Engine Unit: Reassembly

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL TIGHT PLUG
NOTE: If water leaks from the tight plug or the plug corrodes, replace it.
1. Apply adhesive around the tight plugs.
  Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent.
  
  Fig 1: Applying Adhesive Around Tight Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap in new tight plugs as shown in Fig 2.
3. Using SST, tap in the 8 tight plugs A and C.
  SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
4. Using SST, tap in the tight plug B.
  SST 09950-60010 (09951-00300), 09950-70010 (09951-07100)
5. Using SST, tap in the 3 tight plugs D.
  SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)
  
  Fig 2: Tapping In New Tight Plugs Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 3: Identifying Tight Plug Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STUD BOLT
1. Using an E7 "Torx" socket wrench, install the stud bolts B and D.
  Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) for stud bolts B and D
2. Using an E8 "Torx" socket wrench, install the stud bolts A.
  Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) for stud bolts A
3. Apply adhesive to the hole for the stud bolt C on the cylinder block. Using an E7 "Torx" socket wrench, install the stud bolts C.
  Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) for stud bolt C
  
  NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
  
  Fig 4: Identifying Stud Bolt Installation Location & Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STRAIGHT PIN
1. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.
INSTALL RING PIN
1. Using a plastic-faced hammer, tap in new ring pins to the cylinder block.
  
  Fig 5: Identifying Straight Pin Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 6: Identifying Ring Pin Installation Location & Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 BALANCER SHAFT DRIVEN GEAR
1. Mount the head portion of the balancer shaft in a vise.
  NOTE: Be careful not to damage the balancer shaft.
2. Install the balancer shaft thrust washer No.2 (* 1) and balancer shaft driven gear No.2 (* 2).
3. Install and torque the bolt.
  Torque: 36 N*m (365 kgf*cm, 26 ft.*lbf)
  
  Fig 7: Installing Balancer Shaft Thrust Washer No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO.2 BALANCER SHAFT
1. Install the balancer shaft to the cylinder block.
  NOTE: When installing the balancer shaft, make sure to support the balancer shaft with both hands and avoid scratching the balancer shaft bearing on the cylinder block side.
  
  Fig 8: Installing Balancer Shaft To Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install and torque the 2 bolts.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
  
  Fig 9: Installing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 BALANCER SHAFT DRIVEN GEAR
1. Mount the head portion of the balancer shaft in a vise.
  NOTE: Be careful not to damage the balancer shaft.
2. Install the balancer shaft thrust spacer (* 1), balancer shaft thrust washer No.1 (* 2), sliding key (* 3) and balancer shaft driven gear No.1 (* 4).
3. Install and torque the bolt.
  Torque: 36 N*m (365 kgf*cm, 26 ft.*lbf)
  
  Fig 10: Installing Balancer Shaft Thrust Spacer & Balancer Shaft Thrust Washer No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO.1 BALANCER SHAFT
1. Install the No.1 balancer shaft to the cylinder block.
  NOTE: When installing the balancer shaft, make sure to support the balancer shaft with both hands and avoid scratching the balancer shaft bearing on the cylinder block side.
  
  Fig 11: Installing No. 1 Balancer Shaft To Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install and torque the bolt.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
  
  Fig 12: Installing Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive around the drain cock.
  
  Fig 13: Applying Adhesive Around Drain Cock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cylinder block water drain cock as shown in Fig 14.
  Torque: 25 N*m (250 kgf*cm, 18 in.*lbf)
3. Install the water drain cock plug to the water drain cock sub-assembly.
  Torque: 13 N*m (130 kgf*cm, 9 in.*lbf)
  
  Fig 14: Installing Cylinder Block Water Drain Cock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using an E7 "Torx" socket wrench, install the oil nozzles.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  
  Fig 15: Installing Oil Nozzles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WITH PIN PISTON SUB-ASSEMBLY
1. Assemble the piston and connecting rod.
  1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
    
    Fig 16: Installing New Snap Ring Using Screwdriver
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
    
    Fig 17: Gradually Heating Piston
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Coat the piston pin with engine oil.
  4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
    HINT:
    
    The piston and pin are a matched set.
    
    Fig 18: Aligning Front Marks Of Piston, Connecting Rod & Push In Piston Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
    
    Fig 19: Checking Fitting Condition Between Piston & Piston Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.
    
    Fig 20: Installing New Snap Ring Using Screwdriver
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON RING SET
1. Install the oil ring expander by hand.
2. Using a piston ring expander, install the oil ring rail.
  
