Partial Engine ASSY: Overhaul

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the gasket from the oil filler cap.

1. Remove the bolt and crankshaft position sensor.
   Fig 4: Removing Gasket From Oil Filler Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Remove the gasket from the cylinder head cover.
   Fig 6: Removing Cylinder Head Cover 9 Bolts And 2 Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, hold the pump pulley.

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

2. Remove the 3 bolts and pump pulley.
   Fig 8: Holding Water Pump Pulley With SST

   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 the 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

   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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 15 bolts and nut.
   Fig 13: Removing Oil Pump Assy 15 Bolts And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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, cylinder head and cylinder block.
3. Remove the 2 O-rings from the cylinder block and oil pan No. 1.
4. Using an 8 mm hexagon wrench, remove the screw plug from the oil pump.
   Fig 14: Inserting Screwdriver Between Cylinder Head And Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Rotate the stopper plate of the chain tensioner upward with a screwdriver, push in the plunger of the tensioner as shown in the illustration.
2. Rotate 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 tensioner to hold the stopper plate.
3. Remove the 2 bolts and chain tensioner.
   Fig 16: Inserting 2.5mm (0.098 in.) Diameter Bar Into Holes Of Stopper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and chain tensioner slipper.

1. Remove the 2 bolts and 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 measurement by pulling at 3 or more random places to obtain an average length.

Fig 17: Measuring Length Of Timing Chain

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors.

1. Pull out the 4 injectors from the delivery pipe.
   Fig 18: Removing Fuel Delivery Pipe 3 Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 20: Locating Timing Mark

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Removing No. 2 Camshaft Bearing Caps

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 22: Removing Camshaft Timing Sprocket Fringe Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

1. Check the lock of the camshaft timing gear.
   1. Clamp the camshaft in a vise, and check that the camshaft timing gear is locked.
   NOTE: Be careful not to damage the camshaft.
   Fig 23: Removing 4 Bearing Caps And Camshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Release the lock pin.
   1. Cover the 4 oil paths of the 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 Advance Oil Path And Retard Oil Path

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 prevent oil splashing.
      Fig 25: Inserting Air Pressure Into Two Broken Paths

      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 the camshaft timing gear revolves in the timing 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 the timing advance side path.
      Fig 26: Locating Decompress Condition

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Camshaft timing assembly gear 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 is at 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.

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

1. Using SST, remove the oil filter.

   SST 09228-06501

   Fig 29: Removing Oil Filter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

1. Remove the oil pan drain plug and gasket.
   Fig 31: Removing Engine Rear Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 9 bolts and 2 nuts.
   Fig 32: Removing 9 Bolts And 2 Nuts

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

   SST 09032-00100

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and 2 nuts.
2. Remove the oil strainer and gasket.
   Fig 34: Removing Oil Strainer Bolt And 2 Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Loosen and remove the 13 bolts uniformly in several steps.
   Fig 35: Removing Oil Pan Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using screwdriver, remove the oil pan No. 1 by prying between the cylinder block and oil pan No. 1.
   NOTE: Be careful not to damage the contact surfaces of the oil pan No. 1 and cylinder block.
3. Remove the 2 O-rings from the cylinder block.
4. Remove the 4 stud bolts.
   Fig 36: Removing 2 O-Rings From Cylinder Block

   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 pushing with your finger.
   Fig 37: Inspecting Chain Tensioner Assy No. 1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Minimum gear diameter (w/ chain): 

   96.2 mm (3.787 in.) 

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

Fig 38: Measuring Diameter Of Timing Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Minimum gear diameter (w/ chain): 

   96.2 mm (3.787 in.) 

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

Fig 39: Measuring Diameter Of Timing Gear With Chain Wrapped

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 40: Measuring Chain Tensioner Slipper Wear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 41: Measuring Vibration Damper Wear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

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

   Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf) 

   Fig 42: Measuring Length Of Head Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 43: Identifying Stud Bolts Length

   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 the seal packing.
   • Do not expose the seal to engine oil within 2 hours of installation.
4. Install 2 new O-rings to the cylinder block.
   Fig 44: Identifying Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

1. Bolt A: 49 mm (1.93 in.)
2. Bolt B: 88 mm (3.47 in.)
3. Bolt C: 144 mm (5.67 in.)

Fig 45: Installing 13 Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

1. Remove any old packing material from the contact surface.
   Fig 46: Installing Oil Strainer With 2 Nuts And Bolt

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

   Fig 47: Applying Seal Packing To Oil Pan Mating Surface

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

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.
   Fig 48: Installing Oil Filter Union

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, tighten it an additional 3/4 turn.

   SST 09228-06501

   Fig 49: Installing Oil Filter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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 51: Identifying 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 52: Installing 10 Cylinder Head Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the front of the cylinder head bolt with paint.
5. Using the same sequence as step ( c), retighten the cylinder head bolts by additional 90° and one more additional 90° as shown in the illustration.
6. Check that each paint mark is now at the 180° angle to the front.

