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Partial Engine ASSY: Overhaul

WARNING: This page is about a different car, the 2004 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE SPARK PLUG 
  2. REMOVE OIL FILLER CAP SUB-ASSY 
  3. REMOVE CYLINDER HEAD COVER SUB-ASSY LH 
    1. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
  4. REMOVE CYLINDER HEAD COVER SUB-ASSY 
    1. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
  5. REMOVE TIMING CHAIN OR BELT COVER NO. 2 
    1. Disconnect the 2 PS air hoses from the clamp on the cover.
    2. Remove the cap nut, 3 bolts, cover and gasket.
      Fig 1: Removing Timing Chain Or Belt Cover
      G01029184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE TIMING BELT COVER SUB ASSY NO.3 LH 
    1. Remove the cap nut, and disconnect the No. 3 water bypass pipe from the cover.
    2. Disconnect the 2 water by pass hoses as shown in the illustration.
      Fig 2: Removing Timing Belt Cover Sub-Assy
      G01029185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the engine wire from the 2 wire clamps.
    4. Disconnect the camshaft position sensor connector.
    5. Disconnect the camshaft position sensor wire from the wire clamp on the cover.
    6. Remove the wire grommet from the cover.
    7. Remove the 4 bolts.
    8. Disconnect the cover from the timing plate and camshaft bearing cap.
    9. Disconnect the wire clamp for the sensor from the cover.
    10. Remove the connector holder from the sensor connector.
    11. Remove the cover and gasket.
      Fig 3: Identifying Engine Wire, Wire Grommet, Sensor Connector And Bolts
      G01029186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE IDLER PULLEY ASSY 
    1. Remove the 2 bolts, 2 nuts and idler pulley.
  8. REMOVE TIMING BELT COVER SUB-ASSY NO.2 
    1. Remove the 2 bolts and timing belt cover.
  9. REMOVE IDLER PULLEY SUB-ASSY NO.2 
    1. Remove the pulley bolt, cover plate and idler pulley.
  10. REMOVE V-RIBBED BELT TENSIONER ASSY 
    1. Remove the bolt, 2 nuts and belt tensioner.
  11. REMOVE CRANKSHAFT DAMPER SUB-ASSY 
    1. Using SST, remove the damper bolt.

      SST 09213-70011, 09330-00021

      Fig 4: Removing Damper Bolt
      G01029187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the damper.

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

      Fig 5: Removing Damper
      G01029188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE TIMING BELT NO.1 COVER 
    1. Remove the 4 bolts and cover.
  13. REMOVE TIMING GEAR COVER SPACER 
  14. REMOVE CRANKSHAFT POSITION SENSOR PLATE 
  15. REMOVE TIMING BELT 
    1. If planning to reuse the timing belt, check the installation marks on the belt.
      1. Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.

        If the installation marks have disappeared, place a new installation mark on the timing belt before removing each part.

        Fig 6: Identifying Timing Belt Installation Mark
        G01029189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Set the No. 1 cylinder to approximately 50° BTDC/compression.
      1. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
        Fig 7: Turning Crankshaft
        G01029190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned.

        If not, turn the crankshaft 1 revolution (360°).

        Fig 8: Checking Timing Mark
        G01029191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approximately 50°.
      NOTE: With timing belt disengaged: The crankshaft damper must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and then the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and be damaged.
    3. Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot.
      Fig 9: Identifying Timing Mark
      G01029192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley counterclockwise.

      SST 09960-10010 (09962-01000, 09963-00350)

    5. Disconnect the belt from the timing belt idler No. 1, and remove the belt.
      Fig 10: Using SST
      G01029193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT TIMING BELT 
    NOTE:
    • Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to come into contact with oil, water or steam.
    • Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley.

    If there are any defects, as shown in the illustrations, check these points:

    1. Premature parting
      1. Check for proper installation.
      2. Check the timing cover gasket for damage and proper installation.
    2. If the belt teeth are cracked or damaged, check to see if either camshaft is locked.
      Fig 11: Inspecting Timing Belt
      G01029194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump.
    4. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
    5. If there is noticeable wear on the belt teeth, check the timing cover for damage, check that the gasket has been installed correctly, and check for foreign material on the pulley teeth.