  Fig 21: Installing Oil Ring Rail Using Piston Ring Expander
  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 Fig 22.
  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.
    
    Fig 22: Identifying Compression Rings Code Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Position the piston rings so that the ring ends are as shown in Fig 23.
  NOTE: Do not align the ring ends.

INSTALL CRANKSHAFT BEARING

NOTE:

Do not apply engine oil to the bearing's contact area and backside.
The crankshaft bearing cap bolt is tightened in 2 progressive steps.

Clean the main journal, and the both surfaces of the bearing.
Install the upper bearing.
1. Install the upper bearing to the cylinder block as shown in Fig 24.
  NOTE: Do not apply engine oil to the bearing's contact area and backside.
  
  Fig 24: Installing Upper Bearing To Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the lower bearing.

Install the lower bearing to the bearing cap.

Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.

Dimension (A - B): 0.3 mm (0.0118 in.) or less

HINT:

Fig 25: Measuring Distance Between Bearing Cap's Edge & Lower Bearing's Edge Using Vernier Calipers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

LOWER BEARING DISTANCE SPECIFICATION

Journal	Dimension (A)
#1, 5	3.75 mm (0.1476 in.)
#3	1.75 mm (0.0689 in.)
#2, 4	2.75 mm (0.1083 in.)

NOTE: Do not apply engine oil to the bearing's contact area and backside.

With the upper bearing and lower bearing installed, use a plastic-faced hammer to install the bearing caps to the cylinder block.
NOTE: Make sure that the bearing caps are installed in the correct positions and direction.
Using vernier calipers, measure the amount of misalignment between the upper bearing and lower bearing, as shown in Fig 26.
Standard: 0.9 mm (0.035 in.) or less

Fig 26: Measuring Amount Of Misalignment Between Upper Bearing & Lower Bearing Using Vernier Calipers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the bearing cap.
Install the crankshaft thrust washer upper to the cylinder block.
1. Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward.
  NOTE: Be careful when installing the thrust bearing upper and lower as they are similar but cannot be interchanged.
  
  Fig 27: Installing Crankshaft Thrust Washer Upper To Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.
NOTE: Be careful when installing the thrust bearing upper and lower as they are similar but cannot be interchanged. The bearing lower has a claw as shown in Fig 28.

Fig 28: Installing Thrust Washers On No. 3 Bearing Cap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply engine oil to the lower bearing.

INSTALL CRANKSHAFT
1. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
2. Install the 5 crankshaft bearing caps in their proper locations.
  
  Fig 29: Installing Crankshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the crankshaft bearing cap bolts.
  HINT:
  
  The main bearing cap bolts are tightened in 2 progressive steps.
4. Step 1
  1. Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in Fig 30.
    Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
    
    If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
    
    Fig 30: Identifying Tightening Sequence Of Main Bearing Cap Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Step 2
  1. Mark the front of the bearing cap bolts with paint.
  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.
6. Check that the crankshaft turns smoothly.
7. Check the crankshaft thrust clearance (see step 5).
  
  Fig 31: Marking Front Of Bearing Cap Bolts With Paint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD BEARING
1. Align the bearing claw with the groove of the connecting rod or connecting cap.
2. Install the bearings in the connecting rod and connecting rod cap.
  NOTE: Clean the backside of the bearing and the bearing surface of the connecting rod.
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.
  
  Fig 32: Aligning Bearing Claw With Groove Of Connecting Rod Or Connecting Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Position the piston rings so that the ring ends are as shown in Fig 33.
  CAUTION: Do not align the ring ends.
  
  Fig 33: Positioning Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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.
4. Match the numbered connecting rod cap with the connecting rod.
  NOTE:
  - Match the numbered connecting rod cap with the connecting rod.
    
    Fig 34: Pushing Piston Using Piston Ring Compressor
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check that the front mark of the connecting rod cap is facing forward.
6. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
  
  Fig 35: Checking Front Mark Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install and alternately tighten the bolts of the connecting rod cap in several steps.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
  
  Fig 36: Tightening Bolts Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Mark the front side of each connecting cap bolt with paint.
9. Retighten the cap bolts by 90° as shown in Fig 37.
10. Check that the painted mark is now at a 90° angle to the front.
11. Check that the crankshaft turns smoothly.
12. Check the connecting rod thrust clearance (see step 1).
  
  Fig 37: Marking Front Side Of Each Connecting Cap Bolt With Paint
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
NOTE: It is not necessary to remove with head pin unless it is being replaced.
1. Using a plastic-faced hammer, tap in a new ring pin until the pin stops.
  
