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ENGINE UNIT > REASSEMBLY

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1. INSTALL STIFFENING CRANKCASE RING PIN


A152991E06

NOTICE:
It is not necessary to remove a ring pin unless it is being replaced.

Text in Illustration 
*a
Width
*b
Height
*c
Protrusion Height

  1. Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

    Standard Ring Pin:
    Item
    		Protrusion Height
    		Height
    		Width
    Ring pin
    		3.0 mm (0.118 in.)
    		11 mm (0.433 in.)
    		8 mm (0.315 in.)



2. INSTALL STIFFENING CRANKCASE STUD BOLT


A150942E05

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

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

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    A150919E02

  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 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.)

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the crankcase within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
    3. Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.



    A152989E02

  1. Install the stiffening crankcase with the 11 bolts in the sequence 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.)

  1. Recheck the torque for bolts 1 and 2.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Wipe off any excess seal packing with a clean piece of cloth.



4. INSTALL OIL PUMP ASSEMBLY


    A150895

  1. Install the oil pump with the 3 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf }



5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

  1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.



    A150920E06

  1. Apply a continuous bead of seal packing (Diameter 4.0 mm (0.157 in.)) as shown in the illustration.

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

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the oil pan within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing the oil pan.



    A150894

  1. Install the No. 2 oil pan with the 10 bolts and 2 nuts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



6. INSTALL OIL PAN DRAIN PLUG


    A150893

  1. Install a new gasket and the drain plug.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



7. INSTALL ENGINE REAR OIL SEAL

  1. Apply MP grease to the lip of a new oil seal.

    NOTICE:
    Keep the lip free from foreign matter.



    A154926E01

  1. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

    SST
    09223-15030  
    09950-70010   (09951-07100)

    NOTICE:
    1. Wipe any extra grease off the crankshaft.
    2. Do not tap the oil seal at an angle.



8. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    A076531E09

  1. Apply adhesive to the threads of the cylinder block water drain cock.
    Text in Illustration 
    *1
    		Adhesive

    Adhesive:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent



    A150901E01

  1. Install the drain cock as shown in the illustration.

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }

    NOTICE:
    1. Do not rotate the drain cock more than 1 revolution (360°) after tightening it to the specified torque.
    2. Do not loosen the drain cock to adjust it. If an adjustment is necessary, remove the drain cock and reinstall it.
    3. Install the drain cock within 3 minutes of applying adhesive.
    4. Do not start the engine for at least 1 hour after installing the drain cock.

  1. Install the drain cock plug to the drain cock.

    Torque:
    13 N*m{ 130 kgf*cm , 9 ft.*lbf }



9. INSTALL NO. 1 TAPER SCREW PLUG


    A056815E03

  1. Apply adhesive to 2 or 3 threads of the taper screw plug.
    Text in Illustration 
    *1
    		Adhesive

    Adhesive:
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent



    A150900

  1. Install the taper screw plug.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }

    NOTICE:
    1. Install the plug within 3 minutes of applying adhesive.
    2. Do not start the engine for at least 1 hour after installation.



10. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    A092670E08

  1. Apply adhesive to the threads of the ventilation valve sub-assembly.
    Text in Illustration 
    *1
    		Adhesive

    Adhesive:
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    NOTICE:
    1. Install the ventilation valve sub-assembly within 3 minutes after applying seal packing.
    2. Do not start the engine for at least 2 hours after installing the ventilation valve sub-assembly.



    A150899

  1. Install the ventilation valve sub-assembly.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



11. INSTALL CYLINDER HEAD GASKET


    A215254E05

  1. Apply seal packing (Diameter 4.0 mm (0.157 in.)) to the cylinder block as shown in the illustration.
    Text in Illustration 
    *1
    		Cylinder Block
    V100135
    		Engine Front

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

    NOTICE:
    Remove any oil from the cylinder block.