1. Apply multi-purpose grease to a new oil seal lip.
   NOTE: Keep the lip free of foreign materials.
   Fig 53: Retightening Cylinder Head Bolts By Additional 90 Degree

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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

1. Put the camshaft timing gear assembly and 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 side (to the right).
   Fig 55: Locating Straight Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that there is no clearance between the gear fringe and camshaft.
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 56: Identifying Front Marks And Numbers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clamp the camshaft in a vise.
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) 

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.
   Fig 57: Installing Camshaft Timing Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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) 

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) 

   Fig 58: Identifying Front Marks And Numbers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. After setting the crankshaft at ATDC 40 to 140°, set 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 springing 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 59: Aligning Matchmarks Of Camshaft Timing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Rotate the stopper plate of the chain tensioner upward as shown in the illustration, push in the plunger of the tensioner.
6. Rotate 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 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 sprockets.
   Fig 60: Inserting A Bar Into Holes Of Stopper Plate

   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 61: Installing Oil Pump Seal

   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 62: Installing 2 New O-Rings To 2 Locations

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing to the oil pump assembly, cylinder head and 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 the 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 63: Applying Seal Packing To Oil Pump Assembly, Cylinder Head And Cylinder Block

     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 64: Locating 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 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 65: Installing Oil Pump Assembly With 15 Bolts And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 and 14 mm (0.79 and 0.55 in.) double ended bolt

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 66: Installing Water Pump 3 Bolts And 2 Nuts

   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 67: Installing Engine Mounting Bracket RH 4 Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

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

   Fig 68: Installing Pump Pulley 3 Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the hole of the crankshaft damper with the pin position and install 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 69: Installing Crankshaft 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 "0" of the chain cover.
   2. Check that both timing marks on the camshaft timing sprocket and 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 70: Identifying Timing Marks

   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 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 "0" of the chain cover.
   Fig 71: Measuring Clearance Between Valve Lifter And Camshaft (1 Of 2)

   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 72: Measuring Clearance Between Valve Lifter And Camshaft (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 73: Rotating Crankshaft Damper Counterclockwise 40 Degree From TDC

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 the timing mark "0" of the chain cover.
   2. Check that both timing marks on the camshaft timing sprocket and 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 74: Identifying Timing Marks

   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 camshaft timing gear are located.
   Fig 75: Identifying Paint Marks On Timing Chain

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using an 8 mm hexagon wrench, remove the screw plug.
   Fig 76: Removing Screw Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert a screwdriver into 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 the plunger of the chain tensioner.
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.
   Fig 77: Inserting Screwdriver Into Service Hole

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.
   Fig 78: Removing Camshaft 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 79: Removing 5 Bearing Caps

   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 camshaft timing sprocket.
   Fig 80: Removing Fringe Bolt With No. 2 Camshaft Lifted Up

   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 81: Removing 4 Bearing Caps

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Hold the timing chain by hand, and remove the camshaft and camshaft timing gear assembly.
    Fig 82: 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 83: Tieing Timing Chain With String

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

    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.)) 

    Fig 85: Valve Thickness Specification

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. Select a new lifter with a thickness as close to the calculated values as possible.
    Fig 86: Example Of Specification Valve Clearance

    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 2 pages.
    Fig 87: Valve Lifter Selection Chart (Intake)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 88: 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 painted link and timing marks are aligned as shown in the illustration.
    Fig 89: Installing Timing Chain To Camshaft Timing Gear

    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 90: Identifying Front Marks And Numbers And Tighten Bolts In Sequence

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. Hold the timing chain, and align the timing mark on the camshaft timing sprocket with the painted link on the timing chain.
    Fig 91: Identifying Timing Mark And Painted Link

    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 92: Installing Timing Sprocket Bolt

    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 93: Identifying Front Marks And Numbers And Tighten Bolts In Sequence

    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) 

27. Remove the bar from the timing chain tensioner.
    Fig 94: Tightening 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 95: Inspecting Timing Mark

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. Apply the 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 96: Installing Screw Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install new insulators to each fuel injector.
2. Apply a light coat of grease or gasoline to a new O-ring and install it to each fuel injector.
3. Apply a light coat of grease or gasoline on the place where a delivery pipe contacts the O-ring.
   Fig 97: Installing New Insulator And O-Ring

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

1. Install the 2 spacers to the cylinder head.
   Fig 98: Turning Injector Clockwise And Counterclockwise, Push It To Delivery Pipe

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

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 100: Installing Camshaft Timing Oil Control Valve Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Seal packing: 

   Part No. 08826 - 00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying the seal packing.
   • Do not start the engine within 2 hours of installation.
     Fig 101: Applying Seal Packing To 2 Locations

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cylinder head cover with the 9 bolt, 2 seal washers and 2 nuts.
4. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

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

   Fig 102: Installing Cylinder Head Cover With 9 Bolt, 2 Seal Washers And 2 Nuts

   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 103: 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 gauge 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 104: 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 105: Installing Water Inlet 2 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)