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Section 50 (Partial Engine): Overhaul

WARNING: This page is about a different car, the 2004 Toyota Sienna. 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-ASSEMBLY 
  3. REMOVE OIL FILLER CAP GASKET 
  4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
  5. REMOVE CYLINDER HEAD COVER GASKET NO. 2 
  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
  7. REMOVE CYLINDER HEAD COVER GASKET 
  8. REMOVE VENTILATION VALVE SUB-ASSEMBLY 
  9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Remove both camshaft oil control valves.
    2. Remove the O-ring from each camshaft oil control valve.
  10. REMOVE VVT SENSOR 
  11. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY 
  12. REMOVE OIL LEVEL GAGE GUIDE 
  13. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, loosen the pulley bolt.

      SST 09213-54015 (91651-60855), 09330-00021

      Fig 1: Loosening Pulley Bolt By Using SST
      G03062168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and the pulley bolt, remove the pulley.

      SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)

    NOTE: Before using SST, apply lubricating oil on the threads and tip of the center bolt 150.
    Fig 2: Removing Pulley
    G03062169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE TIMING BELT NO. 1 COVER 
  15. REMOVE TIMING BELT NO. 2 COVER 
  16. REMOVE ENGINE MOUNTING BRACKET RH 
  17. REMOVE TIMING BELT GUIDE NO. 2 
  18. REMOVE TIMING BELT 
    1. Set No. 1 cylinder to TDC/compression.
      1. Temporarily install the crankshaft pulley bolt and the washer to the crankshaft.
      2. Turn the crankshaft clockwise, and align the timing marks of the crankshaft timing pulley and the oil pump body.
        Fig 3: Aligning The Timing Marks
        G03062170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Check that timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned.
        Fig 4: Checking Timing Marks Of Camshaft Timing Pulleys
        G03062171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      4. Remove the crankshaft pulley bolt.
    2. If re-using the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.
      1. If the installation marks have disappeared, put new installation marks on the timing belt before removing.
      Fig 5: Identifying Installation Marks On Timing Belt
      G03062172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set No. 1 cylinder to approx. 60°BTDC/ compression.
      1. Turn the crankshaft counterclockwise by approx. 60°.
        2. Fig 6: Turning Crankshaft
        G03062173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.
    4. Remove the timing belt tensioner.
      NOTE: Do not install the tensioner as it removed.
    5. Remove the timing belt in this order.
    TIMING BELT SPECIFICATION

    1st No. 1 idler pulley
    2nd RH camshaft timing pulley
    3rd No. 2 idler pulley
    4th LH camshaft timing pulley
    5th Water pump pulley
    6th Crankshaft timing pulley
    Fig 7: Timing Belt
    G03062174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 1 
    1. Using a 10 mm socket hexagon wrench, remove the pivot bolt, the timing belt idler No. 1 and the plate washer.
  20. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 2 
  21. REMOVE CRANKSHAFT POSITION SENSOR 
  22. REMOVE CAMSHAFT TIMING PULLEY 
    1. Using SST, remove the bolt and the RH timing pulley.

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

      Fig 8: Removing Bolt Of RH Timing Pulley
      G03062175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the bolt and the LH timing pulley.

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

    HINT:

    Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when re-assembling.

    Fig 9: Removing Bolt And LH Timing Pulley
    G03062176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TIMING BELT NO. 3 COVER 
  24. REMOVE TIMING BELT IDLER BRACKET 
  25. REMOVE CRANKSHAFT TIMING PULLEY 
    1. Remove the bolt and the timing belt plate.
    2. Install the pulley bolt to the crankshaft.
    3. Using SST, remove the crankshaft timing pulley.

      SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)

    Fig 10: Removing Crankshaft Timing Pulley
    G03062177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Do not scratch the sensor part of the crankshaft timing pulley.
    • Before using SST, apply lubricating oil on the threads and tip of the center bolt 150.
  26. REMOVE WATER PUMP ASSEMBLY 
    1. Remove the 3 bolts, the 3 nuts, the water pump and the gasket.
      2. Fig 11: Removing Bolts And Nuts Of Water Pump
      G03062178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Align the timing marks (2 dot marks) of the camshaft drive and the driven gears by turning the camshaft with a wrench.
      Fig 12: Aligning Timing Marks (2 Dot Marks)
      G03062179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Secure the exhaust camshaft sub-gear to the main gear with a service bolt.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

      Recommended service bolt 

      RECOMMENDED SERVICE BOLT SPECIFICATION

      Thread diameter 6 mm
      Thread pitch 1.0 mm
      Bolt length 16 to 20 mm

      HINT:

      When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installation of the service bolt.