      If necessary, replace the timing belt.

  17. INSPECT TIMING BELT TENSIONER 
    1. Visually check the seal portion of the tensioner for oil leakage.

      HINT:

      If there is only the faint trace of oil on the push rod, the tensioner does not need to be replaced.

      If leakage is found, replace the tensioner.

      Fig 12: Inspecting Timing Belt Tensioner
      G01029195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hold the tensioner with both hands and push the push rod strongly as shown to check that it does not move.

      If the push rod moves, replace the tensioner.

      NOTE: Never hold the tensioner push rod facing downward.
      Fig 13: Checking Push Rod Of Timing Belt Tensioner
      G01029196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the protrusion of the push rod from the housing end.

      Protrusion: 9.5 to 10.5 mm (0.374 to 0.413 in.) 

      If the protrusion is not as specified, replace the tensioner.

      Fig 14: Measuring Protrusion Of Push Rod From Housing End
      G01029197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE TIMING BELT IDLER SUB-ASSY NO. 1 
    1. Using a 10 mm hexagon wrench, remove the bolt, and plate washer.
  19. REMOVE TIMING BELT IDLER SUB-ASSY NO. 2 
    1. Remove the bolt and idler.
  20. INSPECT TIMING BELT IDLER SUB-ASSY NO.1 
    1. Visually check the seal portion of the idler for oil leakage.

      If leakage is found, replace the idler.

    2. Check that the idler turns smoothly.

      If necessary, replace the idler.

      Fig 15: Inspecting Timing Belt Idler Sub-Assy
      G01029198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE CRANKSHAFT TIMING PULLEY 
    1. Using SST, remove the timing pulley.

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

      NOTE: Do not turn the timing pulley.
      Fig 16: Removing Crankshaft Timing Pulley
      G01029199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE CAMSHAFT TIMING PULLEY 
    1. Remove the 4 bolts and timing pulley.
      Fig 17: Removing Camshaft Timing Pulley
      G01029200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSY LH 
    1. Remove the 4 bolts and timing pulley.
  24. REMOVE CAMSHAFT 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    Fig 18: Removing Camshaft Timing Pulley Sub-Assy LH
    G01029201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the camshafts of the RH bank.
      1. Bring the service bolt hole of the sub gear upward by turning the hexagon wrench head portion oft No. 2 camshaft with a wrench.
      2. Secure the sub gear to the main gear with a service bolt.

        Recommended service bolt: 

        Fig 19: Recommended Service Bolt Chart
        G01029202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Fig 20: Identifying Service Bolt
        G01029203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        When removing the camshafts, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

      3. Set the timing mark (1 dot mark) of the camshaft main gear at approximately 10° angle by turning the hexagon wrench head portion of the No. 2 camshaft with a wrench.
        Fig 21: Setting Timing Mark
        G01029204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
      5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.
  25. REMOVE NO.3 CAMSHAFT SUB-ASSY 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    Fig 22: Identifying Bearing Caps Bolts
    G01029205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the camshafts of the LH bank.
      1. Boring the service bolt hole of the sub gear upward by turning the hexagon wrench head portion of the No. 4 camshaft with a wrench.
      2. Secure the sub gear to the main gear with a service bolt.
        Fig 23: Removing Camshafts Of LH Bank
        G01029206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Recommended service bolt: 

        Fig 24: Recommended Service Bolt Chart
        G01029207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

      3. Align the timing mark (2 clot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the No. 4 camshaft with a wrench.
        Fig 25: Identifying Dot Marks
        G01029208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
      5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.
        Fig 26: Identifying Bearing Caps Bolts
        G01029209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE SEMICIRCULAR PLUG 
  27. REMOVE TIMING BELT PLATE RR RH NO.2 
    1. Remove the 2 bolts and timing belt plate.
  28. REMOVE TIMING BELT PLATE RRRH 
    1. Remove the bolt, stud bolt and timing belt plate.
  29. REMOVE TIMING BELT PLATE RR LH NO.2 
    1. Remove the 2 bolts and timing belt plate.
  30. REMOVE TIMING BELT PLATE RR LH 
    1. Remove the bolt and timing belt plate.
  31. REMOVE CYLINDER HEAD SUB-ASSY 
    1. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes in the sequence shown in the illustration.
      Fig 27: Identifying Bolts Position
      G01029210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Cylinder head warpage or cracking could result from removing bolts in incorrect order.
      • Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
        Fig 28: Identifying Portion A
        G01029211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

      HINT:

      If the cylinder head cannot be removed, pry between the cylinder head and cylinder block with a screwdriver.

      NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
      Fig 29: Lifting Cylinder Head
      G01029212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE CYLINDER HEAD LH 
    1. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes in the sequence shown in the illustration.
      Fig 30: Removing Cylinder Head LH
      G01029213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Cylinder head warpage or cracking could result from removing bolts in incorrect order.
      • Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
      Fig 31: Identifying Portion A
      G01029214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

      HINT:

      If the cylinder head cannot be removed, pry between the cylinder head and cylinder block with a screwdriver.

      NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
      Fig 32: Lifting Cylinder Head From Dowel
      G01029215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE WATER PUMP ASSY 
    1. Remove the 5 bolts, 2 stud bolts and nut, water pump and gasket.
  34. REMOVE OIL PAN SUB-ASSY NO. 2 (See  OVERHAUL  ) 
  35. REMOVE OIL PAN BAFFLE PLATE 
    1. Remove the 3 bolts, 2 nuts and baffle plate.
  36. REMOVE OIL PAN SUB-ASSY (See  OVERHAUL  ) 
  37. REMOVE OIL STRAINER SUB-ASSY 
    1. Remove the bolt, 2 nuts, oil strainer and gasket.
  38. REMOVE OIL PUMP ASSY (See  OVERHAUL  ) 
  39. REMOVE ENGINE REAR OIL SEAL RETAINER 
    1. Remove the 7 bolts.
    2. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
    3. Remove the O-ring.
      Fig 33: Removing Engine Rear Oil Seal Retainer
      G01029216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE SPARK PLUG TUBE GASKET 
    1. Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more.
    2. Using a screwdriver, pry out the gasket.

      HINT:

      Tape the screwdriver tip before use.

      NOTE: Be careful not to damage the cylinder head cover.
      Fig 34: Removing Spark Plug Tube Gasket
      G01029217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL SPARK PLUG TUBE GASKET 
    1. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.

      SST 09950-60010, 09950-70010 (09951-00240, 09951-00440, 09951-07100, 09952-06010)

      Fig 35: Installing Spark Plug Tube Gasket
      G01029218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful of the installation direction.
    2. Apply a light coat of MP grease to the gasket lip.
    3. Return the 4 ventilation case claws to its original position.
  42. REMOVE CAMSHAFT TIMING TUBE ASSY 
    1. Mount the hexagon wrench head portion of the camshaft in a vise.
      NOTE:
      • Be careful not to damage the camshaft.
      • Do not remove the 4 bolts shown in the illustration. The bolts determine the backlash of the gear in the timing tube. If any of the bolts are removed, install a new timing tube assembly.
      Fig 36: Removing Camshaft Timing Tube Assy
      G01029219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the screw plug and seal washer.
    3. Using a 10 mm hexagon wrench, and remove the bolt.
    4. Pull out the timing tube and drive gear assembly from the camshaft.
      Fig 37: Removing Timing Tube And Drive Gear Assembly
      G01029220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.

      SST 09960-10010 (09962-01000, 09963-00500)

      NOTE: Be careful not to damage the timing tube.
      Fig 38: Identifying Hexagon Wrench
      G01029221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL CAMSHAFT SETTING OIL SEAL 
    1. Place a new oil seal onto the timing tube.
      NOTE: Be careful of the installation direction.
      Fig 39: Installing Camshaft Setting Oil Seal
      G01029222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CAMSHAFT TIMING TUBE ASSY 
    1. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
    2. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.

      SST 09960-10010 (09962-01000, 09963-00500)

      Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf) 

      Fig 40: Installing Camshaft Timing Tube Assy
      G01029223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the timing tube.
    3. Mount the hexagon wrench head portion of the camshaft in a vise.
      NOTE: Be careful not to damage the camshaft.
      Fig 41: Mounting Hexagon Wrench Head Portion Of Camshaft In A Vise
      G01029224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
    5. Using a 10 mm hexagon wrench, install the bolt.