    A150921E03

  1. Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
    Text in Illustration 
    *a
    		Lot No.
    V100135
    		Engine Front

    NOTICE:
    Install the cylinder head gasket within 3 minutes after applying seal packing.



    A214975E04

  1. Apply seal packing (Diameter 4.0 mm (0.157 in.)) to the new cylinder head gasket as shown in the illustration.
    Text in Illustration 
    *1
    		Cylinder Head Gasket
    V100135
    		Engine Front

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

    NOTICE:
    1. Remove any oil from the cylinder head gasket and cylinder head.
    2. Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.



    A214976E02

  1. After tightening the cylinder head bolts, wipe off the seal packing material seeped out from the contact surfaces between the cylinder head and cylinder block.
    Text in Illustration 
    *a
    		Before wiping off:
    *b
    		After wiping off:



12. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT:
The cylinder head bolts are tightened in 3 progressive steps.

  1. Place the cylinder head on the cylinder block.

    NOTICE:
    1. Make sure that no oil is on the mounting surface of the cylinder head.
    2. Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

  1. Install the plate washers to the cylinder head bolts.

  1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.



    A150891E02

  1. Step 1:

    1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.

      Torque:
      49 N*m{ 500 kgf*cm , 36 ft.*lbf }

      NOTICE:
      Do not drop the plate washers into the cylinder head.



    A156439E06

  1. Step 2:
    Text in Illustration 
    *a
    		Paint Mark
    V100136
    		Engine Front

    1. Mark each cylinder head bolt head with paint as shown in the illustration.

    2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.

  1. Step 3:

    1. Tighten the cylinder head bolts another 45° in the sequence shown in step 1.

  1. Check that the paint mark is now at a 135° angle to the front.



13. INSTALL VALVE STEM CAP

  1. Apply a light coat of engine oil to the valve stem ends.

  1. Install the 16 valve stem caps to the cylinder head.

    NOTICE:
    Do not drop the valve stem caps into the cylinder head.



14. INSTALL VALVE LASH ADJUSTER ASSEMBLY

  1. Inspect each valve lash adjuster before installing it (Click here).

  1. Install the 16 valve lash adjusters to the cylinder head.

    NOTICE:
    Install the valve lash adjuster to the same place it was removed from.



15. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    A131901E06

  1. Apply engine oil to the valve lash adjuster tips and valve stem cap ends.
    Text in Illustration 
    *1
    		Valve Rocker Arm
    *2
    		Valve Lash Adjuster
    *3
    		Valve Stem
    *4
    		Valve Stem Cap

  1. Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.



16. INSTALL CAMSHAFT HOUSING STRAIGHT PIN


A206182E02

NOTICE:
It is not necessary to remove a straight pin unless it is being replaced.

Text in Illustration 
*a
Width
*b
Height
*c
Protrusion Height

  1. Using a plastic-faced hammer, tap in a new straight pin to the specified protrusion height.

    Standard Straight Pin:
    Item
    		Protrusion Height
    		Height
    		Width
    Straight pin
    		6.5 to 7.5 mm (0.256 to 0.295 in.)
    		14 mm (0.551 in.)
    		6.0 mm (0.236 in.)



17. INSTALL NO. 1 CAMSHAFT BEARING

  1. Clean both surfaces of the bearings.

  1. Install the 2 No. 1 camshaft bearings.



    A214944E01

  1. Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.
    Text in Illustration 
    *1
    		Vernier Caliper

    Standard dimension (A - B):
    0.7 mm (0.0276 in.) or less

    NOTICE:
    Position the bearings to the center of the bearing cap by measuring dimensions A and B.



18. INSTALL OIL CONTROL VALVE FILTER


    A214981

  1. Check that no foreign matter is on the mesh part of the oil control valve filter.

  1. Install the oil control valve filter.

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



19. INSTALL NO. 2 CAMSHAFT BEARING

  1. Clean both surfaces of the bearings.

  1. Install the 2 No. 2 camshaft bearings.



    A330339E01

  1. Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.
    Text in Illustration 
    *1
    		Vernier Caliper

    Standard dimension (A):
    1.05 to 1.75 mm (0.0413 to 0.0689 in.)