      Fig 13: Securing Exhaust With A Service Bolt
      G03062180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft.
      4. Fig 14: Removing Bearing Cap Bolts
      G03062181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Do not pry out the camshaft.
    • Be careful not to damage the portion of the cylinder head receiving the shaft thrust.
  28. REMOVE NO. 2 CAMSHAFT 
    1. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 2 camshaft.
      Fig 15: Removing Bearing Caps And Camshaft
      G03062182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not pry out the camshaft.
      • Be careful not to damage the portion of the cylinder head receiving the shaft thrust.
    2. Remove the oil seal from the No. 2 camshaft.
  29. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY 
    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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Align the timing marks (1 dot marks) of the camshaft drive and the driven gears by turning the camshaft with a wrench.
      Fig 16: Aligning Timing Marks (1 Dot Marks)
      G03062183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Secure the exhaust camshaft sub-gear to the main gear with a service bolt.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

      Recommended service bolt 

      RECOMMENDED SERVICE BOLT SPECIFICATION

      Thread diameter 6 mm
      Thread pitch 1.0 mm
      Bolt length 16 to 20 mm

      HINT:

      When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installation of the service bolt.

      Fig 17: Securing Exhaust Camshaft Sub-Gear With A Service Bolt
      G03062184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using several steps loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 3 camshaft.
      NOTE:
      • Do not pry out the camshaft.
      • Be careful not to damage the portion of the cylinder head receiving the shaft thrust.
    Fig 18: Removing Bearing Caps And Camshaft
    G03062185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 4 camshaft.
      Fig 19: Removing Camshaft Sub-Assembly
      G03062186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not pry out the camshaft.
      • Be careful not to damage the portion of the cylinder head receiving the shaft thrust.
    2. Remove the oil seal from the No. 4 camshaft.
  31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
      Fig 20: Inspecting Camshaft Timing Gear Assembly
      G03062187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Clamp the camshaft in a vise on the hexagonal lobe.
    2. Check that VVT-i will not turn.
    3. Cover all the oil ports except the port on the advance angle side (nearest to the convex portion) shown in the illustration with vinyl tape.
      4. Fig 21: Identifying Convex Portion
      G03062188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using the air gun, apply about 100 kPa (1 kgf/cm2 , 14 psi) of air pressure to the port on the advance side shown in the illustration.
      NOTE: Some oil spraying will occur. Be prepared to catch the spray with a shop rag.

      HINT:

      Perform this in order to release the lock pin for the maximum delay angle lock.

    5. Under the condition above, turn VVT-i to the advance angle side (the white arrow marked direction in the illustration) by hand.

      Standard: Must turn 

      HINT:

      Depending on the air pressure, VVT-i will turn to the advance angle side without applying force by hand. Also, if the pressure can be hardly applied because of the air leakage from the port, it might be difficult to get the lock-pin to release.

    6. Check that the VVT-i moves freely within about 30° range. Avoid moving the VVT-i unit to the maximum delay angle position as the lock-pin will re-engage.

      Standard: Smooth movable range is about 30° 

    7. Turn VVT-i by hand and lock it at the maximum delay angle position.
  32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    NOTE: Do not remove or install the camshaft timing gear (VVT-i) unless you are changing the VVT-i or the camshaft.
    1. Clamp the camshaft in a vise on the hexagonal lobe.
      Fig 22: Securing Camshaft Timing Gear Assembly
      G03062189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the camshaft.
    2. Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.
      NOTE:
      • Remove it with the lock-pin engaged and locked at the maximum delay angle position.
      • The lock nut has LH threads.
        Fig 23: Removing Lock Nut By Turning Clockwise
        G03062190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.
    3. Remove the camshaft VVT-i.
      NOTE: Never remove the 3 bolts on the gear.

      If it is difficult to remove VVT-i, tap it lightly using a plastic-faced hammer and then remove it.

  33. REMOVE CAMSHAFT SUB GEAR 
      Fig 24: Securing Camshaft In Vise
      G03062191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Clamp the camshaft in a vise on the hexagonal lobe.
      NOTE: Be careful not to damage the camshaft.
    2. Using SST, turn the sub-gear counterclockwise, and remove the service bolt.

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

      Fig 25: Removing The Service Bolt
      G03062192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using snap ring pliers, remove the snap ring.
      4. Fig 26: Removing Snap Ring
      G03062193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the wave washer, the camshaft sub-gear and the camshaft gear bolt washer.

    HINT:

    Arrange the camshaft sub-gears and gear bolt washers (RH and LH sides) so that they can be returned to the original location when re-assembling.

