Engine Unit: Reassembly: Reassembly

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INSTALL TIGHT PLUG
NOTE:
If water leaks from the tight plug or the plug corrodes, replace it.
1. Apply adhesive around the tight plugs.
  
  Fig 1: Applying Adhesive Around Tight Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Using SST, tap in the tight plugs.
  - SST: 09950-60010
    - 09951-00340
  - SST: 09950-70010
    - 09951-07100
  Fig 2: Identifying Tight Plugs Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL STRAIGHT PIN

Using a plastic hammer, tap in new straight pins to the cylinder block.

Standard protrusion

Item	Protrusion
Pin A	23 mm (0.906 in.)
Pin B	6 mm (0.236 in.)
Pin C	11 mm (0.433 in.)
Pin D	9 mm (0.354 in.)

Fig 3: Identifying Straight Pins Dimension In Cylinder Block

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL STUD BOLT
1. Using E8 and E10 "TORX" socket wrenches, install the stud bolt.
  A bolt
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  B bolt
  
  Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
  
  Fig 4: Locating No 1 Oil Nozzle Sub-Assembly And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assembly.
  
  Fig 5: Locating Oil Nozzles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL PISTON SUB-ASSEMBLY WITH PIN
1. Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.
  
  Fig 6: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
2. Gradually heat the piston to approximately 80°C (176°F).
  
  Fig 7: Applying Heat To Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the piston pin with engine oil.
  
  Fig 8: Aligning Front Marks Of Piston And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
  HINT:
  
  The piston and pin are a matched set.
5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
  
  Fig 9: Checking Fitting Condition Between Piston And Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.
  
  Fig 10: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
INSTALL PISTON RING SET
1. Install the oil ring expander and 2 side rails by hand.
  
  Fig 11: Identifying Compression Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.
3. Position the piston rings so that the ring ends are as shown in the illustration.
  
  Fig 12: Identifying Piston Rings Gap Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not align the ring ends.
INSTALL CRANKSHAFT BEARING
NOTE:
Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.
1. Clean the main journal and both surfaces of the bearing.
  
  Fig 13: Identifying Journal Bearings Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the upper bearing.
  
  Fig 14: Installing Upper Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the upper crankshaft bearings to the cylinder block as shown in the illustration.
    NOTE:
    Do not apply engine oil to the bearings and the contact surfaces.
    
    Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.
3. Install the lower bearing.
  
  Fig 15: Identifying Lower Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the lower crankshaft bearings to the crankshaft bearing caps.
  2. Using a vernier caliper, measure the distance between the crankshaft bearing cap's edge and the lower crankshaft bearing's edge.
    Dimension (A - B)
    
    0.7 mm (0.0276 in.) or less.
    
    NOTE:
    Do not apply engine oil to the crankshaft bearings and the contact surfaces.
REMOVE CRANKSHAFT THRUST WASHER SET
1. Apply engine oil to the crankshaft thrust washer.
2. Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.
  
  Fig 16: Identifying Oil Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT
1. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
2. Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.
  
  Fig 17: Identifying Front Marks And Numbers Of Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  A number is marked on each main bearing cap to indicate the installation position.
3. Apply a light coat of engine oil to the threads and under the head of the bearing cap bolts.
4. Temporarily install the 8 main bearing cap bolts to the inside positions.
5. Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
  
  Fig 18: Identifying Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt length
  
  100 to 102 mm (3.94 to 4.02 in.)
6. Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
  
  Fig 19: Tapping Bearing Cap To Ensure Proper Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
8. Install the 8 main bearing cap bolts to the outside positions.
  
  Fig 20: Identifying Main Bearing Cap Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt length
  
  105.5 to 107.5 mm (4.15 to 4.23 in.)
9. Install the crankshaft bearing cap bolts.
  
