Partial Engine ASSY: Overhaul

1. Using a spark plug wrench, remove the spark plugs.
   Fig 1: Removing Spark Plugs

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1. Remove the 2 nuts and the water inlet.
2. Remove the thermostat.
3. Remove the gasket from the thermostat.
   Fig 2: Removing Thermostat

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1. Remove the oil filler cap from the cylinder head cover.
   Fig 3: Removing Oil Filler Cap From Cylinder Head Cover

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1. Using a screwdriver, remove the gasket from the oil filler cap.
   Fig 4: Removing Gasket From Oil Filler Cap

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1. Remove the bolt and the crankshaft position sensor.

1. Remove the ventilation valve from the cylinder head cover.
   Fig 5: Removing Ventilation Valve From Cylinder Head Cover

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1. Remove the 9 bolts, the 2 nuts and the cylinder head cover.

1. Remove the gasket from the cylinder head cover.
   Fig 6: Removing Nuts And Bolts Of Cylinder Head Cover

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1. Remove the bolt and the camshaft timing oil control valve.

1. Remove the bolt and the oil level gage guide.
   Fig 7: Removing Camshaft Timing Oil Control Valve

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1. Using SST, hold the pump pulley.

   SST 09960-10010 (09962-01000, 09963-00600)

2. Remove the 3 bolts and the pump pulley.
   Fig 8: Removing Water Pump Pulley

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1. Set the No. 1 cylinder to TDC/compression.
   1. Turn the crankshaft damper, and align its timing notch with timing mark "0" of the chain cover.
   2. Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.

   HINT: 

   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

   Fig 9: Aligning Timing Notch With Timing Mark "0" Of Chain Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the pulley bolt.

   SST 09213-58012 (91111-50845), 09330-00021

   HINT: 

   If necessary, remove the damper with SST.

   SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

   Fig 10: Removing Pulley Bolt And Damper

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1. Remove the 4 bolts and the engine mounting bracket RH.
   Fig 11: Removing Engine Mounting Bracket RH Bolts

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1. Remove the 3 bolts and 2 nuts.
2. Remove the water pump and the gasket.
   Fig 12: Removing Water Pump Assembly Bolts

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1. Remove the 15 bolts and nut.
   Fig 13: Removing Oil Pump Assembly Bolts

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2. Using a screwdriver with the tip wrapped in tape, remove the oil pump by prying between the cylinder head and cylinder block.
   NOTE: Be careful not to damage the contact surfaces of the oil pump, the cylinder head and the cylinder block.
3. Remove the 2 O-rings from the cylinder block and the oil pan No. 1.
4. Using an 8 mm hexagon wrench, remove the screw plug from the oil pump.
   Fig 14: Removing Oil Pump By Prying Between Cylinder Head And Cylinder Block

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1. Using a screwdriver with the tip wrapped in tape, remove the oil seal.
   Fig 15: Removing Oil Seal

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1. While rotating the stopper plate of the chain tensioner upward with a screwdriver, push in the plunger of the tensioner as shown in the illustration.
2. While rotating the stopper plate of the tensioner downward, insert a 2.5 mm (0.098 in.) diameter bar into the holes of the stopper plate and the tensioner to hold the stopper plate.
3. Remove the 2 bolts and the chain tensioner.
   Fig 16: Pushing The Plunger Of Tensioner

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1. Remove the bolt and the chain tensioner slipper.

1. Remove the 2 bolts and the chain vibration damper.

1. Using a spring scale, pull the timing chain with 140 N (14.3 kgf, 31.5 lb) and measure the length of it.

   Maximum chain elongation: 123.2 mm (4.850 in.) 

If the elongation is greater than maximum, replace the chain.

HINT: 

Perform the same measurements by pulling at 3 or more random places to obtain the average length.

Fig 17: Pulling Timing Chain And Measuring Its Length

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1. Remove the 3 bolts and the fuel delivery pipe together with the 4 fuel injectors.
   Fig 18: Removing Fuel Delivery Pipe Sub-Assembly

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1. Pull out the 4 injectors from the delivery pipe.

1. Remove the bolt and the camshaft position sensor.
   Fig 19: Removing Camshaft Position Sensor

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Fig 20: Aligning Oil Jet Hole With Paint Mark

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1. Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the 5 bearing caps and No. 2 camshaft.