  34. REMOVE ENGINE HANGER NO. 2 
  35. REMOVE CYLINDER HEAD COVER REAR 
  36. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the plug, the gasket and the valve filter.
    Fig 27: Removing Oil Control Valve Plug
    G03062194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. Using an 8 mm hexagon wrench, remove the hexagon bolt.
      Fig 28: Removing Hexagon Bolt In Cylinder Head
      G03062195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and the plate washers.
    Fig 29: Loosening Cylinder Head Bolts Uniformly In Sequence
    G03062196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Be careful not to drop washers into the cylinder head.
    • Head warpage or cracking could result from removing bolts in an incorrect order.
  38. REMOVE CYLINDER HEAD GASKET 
  39. REMOVE CYLINDER HEAD LH 
    1. Using an 8 mm hexagon wrench, remove the hexagon bolt.
      Fig 30: Removing Hexagon Bolt In Cylinder Head LH
      G03062197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and the plate washers.
      Fig 31: Removing Cylinder Head Bolts Uniformly In Sequence
      G03062198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Be careful not to drop washers into the cylinder head.
    • Head warpage or cracking could result from removing bolts in an incorrect order.
  40. REMOVE CYLINDER HEAD GASKET NO. 2 
  41. REMOVE WATER INLET HOUSING 
    1. Remove the 8 bolts, the 2 nuts and the water inlet housing.
    Fig 32: Removing Water Inlet Housing
    G03062199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE OIL FILTER SUB-ASSEMBLY 
    1. Using SST, remove the oil filter.

      SST 09228-07501

      Fig 33: Removing Oil Filter
      G03062200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 12 mm socket hexagon wrench, remove the oil filter union.
  43. REMOVE OIL PAN DRAIN PLUG 
  44. REMOVE OIL PAN SUB-ASSEMBLY NO. 2 
    1. Remove the 10 bolts and the 2 nuts.
      Fig 34: Removing Oil Pan Bolts (1 of 2)
      G03062201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of SST between oil pan No. 1 and oil pan No. 2, cut off the sealer and remove the oil pan No. 2.

      SST 09032-00100

      Fig 35: Removing Oil Pan Bolts (2 of 2)
      G03062202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Be careful not to damage the contact surface of oil pan No. 1 where oil pan No. 2 is mounting.
    • Do not damage flange portion of oil pan No. 2 when removing.
  45. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the bolt, the 2 nuts, the oil strainer and the gasket.
  46. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Loosen and remove the 15 bolts and the 2 nuts uniformly.
      Fig 36: Removing Oil Pan Sub-Assembly
      G03062203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.
      3. Fig 37: Separating Oil Pan From Cylinder Block
      G03062204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.
  47. REMOVE OIL PAN BAFFLE PLATE 
  48. REMOVE ENGINE REAR OIL SEAL RETAINER 
    1. Remove the 6 bolts.
    2. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and the main bearing cap.
    Fig 38: Removing Bolts & Oil Seal Retainer
    G03062205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE ENGINE REAR OIL SEAL 
    1. Using a screwdriver and a hammer, tap out the oil seal.
    Fig 39: Removing Engine Rear Oil Seal
    G03062206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 9 bolts.
    2. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.
    3. Remove the O-ring.
    Fig 40: Removing Oil Pump Assembly
    G03062207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE OIL PUMP SEAL 
    1. Using a screwdriver, pry out the oil seal.
    Fig 41: Removing Oil Pump Seal
    G03062208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE SPARK PLUG TUBE GASKET 
    1. Bend up the tab on the ventilation baffle plate which prevents the gasket from the slipping out.
      NOTE: Be careful not to damage the baffle plate of the cylinder head cover.
    2. Using a screwdriver and a hammer, tap out the gasket.
      Fig 42: Removing Spark Plug Tube Gasket
      G03062209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using needle-nose pliers, pry out the gasket.
    Fig 43: Using Needle-Nose Pliers, Pry Out Gasket
    G03062210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Be careful not to damage the cylinder head cover.
  53. INSPECT TIMING BELT 
    Fig 44: Inspecting Timing Belt
    G03062211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 mounting bolt of the camshaft timing pulley.

    Check the belt for any defects, as shown in the illustrations. Also check these points:

    1. If there is premature parting,
      • Check for proper installation.
      • 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.
    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 timing cover for damage.
      • Check gasket has been installed correctly.
      • Check for foreign object on the pulley teeth.

    If there is any doubt about the belt condition, replace the timing belt.

  54. INSPECT CAMSHAFT 
    1. Inspect camshaft for runout.
      1. Place the camshaft on V-blocks.
      2. Using a dial indicator, measure the runout at the center journal.
        3. Fig 45: Measuring Camshaft Runout At Center Journal
        G03062212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum circle runout: 0.06 mm (0.0024 in.) 

      If the runout is greater than maximum, replace the camshaft.

    2. Inspect cam lobes.
      1. Using a micrometer, measure the cam lobe height.
        2. Fig 46: Measuring Cam Lobe Height
        G03062213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard cam lobe height: 

      Intake 43.132 to 43.232 mm (1.6981 to 1.7020 in.) 

