Engine Unit: Reassembly: Reassembly

INSTALL STRAIGHT PIN

Using a plastic hammer, tap in new straight pins to the cylinder block.

Fig 1: Identifying Positions Of Straight Pin

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

STANDARD PROTRUSION

Item	Protrusion
Pin A	23 mm (0.906 in.)
Pin B	6 mm (0.236 in.)
Pin C	11 mm (0.433 in.)
Pin D	9 mm (0.354 in.)

INSTALL STUD BOLT
1. Using an E8 "TORX" socket, install the stud bolts.
  
  Fig 2: Identifying Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL TIGHT PLUG
NOTE:
If water leaks from the tight plug or the plug is corroded, replace it.
1. Apply adhesive around the tight plugs.
  
  Fig 3: Applying Adhesive Around Tight Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Using SST and a hammer, tap in new tight plugs as shown in the illustration.
  
  Fig 4: Taping In Tight Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using SST, tap in the 2 tight plugs A.
    - SST: 09950-60010
      1. 09951-00340
    - SST: 09950-70010
      1. 09951-07100
  2. Using SST, tap in the tight plug B.
    - SST: 09950-60010
      1. 09951-00200
    - SST: 09950-70010
      1. 09951-07100
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the oil nozzles.
  
  Fig 5: Remove/Install Bolt And Oil Nozzle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL CONNECTING ROD SMALL END BUSH
1. Align the oil holes of a new bush and the connecting rod.
  
  Fig 6: Identifying Oil Holes Of Bush And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the bush.
  
  Fig 7: Pressing Rod Small End Bushing Using SST And Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09222-30010
3. Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin.
  
  Fig 8: View Of Honing Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard oil clearance
  
  -0.002 to 0.004 mm (-0.00007 to 0.0001 in.)
4. Check that the piston pin fits at normal room temperature.
  
  Fig 9: Checking Piston Pin Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

INSTALL PISTON SUB-ASSEMBLY WITH PIN

Using a screwdriver, install a new snap ring at one end of the piston pin hole.

Fig 10: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
Gradually heat the piston to approximately 80°C (176°F).

Fig 11: Heating Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Coat the piston pin with engine oil.

Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

Fig 12: Identifying Front Marks Of Piston And Connecting Rod

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

FRONT MARK

Item	Front Mark
Piston LH	1
Piston RH	2

HINT:

The piston and pin are a matched set.

Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

Fig 13: Checking Fitting Condition Between Piston And Piston Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

Fig 14: Identifying Snap Ring & Service Hole
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

INSTALL PISTON RING SET
1. Install the oil ring expander by hand.
2. Using a piston ring expander, install the oil ring rail as shown in the illustration.
  
  Fig 15: Identifying Piston Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.
  
  Fig 16: Identifying 2 Compression Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Install the compression ring No. 1 with the code mark (1N) facing upward.
  - Install the compression ring No. 2 with the code mark (2N) facing upward.
4. Position the piston rings so that the ring ends are as shown in the illustration.
  
  Fig 17: Positioning Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not align the ring ends.
INSTALL CRANKSHAFT BEARING
1. Clean the main journal and the both surfaces of the bearing.
  
  Fig 18: Identifying Journal Bearings Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.
2. Install the upper bearing.
  
  Fig 19: Installing Upper Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the upper bearings to the cylinder block as shown in the illustration.
    NOTE:
    Do not apply engine oil to the bearings or the contact surfaces.
    
    Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.
    
    Do not allow coolant to come into contact with the bearing inner surface.
    
    If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
3. Install the lower bearing.
  
  Fig 20: Identifying Lower Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the lower bearings to the bearing caps.
  2. Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
    Dimension (A - B)
    
    0.7 mm (0.0276 in.) or less
    NOTE:
    Do not apply engine oil to the bearings or the contact surfaces.
    
    Do not allow coolant to come into contact with the bearing inner surface.
    
    If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
INSTALL CRANKSHAFT THRUST WASHER SET
1. Apply engine oil to the crankshaft thrust washer.
2. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
  
  Fig 21: Identifying Oil Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CRANKSHAFT

Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.

Fig 22: Identifying Numbers Of Main Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

A number is marked on each main bearing cap to indicate the installation position.
Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
Temporarily install the 8 main bearing cap bolts to the inside positions.
Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

Fig 23: Identifying Bearing Cap Bolts Dimension
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length

100 to 102 mm (3.94 to 4.02 in.)
Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.

