAFT 

    Refer to PROCEDURE - Step 6

  18. INSTALL CAMSHAFT 

    HINT: 

    Perform Inspection After Repair after replacing the camshaft.

    Refer to INITIALIZATION [01/2019 - 09/2022]

    1. Clean the camshaft journals.
    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.
      GTY588985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL CAMSHAFT BEARING CAP 
    1. Confirm the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
      GTY584692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
    2. Tighten the 10 bearing cap bolts in the order shown in the illustration.

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

      Fig 3: Bearing Cap Bolts Tightening Sequence
      GTY544223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. SET NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. GTY590179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
      *a Correct
      *b Incorrect

      Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

  21. INSTALL CAMSHAFT HOUSING 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

      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.
      GTY563215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cylinder Head Sub-assembly Upper Side
      *b Seal Packing
      *c 3.5 to 4.0 mm (0.138 to 0.157 in.)
    2. Set the camshaft and No. 2 camshaft as shown in the illustration.
      Fig 4: Camshaft Housing Sub-Assembly Bolts Tightening Sequence
      GTY727081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
      Bolt (B)
    3. Install the camshaft housing sub-assembly with the 17 bolts and tighten them in the order shown in the illustration.

      Bolt (A) 

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

      Bolt (B) 

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

      NOTE:
      • After installing the camshaft housing sub-assembly, make sure that the cam lobes are positioned as shown in the illustration.
      • If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly, clean the installation surfaces, and reapply seal packing.
      • If it is necessary to remove the camshaft housing sub-assembly during installation, make sure that the previously applied seal packing does not enter any oil passages.
      • After installing the camshaft housing sub-assembly, wipe off any seal packing that seeped out from between the camshaft housing sub-assembly and cylinder head sub-assembly.
  22. INSTALL CAMSHAFT TIMING SPROCKET 
    1. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt.

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

      GTY588911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.
      GTY572998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Knock Pin Hole
    2. Check that there is no gap between the camshaft timing gear assembly and camshaft flange.
      GTY603860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *a Camshaft Flange
      *b No Gap
    3. Using a wrench to hold the hexagonal portion of the camshaft, tighten the bolt.

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

      GTY588912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and locks in the most retarded position.
      GTY552823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lock
  24. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Using a plastic hammer, tap in the 2 crankshaft timing gear keys.
      GTY562563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  25. 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.
      GTY589172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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.
      GTY576630Courtesy 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.
      GTY602221Courtesy 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) 

      GTY576652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring
    9. Temporarily install the crankshaft pulley to the crankshaft with the crankshaft pulley set bolt.
    10. Using SST, hold the crankshaft pulley and tighten the oil pump drive shaft gear nut.
      • SST: 09213-58014 
        1. 91551-80840
      • SST: 09330-00021 

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

      GTY610650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove SST, the crankshaft pulley set bolt and crankshaft pulley.
  27. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket to the crankshaft.
      GTY609005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. Temporarily install the crankshaft pulley set bolt to the crankshaft.
    2. Turn the crankshaft clockwise until the crankshaft timing gear key is facing upward.
      GTY570887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
    3. Check that the timing marks on the camshaft timing gear assembly and camshaft timing sprocket are aligned as shown in the illustration.

      HINT: 

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

      GTY593591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Timing Mark (Rectangle)
      *c Mark (Circle)
    4. Remove the crankshaft pulley set bolt from the crankshaft.
  29. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13

  30. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the No. 2 chain vibration damper to the camshaft housing sub-assembly with the 2 bolts.

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

      GTY588899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper to the cylinder block sub-assembly.
      GTY589157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL OIL FILTER BRACKET WITH HEAD STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon socket wrench, install 2 new gaskets and the 2 oil filter bracket with head straight screw plugs to the oil filter bracket.
      GTY609007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    NOTE:

    If the stud bolts are deformed or the threads are damaged, replace them.

    1. Type A:
      1. Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
        GTY561561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 21 mm (0.827 in.)
        *b 9 mm (0.354 in.)
        *c 34 mm (1.34 in.)

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

    2. Install the 2 stud bolts as shown in the illustration.
      GTY588971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Remove any remaining seal packing.
    4. GTY588900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install a new gasket to the engine water pump assembly.

      HINT: 

      Be sure to clean the contact surfaces.