      Exhaust 43.010 to 43.110 mm (1.6933 to 1.6972 in.) 

      Minimum cam lobe height: 

      Intake 42.98 mm (1.6921 in.) 

      Exhaust 42.86 mm (1.6874 in.) 

      If the cam lobe height is less than minimum, replace the camshaft.

    3. Inspect camshaft journals.
      1. Using a micrometer, measure the journal diameter.
        2. Fig 47: Measuring Camshaft Journal Diameter
        G03062214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Journal diameter: 

      26.959 to 26.975 mm (1.0614 to 1.0620 in.) 

      If the journal diameter is not as specified, check the oil clearance.

    4. INSPECT CYLINDER HEAD SET BOLT 
      1. Using vernier calipers, measure the tension portion diameter of the bolt.
        Fig 48: Measuring Tension Portion Diameter Of Bolt
        G03062215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard outside diameter: 

        8.95 to 9.05 mm (0.3524 to 0.3563 in.) 

        Minimum outside diameter: 8.75 mm (0.3445 in.) 

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

    5. 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 (09951-00430), 09950-70010 (09951-07100)

        Fig 49: Installing Spark Plug Tube Gasket
        G03062216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Return the ventilation plate tab to its original position.
      3. Apply a light coat of MP grease to the gasket lip.
    6. 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 09223-15030, 09950-70010 (09951-07100)

        Fig 50: Installing Engine Rear Oil Seal
        G03062217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Be careful not to tap the oil seal at an angle.
        • Keep the lip free of foreign objects.
      2. Apply MP grease to the oil seal lip.
    7. INSTALL ENGINE REAR OIL SEAL RETAINER 
      1. Remove any old packing material from the contact surface.
      2. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration.

        Seal packing: Part No. 08826-00080 or equivalent 

        Fig 51: Applying Continuous Bead Of Seal Packing To Engine Rear Oil Seal Retainer
        G03062218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Remove any oil from the contact surface.
        • Install the oil seal retainer within 3 minutes after applying seal packing.
        • Do not expose the seal to engine oil within 2 hours after installing.
      3. Install the oil seal retainer with the 6 bolts. Tighten the bolt uniformly in several steps.

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

    8. 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 09223-00010

        Fig 52: Installing Oil Pump Seal
        G03062219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Be careful not to tap the oil seal at an angle.
        • Keep the lip free of foreign objects.
      2. Apply MP grease to the oil seal lip.
    9. INSTALL OIL PUMP ASSEMBLY 
      1. Remove any old packing material from the contact surface.
      2. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.
        Fig 53: Identifying Location Of O-Ring
        G03062220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration.

        Seal packing: Part No. 08826-00080 or equivalent 

        Fig 54: Applying Continuous Bead Of Seal Packing To Oil Pump Assembly
        G03062221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from contact surface.
      • Apply seal packing to the inner side of the bolt holes.
      • Install the oil pump within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    10. Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.
      Fig 55: Aligning Key Of Oil Pump Drive Gear With Keyway Located On Crankshaft
      G03062222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.

      Torque: 

      Fig 56: Identifying Bolt Torque
      G03062223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt A 8.0 N.m (82 kgf.cm, 71 in.lbf) 

      Bolt B 20 N.m (199 kgf.cm, 14 ft.lbf) 

      Bolt C 43 N.m (439 kgf.cm, 32 ft.lbf) 

  55. INSTALL CRANKSHAFT POSITION SENSOR 

    Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

  56. INSTALL OIL PAN BAFFLE PLATE 

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

  57. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Remove any old seal packing from the contact surface.
    2. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      Fig 57: Applying Continuous Bead Of Seal Packing To Oil Pan Sub-Assembly
      G03062224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Apply seal packing to the outer side of the bolt holes in the region "X".
      • Apply seal packing to the inner side of the bolt holes in the region "Y".
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    3. Install the oil pan No. 1 with the 15 bolts and the 2 nuts. Tighten the bolts uniformly in several steps.

      Torque: 

      10 mm head 8.0 N.m (82 kgf.cm, 71 in.lbf) 

      12 mm head 20 N.m (199 kgf.cm, 14 ft.lbf) 

  58. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Install a new gasket and the oil strainer with the bolt and the 2 nuts.

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

  59. INSTALL OIL PAN SUB-ASSEMBLY NO. 2 
    1. Remove any old seal packing from the contact surface.
    2. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      Fig 58: Applying Continuous Bead Of Seal Packing To Oil Pan Sub-Assembly No. 2
      G03062225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Apply seal packing to the inner side of the bolt holes.
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    3. Install the oil pan No. 2 with the 10 bolts and the 2 nuts.