Fig 24: View Of Tapping Bearing Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

Install the 8 main bearing cap bolts to the outside positions.

Fig 25: Identifying Main Bearing Cap Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length

Item	Length
Bolt A	100 to 102 mm (3.94 to 4.02 in.)
Except bolt A	105.5 to 107.5 mm (4.15 to 4.23 in.)

Install the crankshaft bearing cap bolts.
HINT:

The main bearing cap bolts are tightened in 2 progressive steps.
Step 1
1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
  
  Fig 26: Tightening Main Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
  
  If any of the main bearing cap bolts does not meet the torque specified, replace it.
Step 2
1. Mark the front of the bearing cap bolts with paint.
  
  Fig 27: Retightening Bearing Cap Bolts An Additional 90 Degrees
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Retighten the bearing cap bolts by 90° in the order above.
3. Check that the painted mark is now at a 90° angle to the front.

Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig 28: Tightening Main Bearing Cap Bolts In Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)

Bolt length

Item	Length
Bolt A	45 mm (1.77 in.)
Except bolt A	30 mm (1.18 in.)

Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance See step 31.

INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearing to the connecting rod and bearing cap.
2. Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.
  
  Fig 29: Measuring Distance Between Connecting Rod's And Bearing Cap's Edges And Connecting Rod Bearing's Edge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Dimension (A - B)
  
  0.7 mm (0.0276 in.) or less
  NOTE:
  - Do not apply engine oil to the bearings or the contact surfaces.
  - Do not allow coolant to come into contact with the bearing inner surface.
  - If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
Position the piston rings so that the ring ends are as shown in the illustration.

Fig 30: Positioning Piston Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:
Do not align the ring ends.

Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

Fig 31: Pushing Correctly Numbered Piston And Connecting Rod Assembly Into Cylinder

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Match the numbered connecting rod cap with the connecting rod.

Front Mark

Item	Front Mark
Piston LH	1
Piston RH	2

Check that the front mark of the connecting rod cap is facing forward.

Fig 32: Checking Front Mark Of Connecting Rod Cap Facing Forward
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
Install the connecting rod cap bolts.
HINT:

The connecting rod cap bolts are tightened in 2 progressive steps.
Step 1
1. Install and alternately tighten the connecting rod cap bolts in several steps.
  
  Fig 33: View Of Tightening Bolts Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
Step 2
1. Mark the front side of each connecting rod cap bolt with paint.
  
  Fig 34: Identifying Retightening Angle Of Connecting Rod Cap Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Retighten the cap bolts by 90° as shown in the illustration.
3. Check the painted mark is now at a 90° angle to the front.
Check that the crankshaft turns smoothly.
Check the connecting rod thrust clearance See step 29.

INSTALL INTAKE VALVE GUIDE BUSH

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Fig 35: Measuring Bush Bore Diameter Of Cylinder Head Using Caliper Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Cylinder bore diameter

10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Select a new guide bush (STD or O/S 0.05)

Bush size	Bush bore diameter
Use STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush.

If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

Heat the cylinder head to 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
Using SST, tap in new valve guide bushes to the specified protrusion height.

Fig 36: Tapping Valve Guide Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09201-10000
  1. 09201-01050
- SST: 09950-70010
  1. 09951-07100
Protrusion height

9.1 to 9.9 mm (0.3583 to 0.3898 in.)
Using a sharp 5.5 mm reamer, ream the valve guide bushes to obtain the specified clearance.

Fig 37: Reaming Valve Guide Bushings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.030 to 0.060 mm (0.0012 to 0.0023 in.)

INSTALL EXHAUST VALVE GUIDE BUSH

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Fig 38: Measuring Bush Bore Diameter Of Cylinder Head

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Cylinder bore diameter

10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Select a new guide bush (STD or O/S 0.05)

Bush size	Bush bore diameter
Use STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
Use O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)

If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

Heat the cylinder head to 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
Using SST, tap in new valve guide bushes to the specified protrusion height.

Fig 39: Tapping Valve Guide Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09201-10000
  1. 09201-01050
- SST: 09950-70010
  1. 09951-07100
Protrusion height

9.1 to 9.9 mm (0.3583 to 0.3898 in.)
Using a sharp 5.5 mm reamer, ream the valve guide bushes to obtain the specified clearance.