Fig 21: Identifying Sequence Of Removing Bearing Cap Bolts Of No. 2 Camshaft

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1. Clamp the camshaft in a vice.
2. Remove the fringe bolt and the camshaft timing sprocket.

Fig 22: Removing Fringe Bolt And Camshaft Timing Sprocket

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1. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the 4 bearing caps and camshaft.

Fig 23: Identifying Sequence Of Removing Bearing Cap Bolts Of Camshaft

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1. Check the lock of camshaft timing gear.
   1. Clamp the camshaft in a vice, and check that the camshaft timing gear is locked.
   NOTE: Be careful not to damage the camshaft.
2. Release the lock pin.
   1. Cover the 4 oil paths of cam journal with tape as shown in the illustration.

      HINT: 

      One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with the tape.

   2. Punctuate the tape for the advance oil path and for the retard oil path on the opposite side from the advance oil path.
      Fig 24: Identifying Retard Side Path And Advance Side Path

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   3. Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa (1.5 kgf/cm² ).
      NOTE: Cover the paths with shop rag to prevent oil splashing.
      Fig 25: Putting Air Pressure Into Two Broken Paths (Advance Side Path And Retard Side Path)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Confirm if the camshaft timing gear assembly revolves in the timing advance direction when reducing the air pressure of the timing retard path.

      HINT: 

      The lock pin is released, and camshaft timing gear revolves in the advance direction.

   5. When the camshaft timing gear reaches the most advanced position, remove the air pressure of the timing retard side path, and then release the air pressure of timing advance side path.
      Fig 26: Camshaft Timing Gear Assembly Revolving In Timing Advance Direction When Reducing Air Pressure Of Timing Retard Path

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released first. It often results in the breakage of the lock pin.
3. Check smooth revolution
   1. Except the position where the lock pin meets at the most retarded angle, let the valve timing controller assembly turn back and forth and check the movable range and that there is no disturbance.

   Standard: Smooth movable range is about 22.5° 

   NOTE: Be sure to perform this check by hand, instead of air pressure.
4. Check the lock in the most retarded position.
   1. Confirm that the camshaft timing gear assembly is locked at the most retarded position.

1. Turn the valve timing controller assembly at the most advanced angle.
2. Remove the fringe bolt and camshaft timing gear assembly.

Fig 27: Removing Fringe Bolt And Camshaft Timing Gear Assembly

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1. Using several steps, loosen and remove the 10 cylinder head bolts uniformly with an 8 mm bihexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and the plate washers.

Fig 28: Identifying Removing Sequence Of Cylinder Head Sub Assembly Bolts

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1. Using SST, remove the oil filter.

   SST 09228-06501

   Fig 29: Removing Oil Filter

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1. Using a 12 mm hexagon wrench, remove the oil filter union.
   Fig 30: Removing Oil Filter Union

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1. Using a knife, cut off the oil seal lip.
2. Using a screwdriver with the tip wrapped in tape, pry out the oil seal.

Fig 31: Prying Out Oil Seal Using A Screwdriver

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1. Remove the oil pan drain plug and the gasket.
2. Remove the 9 bolts and the 2 nuts.
   Fig 32: Removing Nuts And Bolts Of Oil Pan Sub-Assembly No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert the blade of SST between oil pan No. 1 and oil pan No. 2, and cut off applied sealer and remove the oil pan No. 2.

   SST 09032-00100

Fig 33: Cutting Off Applied Sealer And Removing Oil Pan No. 2

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1. Remove the bolt and 2 nuts.
2. Remove the oil strainer and the gasket.

1. Loosen and remove the 13 bolts uniformly in several steps.
   Fig 34: Removing Bolts Of Oil Pan Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, remove the oil pan No. 1 by prying between the cylinder block and the oil pan No. 1
   NOTE: Be careful not to damage the contact surfaces of the oil pan No. 1 and the cylinder block.
3. Remove the 2 O-rings from the cylinder block.
4. Remove the 4 stud bolts.
   Fig 35: Removing Stud Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
2. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
   Fig 36: Inspecting Chain Tensioner Assembly No. 1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Wrap the chain around the timing sprocket.
2. Using a vernier calipers, measure the diameter of the timing gear with the chain.

   Minimum gear diameter (w / chain): 

   96.2 mm (3.787 in.) 

If the diameter is less than minimum, replace the sprocket.

Fig 37: Inspecting Camshaft Timing Gear Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Wrap the chain around the timing sprocket.
2. Using a vernier calipers, measure the diameter of the timing gear with the chain.