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

  60. INSTALL OIL PAN DRAIN PLUG 
    1. Install the drain plug with a new gasket.

      Torque: 45 N.m (459 kgf.cm, 33 ft.lbf) 

  61. INSTALL WATER INLET HOUSING 
    1. Remove any old packing material form the contact surface.
    2. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 in.)) as shown in the illustration.

      Seal packing: Part No. 08826-00100 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the water inlet housing within 3 minutes after applying seal packing.
      • Do not expose the seal to coolant within 2 hours after installing.
      Fig 59: Applying Continuous Bead Of Seal Packing To Water Inlet Housing
      G03062226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the water inlet housing with the 8 bolts and the 2 nuts. Using several steps, tighten the bolts and the nuts uniformly in the sequence shown in the illustration.

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

    Fig 60: Installing Water Inlet Housing Uniformly In Sequence
    G03062227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL CYLINDER HEAD GASKET 
    1. Place a new cylinder head gasket on the cylinder block with the R mark upward.
    NOTE:
    • Remove any oil from the contact surface.
    • Be careful of the installing orientation.
    • Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
    Fig 61: Installing Cylinder Head Gasket
    G03062228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL CYLINDER HEAD SUB-ASSEMBLY 
    NOTE: The cylinder head bolts are tightened in 2 successive steps.
    1. Apply a light coat of engine oil on the threads of the cylinder head bolts.
    2. Install the plate washers to the cylinder head bolts.
    3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.

      Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) 

      Fig 62: Installing Cylinder Head Bolts Uniformly In Sequence
      G03062229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
    5. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
    6. Check that the painted mark is now at a 90° angle to the front.
      Fig 63: Retightening Cylinder Head Bolts By 90°
      G03062230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using an 8 mm socket hexagon wrench, install the hexagon bolt.

      Torque: 19 N.m (189 kgf.cm, 14 ft.lbf) 

    Fig 64: Installing Hexagon Bolt In Cylinder Head
    G03062231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL CYLINDER HEAD GASKET NO. 2 
    1. Place a new cylinder head gasket on the cylinder block with the L mark upward.
      2. Fig 65: Installing Cylinder Head Gasket
      G03062232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Remove any oil from the contact surface.
    • Be careful of the installing orientation.
    • Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
  65. INSTALL CYLINDER HEAD LH 
    NOTE: The cylinder head bolts are tightened in 2 successive steps.
    1. Apply a light coat of engine oil on the threads of the cylinder head bolts.
    2. Install the plate washers to the cylinder head bolts.
    3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.

      Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) 

      Fig 66: Installing Cylinder Head Bolts
      G03062233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
    5. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
    6. Check that the painted mark is now at a 90° angle to the front.
      Fig 67: Checking Painted Mark Is Now At A 90° Angle To Front
      G03062234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using an 8 mm socket hexagon wrench, install the hexagon bolt.

      Torque: 19 N.m (189 kgf.cm, 14 ft.lbf) 

    Fig 68: Installing Hexagon Bolt In Cylinder Head
    G03062235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL OIL CONTROL VALVE FILTER 
    1. Check that no foreign object is on the mesh part of the filter.
    2. Assemble the valve filter and the plug.
    3. Install the plug with a new gasket.

      Torque: 45 N.m (459 kgf.cm, 33 ft.lbf) 

    Fig 69: Installing Oil Control Valve Plug With A New Gasket
    G03062236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. INSTALL CYLINDER HEAD COVER REAR 
    1. Install the rear cover and a new gasket.

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

  68. INSTALL CAMSHAFT SUB GEAR 
    1. Clamp the camshaft in a vise on the hexagonal lobe.
      NOTE: Be careful not to damage the camshaft.
      Fig 70: Securing Camshaft In Vise
      G03062237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the camshaft gear bolt washer and the camshaft sub-gear.

      HINT:

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

    3. Install the wave washer.
      Fig 71: Installing Wave Washer
      G03062238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using snap ring pliers, install the snap ring.
      Fig 72: Installing Snap Ring
      G03062239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.

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

    6. Align the gear teeth of the main gear and sub-gear and tighten the service bolt.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

    Fig 73: Aligning Gear Teeth Of Main Gear And Sub-Gear
    G03062240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Be careful not to damage the camshaft journals.

    HINT:

    When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installation of the service bolt.

  69. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Align the alignment pin with the alignment pin groove and install VVT-i on the camshaft.
      NOTE: Install it with the lock-pin engaged and locked at the maximum delay angle position.
      Fig 74: Installing Camshaft Timing Gear Assembly
      G03062241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply engine oil on the nut, the mounting surface of VVT-i and the screw threads.
      NOTE:
      • Be sure to apply the oil, otherwise the specified torque cannot be obtained.
      • New nuts must be used when replacing VVT-i unit.
    3. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.