Fig 40: Reaming Valve Guide Bushings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.025 to 0.065 mm (0.0010 to 0.0026 in.)

INSTALL RING PIN
1. Using a plastic hammer, tap in new ring pins to the specified protrusion height.
  
  Fig 41: Identifying Protrusion Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Specified protrusion height
  
  2.5 to 3.8 mm (0.098 to 0.150 in.)
INSTALL NO. 1 STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
  
  Fig 42: Identifying Screw Plugs And Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
INSTALL NO. 2 STRAIGHT SCREW PLUG
1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
  
  Fig 43: Locating No. 2 Straight Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
INSTALL STUD BOLT
NOTE:
If the stud bolt is deformed or the threads are damaged, replace it.
1. Using E6 and E8 "TORX" sockets, install the stud bolts.
  
  Fig 44: Identifying Stud Bolts Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolts A, B and C
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  for bolt D
INSTALL UNION
1. Apply adhesive to the union of the cylinder head.
  
  Fig 45: Applying Adhesive To Union Of Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Using SST, install the union to the cylinder head as shown in the illustration.
  
  Fig 46: Installing Union To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09023-38201
  Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
INSTALL STRAIGHT PIN
1. Using a plastic hammer, tap in new straight pins as shown in the illustration.
  
  Fig 47: Straight Pins Dimension Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Protrusion height
  
  17.5 to 19.5 mm (0.689 to 0.768 in.)
INSTALL VALVE SPRING SEAT
1. Install the valve spring seats to the cylinder head.
INSTALL VALVE STEM OIL SEAL
1. Apply a light coat of engine oil to new oil seals.
  
  Fig 48: Identifying Valve Stem Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.
  
  HINT:
  
  The intake valve oil seals are gray and the exhaust valve oil seals are black.
2. Using SST, push in the oil seals.
  
  Fig 49: View Of Pushing In Oil Seals Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09201-41020
  NOTE:
  Failure to use SST will cause the seal to be damaged or improperly seated.
INSTALL EXHAUST VALVE
1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
  
  Fig 50: Identifying Tip Area Of Intake Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the valve, compression spring and spring retainer to the cylinder head.
  NOTE:
  Install the same parts in the same combination to the original locations.
3. Using SST, compress the spring and install the 2 retainer locks.
  
  Fig 51: View Of Compressing Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09202-70020
    1. 09202-00010
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  
  Fig 52: View Of Taping Valve Stem Tip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to damage the retainer.
INSTALL INTAKE VALVE
1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
  
  Fig 53: Identifying Tip Area Of Intake Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the valve, compression spring and spring retainer to the cylinder head.
  NOTE:
  Install the same parts in the same combination to the original locations.
3. Using SST, compress the spring and install the 2 retainer locks.
  
  Fig 54: View Of Compressing Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09202-70020
    1. 09202-00010
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  
  Fig 55: View Of Taping Valve Stem Tip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to damage the retainer.
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the valve stem caps on the valves.
INSTALL ENGINE REAR OIL SEAL
1. Place the oil seal retainer on wooden blocks.
2. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
  
  Fig 56: View Of Installing Engine Rear Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09223-15030
  - SST: 09950-70010
    1. 09951-07100
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the oil seal at an angle.
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 57: Identifying Seal Packing Application Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal Diameter
  
  3.0 to 4.0 mm (0.118 to 0.157 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil seal retainer within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installation.
2. Install the oil seal retainer with the 6 bolts.
  
  Fig 58: Identifying Oil Seal Retainer With 6 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE:
  Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
INSTALL WATER OUTLET PIPE SUB-ASSEMBLY
1. Install the water outlet pipe with the 2 bolts.
  
  Fig 59: Identifying Water Outlet Pipe With 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL KNOCK SENSOR
1. Install the 2 knock sensors with the 2 bolts as shown in the illustration.
  
  Fig 60: Identifying Knock Sensors With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
2. Connect the 2 knock sensor connectors.
3. Connect the knock sensor wire clamp.
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
1. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.
  