  Fig 21: Tightening Main Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The main bearing cap bolts are tightened in 2 progressive steps.
10. Step 1
  1. Install and uniformly tighten the 16 crankshaft bearing cap bolts in the sequence shown in the illustration.
    Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
    
    If any of the main bearing cap bolts does not meet the torque specified, replace it.
11. Step 2
  
  Fig 22: Identifying Paint Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Mark the front of the bearing cap bolts with paint.
  2. Retighten the bearing cap bolts 90° in the order above.
  3. Check that the painted mark is now at a 90° angle to the front.
12. Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.
  
  Fig 23: Identifying Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf)
  
  HINT:
  - Bolt (A) length: 45 mm (1.77 in.)
  - Except bolt (A) length: 30 mm (1.18 in.)
13. Check that the crankshaft turns smoothly.
14. Check the crankshaft thrust clearance Refer to step 30.
INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearing to the connecting rod and connecting rod cap.
  
  Fig 24: Identifying Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.
  Dimension (A - B)
  
  0.7 mm (0.0276 in.) or less
  
  NOTE:
  Do not apply engine oil to the bearings and the contact surfaces.
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
2. Position the piston rings so that the ring ends are as shown in the illustration.
  
  Fig 25: Identifying Piston Rings Gap Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not align the ring ends.
3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
  
  Fig 26: Pushing Piston And Connecting Rod Assembly Into Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Match the numbered connecting rod cap with the connecting rod.
4. Check that the front mark of the connecting rod cap is facing forward.
  
  Fig 27: Identifying Front Mark Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
6. Install the connecting cap bolts.
  HINT:
  
  The connecting cap bolts are tightened in 2 progressive steps.
7. Step 1
  
  Fig 28: Tightening Connecting Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install and alternately tighten the bolts of the connecting rod cap in several steps.
    Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
8. Step 2
  
  Fig 29: Identifying Retightening Angle Of Connecting Rod Cap Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Mark the front side of each connecting cap bolt with paint.
  2. Tighten the cap bolts another 90° as shown in the illustration.
  3. Check the painted mark is now at a 90° angle to the front.
9. Check that the crankshaft turns smoothly.
10. Check the connecting rod thrust clearance Refer to step 28.
INSTALL RING PIN
1. Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.
  
  Fig 30: Identifying Protrusion Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Specified protrusion height
  
  2.5 to 3.5 mm (0.098 to 0.138 in.)
INSTALL NO. 1 STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs.
  
  Fig 31: Locating No. 1 Straight Screw Plugs And Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
INSTALL NO. 2 STRAIGHT SCREW PLUG
1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs.
  
  Fig 32: Locating No. 2 Straight Screw Plugs And Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
INSTALL STUD BOLT
NOTE:
If the stud bolt is deformed or the threads are damaged, replace it.
1. Using E6 and E8 "TORX" socket wrenches, install the stud bolts.
  A and B bolts
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  C bolt
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 33: Identifying Straight Pins Installing Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STRAIGHT PIN
1. Using a plastic hammer, tap in 4 new straight pins as shown in the illustration.
  Specified protrusion height
  
  17.5 to 19.5 mm (0.689 to 0.768 in.)
  
  Fig 34: Identifying Straight Pin Installation Procedure
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE SPRING SEAT
1. Install the valve spring seats to the cylinder head.
INSTALL VALVE STEM OIL SEAL
1. Apply a light coat of engine oil to new valve stem oil seals.
  
  Fig 35: Identifying Intake And Exhaust Valve Oil Seals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later.
  
  HINT:
  
  The intake valve oil seals are gray and the exhaust valve oil seals are black.
2. Using SST, push in the oil seals.
  