   Minimum gear diameter (w / chain): 

   96.2 mm (3.787 in.) 

If the diameter is less than minimum, replace the sprocket.

Fig 38: Inspecting Camshaft Timing Gear Or Sprocket

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1. Measure the chain tensioner slipper wear.

   Maximum wear: 1.0 mm (0.039 in.) 

If the wear is greater than maximum, replace the slipper.

Fig 39: Measuring Chain Tensioner Slipper Wear

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1. Measure the vibration damper wear.

   Maximum wear: 1.0 mm (0.039 in.) 

If the wear is greater than maximum, replace the damper.

Fig 40: Measuring Vibration Damper Wear

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1. Using vernier calipers, measure the length of head bolts from the seat to the end.

   Standard bolt length: 

   142.8 to 144.2 mm (5.622 to 5.677 in.) 

   Maximum bolt length: 147.1 mm (5.791 in.) 

If the length exceeds the maximum, replace the bolt.

Fig 41: Measuring Length Of Head Bolts From Seat To End

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using Torx socket wrench E5, install the 4 stud bolts.

   Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) 

   Fig 42: Identifying Location And Dimension Of Stud Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove any old packing material from the contact surface.
3. Apply a continuous bead of seal packing (Diameter 2.0 mm to 3.0 mm (0.079 to 0.118 in.)) to the oil pan mating surface as shown in the illustration.

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes after applying seal packing.
   • Do not expose the seal to engine oil within 2 hours of installation.
   Fig 43: Applying A Continuous Bead Of Seal Packing To Oil Pan Mating Surface

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install 2 new O-rings to the cylinder block.
5. Using several steps, install and tighten the 13 bolts uniformly in the sequence shown in the illustration.

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

HINT: 

Each bolt length as follows:

Bolt A 49 mm (1.93 in.)

Bolt B 88 mm (3.47 in.)

Bolt C 144 mm (5.67 in.)

Fig 44: Tightening Sequence Of Oil Pan Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket and the oil strainer with the 2 nuts and the bolt.

   Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

1. Remove any old packing material from the contact surface.
2. Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan mating surface as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes after applying seal packing.
   • Do not expose the seal to engine oil within 2 hours of installation.
   • Do not start the engine within 2 hours of installation.
   Fig 45: Identifying Seal Width

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil pan No. 2 with the 9 bolts and the 2 nuts.

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

4. Install the drain plug with a new gasket.

   Torque: 38 N.m (382 kgf.cm, 28 ft.lbf) 

1. Using a 12 mm hexagon wrench, install the oil filter union.

   Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) 

   Fig 46: Installing Oil Filter Union

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of the new oil filter.
3. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
4. Using SST, tighten it an additional 3/4 turn.

   SST 09228-06501

   Fig 47: Installing Oil Filter Sub-Assembly

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1. Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.

Fig 48: Identifying Lot No.

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HINT: 

The cylinder head bolts are tightened in 2 successive steps.

1. Apply a continuous bead of seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.)) as shown in the illustration.
   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes after applying seal packing.
2. Apply a light coat of engine oil on the threads of the cylinder head bolts.
   Fig 49: Applying Continuous Bead Of Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.

   Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

   Fig 50: Tightening Sequence Of Cylinder Head Sub-Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the front of the cylinder head bolt with paint.
5. Retighten the cylinder head bolts by additional 90° and one more additional 90° as shown in the illustration.
6. Check that the paint mark is now at a 180° angle to the front.
   Fig 51: Retightening Cylinder Head Bolts By Additional 90° And One More Additional 90°

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply multi-purpose grease to a new oil seal lip.
   NOTE: Keep the lip free of foreign materials.
2. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

   SST 09223-56010

   NOTE:

   • Be careful not to tap the oil seal at an angle.
   • Wipe off extra grease on the crankshaft.
   Fig 52: Taping In Oil Seal Until Its Surface Is Flush With Rear Oil Seal Retainer Edge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Put the camshaft timing gear assembly and the camshaft together with the straight pin off the groove.
2. Turn the camshaft timing gear assembly clockwise while pushing it lightly towards the camshaft. Push further at the position where the pin fits into the groove.
   NOTE: Be careful not to turn the camshaft timing gear to the retard angle (to the right).
3. Check that there is no clearance between the gear fringe and the camshaft.
   Fig 53: Fitting Pin Into Groove

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the fringe bolt with the camshaft timing gear fixed.

   Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 

5. Check that the camshaft timing gear assembly can move to the retard angle (to the right) and is locked at the most retarded position.

1. Apply a light coat of engine oil on the camshaft journals.
2. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
3. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.

   Torque: 13 N.m (129 kgf.cm, 9.4 ft.lbf) 

Fig 54: Tightening Sequence Of Camshaft Bolts

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1. Clamp the camshaft in a vice.
2. Align the knock pin hole of the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket.

   Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 

Fig 55: Installing Camshaft Timing Gear Or Sprocket

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1. Apply a light coat of engine oil on the camshaft journals.
2. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
3. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.

   Torque: 13 N.m (129 kgf.cm, 9.4 ft.lbf) 

   NOTE: Tighten each bolt uniformly keeping the camshaft level.
4. Install the bearing cap No. 1.

   Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) 

   Fig 56: Tightening Sequence Of Camshaft No. 2 Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply engine oil to the O-ring.
   NOTE: If the O-ring is damaged, replace the camshaft position sensor.
2. Install the camshaft position sensor with the bolt.

   Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

1. After setting the crankshaft at ATDC 40 to 140°, set the cams of intake and exhaust timing sprockets at ATDC 20° and then reset the crankshaft at ATDC 20°.
2. Install the chain vibration damper with the 2 bolts.

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

3. Align the matchmarks of the camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket with each mark plate (colored in yellow) of the timing chain.

   HINT: 

   To prevent the exhaust camshaft from spring back, turn it using a wrench and set it at the mark on the chain.

4. Install the chain tensioner slipper with the bolt.

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

   Fig 57: Aligning Matchmarks Of Camshaft Timing Sprocket, Camshaft Timing Gear And Crankshaft Timing Sprocket With Each Mark Plate Of Timing Chain

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. While rotating the stopper plate of the chain tensioner upward as shown in the illustration push in the plunger of the tensioner.
6. While rotating the stopper plate of the tensioner downward, insert a 2.5 mm (0.098 in.) diameter bar into the holes of the stopper plate and the tensioner to hold the stopper plate.
7. Install the chain tensioner with the 2 bolts.

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

8. Remove the bar from the chain tensioner.
9. Check the tension between the intake and exhaust camshaft timing sprocket.
   Fig 58: Rotating Stopper Plate Of Chain Tensioner Upward And Pushing Plunger Of Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

   SST 09950-60010 (09951-00250, 09951-00380, 09952-06010), 09950-70010 (09951-07100)

   NOTE:

   • Be careful not to tap the oil seal at an angle.
   • Keep the lip free of foreign objects.
2. Apply multi-purpose grease to the oil seal lip.
   Fig 59: taping In A New Oil Seal Until Its Surface Is Flush With Timing Chain Cover Edge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 new O-rings to the 2 locations as shown in the illustration.
2. Remove any old packing material from the contact surface.
   Fig 60: Installing New O-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing to the oil pump assembly, the cylinder head and the cylinder block as shown in the illustration below.

   Seal packing: 

   Water pump part: part No. 08826 - 00100 or equivalent Other part: part No. 08826 - 00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pump within 3 minutes after applying seal packing.
   • Do not expose the seal to engine oil within 2 hours of installation.
   • Do not start the engine within 2 hours of installation.
   Fig 61: Applying Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the keyway of the oil pump drive rotor with the rectangular portion of the crankshaft, and slide the oil pump into place.
   Fig 62: Aligning Keyway Of Oil Pump Drive Rotor With Rectangular Portion Of Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the oil pump assembly with the 15 bolts and nut. Tighten the bolts and the nut uniformly in several steps.

   Torque: 

   Bolt A 24 N.m (245 kgf.cm, 18 ft.lbf) 

   Bolt B 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

   Bolt C 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

   Nut D 24 N.m (245 kgf.cm, 18 ft.lbf) 

   Bolt E 24 N.m (245 kgf.cm, 18 ft.lbf) 

   Fig 63: Identifying Oil Pump Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Pay attention not to disturb the seal packing.
   • After installing the oil pump assembly, must install the mounting bracket and water pump within 15 minutes.

HINT: 

Each bolt length is as follows:

A 30 mm (1.18 in.)

B 35 mm (1.38 in.)

C 20 mm (0.79 in.)

E 20 to 14 mm (0.79 to 0.55 in.)