    NOTICE:
    Position the bearings to the center of the bearing cap by measuring dimension A.



20. INSTALL NO. 2 CAMSHAFT

  1. Clean the camshaft journals.

  1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.



    A214945

  1. Install the No. 2 camshaft to the camshaft housing.



21. INSTALL CAMSHAFT

  1. Clean the camshaft journals.

  1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.



    A214946

  1. Install the camshaft to the camshaft housing.



22. INSTALL CAMSHAFT BEARING CAP

  1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.



    A214947E01

  1. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
    Text in Illustration 
    *1
    		Knock Pin
    *2
    		Camshaft



    A214948E01

  1. Tighten the 10 bolts in the order shown in the illustration.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf }



23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    A153836E01

  1. Check that the valve rocker arms are installed as shown in the illustration.
    Text in Illustration 
    *1
    		Valve Stem Cap
    *2
    		Valve Rocker Arm
    *3
    		Valve Lash Adjuster



    A206178E01

  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 Diameter:
    Area
    		Specified Condition
    Continuous line
    		3.5 to 4.5 mm (0.138 to 0.177 in.)
    A
    		8.0 mm (0.315 in.)
    B
    		7.0 mm (0.276 in.)

    Application Length A and B:
    15 mm (0.591 in.)

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
    3. Do not start the engine for at least 2 hours after installation.



    A214949E01

  1. Set the camshaft and No. 2 camshaft as shown in the illustration.

  1. Install the camshaft housing with the 17 bolts and tighten them in the order shown in the illustration.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }

    NOTICE:
    1. After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
    2. If any of the bolts is loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
    3. If the camshaft housing is removed because any of the bolts is loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
    4. After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and cylinder head.



24. INSTALL CAMSHAFT TIMING SPROCKET


    A214937

  1. Tighten the flange bolt with the camshaft timing sprocket secured in place.

    Torque:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }



25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    A146265E04

  1. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned as shown in the illustration.
    Text in Illustration 
    *1
    		Straight Pin
    *2
    		Key Groove

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



    A153570E03

  1. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
    Text in Illustration 
    *1
    		Straight Pin
    *2
    		Key Groove

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



    A146267E03

  1. Check that there is no clearance between the camshaft timing gear and camshaft flange.
    Text in Illustration 
    *1
    		Camshaft Timing Gear
    *2
    		Flange
    *a
    		Clearance
    *b
    		No Clearance



    A214936

  1. Tighten the flange bolt with the camshaft timing gear secured in place.

    Torque:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }



    A214982E02

  1. Check that the camshaft timing gear can move in the retard direction (clockwise) and is locked in the most retarded position.
    Text in Illustration 
    *a
    		Lock



26. INSTALL CRANKSHAFT TIMING GEAR KEY


    A150910

  1. Using a plastic-faced 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.



27. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    A150874

  1. Install the crankshaft position sensor plate with the "F" mark facing forward.



28. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

  1. Temporarily install the crankshaft pulley bolt.



    A218459

  1. Turn the crankshaft counterclockwise to position the timing gear key to the 9 o'clock position.

  1. Turn the drive shaft so that the cutout faces the 12 o'clock position.



    A165306E02

  1. Align the yellow mark links with the timing marks of each gear as shown in the illustration.
    Text in Illustration 
    *1
    		Front
    *2
    		Mark Plate (Yellow)
    *3
    		Timing Mark
    *4
    		Oil Pump Drive Gear
    *5
    		Oil Pump Drive Shaft Gear

    HINT:
    Be sure to position the mark plate at the front of the engine.

  1. Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.