  Fig 36: Pushing In Oil Seals Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09201-41020
  NOTE:
  Failure to use SST will cause the seal to be damaged or improperly seated.
INSTALL INTAKE VALVE
1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
  
  Fig 37: Identifying Intake Valve Tip Area Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.
  NOTE:
  Install the same parts in the same combination to the original locations.
3. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
  
  Fig 38: Compressing Inner Compression Spring To Remove Valve Spring Retainer Locks Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09202-70020
    - 09202-00010
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  
  Fig 39: Tapping Valve Stem Tip To Ensure Proper Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to damage the retainer.
INSTALL EXHAUST VALVE
1. Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration.
  
  Fig 40: Identifying Intake Valve Tip Area Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.
  NOTE:
  Install the same parts in the same combination to the original locations.
3. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
  
  Fig 41: Compressing Inner Compression Spring To Remove Valve Spring Retainer Locks Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09202-70020
    - 09202-00010
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  
  Fig 42: Tapping Valve Stem Tip To Ensure Proper Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to damage the retainer.
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the valve stem caps on the valves.
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 43: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  2.0 to 3.0 mm (0.079 to 0.118 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil seal retainer within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installation.
2. Install the engine rear oil seal retainer with the 6 bolts.
  
  Fig 44: Installing Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE:
  Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
INSTALL WATER INLET PIPE
1. Install the water inlet pipe with the 2 bolts.
  
  Fig 45: Locating Water By-Pass Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install the No. 1 water by-pass hose.
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
1. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
  
  Fig 46: Identifying Cylinder Head Gasket And Lot No. Stamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to allow oil to adhere to the bottom part of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
3. Step 1
  
  Fig 47: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
4. Step 2
  
  Fig 48: Identifying Painted Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  2. Tighten the cylinder head bolts another 90°.
5. Step 3
  1. Tighten the cylinder head bolts by an additional 90°.
  2. Check that the painted mark is now facing rearward.
6. Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
  
  Fig 49: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
1. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
  
  Fig 50: Placing Cylinder Head Gasket On Cylinder Block Surface With Front Face
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful of the installation direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
2. Place the cylinder head on the cylinder block.
  NOTE:
  Be careful not to allow oil to adhere to the bottom part of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
4. Step 1
  
  Fig 51: Locating Cylinder Head Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
5. Step 2
  
  Fig 52: Identifying Painted Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  2. Tighten the cylinder head bolts another 90°.
6. Step 3
  1. Tighten the cylinder head bolts by an additional 90°.
  2. Check that the painted mark is now facing rearward.
7. Tighten the 2 bolts in the order shown in the illustration.
  
  Fig 53: Identifying Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  NOTE:
  Only use the specifications stated above when tightening the bolts 1 and 2 shown in the illustration.
8. Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
  
  Fig 54: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.
1. Place the lash adjuster into a container filled with engine oil.
  
  Fig 55: Checking Movement Of Plunger And Bleed Air
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the SST tip into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
  - SST: 09276-75010
3. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed the air.
  OK
  
  Plunger moves up and down.
  
  NOTE:
  When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.
5. After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly with a finger.
  OK
  
  Plunger is very difficult to move.
  
  If the result is not as specified, replace the lash adjuster.
6. Install the lash adjusters.
  NOTE:
  Install the lash adjuster to the same place where it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Apply engine oil to the lash adjuster tip and valve stem cap end.
  
  Fig 56: Identifying No. 1 Valve Rocker Arm Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Make sure that the 24 No. 1 valve rocker arms are installed as shown in the illustration.
INSTALL CAMSHAFT BEARING CAP RH
1. Apply engine oil to the camshaft journals, camshaft housing sub-assembly RH and camshaft bearing caps.
  
  Fig 57: Identifying Marks And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly RH.
3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
4. Temporarily tighten the 8 bolts in the order shown in the illustration.
  
  Fig 58: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
1. Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 59: Seal Packing In A Continuous Line
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.5 to 4.5 mm (0.138 to 0.177 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing sub-assembly RH within 3 minutes.
  - Do not start the engine for at least 2 hours after installing.
2. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.
  