  Fig 38: Identifying Ring Pin Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TIGHT PLUG
NOTE: If water leaks from the tight plug or the plug corrodes, replace it.
1. Apply adhesive to the tight plug hole of the cylinder head.
  Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent.
  
  Fig 39: Applying Adhesive To Tight Plug Hole Of Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, tap in a new tight plug to the cylinder head as shown in Fig 40.
  SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
INSTALL STUD BOLT
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
1. Using E6 and E7 "Torx" socket wrenches, install the stud bolts.
  Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) for stud bolt A
  
  7.5 N*m (76 kgf*cm, 66 in.*lbf) for stud bolt B
  
  9.5 N*m (97 kgf*cm, 84 in.*lbf) for stud bolt C
  
  Fig 41: Identifying Stud Bolt Installation Location & Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 WITH HEAD STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, install 3 new gaskets and the straight screw plugs.
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
  
  Fig 42: Installing New Gaskets & Straight Screw Plugs Using Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 WITH HEAD STRAIGHT SCREW PLUG
1. Using a 19 mm hexagon wrench, install a new gasket and the straight screw plug.
  Torque: 90 N*m (918 kgf*cm, 66 ft.*lbf)
  
  Fig 43: Installing New Gasket & Straight Screw Plug Using Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL CONTROL VALVE FILTER
1. Check that no foreign matter is on the mesh part of the filter.
  If foreign objects are present, clean the part thoroughly.
2. Using a 8 mm hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
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.
  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 white and the exhaust valve oil seals are black.
  
  Fig 45: Identifying Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, push in the oil seals.
  SST 09201-41020
  
  NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
  
  Fig 46: Pushing In Oil Seals Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE VALVE
1. Apply plenty of engine oil to the tip area of the intake valve shown in Fig 47.
  
  Fig 47: 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.
  
  Fig 48: Installing Valve, Compression Spring & Spring Retainer To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
  SST 09202-70020 (09202-00010)
  
  Fig 49: Compressing Spring & Installing Retainer Locks Using SST & Wooden Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
  NOTE: Be careful not to damage the valve stem tip.
  
  Fig 50: Tapping Valve Stem Tip Using Pin Punch & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST VALVE
1. Apply plenty of engine oil to the tip area of the intake valve shown in Fig 51.
  
  Fig 51: Identifying Tip Area Of Exhaust 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.
  
  Fig 52: Installing Valve, Compression Spring & Spring Retainer To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
  SST 09202-70020 (09202-00010)
  
  Fig 53: Compressing Spring & Installing Retainer Locks Using SST & Wooden Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
  NOTE: Be careful not to damage the valve stem tip.
  
  Fig 54: Tapping Valve Stem Tip Using Pin Punch & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the lash adjuster free from dirt and foreign objects.
- Only use clean engine oil.
1. Place the lash adjuster into a container full of engine oil.
2. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.
  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 checkball as shown in Fig 55. If the checkball is not pressed, air will not bleed.
5. After bleeding the air, remove the SST. Then 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.
  
  Fig 55: Inserting SST's Tip Into Lash Adjuster's Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the lash adjusters.
  NOTE: Install the lash adjuster to the original position.
  
  Fig 56: Installing Lash Adjusters
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the valve stem caps to the cylinder head.
  
  Fig 57: Installing Valve Stem Caps To Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY
1. Install the 2 pulley keys to the crankshaft.
  
  Fig 58: Installing Pulley Keys To Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 4 CHAIN VIBRATION DAMPER
1. Install the vibration damper No.4 with the 2 bolts.
  Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
  
  Fig 59: Installing Vibration Damper No. 4 With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO.2 CHAIN SUB-ASSEMBLY
1. Install the timing sprocket No.2 as shown in Fig 60.
  NOTE: Check that the No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side.
  
  HINT:
  
  Install the sensor plate with the front mark facing forward.
  
  Fig 60: Installing Timing Sprocket No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. As shown in Fig 61, install the chain on the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.
  
  Fig 61: Installing Chain On Sprocket & Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Fit the other mark link of the crankshaft timing sprocket behind the large timing mark of the balancer shaft drive gear.
4. Insert the balancer shaft drive gear shaft through the balancer shaft drive gear so that it fits into the thrust plate hole.
  