  Fig 61: Locating Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  2.5 to 3.0 mm (0.098 to 0.118 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head gasket within 3 minutes after applying the seal packing.
  - Do not apply engine oil within 2 hours of installation.
2. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
  
  Fig 62: Identifying Lot No.
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful of the installation direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
3. Place the cylinder head on the cylinder block.
  NOTE:
  Be careful not to allow oil to adhere to the bottom part of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
5. Step 1
  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
    
    Fig 63: Identifying Cylinder Head Bolts Tightening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
6. Step 2
  
  Fig 64: Identifying Painted Mark Of Cylinder Head Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  2. Tighten the cylinder head bolts another 90°.
7. Step 3
  1. Tighten the cylinder head bolts by an additional 90°.
  2. Check that the painted mark is now facing rearward.
8. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
  
  Fig 65: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
1. Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.
  
  Fig 66: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  2.5 to 3.0 mm (0.098 to 0.118 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head gasket within 3 minutes after applying the seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
  
  Fig 67: Installing Head Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful of the installation direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
3. Place the cylinder head on the cylinder block.
  NOTE:
  Be careful not to allow oil to adhere to the bottom part of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
5. Step 1
  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
    
    Fig 68: Identifying Cylinder Head Bolts Tightening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
6. Step 2
  
  Fig 69: Identifying Painted Mark Of Cylinder Head Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  2. Tighten the cylinder head bolts by 90°.
7. Step 3
  1. Tighten the cylinder head bolts by an additional 90°.
  2. Check that the painted mark is now facing rearward.
8. Tighten the 2 bolts in the order shown in the illustration.
  
  Fig 70: Identifying Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
9. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
  
  Fig 71: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.
1. Place the lash adjuster into a container filled with engine oil.
2. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
  
  Fig 72: Bleeding Plunger Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09276-75010
3. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed the air.
  OK
  
  Plunger moves up and down.
  
  NOTE:
  When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.
5. After bleeding the air, remove SST. Then, try to quickly and firmly press the plunger with a finger.
  OK
  
  Plunger is very difficult to move.
  
  If the result is not as specified, replace the lash adjuster.
6. Install the lash adjusters.
  NOTE:
  Install the lash adjuster to the same position it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Apply engine oil to the lash adjuster tip and valve stem cap end.
2. Make sure that the valve rocker arms are installed as shown in the illustration.
  
  Fig 73: Installing Positions Of Valve Rocker Arms
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP (for Bank 1)
1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
2. Install the camshaft and camshaft No. 2 to the camshaft housing RH.
3. Check the marks and numbers on the camshaft bearing caps and place each of them in the proper position and direction.
  
  Fig 74: Identifying Marks And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 9 bolts in the order shown in the illustration.
  
  Fig 75: Tightening Camshaft Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
1. Make sure that the valve rocker arm is installed as shown in the illustration.
  
  Fig 76: Identifying Positions Of Valve Rocker Arm
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 77: Applying Seal Packing In Continuous Line
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.5 to 4.0 mm (0.138 to 0.158 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing sub-assembly RH within 3 minutes.
  - Do not start the engine for at least 2 hours after installing.
3. Install the camshaft housing RH and tighten the 14 bolts in the order shown in the illustration.
  
  Fig 78: Tightening Camshaft Housing Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
  - If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
4. Tighten the 9 bolts in the order shown in the illustration.
  
  Fig 79: Tightening Camshaft Housing Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
INSTALL CAMSHAFT BEARING CAP (for Bank 2)
1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
2. Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing LH.
3. Check the marks and numbers on the camshaft bearing caps and place each of them in the proper position and direction.
  
  Fig 80: Identifying Marks And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 8 bolts in the order shown in the illustration.
  
  Fig 81: Tightening Camshaft Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
1. Make sure that the valve rocker arm is installed as shown in the illustration.
  
  Fig 82: Identifying Positions Of Valve Rocker Arm
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 83: Applying Seal Packing In Continuous Line
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  5.0 to 5.5 mm (0.197 to 0.217 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing sub-assembly LH within 3 minutes.
  - Do not start the engine for at least 2 hours after installing.
3. Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration.
  
  Fig 84: Tightening Camshaft Housing Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
  - If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
4. Tighten the 8 bolts in the order shown in the illustration.
  
  Fig 85: Identifying Camshaft Housing Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
1. Install the No. 2 chain tensioner with the bolt.
  
  Fig 86: Pushing In No. 2 Chain Tensioner Assembly & Inserting Pin Into Hole To Hold It
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
1. Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.
  
