LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2016 >> GS 200t Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - Service Information >> Engine Unit >> Reassembly [10/2015 - ] >> Procedure

Reassembly [10/2015 - ]: Procedure

  1. INSTALL RING PIN 
    NOTE:

    It is not necessary to remove the ring pin unless it is being replaced.

    1. for Camshaft Housing Sub-assembly Side:
      1. Using a plastic-faced hammer, tap in 8 new ring pins to the camshaft housing sub-assembly.

        Standard protrusion height

        2.7 to 3.3 mm (0.106 to 0.130 in.)

        GTY627336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion Height
    2. for Stiffening Crankcase Assembly Side:
      1. Using a plastic-faced hammer, tap in 2 new ring pins to the stiffening crankcase assembly.

        Standard protrusion height

        4.3 to 5.3 mm (0.169 to 0.209 in.)

        GTY644262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion Height
  2. INSTALL STUD BOLT 
    NOTE:

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

    1. for Camshaft Housing Sub-assembly Side:
      1. Apply adhesive to the camshaft housing sub-assembly side threads of the stud bolt.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

        GTY504526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 20 mm (0.787 in.)
        *b 13 mm (0.512 in.)
        *c 35 mm (1.38 in.)
      2. Using an E8 "TORX" socket wrench, install the stud bolt to the camshaft housing sub-assembly.

        Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    2. for Stiffening Crankcase Assembly Side:
      1. Using an E5 "TORX" socket wrench, install the stud bolts to the stiffening crankcase assembly.

        Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

        GTY655111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 8.5 mm (0.335 in.)
        *b 8.0 mm (0.315 in.)
        *c 18 mm (0.709 in.)
    3. for Timing Chain Cover Assembly Side:
      1. Using an E6 "TORX" socket wrench, install the stud bolts to the timing chain cover assembly.

        Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

        GTY658960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 16 mm (0.630 in.)
        *b 9.0 mm (0.354 in.)
        *c 27 mm (1.06 in.)
  3. SET ENGINE BALANCER ASSEMBLY 
    1. Make sure that the alignment marks on the No. 1 balance shaft driven gear and No. 2 balance shaft driven gear are aligned.
      GTY683598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 1 Balance Shaft Driven Gear
      *b No. 2 Balance Shaft Driven Gear
      *c Alignment Mark
    2. If the alignment marks are not aligned, hold the No. 2 balance shaft with a wrench at its flat portions, and rotate the No. 1 balance shaft as shown in the illustration to align the marks.
      GTY631676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 1 Balance Shaft Driven Gear
      *b No. 2 Balance Shaft Driven Gear
  4. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Clean the bolts and their installation holes.
    2. Clean and degrease the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.
    3. Apply seal packing to the areas as shown in the illustration.

      Seal packing

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

      Standard Seal Dimension

      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick

      Application length A

      28 mm (1.10 in.)

      GTY638279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      *b 28 mm (1.10 in.)
      *c 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *d 7.0 to 9.0 mm (0.276 to 0.354 in.)
      NOTE:
      • Remove any oil from the contact surface.
      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
      • Do not add engine oil within 2 hours of installation.
      • Do not start the engine for at least 2 hours after the installation.
    4. Align the crankshaft pulley set key groove, timing marks on the balance shaft and balance shaft housing as shown in the illustration, and then set the stiffening crankcase assembly and engine balancer assembly on the cylinder block sub-assembly.
      GTY649458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      (Balance Shaft Housing Side)
      *b Timing Mark
      (Balance Shaft Side)
      *c Crankshaft Pulley Set Key Groove
    5. Apply adhesive 1344 to the threaded portion of bolt D (*c) shown in the illustration.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      GTY656126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Type
      *b Tightening Order
      *c Apply Adhesive
      NOTE:

      Install the bolt within 3 minutes of applying adhesive.

    6. Temporarily install the stiffening crankcase assembly to the cylinder block sub-assembly with the 12 bolts.

      Bolt Length

      Item Length Diameter
      Bolt A 65 mm (2.56 in.) 8.0 mm (0.315 in.)
      Bolt B 85 mm (3.35 in.) 10 mm (0.394 in.)
      Bolt C 140 mm (5.51 in.)
      Bolt D 125 mm (4.92 in.)
    7. Tighten the 12 bolts in the sequence shown in the illustration.
      Fig 1: Stiffening Crankcase Bolts Tightening Sequence (1 Of 2)
      GTY656126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A 

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

      except bolt A 

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 
    8. Tighten the bolt.
      Fig 2: Stiffening Crankcase Bolts Tightening Sequence (2 Of 2)
      GTY679086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 
  5. INSTALL ENGINE OIL TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  6. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. Install the No. 1 oil pan baffle plate to the engine balancer assembly with the 4 bolts.