      Torque: 78 N.m (795 kgf.cm, 58 ft.lbf) 

    6. Install the seal washer and screw plug.

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

      Fig 42: Identifying Hexagon Wrench
      G01029225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CAMSHAFT SUB GEAR 
    1. Mount the hexagon wrench head portion of the camshaft in a vise.
      NOTE: Be careful not to damage the camshaft.
      Fig 43: Removing Camshaft Sub Gear
      G01029226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, turn the sub gear clockwise and remove the service bolt.

      SST 09960-10010 (09962-01000, 09963-00500)

      Fig 44: Removing Service Bolt
      G01029227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using snap ring plier, remove the snap ring.
    4. Remove the wave washer, sub gear and bolt washer.

      HINT:

      Arrange the driven sub gears and bolt washers (RH and LH sides).

      Fig 45: Removing Snap Ring
      G01029228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSPECT CAMSHAFT TIMING GEAR BOLT WASHER 
    1. Using a vernier caliper, measure the gap between the washer ends.

      Gap: 18.2 to 18.8 mm (0712 to 0.740 in.) 

      If the is not as specified, replace the washer.

      Fig 46: Measuring Gap Between Washer Ends
      G01029229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL CAMSHAFT SUB GEAR 
    1. Install the bolt washer (1), sub gear (2) and wave washer (3).

      HINT:

      Attach the pins on the gears to the gear bolt washer ends.

      Fig 47: Installing Bolt Washer, Sub Gear And Wave Washer
      G01029230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using snap ring pliers, install the snap ring.
      Fig 48: Installing Snap Ring
      G01029231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount the hexagon wrench head portion of the camshaft in a vise.
      NOTE: Be careful not to damage the camshaft.
      Fig 49: Mounting Hexagon Wrench Head Portion Of Camshaft In Vise
      G01029232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, again the holes of the drives main gear and sub gear by turning the sub gear clockwise. Temporarily install a service bolt.

      SST 09960-10010 (09962-01000, 09963-00500)

    5. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.
      Fig 50: Aligning Gear Teeth Of Driven Main Gear And Sub Gear
      G01029233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE OIL PUMP SEAL 
    1. Using a screwdriver and wooden block, pry out the oil seal.

      HINT:

      Tape the screwdriver tip before use.

      NOTE: Be careful not to damage the oil pump body.
      Fig 51: Removing Oil Pump Seal
      G01029234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL OIL PUMP SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.

      SST 09316-60011 (09316-00011)

    2. Apply MP grease to the oil seal lip.
      Fig 52: Installing Oil Pump Seal
      G01029235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE ENGINE REAR OIL SEAL 
    1. Using a screwdriver and hammer, tap out the oil seal.
      Fig 53: Removing Engine Rear Oil Seal
      G01029236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL ENGINE REAR OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.

      SST 09223-56010

    2. Apply MP grease to the oil seal lip.
  52. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
      1. Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
      2. Thoroughly clean all components to remove all the loose material.
      3. Using a non-residue solvent, clean both sealing surfaces.
        Fig 54: Installing Engine Rear Oil Seal
        G01029237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing to the oil seal retainer as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      1. Install a nozzle that has its opening cut to 3 to 4 mm (0.12 to 0.16 in.).
      2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
      3. Immediately remove the nozzle from the tube and
        Fig 55: Applying Seal Packing To Oil Seal Retainer
        G01029238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new O-ring to the cylinder block.
    4. Install the oil seal retainer with the 7 bolts.

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

      Fig 56: Installing New O-Ring To Cylinder Block
      G01029239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL OIL PUMP ASSY (See  OVERHAUL  ) 
  54. INSTALL OIL STRAINER SUB-ASSY (See  OVERHAUL  ) 
  55. INSTALL OIL PAN STUD BOLT 
    Fig 57: Installing Oil Pan Stud Bolt
    G01029240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL OIL PAN SUB-ASSY (See  OVERHAUL  ) 
  57. INSTALL OIL PAN BAFFLE PLATE (See  OVERHAUL  ) 
  58. INSTALL OIL PAN SUB-ASSY NO.2 (See  OVERHAUL  ) 
  59. INSTALL WATER PUMP ASSY 
    1. Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.

