REASSEMBLY

PROCEDURE

1. INSTALL STIFFENING CRANKCASE ASSEMBLY

NOTICE:

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

(a) Using a plastic hammer, tap 2 new ring pins into the stiffening crankcase assembly. Standard Ring Pin: Item Protrusion Height Height Width Ring pin 4.0 mm (0.157 in.) 8.0 mm (0.315 in.) 11 mm (0.433 in.)

*a Protrusion Height *b 11 mm *c 8.0 mm

(b) Apply seal packing as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Seal Packing Diameter: Area Specified Condition Continuous Line 2.0 to 3.0 mm (0.0787 to 0.118 in.) (A) 4.5 to 5.5 mm (0.177 to 0.217 in.) Application Length (A): 56 mm (2.20 in.) NOTICE: Remove any oil from the contact surfaces. Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing. Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.

(c) Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf} Bolt Length: Item Specified Condition Bolt (A) 138 mm (5.43 in.) Bolt (B) 35 mm (1.38 in.) Bolt (C) 70 mm (2.76 in.)

(d) Recheck the torque for the bolts (1) and (2).

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(e) Wipe off any excess seal packing with a clean piece of cloth.

2. INSTALL OIL PUMP ASSEMBLY

NOTICE:

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

(a) Using a plastic hammer, tap 2 new ring pins into the stiffening crankcase assembly. Standard Ring Pin: Item Protrusion Height Height Width Ring pin 3.0 mm (0.118 in.) 8.0 mm (0.315 in.) 11 mm (0.433 in.)

*a Protrusion Height *b 11 mm *c 8.0 mm

(b) Install the oil pump assembly.

Click here

3. INSTALL ENGINE OIL LEVEL SENSOR

Click here

4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

NOTICE:

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

(a) Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

*a 9 mm (0.354 in.) *b 19 mm (0.748 in.)

(b) Remove any remaining seal packing.

(c) Apply seal packing in a continuous line as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Application Specification: Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing (A) - (A) 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.) (B) - (B) -

*a Seal Packing *b 6.0 mm *c 3.0 to 4.5 mm

(d) Install the No. 2 oil pan sub-assembly to the stiffening crankcase assembly with the 10 bolts and 2 nuts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

*a Nut

5. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and oil pan drain plug to the No. 2 oil pan sub-assembly. Torque: 37 N·m {377 kgf·cm, 27 ft·lbf}

6. INSTALL REAR ENGINE OIL SEAL

Click here

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

Click here

8. INSTALL CYLINDER HEAD GASKET

Click here

9. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT:

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

(a) Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

(b) Place the cylinder head sub-assembly on the cylinder block sub-assembly.

(c) Install the 10 cylinder head set plate washers to the 10 cylinder head set bolts.

(d) Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

(e) Step 1:

(1) Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration. Torque: 49 N·m {500 kgf·cm, 36 ft·lbf} NOTICE: Do not drop the cylinder head set plate washers for the cylinder head set bolts into the cylinder head sub-assembly.

(f) Step 2:

*a	Paint Mark
	Front of Engine

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

(2) Tighten the cylinder head set bolts 90° in the order shown in step 1.

(g) Step 3:

(1) Tighten the cylinder head set bolts another 45° in the order shown in step 1.

(h) Check that the paint marks are now at a 135° angle.

NOTICE:

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

(i) After tightening the cylinder head set bolts, wipe off any seal packing that seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly. NOTICE: Be sure to wipe off the seal packing from inside to outside, parallel to the joint line. Be sure to avoid clogging the bolt holes when wiping off the seal packing.

*a Before Wiping Off *b After Wiping Off

10. INSTALL VALVE STEM CAP

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

(b) Install the 16 valve stem caps to the cylinder head sub-assembly. NOTICE: Install each part to its original location. Do not drop the valve stem caps into the cylinder head sub-assembly.

11. INSTALL VALVE LASH ADJUSTER ASSEMBLY

(a) Inspect the 16 valve lash adjuster assemblies before installing them.

Click here

(b) Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly. NOTICE: Install each part to its original location.

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

(a) Apply engine oil to the tips of the valve lash adjuster assemblies and valve stem caps.

*1 Valve Lash Adjuster Assembly *2 No. 1 Valve Rocker Arm Sub-assembly *3 Valve Stem Cap

(b) Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

NOTICE:

Install each part to its original location.

13. INSTALL RING PIN

NOTICE:

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

(a) Using a plastic hammer, tap 10 new ring pins into the camshaft housing sub-assembly. Standard Ring Pin: Item Protrusion Height Height Width Ring pin 3.0 mm (0.118 in.) 13 mm (0.512 in.) 20 mm (0.787 in.)

*a Protrusion Height *b 20 mm *c 13 mm

14. INSTALL NO. 1 CAMSHAFT BEARING

(a) Clean both surfaces of the No. 1 camshaft bearings.

(b) Install the 2 No. 1 camshaft bearings.

(c) Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge. Standard Dimension (A) - (B): 0.7 mm (0.0276 in.) or less NOTICE: Position the No. 1 camshaft bearings to the center of the camshaft bearing cap by measuring dimensions (A) and (B).