  Fig 60: Tightening Camshaft Housing Sub-Assembly RH Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
  - If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
3. Tighten the 8 bolts in the order shown in the illustration.
  
  Fig 61: Tightening Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
4. Install 3 new gaskets.
  
  Fig 62: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP
1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
  
  Fig 63: Identifying Marks And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing LH.
3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
4. Temporarily tighten the 8 bolts in the order shown in the illustration.
  
  Fig 64: Tightening Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
1. Apply seal packing in a continuous bead as shown in the illustration.
  
  Fig 65: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.5 to 4.5 mm (0.138 to 0.177 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing sub-assembly LH within 3 minutes.
  - Do not start the engine for at least 2 hours after installing.
2. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.
  
  Fig 66: Tightening Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
  - If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
3. Tighten the 8 bolts in the order shown in the illustration.
  
  Fig 67: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
4. Install 3 new gaskets.
  
  Fig 68: Locating Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
1. Install the No. 2 chain tensioner assembly with the bolt.
  
  Fig 69: Locating No 2 Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
1. Align the mark plates (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.
  
  Fig 70: Identifying Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.
4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
  
  Fig 71: Tightening Flange Bolts Of Camshaft Timing Gear Assembly Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
5. Remove the pin from the No. 2 chain tensioner assembly.
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
1. Install the No. 3 chain tensioner assembly with the bolt.
  
  Fig 72: Identifying No. 3 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to hold it.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
1. Align the mark plates (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration.
  
  Fig 73: Identifying Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.
4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
  
  Fig 74: Identifying Flange Bolts Of The Camshaft Timing Gear Assembly And Timing Exhaust Gear Assembly Components LH Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
5. Remove the pin from the No. 3 chain tensioner assembly.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the No. 1 chain vibration damper with the 2 bolts.
  
  Fig 75: Locating Chain Vibration Damper With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
INSTALL NO. 2 CHAIN VIBRATION DAMPER
1. Install the 2 No. 2 chain vibration dampers.
INSTALL CRANKSHAFT TIMING GEAR
1. Install the timing gear set keys and timing gear as shown in the illustration.
  
  Fig 76: Identifying Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL IDLE SPROCKET ASSEMBLY
1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
2. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.
  
  Fig 77: Installing Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful of the idle gear direction.
  
  HINT:
  
  Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.
3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
  
  HINT:
  
  After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
INSTALL CHAIN SUB-ASSEMBLY
1. Align the mark plates and timing marks as shown in the illustration and install the chain.
  
  Fig 78: Identifying Timing Mark On Marking Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The camshaft mark plate is orange.
2. Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.
  
  Fig 79: Identifying Chain Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks.
  
  Fig 80: Aligning Mark Plate And Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.
4. Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.
  
  Fig 81: Aligning Mark Plate And Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The crankshaft mark plate is yellow.
5. Temporarily tighten the pulley set bolt.
6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).
  
  Fig 82: Identifying Sensor Plate And Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
  
  Fig 83: Moving Stopper Plate Upward To Release Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
3. Install the chain tensioner with the 2 bolts.
  
  Fig 84: Locating Chain Tensioner With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. Remove the hexagon wrench of the chain tensioner.
INSPECT VALVE TIMING
1. Check the camshaft timing marks.
  NOTE:
  - Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear.
  - If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
2. Check that each camshaft timing mark is positioned as shown in the illustration.
  
  Fig 85: Identifying Camshaft Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 86: Identifying Camshaft Timing Mark Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  For the intake camshaft:
  
  Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.
3. If the valve timing is misaligned, reinstall the timing chain.
4. Remove the pulley set bolt.
INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket and the water pump assembly with the 8 bolts.
  
  Fig 87: Locating Water Pump With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  NOTE:
  Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Fig 88: Apply Seal Packing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Seal packing

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

Seal diameter

3.0 mm (0.118 in.) or more
NOTE:
- Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
- When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain cover within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Fig 89: Applying Seal Packing In Continuous Line To Timing Chain Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Seal packing

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

Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent

NOTE:

When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.