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

  7. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new gasket.
    2. Align the protrusion of the gasket with the cutout of the oil strainer sub-assembly and install the gasket to the oil strainer sub-assembly.
      GTY658387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
    3. Install the oil strainer sub-assembly to the stiffening crankcase assembly and engine balancer assembly with the 3 bolts in several steps in the sequence shown in the illustration.
      Fig 3: Oil Strainer Sub-Assembly Bolts Tightening Sequence
      GTY658387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 
  8. INSTALL ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 1

  9. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.

      Seal packing

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

      Standard seal diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      GTY665766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
      • Do not add engine oil within 2 hours of installation.
      • Do not start the engine for at least 2 hours after the installation.
    2. Install the oil pan sub-assembly to the stiffening crankcase assembly with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration.
      Fig 4: Engine Oil Pan Sub-Assembly Bolts And Nuts Tightening Sequence
      GTY684204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 
  10. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug to the oil pan sub-assembly.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  11. INSTALL OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  12. INSTALL OIL FILTER BRACKET CLIP 
    1. Install the oil filter bracket clip to the stiffening crankcase assembly.
  13. INSTALL OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 3

  14. INSTALL REAR ENGINE OIL SEAL 

    See step  1

  15. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the cylinder block water jacket spacer to the cylinder block sub-assembly shown in the illustration.
      GTY652673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Front Side
      *b Protrusion
      NOTE:

      Make sure that the protrusion of the cylinder block water jacket spacer is facing up when installing it.

  16. INSTALL CYLINDER HEAD GASKET 

    See step  1

  17. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    See step  2

  18. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem caps.
    2. Install the 16 valve stem caps to the valve stem.
      NOTE:
      • Install the valve stem cap at the same place it was removed from.
      • Do not drop the valve stem caps into the cylinder head sub-assembly.
  19. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the valve lash adjuster assembly free from dirt and foreign objects.
    • Only use clean engine oil.
    • If the valve lash adjuster assembly is tilted after bleeding, oil will leak. Make sure to bleed the valve lash adjuster assembly again.
    1. Bleed the valve lash adjuster assembly.

      See step  2

    2. If the plunger moves, bleed the valve lash adjuster assembly again.
    3. Place the valve lash adjuster assembly into a container full of new engine oil, and then fill the low pressure chamber with engine oil.
    4. Apply engine oil to the outer surface of the valve lash adjuster body and the tip of the plunger, and then install the valve lash adjuster assembly while turning it.
      NOTE:

      Install the valve lash adjuster assembly into the same place it was removed from.

  20. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.
      GTY497302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
      NOTE:

      Install the No. 1 valve rocker arm sub-assemblies at the same place it was removed from.

  21. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean the No. 1 camshaft bearing.
      NOTE:

      Do not apply engine oil to the No. 1 camshaft bearing or contact surfaces.

    2. Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.
      GTY509914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper
    3. 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 or B - A = 0 to 0.7 mm (0 to 0.0276 in.)

  22. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean the No. 2 camshaft bearing.
      NOTE:

      Do not apply engine oil to the No. 2 camshaft bearing or contact surfaces.

    2. Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.
      GTY501895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper
    3. Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

      Standard distance

      A = 1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  23. INSTALL OIL CONTROL VALVE FILTER 
    1. Check that there is no foreign matter on the mesh section.
    2. Install the oil control valve filter to the No. 1 camshaft bearing cap.
      NOTE:

      Do not touch the mesh section on the oil control valve filter.

  24. INSTALL NO. 2 CAMSHAFT 

    HINT: 

    Perform "Inspection After Repair" after replacing the No. 2 camshaft.

    Refer to INITIALIZATION [10/2015 - 09/2018] or INITIALIZATION [09/2018 - ]

    1. Clean the No. 2 camshaft journals and camshaft housing sub-assembly.
    2. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.
    3. Set the No. 2 camshaft to the camshaft housing sub-assembly.
  25. INSTALL CAMSHAFT 

    HINT: 

    Perform "Inspection After Repair" after replacing the camshaft.

    Refer to INITIALIZATION [10/2015 - 09/2018] or INITIALIZATION [09/2018 - ]

    1. Clean the camshaft journals and camshaft housing sub-assembly.
    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.
    3. Set the camshaft to the camshaft housing sub-assembly.
  26. INSTALL CAMSHAFT BEARING CAP 
    1. Clean the camshaft bearing caps.
    2. Apply a light coat of engine oil to the camshaft journals and camshaft bearing caps.
    3. Place the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps to the camshaft housing sub-assembly.
    4. Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.
      Fig 5: Camshaft Bearing Cap Bolts Tightening Sequence
      GTY520314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      After installing the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps, make sure that the camshaft and No. 2 camshaft rotate smoothly.
  27. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. Install a new gasket and the No. 3 water by-pass pipe to the cylinder head sub-assembly with the 3 bolts in the order shown in the illustration.