      Torque: 

      21 N.m (214 kgf.cm, 16 ft.lbf) for bolt 

      18 N.m (184 kgf.cm, 13 ft.lbf) for stud bolt and nut 

      HINT:

      Use bolts that are 30 mm (1.18 in.) in length.

      Fig 58: Installing Water Pump Assy
      G01029241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL CYLINDER HEAD SUB-ASSY 
    1. Place a new cylinder head gasket on the cylinder block.

      HINT:

      The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3R" mark is on the RH bank's gasket.

      NOTE: Be careful of the installation direction.
    2. Place the cylinder head on the cylinder head gasket.
      Fig 59: Identifying New Cylinder Gasket
      G01029242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cylinder head bolts.

      HINT:

      • The cylinder head bolts are tightened in 2 progressive steps (steps ( 3) and ( 5).
      • If any cylinder head bolt is broken or deformed, replace it.
      1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
      2. Install the plate washer to the cylinder head bolt.
      3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown in the illustration.

        Torque: 59 N.m (602 kgf.cm, 44 ft.lbf) 

        Fig 60: Identifying Place For Cylinder Head Bolt
        G01029243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

        NOTE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
        Fig 61: Identifying Portion A
        G01029244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Mark the front of the cylinder head bolt head with paint.
      5. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
      6. Check that the painted mark is now at a 90° angle to front.
        Fig 62: Identifying Painted Mark
        G01029245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL CYLINDER HEAD LH 
    1. Place a new cylinder head gasket on the cylinder block.

      HINT:

      The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3L" mark is on the LH bank's gasket.

      NOTE: Be careful of the installation direction.
    2. Place the cylinder head on the cylinder head gasket.
      Fig 63: Placing New Cylinder Head Gasket
      G01029246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cylinder head bolts.

      HINT:

      • The cylinder head bolts are tightened in 2 progressive steps (steps ( 3) and ( 5)).
      • If any cylinder head bolt is broken or deformed, replace it.
      1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
      2. Install the plate washer to the cylinder head bolt.
      3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown in the illustration.

        Torque: 59 N.m (602 kgf.cm, 44 ft.lbf) 

        Fig 64: Identifying Bolts Installing Position
        G01029247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

        NOTE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
        Fig 65: Identifying Portion A
        G01029248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Mark the front of the cylinder head bolt head with paint.
      5. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
      6. Check that the painted mark is now at a 90° angle to front.
        Fig 66: Identifying Painted Mark
        G01029249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL CAMSHAFT 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    1. Set the crankshaft position.
      1. Using the crankshaft damper bolt, turn the crankshaft, and set the set key of the crankshaft to 90° counterclockwise from the timing mark (1 dot mark) of the oil pump body.
        Fig 67: Identifying Set Key
        G01029250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.
    2. Install the camshafts of the RH bank.
      1. Apply MP grease to the thrust portion of the camshafts.
      2. Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts.
      3. Set the timing mark (1 dot mark) of the camshaft drive and driven main gears at approximately 10° angle.
        Fig 68: Identifying Timing Mark (RH Bank)
        G01029251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Apply seal packing to the camshaft housing plug.
        • Remove the old packing (FIPG) material.
        • Apply seal packing to the housing plug.

        Seal packing: Part No. 08826-00080 or equivalent 

        Fig 69: Identifying Seal Packing
        G01029252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Install the camshaft housing plug to the cylinder head as shown in the illustration.
      6. Install the oil control valve filter to the cylinder head.
        NOTE: Be careful of the installation direction.
        Fig 70: Installing Camshaft Housing Plug To Cylinder Head
        G01029253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. Apply seal packing to the front bearing cap.
        • Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
        • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
        • Thoroughly clean all components to remove all loose material.
          Fig 71: Applying Seal Packing To Front Bearing Cap
          G01029254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Using a non-residue solvent, clean both sealing surfaces.
        • Apply seal packing to the bearing cap shown in the illustration.
        • Install a nozzle that has been cut to a 1.5 to 2.0 mm (0.059 to 0.79 in.) opening.
        • Parts must be assembled within 5 minutes of application. Otherwise, the seal packing must be removed and reapplied.
        • Immediately remove the nozzle from the tube and reinstall the cap.