  Fig 87: Aligning Mark Plate (Yellow) With Timing Marks (1-Dot Mark) Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed.
4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.
  
  Fig 88: View Of Loosening Flange Bolts Of Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  Torque: 100 N*m (1, 020 kgf*cm, 74 ft.*lbf)
5. Remove the pin from the chain tensioner.
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
1. Install the chain tensioner with the bolt.
  
  Fig 89: Pushing In Tensioner, Inserting Pin Into The Hole To Hold It
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to hold it.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
1. Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration.
  
  Fig 90: Aligning Mark Plate (Yellow) With Timing Marks (2-Dot Mark) Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed.
4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
  
  Fig 91: Tightening Flange Bolts Of Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  Torque: 100 N*m (1, 020 kgf*cm, 74 ft.*lbf)
5. Remove the pin from the chain tensioner.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper with the 2 bolts.
  
  Fig 92: Identifying No. 1 Chain Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
INSTALL NO. 2 CHAIN VIBRATION DAMPER
1. Install the 2 chain vibration dampers.
  
  Fig 93: Identifying No. 2 Chain Vibration Dampers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING SPROCKET
1. Install the 2 timing gear set keys and timing sprocket as shown in the illustration.
  
  Fig 94: Identifying Crankshaft Timing Sprocket, Keys & Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL IDLE SPROCKET ASSEMBLY
1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
  
  Fig 95: Identifying Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.
  NOTE:
  Make sure that the idle gear is facing the correct direction.
  
  HINT:
  
  Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.
3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
  
  HINT:
  
  After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
INSTALL CHAIN SUB-ASSEMBLY
1. Align the mark plate and timing marks as shown in the illustration and install the chain.
  
  Fig 96: Aligning Mark Plate & Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The camshaft mark plate is orange.
2. Rest the chain on top of the crankshaft.
  
  Fig 97: Location of Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.
  
  Fig 98: Turning Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.
4. Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing sprocket.
  
  Fig 99: Aligning Mark Plate & Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The crankshaft mark plate is yellow.
5. Temporarily tighten the pulley set bolt.
6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
  
  Fig 100: View Of Turning Crankshaft Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
  
  Fig 101: View Of Pushing Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.050 in.) into the hole of the stopper plate.
3. Install the chain tensioner with the 2 bolts.
  
  Fig 102: Identifying Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. Remove the lock pin of the chain tensioner.
INSPECT VALVE TIMING
1. Check the camshaft timing marks.
  NOTE:
  - Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.
  - If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
2. Check that each camshaft timing mark is positioned as shown in the illustration.
  
  Fig 103: Locating Camshaft Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  For the intake camshaft:
  
  Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.
  
  Fig 104: View Of Camshaft Timing Mark Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. If the valve timing is misaligned, reinstall the timing chain.
4. Remove the pulley set bolt.
INSTALL TIMING CHAIN CASE OIL SEAL
1. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
  
  Fig 105: View Of Installing Timing Chain Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09223-22010
  - SST: 09506-35010
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the oil seal at an angle.
  - Make sure that the oil seal edge does not stick out of the timing chain case.
INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket and the water pump with the 16 bolts.
  
  Fig 106: Identifying Gasket And Water Pump With 16 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  NOTE:
  Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Fig 107: Applying Seal Packing In Continuous Line To Engine Unit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Seal packing

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

Seal diameter

A

3.0 to 4.0 mm (0.118 to 0.158 in.)

B

3.0 mm (0.118 in.)
NOTE:
- Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
- When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain cover within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Fig 108: Applying Seal Packing In Continuous Line To Timing Chain Cover

Seal packing

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

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

NOTE:

When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.

SEAL PACKING APPLICATION CHART

Area	Seal Packing Diameter	Application Position from Inside Seal Line
Continuous Line Area	4.5 mm (0.177 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area	6.0 mm (0.236 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Dashed Line Area	3.5 mm (0.138 in.) or more	2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area	3.5 mm (0.138 in.) or more	1.0 to 2.0 mm (0.039 to 0.079 in.)

Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Fig 110: Aligning Oil Pump's Drive Rotor Spline And Crankshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

Fig 111: Locating Timing Chain Cover Bolts And Nuts

BOLT LENGTH

Item	Length
Bolt A	50 mm (1.97 in.)
Bolt B	25 mm (0.98 in.)
Bolt C	55 mm (2.17 in.)