*a Vernier Caliper

15. INSTALL NO. 2 CAMSHAFT BEARING

(a) Clean both surfaces of the No. 2 camshaft bearings.

(b) Install the 2 No. 2 camshaft bearings.

(c) Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge. Dimension (A): 1.05 to 1.75 mm (0.0413 to 0.0689 in.) NOTICE: Position the No. 2 camshaft bearings to the center of the camshaft housing sub-assembly by measuring dimension (A).

*a Vernier Caliper

16. INSTALL OIL CONTROL VALVE FILTER

(a) Check that no foreign matter is on the mesh of the oil control valve filter.

(b) Install the oil control valve filter.

NOTICE:

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

17. INSTALL NO. 2 CAMSHAFT

Click here

18. INSTALL CAMSHAFT

HINT:

Perform Inspection After Repair after replacing the camshaft.

Click here

(a) Clean the camshaft journals.

(b) Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

(c) Install the camshaft to the camshaft housing sub-assembly.

19. INSTALL CAMSHAFT BEARING CAP

(a) Confirm the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

*a Knock Pin

(b) Tighten the 10 bearing cap bolts in the order shown in the illustration. Torque: 16 N·m {163 kgf·cm, 12 ft·lbf}

20. SET NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem Cap *a Correct *b Incorrect

21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

(a) Apply seal packing in a continuous line as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: Remove any oil from the contact surfaces. Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing. Do not start the engine for at least 2 hours after installation.

*a Cylinder Head Sub-assembly Upper Side *b Seal Packing *c 3.5 to 4.0 mm (0.138 to 0.157 in.)

(b) Set the camshaft and No. 2 camshaft as shown in the illustration.

	Bolt (A)
	Bolt (B)

(c) Install the camshaft housing sub-assembly with the 17 bolts and tighten them in the order shown in the illustration.

Torque:

Bolt (A) :

27 N·m {275 kgf·cm, 20 ft·lbf}

Bolt (B) :

16 N·m {163 kgf·cm, 12 ft·lbf}

22. INSTALL CAMSHAFT TIMING SPROCKET

(a) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt. Torque: 54 N·m {551 kgf·cm, 40 ft·lbf}

23. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

(a) Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

*a Knock Pin *b Knock Pin Hole

(b) Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

*1 Camshaft Timing Gear Assembly *a Camshaft Flange *b No Gap

(c) Using a wrench to hold the hexagonal portion of the camshaft, tighten the bolt. Torque: 54 N·m {551 kgf·cm, 40 ft·lbf}

(d) Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and locks in the most retarded position.

Lock

24. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Using a plastic hammer, tap in the 2 crankshaft timing gear keys. HINT: Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

25. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Install the No. 1 crankshaft position sensor plate to the crankshaft with the "F" mark facing forward.

26. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

(a) Temporarily install the crankshaft pulley set bolt to the crankshaft.

(b) Set the crankshaft timing gear keys as shown in the illustration.

*1 Crankshaft Timing Gear Key

(c) Turn the oil pump drive shaft so that the flat face is facing upward.

(d) Remove the crankshaft pulley set bolt from the crankshaft.

(e) Align the mark plates (yellow) with the timing mark of the oil pump drive gear and oil pump drive shaft gear as shown in the illustration.

*1	Oil Pump Drive Gear
*2	Oil Pump Drive Shaft Gear
*a	Mark Plate (Yellow)
*b	Timing Mark
	Front of Engine

HINT:

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

(f) With the No. 2 chain sub-assembly placed around the oil pump drive gear and oil pump drive shaft gear, install the oil pump drive gear to the crankshaft and temporarily install the oil pump drive shaft gear to the oil pump drive shaft.

(g) Temporarily install the oil pump drive shaft gear nut.

(h) Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

*1 Chain Tensioner Plate *2 Chain Damper Spring

(i) Temporarily install the crankshaft pulley to the crankshaft with the crankshaft pulley set bolt.

(j) Using SST, hold the crankshaft pulley and tighten the oil pump drive shaft gear nut. SST: 09213-58014 91551-80840 SST: 09330-00021 Torque: 28 N·m {286 kgf·cm, 21 ft·lbf}

(k) Remove SST, the crankshaft pulley set bolt and crankshaft pulley.

27. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the crankshaft timing sprocket to the crankshaft.

28. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

(a) Temporarily install the crankshaft pulley set bolt to the crankshaft.

(b) Turn the crankshaft clockwise until the crankshaft timing gear key is facing upward.

*1 Crankshaft Timing Gear Key

(c) Check that the timing marks on the camshaft timing gear assembly and camshaft timing sprocket are aligned as shown in the illustration. HINT: There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

*a Timing Mark *b Timing Mark (Rectangle) *c Mark (Circle)

(d) Remove the crankshaft pulley set bolt from the crankshaft.

29. INSTALL CHAIN SUB-ASSEMBLY

Click here

30. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the No. 2 chain vibration damper to the camshaft housing sub-assembly with the 2 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

31. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper to the cylinder block sub-assembly.