  1. Temporarily tighten the oil pump drive shaft gear with the nut.



    A218086

  1. Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

  1. Temporarily tighten the crankshaft pulley with the bolt.



    A218083E01

  1. Using SST, install the oil pump drive shaft gear nut while holding the crankshaft pulley.

    SST
    09213-58014   (91551-80840)
    09330-00021  

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }

  1. Remove the crankshaft pulley and bolt.



29. INSTALL CRANKSHAFT TIMING SPROCKET


    A218082

  1. Install the crankshaft timing sprocket.



30. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    A217740

  1. Install the chain vibration damper with the 2 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    A221683E01

  1. Temporarily install the crankshaft pulley bolt.
    Text in Illustration 
    *1
    		Timing Gear Key

  1. Turn the crankshaft to position the timing gear key to the top.



    A262288E01

  1. Check that the timing marks on the camshaft timing gear and camshaft timing sprocket are aligned as shown in the illustration.
    Text in Illustration 
    *1
    		Timing Mark (Rectangle)
    *2
    		Timing Mark
    *3
    		Mark (Circle)

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

  1. Remove the crankshaft pulley bolt.



32. INSTALL CHAIN SUB-ASSEMBLY


    A262289E01

  1. Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.
    Text in Illustration 
    *1
    		Mark Plate (Orange)
    *2
    		Timing Mark (Rectangle)
    *3
    		Mark (Circle)
    *a
    		Place the Chain on the Sprocket
    *b
    		Pass the Chain through the Damper

    HINT:
    1. There are 3 marks on the camshaft timing sprocket. Make sure to align the mark plate with the timing mark (rectangle).
    2. Be sure to position the mark plate at the front of the engine.
    3. The mark plate on the camshaft side is colored orange.
    4. Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.
    5. Pass the chain through the No. 1 vibration damper.



    A150936

  1. Place the chain on the crankshaft without passing it around the shaft.



    A214963E04

  1. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain.
    Text in Illustration 
    *1
    		Mark Plate (Orange)
    *2
    		Timing Mark
    *a
    		Tension the Chain

  1. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.

    HINT:
    To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.



    A150939E06

  1. Align the mark plate (yellow or pink) and timing mark and install the chain to the crankshaft timing gear.
    Text in Illustration 
    *1
    		Mark Plate (Yellow or Pink)
    *2
    		Timing Mark



33. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


  1. Check each timing mark at TDC/compression.


    A262290E01


    Text in Illustration 
    *1
    		Timing Mark
    		*2
    		Mark Plate (Orange)
    *3
    		Mark Plate (Yellow or Pink)
    		*4
    		Timing Mark (Rectangle)
    *5
    		Mark (Circle)
    		-
    		-

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



34. INSTALL CHAIN TENSIONER SLIPPER


    A214929

  1. Install the chain tensioner slipper to the cylinder block.



35. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    A214931

  1. Install the No. 2 chain vibration damper with the 2 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



36. INSTALL INLET WATER SUB-ASSEMBLY STUD BOLT

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



    A214950E01

  1. Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



37. INSTALL INLET WATER SUB-ASSEMBLY


    A214927

  1. Install a new gasket and the inlet water sub-assembly with the bolt and 2 nuts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


  1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, and cylinder block.


    A214951E01



    A214924

  1. Install 3 new O-rings.



  1. Apply seal packing as shown in the illustration.


    A214953E01

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

    Seal diameter:
    5.0 mm (0.197 in.)

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the chain cover within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.



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

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



    A214952E01


    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 3.0 mm (0.0984 to 0.118 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 3.0 mm (0.0984 to 0.118 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.)
    		-
    		-

    NOTICE:
    1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
    2. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
    3. After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.
    4. Do not add engine oil for at least 2 hours after installation.

  1. Clean the bolt and fitting hole.

  1. Install the timing chain cover.



    A214919

  1. Temporarily tighten the engine mounting bracket RH with the 3 bolts.

    NOTICE:
    1. Install the mounting bracket within 10 minutes after installing the chain cover.
    2. Do not start the engine for at least 2 hours after installation.

