Engine Unit: Reassembly

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

Fig 1: Identifying Straight Pin Installation Location

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Standard protrusion 

1. Using an E8 "torx" socket, install the stud bolts.

Fig 2: Identifying Stud Bolt Installation Location

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

1. Apply adhesive around the tight plugs.

   Adhesive:

   Part No. 08833-00070, THREE BOND 1324 or equivalent. 

2. Using SST and a hammer, tap in new tight plugs.
   Fig 3: Applying Adhesive Around Tight Plugs

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   Fig 4: Identifying Tight Plugs Installation Location

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   1. Using SST, tap in the 2 tight plugs A.

      SST 09950-60010 (09951-00340), 09950-70010 (09951-07100) 

   2. Using SST, tap in the tight plug B.

      SST 09950-60010 (09951-00200), 09950-70010 (09951-07100) 

1. Using a 5 mm hexagon wrench, install the oil nozzles.

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

Fig 5: Identifying Oil Nozzles

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1. Align the oil holes of a new bush and the connecting rod.
   Fig 6: Aligning Oil Holes Of New Bush & Connecting Rod

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2. Using SST and a press, press in the bush.

   SST 09222-30010 

   Fig 7: Pressing In Bush Using SST & Press

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3. Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin.

   Standard oil clearance: 

   -0.002 to 0.004 mm (-0.00007 to 0.0001 in.) 

   Fig 8: Honing Bush For Obtaining Specified Clearance Between Bush & Piston Pin Using Pin Hole Grinder

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the piston pin fits at normal room temperature.
5. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

Fig 9: Identifying Piston Pin

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1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.

   HINT:

   Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

   Fig 10: Identifying New Snap Ring

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2. Gradually heat the piston to approximately 80°C (176°F).
3. Coat the piston pin with engine oil.
   Fig 11: Heating Piston

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4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

   Front Mark 

   FRONT MARK REFERENCE
   
   

   Item	Front Mark
   Piston LH	1
   Piston RH	2

   HINT:

   The piston and pin are a matched set.

   Fig 12: Aligning Front Marks Of Piston & Connecting Rod

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5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
   Fig 13: Checking Fitting Condition Between Piston & Piston Pin

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6. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

   HINT:

   Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

Fig 14: Identifying New Snap Ring

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1. Install the oil ring expander by hand.
2. Using a piston ring expander, install the oil ring rail and 2 compression rings.
   Fig 15: Identifying Piston Ring Set

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3. Position the piston rings so that the ring ends are as shown in Fig 16 .
   NOTE: Do not align the ring ends.

Fig 16: Identifying Piston Rings Ends

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1. Clean the main journal and the both surfaces of the bearing.
   NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.
   Fig 17: Identifying Journal Bearings Diameter

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2. Install the upper bearing.
   1. Install the upper bearings to the cylinder block as shown in Fig 18 .
      NOTE:

      • Do not apply engine oil to the bearings and the contact surfaces.
      • Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. the amount visible on each side of the holes should be equal.
   Fig 18: Installing Upper Bearings To Cylinder Block

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3. Install the lower bearing.
   1. Install the lower bearings to the bearing caps.
   2. Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.

      Dimension (A - B): 

      0.7 mm (0.0276 in.) or less 

      NOTE: Do not apply engine oil to the bearings and the contact surfaces.

Fig 19: Installing Lower Bearings To Bearing Caps

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1. Apply engine oil to the crankshaft thrust washer.
2. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.

1. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
   Fig 20: Identifying Thrust Washers

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2. Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.

   HINT:

   A number is marked on each main bearing cap to indicate the installation position.

3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
4. Temporarily install the 8 main bearing cap bolts to the inside positions.
   Fig 21: Confirming Projection & Numbers Of Main Bearing Caps

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5. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

   Bolt length: 

   100 to 102 mm (3.94 to 4.02 in.) 

   Fig 22: Identifying Clearance Between Main Bearing Cap & Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
7. Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
   Fig 23: Tapping Bearing Cap Using Plastic Hammer

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8. Install the 8 main bearing cap bolts to the outside positions.

   Bolt length 

   BOLT LENGTH SPECIFICATIONS
   
   

   Item	Length
   Bolt A	100 to 102 mm (3.94 to 4.02 in.)
   Except bolt A	105.5 to 107.5 mm (4.15 to 4.23 in.)

9. Install the crankshaft bearing cap bolts.

   HINT:

   The main bearing cap bolts are tightened in 2 progressive steps.