1. Install the water pump and a new gasket with the 3 bolts and 2 nuts.

   Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

   Fig 64: Installing Nuts And Bolts Of Water Pump Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the engine mounting bracket RH with the 4 bolts.

   Torque: 55 N.m (561 kgf.cm, 41 ft.lbf) 

   Fig 65: Install The Engine Mounting Bracket RH Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the pump pulley with the 3 bolts.

   Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

   SST 09960-10010 (09962-01000, 09963-00600)

   Fig 66: Installing Water Pump Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the pin hole of the crankshaft damper with the pin position and install the crankshaft damper.
2. Using SST, install the pulley bolt.

   SST 09330-00021, 09213-58012 (91111-50845)

   Torque: 128 N.m (1,305 kgf.cm, 95 ft.lbf) 

   Fig 67: Installing Pulley Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT: 

Inspect and adjust the valve clearance when the engine is cold.

1. Set the No. 1 cylinder to the TDC/compression.
   1. Turn the crankshaft damper, and align its timing notch with the timing mark "O" of the chain cover.
   2. Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.

   HINT: 

   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

   Fig 68: Aligning Crankshaft Timing Notch With Timing Mark "O" Of Chain Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the valves indicated in the illustration.
   1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

      Valve clearance (Cold) : 

      Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) 

      Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) 

   2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
3. Turn the crankshaft 1 complete revolution (360°) and align its timing notch with the timing mark "O" of the chain cover.
   Fig 69: Identifying Intake (IN) And Exhaust (EX) Valves Of No. 1 Cylinder

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the valves indicated in the illustration.
   1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

      Valve clearance (Cold) : 

      Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) 

      Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) 

   2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
   Fig 70: Identifying Intake (IN) And Exhaust (EX) Valves Of No. 4 Cylinder

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 71: Rotating Crankshaft Damper Counterclockwise 40° From TDC And Aligning Its Timing Notch With Timing Mark Of Chain Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the No. 1 cylinder to the TDC/compression.
   1. Turn the crankshaft damper, and align its timing notch with timing mark "O" of the chain cover.
   2. Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.

   HINT: 

   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

   Fig 72: Aligning Crankshaft Timing Notch With Timing Mark

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Put paint marks on the timing chain in place where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.
   Fig 73: Putting Paint Marks On Timing Chain

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using an 8 mm hexagon wrench, remove the screw plug.
   Fig 74: Removing Screw Plug Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate of the chain tensioner at upward position.
5. Using a wrench, rotate the camshaft No. 2 clockwise to push in plunger of the chain tensioner.
   Fig 75: Pushing Plunger Of Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the screwdriver from the service hole, then align the hole of the stopper plate with the service hole and insert a 2 to 3 mm (0.08 to 0.12 in.) diameter bar into the holes to hold the stopper plate.

   HINT: 

   • Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
   • Hold the bar with tape so that the bar does not come off.
7. Hold the camshaft with a wrench on the hexagonal lobe, and remove the bolt.

   SST 09023-38400

   Fig 76: Removing The Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the 5 bearing caps.
   NOTE: Loosen each bolt uniformly keeping the camshaft level.
   Fig 77: Identifying Removing Sequence Of Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the fringe bolt with the No. 2 camshaft lifted up, then detach the No. 2 camshaft and the camshaft timing sprocket.
   Fig 78: Removing Fringe Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the 4 bearing caps.
    NOTE: Loosen each bolt uniformly keeping the camshaft level.
    Fig 79: Identifying Removing Sequence Of Bearing Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Hold the timing chain by hand, and remove the camshaft and the camshaft timing gear assembly.
    Fig 80: Removing Camshaft And Camshaft Timing Gear Assembly

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Tie the timing chain with a string as shown in the illustration.
    NOTE: Be careful not to drop anything inside the timing chain cover.
    Fig 81: Tieing Timing Chain With A String

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Remove the valve lifters.
    Fig 82: Measuring Thickness Of Removed Lifter

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Using a micrometer, measure the thickness of the removed lifter.
15. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
    Fig 83: Lifter Thickness Table

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Specified value (Cold): 

    Intake A = B + (C - 0.20 mm (0.008 in.)) 

    Exhaust A = B + (C - 0.30 mm (0.012 in.)) 