      Torque: 150 N.m (1,530 kgf.cm, 111 ft.lbf) 

      Fig 75: Tightening A Lock Nut By Turning It Counterclockwise
      G03062242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • The lock nut has LH threads.
      • Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.
  70. INSTALL NO. 2 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2. Place the No. 2 camshaft at a 90° angle of the timing mark (2 dot marks) on the cylinder head.
      3. Fig 76: Identifying Angle Of Timing Mark On Cylinder Head
      G03062243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply MP grease to a new oil seal lip.
    4. Install the oil seal to the camshaft.
      NOTE:
      • Do not turn over the oil seal lip.
      • Insert the oil seal until it stops.
        • Fig 77: Inserting Oil Seal
        G03062244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove any old packing material from the contact surface.
    6. Apply seal packing to the No. 1 bearing cap as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      Fig 78: Identifying Seal Packing
      G03062245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the No. 1 bearing cap within 5 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    7. Install the 5 bearing caps in their proper locations.
    8. Apply a light coat of engine oil on the threads of the bearing cap bolts.
      Fig 79: Installing Bearing Caps In Their Proper Locations
      G03062246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

    Fig 80: Tightening Bearing Cap Bolts Uniformly In Sequence
    G03062247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL 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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2. Align the timing marks (2 dot marks) of the camshaft drive with the driven gears.
      3. Fig 81: Aligning Timing Marks Of Camshaft Drive With Driven Gears
      G03062248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place the camshaft on the cylinder head.
    4. Install the 5 bearing caps in their proper locations.
      5. Fig 82: Installing Bearing Caps In Their Proper Locations
      G03062249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply a light coat of engine oil on the threads of the bearing cap bolts.
    6. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

      Fig 83: Tighten Bearing Cap Bolts Uniformly In Sequence
      G03062250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the service bolt.
  72. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 
    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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2. Place the No. 4 camshaft at a 90° angle of timing mark (1 dot marks) on the cylinder head.
      3. Fig 84: Identifying Angle Of Timing Mark On Cylinder Head
      G03062251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply MP grease to a new oil seal lip.
    4. Install the oil seal to the camshaft.
      Fig 85: Installing Oil Seal To Camshaft
      G03062252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not turn over the oil seal lip.
      • Insert the oil seal until it stops.
    5. Remove any old packing material from the contact surface.
    6. Apply seal packing to the No. 1 bearing cap as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      Fig 86: Identifying Seal Packing
      G03062253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the No. 1 bearing cap within 5 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    7. Install the 5 bearing caps in their proper locations.
      8. Fig 87: Installing Bearing Caps In Their Proper Locations
      G03062254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Apply a light coat of engine oil on the threads of the bearing cap bolts.
    9. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

    Fig 88: Tightening Bearing Cap Bolts Uniformly In Sequence
    G03062255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 
    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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.
    1. Apply new engine oil to the thrust portion and journal of the camshaft.
    2. Align the timing marks (1 dot marks) of the camshaft drive with the driven gears. Place the camshaft on the cylinder head.
      Fig 89: Aligning Timing Marks Of Camshaft Drive With Driven Gears
      G03062256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 5 bearing caps in their proper locations.
      4. Fig 90: Installing Bearing Caps In Their Proper Locations
      G03062257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply a light coat of engine oil on the threads of the bearing cap bolts.
    5. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

      Fig 91: Tighten Bearing Cap Bolts Uniformly In Sequence
      G03062258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the service bolt.
  74. INSTALL CRANKSHAFT TIMING PULLEY 
    1. Align the keyway of the timing pulley with the key located on the crankshaft and slide the timing pulley into place.
      NOTE: Do not scratch the sensor area of the crankshaft timing pulley.
    2. Install the timing belt plate with the bolt.

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

    Fig 92: Installing Crankshaft Timing Pulley
    G03062259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL WATER PUMP ASSEMBLY 
    1. Install a new gasket and the water pump with the 3 bolts and the 3 nuts.

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

    Fig 93: Installing New Gasket And Water Pump
    G03062260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. INSTALL OIL LEVEL GAGE GUIDE 
    1. Apply a light coat of engine oil to a new O-ring and install it to the level gage guide.
    2. Install the level gage guide.

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

  77. INSTALL OIL FILTER SUB-ASSEMBLY 
    1. Using a 12 mm socket hexagon wrench, install the oil filter union.

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

      Fig 94: Installing Oil Filter
      G03062261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check and clean the oil filter installation surface.
    3. Apply clean engine oil to the gasket of a new oil filter.
    4. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
    5. Using SST, tighten it an additional 3/4 turn.

      SST 09228-07501

  78. INSTALL TIMING BELT IDLER BRACKET 

    Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

  79. INSTALL TIMING BELT NO. 3 COVER 
    1. Visually check for cracks and breaks in the gasket of the timing belt cover.

      HINT:

      If there is a trace that water is entering at the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.