Apply seal packing as follows

Area	Seal Packing Diameter	Application Position from Inside Seal Line
Continuous Line Area	4.5 mm (0.177 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Dashed Line Area	3.5 mm (0.138 in.) or more	2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area	3.5 mm (0.138 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area	6.0 mm (0.236 in.) or more	5.0 mm (0.197 in.)

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

Fig 91: Aligning Oil Pump's Drive Rotor Spline And Crankshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Fig 92: Identifying Timing Chain Cover With Bolts

Bolt length

Item	Length
Bolt A	40 mm (1.57 in.)
Bolt B	55 mm (2.17 in.)
Bolt C	25 mm (0.98 in.)

NOTE:

Make sure that there is no oil on the bolt and nut threads.

Fully tighten the bolts in this order: Area 1 and Area 2.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
Fully tighten the bolts and nuts in this order: Area 3.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

HINT:

Tighten the bolts and nuts in the order of upper to lower as shown in the illustration.
Fully tighten the bolts in this order: Area 4.
Bolt A

Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

Bolts except A

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

HINT:

Tighten the bolts in the order of lower to upper as shown in the illustration.
Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)

INSTALL WATER INLET HOUSING
1. Install 2 new O-rings.
  
  Fig 93: Identifying Water Inlet Housing O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply a small amount of water or soapy water to Oring (A) in the illustration before installing it.
2. Install the stud bolts.
  
  Fig 94: Identifying Stud Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
3. Install the water inlet housing with the 2 bolts and nut.
  
  Fig 95: Locating Bolts, Nut, And Water Inlet Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE:
  Be careful that the O-ring does not get caught between the parts.
4. Connect the No. 1 water by-pass hose.
5. Apply adhesive around the drain cock.
  
  Fig 96: Applying Adhesive Around Drain Cock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
6. Install the drain cock assembly to the water inlet housing.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
7. Install the drain cock plug to the water drain cock assembly.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
8. Install a new gasket to the thermostat.
9. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.
  
  Fig 97: Aligning Thermostat Jiggle Valve With Upper Stud Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The jiggle valve may be set within 10° of either side of the prescribed positions.
10. Install the water inlet with the 2 nuts.
  
  Fig 98: Locating Water Inlet With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Install the No. 1 front engine mounting bracket LH with the 6 bolts.
  
  Fig 99: Identifying Stud Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
  NOTE:
  - Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
  - Do not start the engine for at least 2 hours after installation.
2. When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 1 OIL PAN BAFFLE PLATE
1. Install the No. 1 oil pan baffle plate with the 7 bolts.
  
  Fig 100: Locating Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  HINT:
  
  Temporarily tighten the 7 bolts. Fully tighten 2 bolts (A) as shown in the illustration before tightening the other bolts.
INSTALL OIL PAN SUB-ASSEMBLY
1. When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.
  
  Fig 101: Replacing Stud Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install 2 new O-rings.
  
  Fig 102: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 103: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.0 to 4.0 mm (0.118 to 0.156 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
4. Install the oil pan with the 16 bolts and 2 nuts.
  
  Fig 104: Locating Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt A
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Bolts except A
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
  
  Fig 105: Identifying Stud Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
2. Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.
  
  Fig 106: Identifying Oil Strainer Bolt & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
1. Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
  
  Fig 107: Identifying No. 2 Oil Pan Sub-Assembly Stud Bolts Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
2. Apply seal packing in a continuous line as shown in the illustration.
  
  Fig 108: Apply Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.0 to 4.0 mm (0.118 to 0.157 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the No. 2 oil pan within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
3. Install the No. 2 oil pan with the 16 bolts and 2 nuts.
  
  Fig 109: Identifying Oil Pan With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL OIL PAN DRAIN PLUG
1. Install a new oil pan drain plug gasket and the oil pan drain plug.
  