  Fig 62: Fitting Other Mark Link Of Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Align the small timing mark of the balancer shaft drive gear with the timing mark of the balancer shaft timing gear.
6. Install the bolt to the balancer shaft drive gear and tighten it.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 63: Aligning Small Timing Mark Of Balancer Shaft Drive Gear With Timing Mark Of Balancer Shaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Check that each timing mark is matched with the corresponding mark link.
  NOTE: Check that the No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side.
  
  Fig 64: Checking Timing Mark Is Matched With Corresponding Mark Link
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
1. Install the chain tensioner assembly No.2 with the nut.
  Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
  
  NOTE: Assemble the chain tensioner with the pin installed, then remove the pin after assembly. When doing this, avoid pushing the vibration damper against the chain.
  
  Fig 65: Installing Chain Tensioner Assembly No. 2 With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.
3. Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.
  
  Fig 66: Moving Stopper Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper No.3 with the 2 bolts.
  Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
  
  Fig 67: Installing Chain Vibration Damper No. 3 With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper No.2 with the bolt.
  Torque: 27 N*m (270 kgf*cm, 20 ft.*lbf)
2. Remove a pin from the chain tensioner assy No.2 and release the plunger.
  
  Fig 68: Installing Chain Vibration Damper No. 2 With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 WITH HEAD TAPER SCREW PLUG
1. Install the screw plug No.1 to the cylinder block.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
  
  Fig 69: Installing Screw Plug No.1 To Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
1. Using a hexagon wrench, install the oil filter bracket union.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 70: Installing Oil Filter Bracket Union Using Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new oil filter bracket gasket to the oil filter bracket.
3. Install a new O-ring to the oil filter bracket union.
  NOTE: Apply a light coat of engine oil to the new O-ring and oil filter bracket.
4. Install 2 new gaskets and the 2 screw plugs to the oil filter bracket.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
  
  Fig 71: Installing New O-Ring To Oil Filter Bracket Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the oil filter bracket with the 2 bolts and nut.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 72: Installing Oil Filter Bracket With Bolts & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a 27 mm socket wrench, install the oil filter union.
  Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf)
  
  Fig 73: Installing Oil Filter Union Using Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER SUB-ASSEMBLY
1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of a new oil filter.
3. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
4. Using SST, tighten the oil filter.
  SST 09228-07501
  1. When using a torque wrench:
    Using a torque wrench, tighten the oil filter.
    
    Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
  2. When not using a torque wrench:
    Tighten it an additional 3/4 turn.
    
    Fig 74: Tightening Oil Filter Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Apply seal packing in a continuous bead as shown in Fig 75.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Seal width: 2 to 3 mm (0.079 to 0.118 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the crankcase within 3 minutes after applying seal packing.
  - Do not start the engine for at least 4 hours after installing.
2. Install the oil seal retainer with the 6 bolts.
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  
  Fig 75: Identifying Seal Packing Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD GASKET
1. Apply a continuous bead (seal width: 4 to 7 mm (0.15 to 0.28 in.)) of seal packing to the cylinder block upper side and cylinder head gasket upper side as shown in Fig 76.
  Seal packing: Part No. 08826-00100 or equivalent
  
  Seal width: 4 to 7 mm (0.15 to 0.28 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head gasket within 3 minutes after applying the seal packing.
  - Install the cylinder head bolt within 15 minutes after applying the seal packing.
  - Do not put into engine oil within 4 hours of installation.
    
    Fig 76: Applying Continuous Bead Of Seal Packing To Cylinder Block Upper Side
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.
  NOTE:
  - Make sure that the installation direction is correct.
  - Place the cylinder head gently to avoid damaging the gasket with the bottom part of the head.
    
    Fig 77: Identifying Cylinder Head Gasket Upper Side
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
3. Step 1
  1. Install and uniformly tighten the 10 cylinder head bolts with the plate washers, in several steps, in the sequence shown in Fig 78.
    Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
    
    Fig 78: Identifying Tightening Sequence Of Cylinder Head Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Step 2
  1. Mark the cylinder head bolt head with paint as shown in Fig 79.
  2. Retighten the cylinder head bolts by 90°.
5. Step 3
  1. Retighten the cylinder head bolts by an additional 90°.
  2. Check that the painted mark is now facing rearward.
    
    Fig 79: Marking Cylinder Head Bolt Head With Paint
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
  
  Fig 80: Identifying Seal Packing Of Engine's Front Side
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING SPROCKET
1. Clamp the camshaft in a vise and then install the camshaft timing sprocket to the camshaft with the sprocket bolt.
  Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
  
  NOTE: Be careful not to damage the camshaft in the vise.
  