   Fig 24: Identifying Main Bearing Cap Bolts

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10. Step 1
    1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in Fig 25 .

    Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) 

    If any of the main bearing cap bolts does not meet the torque specified, replace it.

    Fig 25: Identifying Tightening Sequence Of Main Bearing Cap Bolts

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11. Step 2
    1. Mark the front of the bearing cap bolts with paint.
    2. Retighten the bearing cap bolts by 90° in the order above in Fig 25.
    3. Check that the painted mark is now at a 90° angle to the front.
    Fig 26: Identifying Retightening Angle Of Main Bearing Cap Bolt

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12. Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in Fig 27 .

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

    Bolt length 

    BOLT LENGTH SPECIFICATIONS
    
    

    Item	Length
    Bolt A	45 mm (1.77 in.)
    Except bolt A	30 mm (1.18 in.)

    Fig 27: Identifying Tightening Sequence Of Main Bearing Cap Bolts

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13. Check that the crankshaft turns smoothly.
14. Check the crankshaft thrust clearance (See Step 31 in INSPECTION  ).

1. Install the connecting rod bearing to the connecting rod and bearing cap.
2. Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.

   Dimension (A - B): 

   0.7 mm (0.0276 in.) or less 

   NOTE: Do not apply engine oil to the bearings and the contact surfaces.

1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
   Fig 28: Installing Connecting Rod Bearing To Connecting Rod & Bearing Cap

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2. Position the piston rings so that the ring ends are as shown.
   NOTE: Do not align the ring ends.
   Fig 29: Identifying Piston Ring Ends

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3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
   NOTE: Match the numbered connecting rod cap with the connecting rod.

   Front Mark 

   PISTON FRONT MARK REFERENCE
   
   

   Item	Front Mark
   Piston LH	1
   Piston RH	2

   Fig 30: Pushing Piston & Connecting Rod Assembly Into Cylinder

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4. Check that the front mark of the connecting rod cap is facing forward.
5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
6. Install the connecting cap bolts.

   HINT:

   The connecting cap bolts are tightened in 2 progressive steps.

   Fig 31: Identifying Front Mark Of Connecting Rod Cap

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7. Step 1
   1. Install and alternately tighten the bolts of the connecting rod cap in several steps.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

   Fig 32: Tightening Bolts Of Connecting Rod Cap

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8. Step 2
   1. Mark the front side of each connecting cap bolt with paint.
   2. Retighten the cap bolts by 90° as shown in Fig 33 .
   3. Check the painted mark is now at a 90° angle to the front.
9. Check that the crankshaft turns smoothly.
10. Check the connecting rod thrust clearance (See Step 29 in INSPECTION  ).
    Fig 33: Identifying Retightening Angle Of Connecting Rod Cap Bolt

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1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

   Cylinder bore diameter: 

   10.285 to 10.306 mm (0.4049 to 0.4057 in.) 

   Select a new guide bush (STD or O/S 0.05) 

   CYLINDER BORE DIAMETER SPECIFICATIONS
   
   

   Bush size	Bush bore diameter
   Use STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
   Use O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)

   Fig 34: Measuring Bush Bore Diameter Of Cylinder Head Using Caliper Gauge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.

   If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

2. Heat the cylinder head to 80 to 100°C (176 to 212°F).
3. Place the cylinder head on wooden blocks.
4. Using SST, tap in new valve guide bushes to the specified protrusion height.

   SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 

   Protrusion height: 

   10.20 to 10.24 mm (0.4016 to 0.4031 in.) 

   Fig 35: Installing New Valve Guide Bush

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5. Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

   Standard oil clearance: 

   0.025 to 0.060 mm (0.0010 to 0.0023 in.) 

Fig 36: Reaming Valve Guide Bushings

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1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

   Cylinder bore diameter: 

   10.285 to 10.306 mm (0.4049 to 0.4057 in.) 

   Select a new guide bush (STD or O/S 0.05) 

   CYLINDER BORE DIAMETER SPECIFICATIONS
   
   

   Bush size	Bush bore diameter
   Use STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
   Use O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)

   Fig 37: Checking Bush Bore Diameter Of Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.

   If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

2. Heat the cylinder head to 80 to 100°C (176 to 212°F).
3. Place the cylinder head on wooden blocks.
4. Using SST, tap in new valve guide bushes to the specified protrusion height.

   SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 

   Protrusion height: 

   9.30 to 9.34 mm (0.3661 to 0.3677 in.) 