NOTE:

Make sure that there is no oil on the bolt threads.

Fully tighten the 3 bolts as shown in the illustration.

Fig 112: Tightening Bolts (1 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

for bolt A

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

for bolts except A
Fully tighten the 3 bolts as shown in the illustration.

Fig 113: Location of Timing Chain Cover Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
Fully tighten the 7 bolts and 2 nuts as shown in the illustration.

Fig 114: Identifying Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

Tighten the bolts and nuts in the order from upper to lower as shown in the illustration.
Fully tighten the 12 bolts as shown in the illustration.

Fig 115: View Of Tightening Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

Tighten the bolts in the order from lower to upper as shown in the illustration.
Install a new gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)

INSTALL OIL STRAINER SUB-ASSEMBLY
1. For 2WD:
  1. Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
    
    Fig 116: Identifying Stud Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  2. Install the baffle plate with the 8 bolts.
    
    Fig 117: Identifying Baffle Plate Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
    
    HINT:
    
    Temporarily tighten the 8 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.
  3. Install a new gasket and the oil strainer with the 3 nuts.
    
    Fig 118: Identifying Oil Strainer Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. For 4WD:
  1. Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
    
    Fig 119: Identifying Stud Bolts (4WD)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  2. Install the baffle plate with the 7 bolts.
    
    Fig 120: Identifying Baffle Plate & Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
    
    HINT:
    
    Temporarily tighten the 7 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.
  3. Install a new gasket and the oil strainer with the bolt and 2 nuts.
    
    Fig 121: Identifying New Gasket & Oil Strainer (For 4WD)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. Install 2 new O-rings.
  
  Fig 122: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN SUB-ASSEMBLY
1. When replacing a stud bolt, install it by using an E6 "TORX" socket wrench.
  
  Fig 123: Identifying Oil Pan Sub-Assembly Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 124: Applying Seal Packing In Continuous Line
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.0 to 4.0 mm (0.118 to 0.156 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install the oil pan with the 16 bolts and 2 nuts.
  
  Fig 125: Identifying Oil Pan Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolt A
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for bolts except A
INSTALL OIL WITH STRAINER PIPE SUB-ASSEMBLY (for 4WD)
1. Install a new gasket and the oil with strainer pipe with the 3 nuts.
  
  Fig 126: Identifying Oil With Strainer Pipe Sub-Assembly Nuts (For 4WD)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
1. Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 127: Applying Seal Packing In Continuous Line To No. 2 Oil Pan Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  4.0 to 6.0 mm (0.156 to 0.236 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan No. 2 within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. For 2WD:
  1. Install the oil pan with the 15 bolts and 2 nuts.
    
    Fig 128: Identifying Oil Pan Sub-Assembly Bolts And Nuts (For 2WD)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. For 4WD:
  1. Install the oil pan with the 14 bolts and 2 nuts.
    
    Fig 129: Identifying Oil Pan Sub-Assembly Bolts And Nuts (For 4WD)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN DRAIN PLUG
1. Install a new gasket and the drain plug.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
INSTALL SPARK PLUG TUBE GASKET
1. Using a cutter, cut off the sealing part of the removed plug tube gasket.
  
  Fig 130: Identifying Spark Plug Tube Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.
  
  Fig 131: Installing Spark Plug Tube Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the oil seal at an angle.
  HINT:
  
  If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.
3. Return the claws of the ventilation baffle plate to their original positions.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Apply seal packing as shown in the illustration.
  
  Fig 132: View Of Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install 3 new gaskets as shown in the illustration.
  
  Fig 133: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket to the head cover.
4. Install the head cover with the 14 bolts.
  
  Fig 134: Identifying Head Cover Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for bolt A
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolts except A
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Apply seal packing as shown in the illustration.
  
  Fig 135: View Of Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install 3 new gaskets as shown in the illustration.
  
  Fig 136: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket to the head cover.
4. Install the head cover with the 12 bolts.
  
  Fig 137: Location of Head Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for bolt A
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolts except A
5. Install the engine hanger with the 2 bolts.
  Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf)
INSTALL REAR WATER BY-PASS JOINT
1. Install 2 new gaskets and a new O-ring.
  
  Fig 138: Location of Gaskets And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply soapy water to the O-ring.
2. Install the water by-pass joint with the 2 bolts and 4 nuts.
  