  Fig 110: Locating Oil Pan Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Apply seal packing as shown in the illustration.
  
  Fig 111: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install a new gasket to the head cover.
3. Install a head cover with the 12 bolts and a new washer.
  
  Fig 112: Identifying Head Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt A
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Bolts except A
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  HINT:
  
  After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Apply seal packing as shown in the illustration.
  
  Fig 113: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
3. Install the cylinder head cover with the 12 bolts and a new washer.
  
  Fig 114: Locating Head Cover With Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt A
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Bolts except A
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  HINT:
  
  After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
INSTALL WATER OUTLET
1. Install 2 new gaskets and a new O-ring.
  
  Fig 115: Locating Gaskets And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply soapy water to the O-ring.
2. Install the water outlet with the 2 bolts and 4 nuts.
  
  Fig 116: Locating Bolts, Nuts And Water Outlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolts
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Nuts
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE:
  Be careful that the O-ring does not get caught between the parts.
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
  
  Fig 117: Installing Crankshaft Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the pulley bolt.
  - SST: 09213-70011
    - 09213-70020
  - SST: 09330-00021
  Torque: 250 N*m (2550 kgf*cm, 184 ft.*lbf)
INSTALL OIL FILTER ELEMENT
1. Clean the inside of the oil filter cap sub-assembly, the threads and O-ring groove.
  
  Fig 118: Identifying Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap sub-assembly.
3. Set a new oil filter element to the oil filter cap.
4. Remove dirt or foreign matter from the installation surface of the engine.
5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap sub-assembly.
  NOTE:
  - Be careful that the O-ring does not get caught between the parts.
  - The O-ring must not be twisted on the groove.
6. Using SST, install the oil filter cap.
  
  Fig 119: Tightening Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09228-06501
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  NOTE:
  Make sure that the oil filter is installed securely as shown in the illustration.
7. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
  
  Fig 120: Locating Oil Filter Drain Plug To Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Remove all dirt and foreign matter from the installation surface.
8. Install the oil filter drain plug to the oil filter cap.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  NOTE:
  Make sure that the O-ring does not get caught between the parts.
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive around the drain cocks.
  
  Fig 121: Applying Adhesive Around Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the cylinder block water drain cocks as shown in the illustration.
  
  Fig 122: Identifying Drain Cocks Rotating Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  NOTE:
  Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
3. Install the water drain cock plug to the water drain cocks.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
INSTALL NO. 1 OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
  
  Fig 123: Locating Oil Pipe Unions And Oil Pipe No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not touch the mesh when installing the oil control valve filter.
2. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union bolt.
4. Tighten the oil pipe union (on the head cover side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
5. Tighten the oil pipe union (on the cylinder head side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
  
  NOTE:
  If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
INSTALL OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
  
  Fig 124: Identifying Oil Pipe Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union bolt.
4. Install the bolt (A) to the cylinder head.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
5. Tighten the oil pipe union (on the head cover side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
6. Tighten the oil pipe union (on the cylinder head side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
  
  NOTE:
  If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the crankshaft position sensor with the bolt.
  
  Fig 125: Locating Crankshaft Position Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Install the 4 camshaft timing oil control valves with the 4 bolts.
  
  Fig 126: Locating Bolts And Camshaft Oil Control Valves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT POSITION SENSOR
1. Install the 4 camshaft position sensors with the 4 bolts.
  
  Fig 127: Locating Bolts And Camshaft Position Sensors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL VENTILATION VALVE SUB-ASSEMBLY
1. Apply adhesive around the ventilation valve sub-assembly.
  
  Fig 128: Identifying Ventilation Valve Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the ventilation valve sub-assembly.
  Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
INSTALL SPARK PLUG
1. Install the 6 spark plugs.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install a new oil filler gasket.
2. Install the oil filler cap sub-assembly.