  Fig 81: Tightening Camshaft Timing Sprocket Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
1. Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin.
2. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
  CAUTION: Be sure not to turn the camshaft timing gear in the retard direction (the right angle).
3. Check that there is no clearance between the gear's fringe and the camshaft.
4. Tighten the fringe bolt with the camshaft timing gear fixed.
  Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
5. Check that the camshaft timing gear can move in the retard direction (the right angle), and is locked at the most retarded position.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Set the 16 rocker arms to the lash adjusters.
  NOTE: Before and after setting the camshaft and No.2 camshaft, firmly set the rocker arm to the lash adjuster.
  
  Fig 83: Setting Rocker Arms To Lash Adjusters
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFTS
1. Apply clean engine oil to the camshaft's cam portion and the cylinder head journals.
2. Set the camshaft and No.2 camshaft as shown in Fig 84.
  NOTE: Before and after setting the camshaft and No.2 camshaft, firmly set the rocker arm to the lash adjuster.
  
  Fig 84: Identifying Camshafts Lobe Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP
1. Temporarily install the camshaft bearing cap No.1.
2. Check the proper location of each camshaft bearing cap No.2 and install them.
  
  Fig 85: Installing Camshaft Bearing Cap No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new O-ring to the camshaft bearing cap No.1.
4. Temporarily install the oil delivery pipe.
  
  Fig 86: Installing Oil Delivery Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Tighten the 21 bolts and 20 washers in the order shown in Fig 87.
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt A
  
  16 N*m (160 kgf*cm, 11 ft.*lbf) for except bolt A
  
  Fig 87: Identifying Tightening Sequence Of Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING SPROCKET
1. Install the timing sprocket as shown in Fig 88.
  
  Fig 88: Installing Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the vibration damper with the bolt and nut.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 89: Installing Vibration Damper With Bolt & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN SUB-ASSEMBLY
1. As shown in Fig 90, install the chain on the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.
  HINT:
  - The camshaft mark plate is yellow.
  - The crankshaft mark plate is orange.
    
    Fig 90: Aligning Timing Marks On Sprocket & Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Use a rope to tie the chain of the crankshaft timing sprocket. Tie the rope near the sprocket.
  NOTE: After the chain tensioner has been installed, the rope must be removed.
  
  HINT:
  
  The rope is tied so that the chain will not jump a tooth.
  
  Fig 91: Tying Chain Of Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN TENSIONER SLIPPER
1. Install the tensioner slipper with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 92: Installing Tensioner Slipper With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Install a new gasket and the chain tensioner No.1 with the bolt and nut.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 93: Installing New Gasket & Chain Tensioner No. 1 With Bolt & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
3. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate's hole.
  
  Fig 94: Moving Stopper Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING CHAIN GUIDE
1. Install a new O-ring and the chain guide with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 95: Installing New O-Ring & Chain Guide With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket and the water pump with the 8 bolts.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 96: Installing New Gasket & Water Pump With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TIMING CHAIN COVER

Install 3 new O-rings to the timing chain cover as shown in Fig 97.

Fig 97: Installing New O-Rings To Timing Chain Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply adhesive to the timing gear case plug.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent

Fig 98: Applying Adhesive To Timing Gear Case Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a 10 mm socket hexagon wrench, install the timing chain cover plug.
Torque: 17 N*m (170 kgf*cm, 12 ft.*lbf)

Apply seal packing in a continuous bead to the timing chain cover as shown.

Seal packing: Part No. 08826-00080 or equivalent

Fig 99: Installing Timing Chain Cover Plug Using Hexagon Wrench

Seal width

SEAL WIDTH SPECIFICATION

Position	Specified Condition
A - A,	2.5 to 3.0 mm (0.098 to 0.118 in.)
B - B, C - C	4.0 to 4.5 mm (0.157 to 0.177 in.)
D - D	2.5 to 3.0 mm (0.098 to 0.118 in.)
E	2.5 to 3.5 mm (0.098 to 0.138 in.)

NOTE:

Be sure to clean and degrease the contact surfaces, especially 4 areas indicated by * in Fig 100.
When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.
Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not start the engine for at least 4 hours after installing.

Fig 100: Identifying Seal Packing Applying Area

Align the oil pump's drive rotor spline and the crankshaft as shown in Fig 101. Install the spline and chain cover to the crankshaft.