16. Select a new lifter with the thickness as close to the calculated values as possible.
    Fig 84: Calculating Lifter Specifications (Examples: Intake)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    • Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).
    • Refer to the New Lifter Thickness table on the next page.
      Fig 85: Valve Lifter Selection Chart (Intake)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 86: Valve Lifter Selection Chart (Exhaust)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Reinstall the valve lifters.
18. Apply a light coat of engine oil on the camshaft journals.
19. Install the timing chain to the camshaft timing gear with the paint mark and the timing marks aligned as shown in the illustration.
    Fig 87: Installing Timing Chain To Camshaft Timing Gear With Paint Mark And Timing Marks Aligned

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.

    Torque: 13 N.m (129 kgf.cm, 9.4 ft.lbf) 

    NOTE: Tighten each bolt uniformly keeping the camshaft level.
    Fig 88: Identifying Numbering And Tighten Sequence Of Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. Hold the timing chain, and align the timing mark on the camshaft timing sprocket with the paint mark on the timing chain.
    Fig 89: Aligning Timing Mark On Camshaft Timing Sprocket With Paint Mark On Timing Chain

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. Align the alignment pin hole on the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket to the camshaft.
23. Temporarily install the timing sprocket bolt.
    Fig 90: Aligning Alignment Pin Hole On Camshaft Timing Sprocket With Alignment Pin Of Camshaft, And Installing Sprocket To Camshaft

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.

    Torque: 13 N.m (129 kgf.cm, 9.4 ft.lbf) 

    NOTE: Tighten each bolt uniformly keeping the camshaft level.
25. Install the bearing cap No. 1.

    Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) 

    Fig 91: Identifying Tightening Sequence Of Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. Hold the camshaft with a wrench on the hexagonal lobe, and install the bolt.

    Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 

    SST 09023-38400

27. Remove the bar from the timing chain tensioner.
    Fig 92: Installing Camshaft Bolt

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the chain cover.
29. Check that all the pairs of the matchmarks are aligned.
    Fig 93: Aligning Crankshaft Timing Notch With Timing Mark "0" Of Chain Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. Apply seal packing 2 or 3 threads to the screw plug end.

    Seal packing: 

    Part No. 08833 - 00070 or equivalent 

31. Using an 8 mm hexagon wrench, install the screw plug.

    Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

    Fig 94: Installing Screw Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install new insulators to each fuel injector.
2. Apply a light coat of spindle oil or gasoline to new O-rings and install it to each fuel injector.
3. Apply a light coat of spindle oil or gasoline on the place where a delivery pipe contacts the O-ring.
   Fig 95: Locating Insulator And O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. While turning the injector clockwise and counterclockwise, push it to the delivery pipe.

1. Install the 2 spacers to the cylinder head.
   Fig 96: Pushing The Injector To Delivery Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the fuel delivery pipe and the 4 fuel injectors together.

   Torque: 

   Bolt A: 19 N.m (194 kgf.cm, 14 ft.lbf) 

   Bolt B: 9.0N.m (92 kgf.cm, 80 in..lbf) 

   Fig 97: Locating Bolts Of Fuel Delivery Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) 

   Fig 98: Installing Camshaft Timing Oil Control Valve With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the gasket to the cylinder head cover.
2. Apply seal packing to the 2 locations as shown in the illustration.

   Seal packing: 

   Part No. 08826 - 00080 or equivalent 

   Fig 99: Identifying Locations Of Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   • Do not start the engine within 2 hours of installation.
3. Install the cylinder head cover with the 9 bolt, the 2 seal washers and the 2 nuts.
4. Using several steps, tighten the bolts and the nuts uniformly in the sequence shown in the illustration.

   Torque: 10 N.m (102 kgf.cm, 7.4 ft.lbf) 

   Fig 100: Tightening Sequence Of Cylinder Head Cover Sub-Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the ventilation valve to the cylinder head cover.

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

   Fig 101: Installing Ventilation Valve To Cylinder Head Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply engine oil to a new O-ring.
2. Install the oil level gage guide with the bolt.

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

1. Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.
   NOTE: If the O-ring is damaged, replace the crankshaft position sensor.
2. Install the crankshaft position sensor with the bolt.

   Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) 

1. Install a new gasket to the thermostat.
2. Install the thermostat with the jiggle valve facing upward.

   HINT: 

   The jiggle valve may be set within 10° at either side as shown in the illustration.

   Fig 102: Installing Thermostat With Jiggle Valve Facing Upward

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the water inlet with the 2 nuts.

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

   Fig 103: Installing Water Inlet Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a spark plug wrench, install the spark plugs.

   Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)