  Fig 139: Identifying Water By-Pass Joint With 2 Bolts And 4 Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE:
  Be careful that the O-ring does not get caught between the parts.
INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
1. Install a new gasket and water inlet with thermostat with the 3 nuts.
  
  Fig 140: Location of Water Inlet With Thermostat Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL WATER INLET SUB-ASSEMBLY
1. Install the 3 water by-pass hoses.
  
  Fig 141: Identifying Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 2 new O-rings.
  
  Fig 142: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installing it.
3. Install the water inlet with the 4 bolts and nut.
  
  Fig 143: Identifying Water Inlet, Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE:
  Be careful that the O-ring does not get caught between the parts.
4. Install the 3 water by-pass hoses.
  
  Fig 144: Location of Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the pulley bolt.
  
  Fig 145: Installing Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09213-70011
    1. 09213-70020
  - SST: 09330-00021
  Torque: 250 N*m (2, 550 kgf*cm, 184 ft.*lbf)
INSTALL OIL FILTER ELEMENT (for 2WD)
1. Clean the inside of the oil filter cap, the threads and O-ring groove.
  
  Fig 146: View Of Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
3. Set a new oil filter element to the oil filter cap.
4. Remove dirt or foreign matter from the installation surface of the engine.
5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
  NOTE:
  Be careful that the O-ring does not get caught between the parts.
6. Using SST, tighten the oil filter cap.
  
  Fig 147: Tightening Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09228-06501
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  NOTE:
  Make sure that the oil filter is installed securely as shown in the illustration.
INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD)
1. Install a new gasket and the oil filter bracket with the bolt and 2 nuts.
  
  Fig 148: Identifying Oil Filter Bracket Sub-Assembly (For 4WD)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL OIL FILTER ELEMENT (for 4WD)
1. Clean the inside of the oil filter cap, the threads and O-ring groove.
  
  Fig 149: View Of Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
3. Set a new oil filter element to the oil filter cap.
4. Remove any dirt or foreign matter from the installation surface of the engine.
5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
  NOTE:
  Be careful that the O-ring does not get caught between the parts.
6. Using SST, tighten the oil filter cap.
  
  Fig 150: Tightening Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09228-06501
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  NOTE:
  - Make sure that the oil filter is installed securely as shown in the illustration.
  - Be careful that the O-ring does not get caught between the parts.
7. Apply a light coat of engine oil to a new drain plug O-ring, and install it to the oil filter cap.
  
  Fig 151: Locating Oil Filter Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  NOTE:
  - Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.
  - Be careful that the O-ring does not get caught between the parts.
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive around the drain cocks.
  
  Fig 152: Identifying Adhesive Around Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the water drain cocks as shown in the illustration.
  
  Fig 153: Identifying Water Drain Cock Plugs To Water Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  NOTE:
  Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.
3. Install the water drain cock plugs to the water drain cocks.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
INSTALL NO. 1 OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
  NOTE:
  Do not touch the mesh when installing the oil control valve filter.
2. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
  
  Fig 154: Identifying Oil Pipe Union And Oil Check Valve Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
4. Tighten the oil pipe union (on the head cover side).
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
5. Tighten the oil check valve bolt (on the cylinder head side).
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
  
  NOTE:
  If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
INSTALL NO. 2 OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
  NOTE:
  Do not touch the mesh when installing the oil control valve filter.
2. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
  
  Fig 155: Locating Oil Pipe Union And Oil Check Valve Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
4. Tighten the oil pipe union (on the head cover side).
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
5. Tighten the oil check valve bolt (on the cylinder head side).
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
  
  NOTE:
  If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the sensor with the bolt.
  
  Fig 156: Location of Crankshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Install the 4 oil control valves with the 4 bolts.
  
  Fig 157: Identifying Camshaft Timing Oil Control Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT POSITION SENSOR
1. Install the 4 sensors with the 4 bolts.
  
  Fig 158: Identifying VVT Sensor & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL VENTILATION VALVE SUB-ASSEMBLY
1. Apply adhesive around the ventilation valve.
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the ventilation valve.
  
  Fig 159: Location of Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
INSTALL SPARK PLUG
1. Install the spark plugs.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL RADIATOR CAP SUB-ASSEMBLY
1. Install the radiator cap.
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install a new gasket.
2. Install the oil filler cap.