Fig 101: Aligning Oil Pump Drive Rotor Spline & Crankshaft

Temporarily install the timing chain cover with the 19 bolts and 2 nuts, but do not tighten the bolts and nuts yet.
Excluding bolts A, fully tighten the bolts and nuts in this order: Area 1, Area 2 and Area 3.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

HINT:

Bolt length:

75 mm (2.95 in.) for bolt A (M10)

75 mm (2.95 in.) for bolt B (M8)

87 mm (3.43 in.) for bolt C

95 mm (3.74 in.) for bolt D
Fully tighten the bolts labeled A in this order: Area 2 and Area 3.
Torque: 46 N*m (469 kgf*cm, 34 ft.*lbf)
Fully tighten the bolts labeled E in Area 4.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

HINT:

Bolt length: 35 mm (1.37 in.) for bolt E

Fig 102: Identifying Bolts Location & Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OIL PAN SUB-ASSEMBLY
1. Install the stud bolt.
  1. Using an E5 "Torx" socket wrench, install the stud bolts labeled A for the oil pan as shown in Fig 103.
  2. Using an E7 "Torx" socket wrench, install the stud bolts labeled B for the oil strainer as shown in Fig 103.
    Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) for stud bolt A
    
    3.0 N*m (31 kgf*cm, 27 in.*lbf) for stud bolt B
    
    Fig 103: Identifying Stud Bolt Location & Dimension
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous bead as shown in Fig 104.
  Seal packing: No. 08826-00080 or equivalent
  
  Seal width: 2 to 3 mm (0.08 to 0.12 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the crankcase within 3 minutes after applying seal packing.
  - Do not start the engine for at least 4 hours after installing.
    
    Fig 104: Identifying Seal Packing Applying Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new O-ring.
  
  Fig 105: Installing New O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install the oil pan with the 16 bolts and 2 nuts.
  HINT:
  
  Bolt length:
  
  20 mm (0.79 in.) for bolt A
  
  40 mm (1.57 in.) for bolt B
5. Uniformly tighten the 16 bolts and 2 nuts in the sequence shown in Fig 106.
  Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
  
  Fig 106: Identifying Tightening Sequence Of Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
  Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
  
  Fig 107: Installing New Gasket & Oil Strainer With Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
1. Apply seal packing in a continuous bead as shown in Fig 108.
  Seal packing: Part No. 08826-00080 or equivalent
  
  Seal width: 2.5 to 3.5 mm (0.098 to 0.138 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the crankcase within 3 minutes after applying seal packing.
  - Do not start the engine for at least 4 hours after installing.
    
    Fig 108: Identifying Seal Packing Applying Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the oil pan with the 18 bolts and 2 nuts.
3. Uniformly tighten the 18 bolts and 2 nuts in the sequence shown in Fig 109.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
4. Install a new gasket and the drain plug.
  Torque: 38 N*m (382 kgf*cm, 28 ft.*lbf)
  
  Fig 109: Identifying Tightening Sequence Of Oil Pan Bolts & Nuts
  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 new pulley bolt.
  SST 09213-54015 (91651-60855), 09330-00021
  
  Torque: 260 N*m (2,650 kgf*cm, 192 ft.*lbf)
  
  NOTE: Do not reuse the pulley bolt.
  
  Fig 110: Installing New Pulley Bolt With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Apply seal packing as shown in Fig 111.
2. Install the 2 gaskets to the head cover.
  Seal packing: Part No. 08826-00080 or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the crankcase within 3 minutes after applying seal packing.
  - Do not start the engine for at least 4 hours after installing.
    
    Fig 111: Identifying Seal Packing Applying Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the cover with the 19 bolts and 2 nuts.
  
  Fig 112: Installing Cover With Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Fully tighten the bolts (A) shown in Fig 113.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
5. Fully tighten the bolts (B) shown in Fig 113.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  HINT:
  
  Make sure the tightening torque of bolts (A).
  
  Fig 113: Identifying Tightening Sequence Of Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Install the camshaft timing oil control valve assembly with the bolt.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 114: Installing Camshaft Timing Oil Control Valve Assembly With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT POSITION SENSOR
1. Apply engine oil to the O-ring.
2. Install the crankshaft position sensor with the bolt.
  Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
  
  Fig 115: Installing Crankshaft Position Sensor With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT POSITION SENSOR
1. Apply engine oil to the O-ring.
2. Install the camshaft position sensor with the bolt.
  Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
  
  Fig 116: Installing Camshaft Position Sensor With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VENTILATION VALVE SUB-ASSEMBLY
1. Install the ventilation valve sub-assembly.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  
  Fig 117: Installing Ventilation Valve Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install the oil filler cap assembly.
  
  Fig 118: Installing Oil Filler Cap Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002