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



    A214921

  1. Install 2 new O-rings.



    A214920

  1. Temporarily tighten the oil filter bracket with the 4 bolts.

    NOTICE:
    1. Install the oil filter bracket within 10 minutes after installing the chain cover.
    2. Do not start the engine for at least 2 hours after installation.

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



  1. Install the timing chain cover with the 25 bolts and seal washer as shown in the illustration.


    A214954E02


    Text in Illustration 
    *1
    		Seal Washer
    		-
    		-

    Torque:
    Bolt A, E, F:
    26 N*m{ 260 kgf*cm , 19 ft.*lbf }
    Bolt B, C:
    51 N*m{ 520 kgf*cm , 38 ft.*lbf }
    Bolt D:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    NOTICE:
    1. Apply adhesive 1324 to screw part of the bolt F.
    2. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
    3. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying the seal packing.
    4. Do not add engine oil for at least 2 hours after installing the chain cover.
    5. Do not start the engine for at least 2 hours after installing the chain cover.

    Bolt Length:
    Item
    		Length
    Bolt A, F
    		35 mm (1.38 in.)
    Bolt B
    		55 mm (2.16 in.)
    Bolt C
    		80 mm (3.15 in.)
    Bolt D
    		40 mm (1.57 in.)
    Bolt E
    		55 mm (2.16 in.)



39. INSTALL TIMING CHAIN COVER OIL SEAL

  1. Apply MP grease to the lip of a new oil seal.

    NOTICE:
    Keep the lip free from foreign matter.



    A215985E01

  1. Using SST and a hammer, tap in the oil seal until its surface is flush with the front oil seal retainer edge.

    SST
    09223-22010  

    NOTICE:
    1. Wipe off extra grease from the crankshaft.
    2. Do not tap the oil seal at an angle.



40. INSTALL CRANKSHAFT PULLEY

  1. Align the pulley set key with the key groove of the pulley.



    A213054E02

  1. Using SST, hold the pulley in place and tighten the bolt.
    Text in Illustration 
    *a
    		Hold
    *b
    		Turn

    SST
    09213-58014   (91551-80840)
    09330-00021  

    Torque:
    190 N*m{ 1937 kgf*cm , 140 ft.*lbf }



41. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    A162975E02

  1. Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.
    Text in Illustration 
    *1
    		Cam
    *2
    		Pin
    *3
    		Hook
    *a
    		Push
    *b
    		Raise
    *c
    		CORRECT
    *d
    		INCORRECT

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



    A214955

  1. Install a new gasket, the bracket and chain tensioner with the 2 nuts.

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf }

    NOTICE:
    If the hook releases the plunger while the chain tensioner is being installed, set the hook again.



    A214956E02

  1. Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.
    Text in Illustration 
    *1
    		Pin
    *2
    		Hook
    *a
    		Push
    *b
    		Turn
    *c
    		Disconnect



    A214957E02

  1. Turn the crankshaft clockwise and check that the plunger is extended.
    Text in Illustration 
    *1
    		Plunger
    *a
    		Turn
    *b
    		Plunger Extended



42. INSTALL OIL FILTER CAP ASSEMBLY

  1. Clean the oil filter cap threads and O-ring groove.

  1. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

  1. Set a new oil filter element in the oil filter cap.

  1. Remove any dirt or foreign matter from the installation surface and inside of the engine.



    A161887

  1. Reapply a small amount of engine oil to the O-ring of the oil filter cap assembly. Align the cutout in the oil filter cap threads 90° to the grooves in the oil filter bracket and temporarily tighten the cap.

    NOTICE:
    Make sure that the O-ring does not get caught between the parts.