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

      GTY655876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure the claws of the gasket face the No. 3 water by-pass pipe.

  28. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY497302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
    2. Apply seal packing to the areas as shown in the illustration.

      Seal packing

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

      Standard seal diameter

      3.0 to 4.0 mm (0.118 to 0.158 in.)

      GTY497278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Check the bolts and bolt holes and clean them.
      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
      • Do not add engine oil within 2 hours of installation.
      • Do not start the engine for at least 2 hours after the installation.
    3. Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.
      GTY501288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin
    4. Install the camshaft housing sub-assembly, and then install the 22 bearing cap bolts in the order shown in the illustration.

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

      GTY510748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the bolts have been loosened during the installation, apply seal packing black to the camshaft housing sub-assembly again.

  29. INSTALL OIL PIPE SUB-ASSEMBLY 
    1. Install the oil pipe sub-assembly to the No. 4 camshaft bearing cap with the bolt.

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

  30. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    NOTE:

    There are different types of camshaft timing gear bolts. Make sure to check the identification mark to determine the tightening torque.

    IDENTIFICATION MARK:

    Item Identification Mark
    for Type A A
    for Type B C
    GTY669127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Identification Mark

    HINT: 

    Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

    Refer to INITIALIZATION [10/2015 - 09/2018] or INITIALIZATION [09/2018 - ]

    1. Align the knock pin of the camshaft with the knock pin hole of the camshaft timing gear assembly and attach the camshaft timing gear assembly to the camshaft.
      GTY498101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
      NOTE:

      Do not forcefully press the camshaft timing gear assembly. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly, leading to poor sealing.

    2. Check that there is no clearance between the camshaft timing gear assembly and portion A of the camshaft indicated in the illustration.
      GTY520814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Portion A of Camshaft
      *d No Clearance
    3. Apply engine oil to the areas of the camshaft timing gear bolt indicated in the illustration.
      GTY504339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the camshaft timing gear bolt.

      HINT: 

      When temporarily installing the camshaft timing gear bolt, make sure that it is screwed in approximately 2 threads.

    5. Use a wrench to hold the hexagonal portion of the camshaft.
      GTY615440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
    6. Tighten the camshaft timing gear bolt.

      for Type A 

      Torque: 120 N*m (1224 kgf*cm, 89 ft.*lbf) 

      for Type B 

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing gear assembly.
  31. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    HINT: 

    Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

    Refer to INITIALIZATION [10/2015 - 09/2018] or INITIALIZATION [09/2018 - ]

    1. Align the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear assembly and attach the camshaft timing exhaust gear assembly to the No. 2 camshaft.
      GTY509728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin Hole
      *b Knock Pin
      NOTE:

      Do not forcefully press the camshaft timing exhaust gear assembly. Otherwise, the tip of knock pin of the No. 2 camshaft may damage the seal surface of the camshaft timing exhaust gear assembly, leading to poor sealing.

    2. Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.
      GTY499465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c No. 2 Camshaft Flange
      *d No Clearance
    3. Use a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      GTY648400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing exhaust gear assembly.
  32. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket to the crankshaft.
  33. ADD ENGINE OIL 
    1. Add 50 cc (3.1 cu.in.) of engine oil into the oil hole shown in the illustration.
      GTY667931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Oil must be added if the valve lash adjuster assemblies were removed.
      • Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.
  34. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Temporarily install the No. 1 chain vibration damper to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.
      GTY654579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the 2 bolts in the order shown in the illustration.

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

  35. INSTALL CHAIN SUB-ASSEMBLY 
    1. Temporarily install the crankshaft pulley set bolt.
    2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley set key as shown in the illustration.
      GTY674378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Set Key
    3. Check that the timing marks (groove) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.
      GTY807158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark (Groove)
      *b Approximately 7°
      *c Approximately 32°
    4. Place the chain sub-assembly onto the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

      HINT: 

      • Make sure the mark plate of the chain sub-assembly faces away from the front of the engine.
      • It is not necessary to install the chain sub-assembly to the teeth of the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.
    5. Align the mark plate (orange) of the chain sub-assembly with the timing mark (groove) of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.
      GTY517421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Orange)
      *b Timing Mark (Groove)
    6. Align the mark plate (yellow) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.
      GTY634328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Yellow)
      *b Timing Mark
    7. Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.
      GTY667927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench, align the timing mark (groove) of the camshaft timing gear assembly with the mark plate (orange) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.
      GTY787801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Orange)
      *b Timing Mark (Groove)

      HINT: 

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    9. Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.
      GTY667924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure the chain sub-assembly is secure.