   Fig 38: Installing New Valve Guide Bushes

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

   Standard oil clearance: 

   0.030 to 0.065 mm (0.0012 to 0.0026 in.) 

Fig 39: Reaming Valve Guide Bushings

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1. Using a plastic hammer, tap in new ring pins to the specified protrusion height.

Specified protrusion height: 

2.5 to 3.8 mm (0.098 to 0.150 in.) 

Fig 40: Installing New Ring Pins

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1. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.

   Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

Fig 41: Installing No. 1 Straight Screw Plug

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1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.

   Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

Fig 42: Installing No. 2 Straight Screw Plug

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1. Using E6 and E8 "torx" sockets, install the stud bolts.
   Fig 43: Identifying Stud Bolts Installation Points

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

   A, B and D 

   4.0 N*m (41 kgf*cm, 35 in.*lbf) for bolt C 

1. Apply adhesive to the union of the cylinder head.

   Adhesive: 

   Part No. 08833-00070, THREE BOND 1324 or equivalent. 

   Fig 44: Applying Adhesive To Union Of Cylinder Head

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2. Using SST, install the union to the cylinder head.
   Fig 45: Installing Union To Cylinder Head

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   SST 09023-38201 

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

1. Using a plastic hammer, tap in new straight pins.
   Fig 46: Identifying New Straight Pins

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Protrusion height: 

   17.5 to 19.5 mm (0.689 to 0.768 in.) 

1. Install the valve spring seats to the cylinder head.

1. Apply a light coat of engine oil to new oil seals.
   NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

   HINT:

   The intake valve oil seals are gray and the exhaust valve oil seals are black.

   Fig 47: Identifying Valve Stem Oil Seals

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2. Using SST, push in the oil seals.

   SST 09201-41020 

   NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.

Fig 48: Pushing In Oil Seals Using SST

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1. Apply a sufficient coat of engine oil to the tip area of the intake valve.
2. Install the valve, compression spring and spring retainer to the cylinder head.
   NOTE: Install the same parts in the same combination to the original locations.
   Fig 49: Identifying Tip Area Of Intake Valve

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3. Using SST, compress the spring and install the 2 retainer locks.

   SST 09202-70020 (09202-00010) 

   Fig 50: Compressing Spring & Installing Retainer Locks Using SST

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4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
   NOTE: Be careful not to damage the retainer.

Fig 51: Tapping In Valve Stem Tip Using Plastic Hammer

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1. Apply a sufficient coat of engine oil to the tip area of the intake valve.
2. Install the valve, compression spring and spring retainer to the cylinder head.
   NOTE: Install the same parts in the same combination to the original locations.
   Fig 52: Identifying Tip Area Of Intake Valve

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3. Using SST, compress the spring and install the 2 retainer locks.

   SST 09202-70020 (09202-00010) 

   Fig 53: Compressing Spring & Installing Retainer Locks Using SST

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4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
   NOTE: Be careful not to damage the retainer.

Fig 54: Tapping Valve Stem Tip Using Plastic Hammer

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1. Apply a light coat of engine oil to the valve stem caps.
2. Install the valve stem caps on the valves.

1. Place the oil seal retainer on wooden blocks.
2. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.

   SST 09223-15030, 09950-70010 (09951-07100) 

   NOTE:

   • Keep the lip free of foreign matter.
   • Do not tap on the oil seal at an angle.

Fig 55: Tapping In New Engine Rear Oil Seal Using SST

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1. Apply seal packing in a continuous line as shown in Fig 56 .

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal diameter: 

   2.0 to 3.0 mm (0.079 to 0.118 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil seal retainer within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installation.
   Fig 56: Applying Seal Packing

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2. Install the oil seal retainer with the 6 bolts.

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

   NOTE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

   Adhesive: 

   Part No. 08833-00070, THREE BOND 1324 or equivalent 

Fig 57: Installing Oil Seal Retainer With Bolts

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1. Install the water outlet pipe with the 2 bolts.

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

Fig 58: Installing Water Outlet Pipe With Bolts

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1. Install the 2 knock sensors with the 2 bolts as shown in Fig 59 .

   Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

2. Connect the 2 knock sensor connectors.
3. Connect the knock sensor wire clamp.

Fig 59: Identifying Knock Sensors With Bolts

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1. Install the water jacket spacer as shown in Fig 60 .

   HINT:

   Be sure to face the slope to the front of the engine.

Fig 60: Installing Cylinder Block Water Jacket Spacer RH

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1. Install the water jacket spacer as shown in Fig 60 .