    2. When repairing the timing belt cover gasket, follow the procedure below.
      1. Repair the cracks and breaks by applying the seal packing to the damaged area.

      Seal packing: Part No. 08826-00080 or equivalent 

      Fig 95: Identifying Seal Packing
      G03062262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When applying the seal packing, apply it as wide and high as the gasket.
    3. When replacing the timing belt cover gasket is needed to replace, follow the procedure below.
      1. Using a screwdriver and gasket scraper, remove the remaining gasket.
        NOTE: Be careful not to damage the timing belt cover.
      2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.
        NOTE:
        • Affix the gasket in the center of the groove.
        • At the corners, try to keep the gasket thickness uniform.

        HINT:

        GASKET THICKNESS SPECIFICATION

        Gasket D E F G
        Length 335 mm (13.19 in.) 180 mm (7.09 in.) 133 mm (5.24 in.) 72 mm (2.83 in.)
        Fig 96: Identifying Seal Packing
        G03062263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. If there is a gap on the joint of the gasket, apply seal packing to close the gap.

        Seal packing: Part No. 08826-00080 or equivalent 

        NOTE: When applying the seal packing, apply it as wide and high as the gasket.
    4. Install the timing belt cover with the 6 bolts.

      Torque: 8.5 N.m (87 kgf.cm, 76 in.lbf) 

  80. INSTALL CAMSHAFT TIMING PULLEY 
    1. Pay attention to the orientation of the belt guide, install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporally.
      Fig 97: Installing Camshaft Timing Pulley
      G03062264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Face the belt guide of the RH timing pulley toward front of the engine.
      • Face the belt guide of the LH timing pulley toward rear of the engine.
    2. Using SST, tighten the RH pulley bolt.

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

      Torque: 125 N.m (1,275 kgf.cm, 92 ft.lbf) 

      Fig 98: Tightening RH Pulley Bolt
      G03062265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, tighten the LH pulley bolt.

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

      Torque: 125 N.m (1,275 kgf.cm, 92 ft.lbf) 

    Fig 99: Tightening LH Pulley Bolt
    G03062266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2 

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

  82. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 1 
    1. Using a 10 mm socket hexagon wrench, install the plate washer and timing belt idler No. 1 with the pivot bolt.

      Torque: 34 N.m (347 kgf.cm, 25 ft.lbf) 

  83. INSTALL TIMING BELT 
    1. Remove any oil or water on the pulleys, and keep them clean.
      NOTE:
      • If there is a trace of water and/or oil on the timing belt repair the leakage and install a new timing belt.
      • Wipe only the pulleys; do not use any cleaning agent.
    2. Inspect the idler pulleys.
      1. Check that the idler pulley turns smoothly.
      2. Visually check the seal portion of the idler pulley for oil leakage.
    3. Inspect the water pump.
      1. Turn the pulley, and check that water pump bearing moves smoothly and does not make noise.
      2. Visually check the drain hole for coolant leakage.
    4. Temporarily install the crankshaft pulley bolt and the washer to the crankshaft.
    5. Turn the crankshaft counterclockwise by approx. 60°.
      NOTE: To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.
      Fig 100: Turning Crankshaft Counterclockwise By Approx. 60°
      G03062267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST, turn the crankshaft pulley, and align the timing marks of the timing pulley and the No. 3 timing belt cover.

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

      Fig 101: Aligning Timing Marks Of Timing Pulley And Timing Belt Cover
      G03062268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and the oil pump body.
      Fig 102: Aligning Timing Marks Of Crankshaft Timing Pulley And Oil Pump Body
      G03062269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Face the front mark on the timing belt forward.
    9. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
    10. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
      Fig 103: Aligning Installation Mark On Timing Belt With Timing Mark Of Crankshaft Timing Pulley
      G03062270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Install the timing belt in this order.
      TIMING BELT SPECIFICATION

      1st Crankshaft timing pulley
      2nd Water pump pulley
      3rd LH camshaft timing pulley
      4th No. 2 idler pulley
      5th RH camshaft timing pulley
      6th No. 1 idler pulley
      Fig 104: Installing Timing Belt
      G03062271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 
    1. Set the timing belt tensioner upright on the press.
    2. Slowly press in the push rod.
      NOTE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.
    3. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
      Fig 105: Locking Tensioner Into Setting Position
      G03062272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Release the press.
    5. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.

      Torque: 27 N.m (280 kgf.cm, 20 ft.lbf) 

      NOTE: Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause failure of its proper operation.
    6. Remove the 1.5 mm hexagon wrench from the tensioner.
    7. Turn the crankshaft 2 revolutions slowly, and align the timing marks of the crankshaft timing pulley and the oil pump body.
      NOTE: Always turn the crankshaft clockwise.
      Fig 106: Aligning Timing Marks Of Crankshaft Timing Pulley And Oil Pump Body
      G03062273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover as shown in the illustration.