    A198242E02

  1. Using SST, tighten the oil filter cap assembly.
    Text in Illustration 
    *1
    		No Clearance
    *2
    		Oil Filter Bracket Clip

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }

    SST
    09228-06501  

    NOTICE:
    1. After tightening the oil filter cap assembly, check for gaps between the installation surfaces.
    2. Do not remove the oil filter bracket clip when installing the oil filter cap assembly.
    3. Do not cross thread the oil filter cap assembly.



43. INSTALL SPARK PLUG TUBE GASKET


    A153838E04

  1. Using a cutter knife, cut off the seal part of the removed gasket.
    Text in Illustration 
    V100155
    		Part to Cut Off



    A214958E02

  1. Using a hammer and the plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.
    Text in Illustration 
    *1
    		Plug Tube Gasket without Sealing Part
    *2
    		New Plug Tube Gasket

    NOTICE:
    1. Keep the lip free of foreign matter.
    2. Do not tap in the plug tube gasket.

    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.

  1. Return the claws of the ventilation baffle plate to their original positions.



44. INSTALL CYLINDER HEAD COVER GASKET


    A214978E01

  1. Install a new cylinder head cover gasket to the cylinder head cover.
    Text in Illustration 
    *1
    		Cylinder Head Cover
    *2
    		Cylinder Head Cover Gasket

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Misalignment between the center of the cylinder head cover rib and the center of the cylinder head gasket tab is within 4 mm (0.157 in.).



45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    A214910

  1. Install 2 new gaskets to the camshaft bearing cap.



    A214959

  1. Apply seal packing as shown the illustration.

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

    Standard diameter:
    4.0 mm (0.157 in.)

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
    3. Do not start the engine for at least 2 hours after the installation.



    A214909

  1. Install the cylinder head cover with a new seal washer and the 13 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }


    NOTICE:
    A214979E01
    Misalignment between the contact surfaces of the timing chain cover and the camshaft housing and the center of the cylinder head gasket tab is within 4 mm (0.157 in.).

    Text in Illustration 
    *1
    		Timing Chain Cover
    *2
    		Camshaft Housing
    *3
    		Cylinder Head Cover Gasket



46. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    A085603E07

  1. Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.
    Text in Illustration 
    *1
    		Adhesive

    Adhesive:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    NOTICE:
    1. Install the oil pressure switch within 3 minutes after applying adhesive.
    2. Do not start the engine within 1 hour after installation.



    A150856

  1. Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.

    Torque:
    15 N*m{ 153 kgf*cm , 11 ft.*lbf }



47. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    A214917

  1. Install a new gasket and the engine coolant temperature sensor.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



48. INSTALL KNOCK SENSOR


    A150904E01

  1. Install the knock sensor with the bolt.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

    NOTICE:
    Make sure that the knock sensor is in the correct position.



49. INSTALL CRANKSHAFT POSITION SENSOR


    A157503

  1. Apply a light coat of engine oil to the O-ring of the sensor.



    A150855

  1. Install the crankshaft position sensor with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



50. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    A195062

  1. Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve.



    A214908

  1. Install the camshaft timing oil control valve with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    NOTICE:
    1. Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover).
    2. Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.



51. INSTALL CAMSHAFT POSITION SENSOR


    A095434E06

  1. Apply a light coat of engine oil to the O-ring of the sensor.



    A214907

  1. Install the camshaft position sensor with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    NOTICE:
    Make sure that the O-ring is not cracked or jammed when installing the sensor.



52. INSTALL SPARK PLUG


    A216701

  1. Using a 14 mm spark plug wrench, install the 4 spark plugs.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



53. INSTALL ENGINE COVER JOINT BOLT


    A214974

  1. Install the 3 engine cover joint bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



54. INSTALL WIRING HARNESS CLAMP BRACKET


    A214973

  1. Install the wiring harness clamp bracket with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



55. INSTALL OIL FILLER CAP GASKET


    A128159

  1. Install the gasket to the oil filler cap.



56. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    A214906

  1. Install the oil filler cap.