        Seal packing: Part No. 08826-00080 or equivalent 

        NOTE: Do not apply seal packing to the front bearing cap grooves.
      8. Install the front bearing cap.

        HINT:

        Installing the front bearing cap will determine the thrust portion of the camshaft.

      9. Install the other bearing caps in the sequence shown with the arrow mark facing forward.
        Fig 72: Installing Front Bearing Cap
        G01029255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      10. Push in the camshaft setting oil seal.
        Fig 73: Installing Camshaft Setting Oil Seal
        G01029256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      11. Install a new seal washer to the bearing cap bolt (A and B).
      12. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (D and E).
        NOTE: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C).

        Bolt length: 

        94 mm (3.70 in.) for A with seal washer 

        72 mm (2.83 in.) for B with seal washer 

        25 mm (0.98 in.) for C 

        52 mm (2.05 in.) for D 

        38 mm (1.50 in.) for E 

      13. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
        Fig 74: Installing Oil Feed Pipe And Bearing Cap Bolts
        G01029257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      14. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.

        Torque: 

        7.5 N.m (77 kgf.cm, 66 in. lbf) for bolt 21 and 22 

        16 N.m (163 kgf.cm, 12 ft.lbf) for others 

        Fig 75: Tightening Bearing Cap Bolts
        G01029258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      15. Remove the service bolt.
        Fig 76: Removing Service Bolt
        G01029259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL NO.3 CAMSHAFT SUB-ASSY 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    1. Check the set key of the crankshaft is at the position of 90° counterclockwise from the timing mark (1 dot mark) of the oil pump body.
      NOTE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.
      Fig 77: Identifying Timing Mark And Set Key
      G01029260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the camshafts of the LH bank.
      1. Apply MP grease to the thrust portion of the camshafts.
      2. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the 2 camshafts.
        Fig 78: Installing Camshafts Of LH Bank
        G01029261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Apply seal packing to the camshaft housing plug.
        • Remove the old packing (FIPG) material.
        • Apply seal packing to the housing plug.

        Seal packing: Part No. 08826-00080 or equivalent 

        Fig 79: Applying Seal Packing To Housing Plug
        G01029262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Install the camshaft housing plug to the cylinder head as shown in the illustration.
      5. Install the oil control valve filter to the cylinder her
        NOTE: Be careful of the installation direction.
        Fig 80: Installing Camshaft Housing Plug To Cylinder Head
        G01029263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Apply seal packing to the front bearing cap.
        • Remove any old packing (FIPG) material and be care not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
        • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
        • Thoroughly clean all components to remove all loose material.
        • Using a non-residue solvent, clean both sealing surfaces.
        • Apply seal packing to the bearing cap as shown in the illustration.
        • Install a nozzle that has its opening cut to 1 5 to 2.0 mm (0.059 to 0.79 in.).
        • Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
        • Immediately remove the nozzle from the tube and reinstall the cap.
          Fig 81: Applying Seal Packing To Bearing Cap
          G01029264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Seal packing: Part No. 08826-00080 or equivalent 

        NOTE: Do not apply seal packing to the front bearing cap grooves.
      7. Install the front bearing cap.

        HINT:

        Installing the front bearing cap will determine the thrust portion of the camshaft.

      8. Install the other bearing cap in the sequence shown with the arrow mark facing forward.
        Fig 82: Installing Front Bearing Cap
        G01029265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      9. Push in the camshaft setting oil seal.
        Fig 83: Pushing In Camshaft Setting Oil Seal
        G01029266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      10. Install a new seal washer to the bearing cap bolt (A and B).
      11. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (D and E).
        NOTE: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C).

        Bolt length: 

        94 mm (3.70 in.) for A with seal washer 

        72 mm (2.83 in.) for B with seal washer 

        25 mm (0.98 in.) for C 

        52 mm (2.05 in.) for D 

        38 mm (1.50 in.) for E 

        Fig 84: Installing A New Seal Washer To Bearing Cap Bolt
        G01029267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      12. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
      13. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.