    5. Install the engine water pump assembly to the timing chain cover sub-assembly with the 3 bolts.
      GTY588902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    6. 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.
      GTY541222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cylinder Head Sub-assembly and Cylinder Block Sub-assembly Side *b Timing Chain Cover Sub-assembly Side
      Clean and degrease - -
    7. GTY588903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install 3 new O-rings to the cylinder head sub-assembly and cylinder block sub-assembly.

    8. Apply seal packing to the engine unit as shown in the illustration.

      Seal Packing

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

      Seal Packing 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.

      GTY589947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Apply seal packing to the timing chain cover sub-assembly in a continuous line as shown in the illustration.
      GTY607004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2.5 mm *b 5.0 mm
      *c 7.5 mm *d 2.5 to 3.5 mm
      *e 4.5 to 5.5 mm *f 7.0 to 8.0 mm

      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.) - 15.5 mm (0.610 in.) 50.4 mm (1.98 in.)
      (G) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 143.1 mm (5.63 in.)
      (H) 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 153.4 mm (6.04 in.)
      (I) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 16.0 mm (0.630 in.) 385.8 mm (1.27 ft.)
      (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.) 121.9 mm (4.80 in.)
      (L) 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 147.2 mm (5.80 in.)
      (M) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.1 mm (0.201 in.) 173.0 mm (6.81 in.)
      (N) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 385.8 mm (1.27 ft.)
      (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.

    10. Clean the bolts and their installation holes.
    11. Apply adhesive to 5 and a half threads or more of the end of the 2 bolts (E).
      GTY567373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    12. Temporarily install the timing chain cover sub-assembly with the 18 bolts and a new seal washer.
      GTY555727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer

      Bolt Length

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

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

    13. Temporarily install the engine mounting bracket RH to the timing chain cover sub-assembly with the 3 bolts.

      Bolt Length

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

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

    14. Install 2 new oil filter bracket O-rings to the timing chain cover sub-assembly.
    15. 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.

    16. Fully tighten the 25 bolts in the order shown in the illustration.
      Fig 5: Timing Chain Cover Sub-Assembly Bolts Tightening Sequence
      GTY596710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque *b Bolt Tightening Order

      Bolt (A), (D), (E) 

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

      Bolt (B), (F) 

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

      Bolt (C) 

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

      NOTE:
      • 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.
  34. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1

  35. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  36. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  37. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  38. 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.
  39. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  40. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 2

  41. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Raise the cam, then fully push in the plunger and engage the hook with the pin so that the plunger is in the position shown in the illustration.
      NOTE:

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

      GTY574282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cam
      *b Hook
      *c Plunger
      *d Pin
      *e Correct
      *f Incorrect
      *g Push
      *h Raise
    2. Install a new gasket, the bracket and No. 1 chain tensioner assembly to the timing chain cover sub-assembly with the 2 nuts.

      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.

      GTY609009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Rotate the crankshaft counterclockwise slightly and check that the hook is released.
      GTY545752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hook
      *b Release
    4. Turn the crankshaft clockwise and check that the plunger is extended.
      GTY540012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
      *b Plunger is extended
  42. 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) 

  43. INSTALL OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 [01/2019 - 06/2021] , or refer to PROCEDURE - Step 4 [06/2021 - 09/2022]

  44. INSTALL SPARK PLUG TUBE GASKET 
    1. GTY589183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

  45. INSTALL CYLINDER HEAD COVER GASKET 
    1. Install 3 new cylinder head cover gaskets to the cylinder head cover sub-assembly.
      NOTE:
      • Remove any oil from the contact surfaces.
      • Misalignment between the center of the cylinder head cover sub-assembly rib and the center of the cylinder head gasket tab should be 4.0 mm (0.157 in.) or less.
      GTY558047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Cover Sub-assembly
      *2 Cylinder Head Cover Gasket
  46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install 2 new gaskets as shown in the illustration.
      GTY589204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing as shown in the illustration.

      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 installation.
      GTY589241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cylinder head cover sub-assembly with the 16 bolts.

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

      NOTE:

      Misalignment between the contact surfaces of the timing chain cover sub-assembly and camshaft housing sub-assembly and the center of the cylinder head cover gasket tab should be 4.0 mm (0.157 in.) or less.

      GTY554422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Chain Cover Sub-assembly
      *2 Camshaft Housing Sub-assembly
      *3 Cylinder Head Cover Gasket
      *a Projection
      GTY589205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  48. INSTALL CAMSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  49. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  50. INSTALL OIL FILLER CAP GASKET 
    1. Install the oil filler cap gasket to the oil filler cap sub-assembly.
      GTY589892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
      GTY588893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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