  36. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper to the cylinder head sub-assembly with the bolt.

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

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Install a new gasket and the No. 1 chain tensioner assembly to the cylinder block sub-assembly with the bolt and nut.

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

    2. Remove the pin from the stopper plate.
  38. INSTALL TIMING CHAIN GUIDE 
    1. Install the timing chain guide to the No. 1 camshaft bearing cap with the bolt.

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

  39. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    See step  31

  40. INSTALL TIMING CHAIN COVER PLATE 
    1. Install a new gasket and the timing chain cover plate to the timing chain cover assembly with the 4 bolts.

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

  41. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  42. INSTALL WATER OUTLET SUB-ASSEMBLY 
    1. Install a new O-ring to the timing chain cover assembly.
    2. Install the nut, 2 bolts and water outlet sub-assembly to the timing chain cover assembly.

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

    3. Connect the No. 6 water by-pass hose to the water outlet sub-assembly, and slide the clamp to secure the hose.
  43. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  44. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 1

  45. INSTALL TIMING CHAIN COVER OIL SEAL 

    See step  1

  46. INSTALL SPARK PLUG TUBE GASKET 
    NOTE:

    Be sure not to disconnect the PCV hose or the No. 4 PCV hose from the cylinder head cover sub-assembly.

    1. Install the 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.
      GTY665938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly
      *a No Clearance
      NOTE:
      • Do not install the spark plug tube gasket at an angle.
      • Keep the lip free from foreign matter.
  47. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  48. INSTALL CRANKSHAFT PULLEY ASSEMBLY 
    1. Align the crankshaft pulley set key with the crankshaft pulley set key groove of the crankshaft pulley assembly.
    2. Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley set bolt.
      • SST: 09213-54015 
      • SST: 09330-00021 

      Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf) 

      GTY662758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn

      HINT: 

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

  49. INSTALL NO. 1 PCV CASE 
    1. Apply seal packing to a new No. 1 PCV case in the areas indicated in the illustration.

      Seal packing

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

      Standard seal diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      GTY512701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      NOTE:
      • Do not reuse the No. 1 PCV case.
      • Remove any oil from the contact surface.
      • Install the No. 1 PCV case within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      • Do not add engine oil within 2 hours of installation.
      • Do not start the engine for at least 2 hours after the installation.

      HINT: 

      Make sure to apply seal packing so that there are no gaps in the areas indicated by A in the illustration.

    2. Install the No. 1 PCV case, and then install the 6 bolts and 2 nuts in the order shown in the illustration.
      Fig 6: No. 1 PCV Case Bolts Tightening Sequence
      GTY672953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 
  50. INSTALL PCV VALVE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  51. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  52. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  53. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  54. INSTALL KNOCK SENSOR 

    Refer to PROCEDURE - Step 1

  55. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  56. INSTALL THERMOSTAT (for Cylinder Block) 

    Refer to PROCEDURE - Step 1

  57. INSTALL WATER INLET HOUSING 

    Refer to PROCEDURE - Step 2

  58. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  59. INSTALL NO. 4 WATER BY-PASS PIPE 
    1. Install a new gasket to the water inlet housing.
    2. Install the No. 4 water by-pass pipe to the cylinder block sub-assembly and water inlet housing with the bolt and 2 nuts.

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

    3. Connect the No. 4 water by-pass hose to the oil cooler assembly, and slide the clamp to secure the hose.
  60. INSTALL WATER BY-PASS PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 4

  61. INSTALL NO. 9 ENGINE WIRE 
    1. Attach the 3 clamps and install the No. 9 engine wire to the water by-pass pipe assembly and water inlet.
    2. Connect the connector to the oil pressure switching valve assembly.
  62. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  63. INSTALL FUEL INJECTOR SEAL (for Direct Injection) 

    Refer to PROCEDURE - Step 1

  64. INSTALL DIRECT FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 2

  65. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 3

  66. INSTALL PORT FUEL INJECTOR ASSEMBLY (for Port Injection) 

    Refer to PROCEDURE - Step 1

  67. INSTALL FUEL DELIVERY PIPE (for Port Injection) 

    Refer to PROCEDURE - Step 2

  68. SET FUEL PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

  69. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 2

  70. INSTALL FUEL PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 3

  71. TIGHTEN NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 4

scientia non olet · About LEMON Manuals