32. INSTALL OIL FILTER BRACKET WITH HEAD STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon socket wrench, install 2 new gaskets and the 2 oil filter bracket with head straight screw plugs to the oil filter bracket. Torque: 44 N·m {449 kgf·cm, 32 ft·lbf}

33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

NOTICE:

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

(a) Type A:

(1) Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

*a 21 mm (0.827 in.) *b 9 mm (0.354 in.) *c 34 mm (1.34 in.)

(b) Install the 2 stud bolts as shown in the illustration. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(c) Remove any remaining seal packing.

(d) Install a new gasket to the engine water pump assembly. HINT: Be sure to clean the contact surfaces.

(e) Install the engine water pump assembly to the timing chain cover sub-assembly with the 3 bolts. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

(f) Clean the contact surfaces of the timing chain cover sub-assembly, camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.

*a	Cylinder Head Sub-assembly and Cylinder Block Sub-assembly Side	*b	Timing Chain Cover Sub-assembly Side
	Clean and degrease	-	-

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

(h) Apply seal packing to the engine unit as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal Packing Diameter: 5.0 mm (0.197 in.) NOTICE: Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

(i) Apply seal packing to the timing chain cover sub-assembly in a continuous line as shown in the illustration.

Seal Packing:

Application Specification:

NOTICE:

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

(j) Clean the bolts and their installation holes.

(k) Apply adhesive to 5 and a half threads or more of the end of the 2 bolts (E). Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

*a Adhesive

(l) Temporarily install the timing chain cover sub-assembly with the 18 bolts and a new seal washer. Bolt Length: Item Length Bolt (A), (E) 35 mm (1.38 in.) Bolt (B), (D) 55 mm (2.17 in.) Bolt (C) 40 mm (1.57 in.) NOTICE: Make sure that there is no oil on the threads of the bolts.

*1 Seal Washer

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

Bolt Length:

NOTICE:

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

(n) Install 2 new oil filter bracket O-rings to the timing chain cover sub-assembly.

(o) Temporarily install the oil filter bracket to the timing chain cover sub-assembly with the 4 bolts.

Bolt Length:

NOTICE:

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

(p) Fully tighten the 25 bolts in the order shown in the illustration.

Torque:

Bolt (A), (D), (E) :

25.5 N·m {260 kgf·cm, 19 ft·lbf}

Bolt (B), (F) :

51 N·m {520 kgf·cm, 38 ft·lbf}

Bolt (C) :

10 N·m {102 kgf·cm, 7 ft·lbf}

34. INSTALL TIMING CHAIN COVER OIL SEAL

Click here

35. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

Click here

36. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

Click here

37. INSTALL KNOCK CONTROL SENSOR

Click here

38. INSTALL NO. 1 TAPER SCREW PLUG

(a) Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

39. INSTALL CRANKSHAFT POSITION SENSOR

Click here

40. INSTALL CRANKSHAFT PULLEY

Click here

41. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Raise the cam, then fully push in the plunger and engage the hook with the pin so that the plunger is in the position shown in the illustration. NOTICE: Make sure that the cam engages with the first tooth of the plunger to allow the hook to pass over the pin.

*a Cam *b Hook *c Plunger *d Pin *e Correct *f Incorrect *g Push *h Raise

(b) Install a new gasket, the bracket and No. 1 chain tensioner assembly to the timing chain cover sub-assembly with the 2 nuts. Torque: 12 N·m {122 kgf·cm, 9 ft·lbf} NOTICE: If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, set the hook again.

(c) Rotate the crankshaft counterclockwise slightly and check that the hook is released.

*a Hook *b Release

(d) Turn the crankshaft clockwise and check that the plunger is extended.

*a Plunger *b Plunger is extended

42. INSTALL OIL FILTER UNION

(a) Using a 12 mm hexagon socket wrench, install the oil filter union to the oil filter bracket.

Torque:

29.5 N·m {301 kgf·cm, 22 ft·lbf}

43. INSTALL OIL FILTER SUB-ASSEMBLY

Click here

44. INSTALL SPARK PLUG TUBE GASKET

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

45. INSTALL CYLINDER HEAD COVER GASKET

(a) Install 3 new cylinder head cover gaskets to the cylinder head cover sub-assembly. NOTICE: Remove any oil from the contact surfaces. Misalignment between the center of the cylinder head cover sub-assembly rib and the center of the cylinder head gasket tab should be 4.0 mm (0.157 in.) or less.

*1 Cylinder Head Cover Sub-assembly *2 Cylinder Head Cover Gasket

46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Install 2 new gaskets as shown in the illustration.

(b) Apply seal packing as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Diameter: 4.0 mm (0.157 in.) NOTICE: Remove any oil from the contact surfaces. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing. Do not start the engine for at least 2 hours after installation.

(c) Install the cylinder head cover sub-assembly with the 16 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

NOTICE:

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

47. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

Click here

48. INSTALL CAMSHAFT POSITION SENSOR

Click here

49. INSTALL SPARK PLUG

Click here

50. INSTALL OIL FILLER CAP GASKET

(a) Install the oil filler cap gasket to the oil filler cap sub-assembly.

51. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.