        Torque: 

        7.5 N.m (77 kgf.cm, 66 in. lbf) for bolt C 

        16 N.m (163 kgf.cm, 12 ft.lbf) for others 

        Fig 85: Installing Bearing Cap Bolts
        G01029268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      14. Remove the service bolt.
        Fig 86: Removing Service Bolt
        G01029269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL TIMING BELT PLATE RR RH 
    1. Install the timing belt plate with the bolt and stub bolt.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in. lbf) 

  65. INSTALL TIMING BELT PLATE RR RH NO. 2 
    1. Install the timing belt plate with the 2 bolts.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in. lbf) 

  66. INSTALL TIMING BELT PLATE RR LH 
    1. Install the timing belt plate with the bolt.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in. lbf) 

  67. INSTALL TIMING BELT PLATE RR LH NO. 2 
    1. Install the timing belt plate with the 2 bolts.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in. lbf) 

  68. INSTALL CAMSHAFT TIMING PULLEY 
    1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
    2. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward.
    3. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.

      Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf) 

      Fig 87: Installing Camshaft Timing Pulley
      G01029270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSY LH 
    1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
    2. Attach the timing pulley to the camshaft timing tube, Face the timing pulley's "L" mark forward.
    3. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.

      Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf) 

      Fig 88: Installing Camshaft Timing Pulley Sub-Assy LH
      G01029271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL CRANKSHAFT TIMING PULLEY 
    1. Align the timing pulley set key with the key groove of the pulley.
    2. Using SST and a hammer, tap in the timing pulley. Face the flange side inward.

      SST 09223-46011

      Fig 89: Installing Crankshaft Timing Pulley
      G01029272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL TIMING BELT IDLER SUB-ASSY NO. 2 
    1. Install the idler with the bolt.

      Torque: 34.5 N.m (352 kgf.cm, 25 ft.lbf) 

    2. Check that the idler moves smoothly.
  72. INSTALL TIMING BELT IDLER SUB-ASSY N0.1 
    1. Apply adhesive to 2 or 3 threads of the pivot bolt.

      Adhesive: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    2. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.

      Torque: 34.5 N.m (352 kgf.cm, 25 ft.lbf) 

    3. Check that the idler bracket moves smoothly.
      Fig 90: Installing Timing Belt Idler Sub-Assy
      G01029273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL TIMING BELT 
    NOTE: The engine should be cold.
    1. Set the No. 1 cylinder to TDC/compression.
      1. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.
        Fig 91: Installing Timing Belt
        G01029274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.

        Camshaft timing pulley of LH bank: 1/2 of a tooth

        Camshaft timing pulley of RH bank: 1 tooth

        Fig 92: Identifying Booths
        G01029275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
        Fig 93: Aligning Timing Marks
        G01029276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the timing belt.
      1. Remove any oil or water on each pulley, and keep them clean.
        NOTE: Only wipe the pulleys. Do not use cleaning agents on the pulleys.
      2. Face the front mark (arrow) on the timing belt forward.
      3. Connect the timing belt to the crankshaft timing pulley.
        Fig 94: Identifying Timing Belt
        G01029277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • Align the installation mark on the tinning belt with the timing mark of the crankshaft timing pulley.
      4. Connect the timing belt to the idler No. 2.
      5. Connect the timing belt to the camshaft timing pulley LH.
        • Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
      6. Connect the timing belt to the water pump pulley.
      7. Connect the timing belt to the camshaft timing pulley (RH bank).
        • Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
      8. Connect the timing belt to the idler No. 1.
      9. Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure.
      10. Align the holes of the push rod and housing. Pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
      11. Release the press.
      12. Install the dust boot to the belt tensioner.
    3. Install the belt tensioner.
      1. Temporarily install the belt tensioner with the 2 bolts.
      2. Alternately tighten the 2 bolts.

        Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) 

        Fig 95: Installing Belt Tensioner
        G01029278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
    4. Check the valve timing.
      1. Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
        NOTE: Always turn the crankshaft pulley clockwise.
        Fig 96: Checking Valve Timing
        G01029279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Check that each pulley aligns with the timing marks as shown in the illustration.

        If the timing marks do not align, remove the timing belt and reinstall it.

        Fig 97: Checking Timing Marks
        G01029280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 
    1. Install the sensor plate. Face the cup side outward.
  75. INSTALL TIMING GEAR COVER SPACER 
    1. Install the gasket to the cover spacer.
    2. Install the cover spacer.
  76. INSTALL TIMING BELT NO. 1 COVER 
    1. Install the timing belt cover with the 4 bolts.

      Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf) 

  77. INSTALL CRANKSHAFT DAMPER SUB-ASSY 
    1. Using SST and a hammer, tap in the crankshaft damper.

      SST 09223-46011

      Fig 98: Installing Crankshaft Damper Sub-Assy
      G01029281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the damper bolt.

      SST 09213-70010, 09330-00021

      Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf) 

    3. Align the pulley set key with the groove of the crankshaft damper.
      Fig 99: Installing Damper Bolt
      G01029282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. ADJUST VALVE CLEARANCE (See  VALVE CLEARANCE  ) 
  79. INSTALL V-RIBBED BELT TENSIONER ASSY 
    1. Install the belt tensioner with the bolt and 2 nuts.

      Torque: 16 N.m (163 kgf.cm, 11 ft.lbf) 

      HINT:

      a bolt that is 106 mm (4.18 in.) in length.

  80. INSTALL IDLER PULLEY SUB-ASSY NO. 2 
    1. Install the idler pulley and cover plate with the bolt.

      Torque: 39 N.m (398 kgf.cm, 29 ft.lbf) 

  81. INSTALL TIMING BELT COVER SUB-ASSY NO.2 
    1. Fit the timing belt cover, matching the claws and pin with each part.
    2. Install the timing belt cover with the 2 bolts.

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

      HINT:

      Use bolts that are 106 mm (4.17 in.) in length.

      Fig 100: Installing Timing Belt Cover Sub-Assy
      G01029283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. INSTALL IDLER PULLEY ASSY 
    1. Install the idler pulley with the 2 bolts and 2 nuts.

      Torque: 

      16 N.m (163 kgf.cm, 12 ft.lbf) for 12 mm head bolt 

      32 N.m (326 kgf.cm, 24 ft.lbf) for 14 mm head bolt 

      Bolt length: 

      114 mm (4.49 in.) for 14 mm head (A) 

      106 mm (4.17 in.) for 12 mm head (B) 

      Fig 101: Installing Idler Pulley Assy
      G01029284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. INSTALL TIMING BELT COVER SUB-ASSY NO.3 LH 
    1. Install the gasket to the cover.
    2. Run the camshaft position sensor wire through the cover hole.
    3. Install the cover with the 4 bolts.

      Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf) 

    4. Install the wire grommet to the cover.
    5. Install the sensor connector to the sensor holder.
    6. Connect the sensor connector.
    7. Install the sensor wire to the wire clamp on the cover,
    8. Install the engine wire to the 2 wire clamps on the cover.
      Fig 102: Installing Timing Belt Cover Sub-Assy
      G01029285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the 2 water by pass hoses, as shown in the illustration.
    10. Install the No. 3 water by pass pipe to the cover with the cap nut.

      Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf) 

    11. Install the engine wire to the 2 wire clamps on the cover.
      Fig 103: Connecting Water By-Pass Hoses
      G01029286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL TIMING CHAIN OR BELT COVER NO. 2 
    1. Install the gasket to the cover.
    2. Install the cover with the cap nut and 3 bolts.

      Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf) 

    3. Install the 2 PS air hoses to the clamp on the cover.
      Fig 104: Identifying PS Air Hose
      G01029287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL SEMICIRCULAR PLUG 
    1. Remove any old packing (FIPG) material
    2. Apply seal packing to the semicircular plug grooves.

      Seal packing: Part No. 08826-00080 or equivalent 

      Fig 105: Identifying Seal Packing
      G01029288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 4 semicircular plugs to the cylinder heads as shown in the illustration.
      Fig 106: Identifying Semicircular Plugs
      G01029289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL CYLINDER HEAD COVER SUB-ASSY 
    1. Remove any old packing (FIPG) material.
    2. Apply seal packing to the cylinder heads as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

    3. Install the gasket to the cylinder head cover.
    4. Install the seal washer to the bolt.
    5. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.

      Torque: 6.0 N.m (61 kgf.cm, 53 in. lbf) 

      Fig 107: Installing Cylinder Head Cover Sub-Assy
      G01029290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. INSTALL OIL FILLER CAP SUB-ASSY 
  88. INSTALL SPARK PLUG 
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