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

    9. Remove the crankshaft pulley bolt.
    Fig 107: Checking Timing Marks Of Timing Pulleys Are Aligned With Timing Marks Of No. 3 Timing Belt Cover
    G03062274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL TIMING BELT GUIDE NO. 2 
    1. Install the timing belt guide, facing the cup side toward the engine front.
    Fig 108: Installing Timing Belt Guide
    G03062275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL ENGINE MOUNTING BRACKET RH 

    Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

  87. INSTALL TIMING BELT NO. 2 COVER 
    1. Visually check for cracks and breaks in the gasket of the timing belt cover.

      If there is a trace that water is entering at the visual check, replace the timing belt cover.

    2. Install the timing belt cover.

      Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) 

  88. INSTALL TIMING BELT NO. 1 COVER 
    1. Visually check for cracks and breaks in the gasket of the timing belt cover.

      If there is a trace that water is entering at the visual check, replace the timing belt cover.

    2. Install the timing belt cover.

      Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) 

  89. INSTALL CRANKSHAFT PULLEY 
    1. Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
    2. Using SST, install the pulley bolt.

      SST 09213-54015 (91651-60855), 09330-00021

      Torque: 220 N.m (2,250 kgf.cm, 162 ft.lbf) 

    Fig 109: Installing Crankshaft Pulley
    G03062276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL VVT SENSOR 

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

  91. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

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

  92. INSTALL ENGINE HANGER NO. 2 

    Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

  93. INSPECT VALVE CLEARANCE 
    1. Turn the crankshaft pulley, and align the timing notch with the timing mark "0" of the No. 1 timing belt cover.
    2. Check that the valve lifters on the No. 1 (IN and EX) are both loose.

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

      Fig 110: Aligning Timing Notch On pulley With Timing Mark "0" On Timing Belt Cover
      G03062277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the valves indicated in the illustration on the left.
      1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

        Valve clearance (Cold): 

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

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

      2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
      Fig 111: Measuring Clearance Between Valve Lifter And Camshaft
      G03062278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
      1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

        Valve clearance (Cold): 

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

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

      2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
      Fig 112: Measuring Clearance Between Valve Lifter And Camshaft
      G03062279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
      1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.

        Valve clearance (Cold): 

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

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

      2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
    Fig 113: Measuring Clearance Between Valve Lifter And Camshaft
    G03062280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. ADJUST VALVE CLEARANCE 
    1. Turn the camshaft so that the cam lobe is facing upward.
    2. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.
      Fig 114: Turning Valve Lifter With A Screwdriver
      G03062281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A).

      SST 09248-55040 (09248-05410, 09248-05420)

      HINT:

      • Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration.
      • When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle.
      SPECIAL SERVICE TOOL SPECIFICATION

      SST (A) 09248-05410
      SST (B) 09248-05420
      Fig 115: Applying SST At A Slight Angle On Side Marked
      G03062282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a small screwdriver and magnetic finger, remove the adjusting shim.
      Fig 116: Removing Adjusting Shim
      G03062283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a micrometer, measure the thickness of the removed shim.
    6. Calculate the thickness of a new shim so the valve clearance comes within the specified value.
      SHIM THICKNESS

      A Thickness of new shim
      B Thickness of used shim
      C Measured valve clearance
      Fig 117: Measuring Thickness Of Shim
      G03062284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified value (Cold): 

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

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

    7. Select a new shim with a thickness as close as possible to the calculated values.
      Fig 118: Select A New Shim With A Thickness As Close As Possible To Calculated Values
      G03062285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
      • Refer to new shim thickness table in the illustrations.
      Fig 119: Adjusting Shim Selection Chart (Intake)
      G03062286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 120: Adjusting Shim Selection Chart (Exhaust)
      G03062287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down.
    9. Press down the valve lifter with SST (A), and remove SST (B).

      SST 09248-55040 (09248-05410, 09248-05420)

      Fig 121: Pressing Down The Valve Lifter With SST(A) To Remove SST(B)
      G03062288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Recheck the valve clearance.
  95. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install the gasket to the cylinder head cover.
    2. Apply seal packing to the cylinder head as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover within 3 minutes after applying seal packing.
      • Do not start the engine within 2 hours after installing.
      Fig 122: Applying Seal Packing To Cylinder Head
      G03062289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.

      Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

  96. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Install the gasket to the cylinder head cover.
    2. Apply seal packing to the cylinder head as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover within 3 minutes after applying seal packing.
      • Do not start the engine within 2 hours after installing.
      Fig 123: Applying Seal Packing To Cylinder Head
      G03062290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.

      Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

  97. INSTALL SPARK PLUG 

    Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

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