   HINT:

   Be sure to face the slope to the front of the engine.

1. Apply a continuous line of seal packing to a new cylinder head gasket as shown in Fig 61 .

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal diameter: 

   2.5 to 3.0 mm (0.098 to 0.118 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head gasket within 3 minutes after applying the seal packing.
   • Do not apply engine oil within 2 hours of installation.
   Fig 61: Applying Continuous Line Of Seal Packing To New Cylinder Head Gasket

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2. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
   NOTE:

   • Be careful of the installation direction.
   • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
3. Place the cylinder head on the cylinder block.
   NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.

   HINT:

   The cylinder head bolts are tightened in 3 progressive steps.

4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
   Fig 62: Placing Cylinder Head Gasket On Cylinder Block Surface With Lot No. Stamp Upward

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5. Step 1
   1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in Fig 63 .

   Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

   Fig 63: Identifying Tightening Sequence Of Cylinder Head Bolts

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6. Step 2
   1. Mark the cylinder head bolt head with paint as shown in Fig 64 .
   2. Tighten the cylinder head bolts another 90°.
7. Step 3
   1. Tighten the cylinder head bolts by an additional 90°.
   2. Check that the painted mark is now facing rearward.
   Fig 64: Identifying Retightening Angle Of Cylinder Head Bolt

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8. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.
   Fig 65: Identifying Seal Packing

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1. Apply a continuous line of the seal packing to a new cylinder head gasket as shown in Fig 66 .
   Fig 66: Applying Continuous Line Of Seal Packing To New Cylinder Head Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal diameter: 

   2.5 to 3.0 mm (0.098 to 0.118 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head gasket within 3 minutes after applying the seal packing.
   • Do not apply engine oil within 2 hours of installation.
2. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
   Fig 67: Placing Cylinder Head Gasket On Cylinder Block Surface With Lot No. Stamp Upward

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Be careful of the installation direction.
   • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
3. Place the cylinder head on the cylinder block.
   NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.

   HINT:

   The cylinder head bolts are tightened in 3 progressive steps.

4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
5. Step 1
   1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in Fig 68 .

      Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

   Fig 68: Identifying Tightening Sequence Of Cylinder Head Bolts

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6. Step 2
   1. Mark the cylinder head bolt head with paint as shown in Fig 69 .
   2. Tighten the cylinder head bolts by 90°.
   Fig 69: Identifying Retightening Angle Of Cylinder Head Bolt
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7. Step 3
   1. Tighten the cylinder head bolts by an additional 90°.
   2. Check that the painted mark is now facing rearward.
8. Tighten the 2 bolts.

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

   Fig 70: Tightening Bolts

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9. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.
   Fig 71: Identifying Seal Packing

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1. Place the lash adjuster into a container filled with engine oil.
2. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

   SST 09276-75010 

   Fig 72: Checking Valve Lash Adjuster Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed the air.

   OK: 

   Plunger moves up and down. 

   NOTE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.
5. After bleeding the air, remove SST. Then, try to quickly and firmly press the plunger with a finger.

   OK: 

   Plunger is very difficult to move. 

   If the result is not as specified, replace the lash adjuster.

6. Install the lash adjusters.
   NOTE: Install the lash adjuster to the same place it was removed from.

1. Apply engine oil to the lash adjuster tip and valve stem cap end.
   Fig 73: Installing Valve Rocker Arms

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2. Make sure that the valve rocker arms are installed as shown in Fig 73 .

1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
2. Install the camshaft and camshaft No. 2 to the camshaft housing RH.
3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
   Fig 74: Identifying Marks & Numbers On Camshaft Bearing Caps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 9 bolts.

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

Fig 75: Tightening Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Make sure that the valve rocker arm is installed.
   Fig 76: Installing Valve Rocker Arm

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown in Fig 77 .

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal diameter: 

   3.5 to 4.0 mm (0.138 to 0.158 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the camshaft housing sub-assembly RH within 3 minutes.
     Fig 77: Applying Seal Packing In Continuous Line

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Do not start the engine for at least 2 hours after installing.
3. Install the camshaft housing RH and tighten the 14 bolts in the order shown in Fig 78 .
   NOTE:

   • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in Fig 78. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
   • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
   • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
     Fig 78: Identifying Tightening Sequence Of Camshaft Housing RH Bolts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 9 bolts.

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

   Fig 79: Identifying Tightening Sequence Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
2. Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing LH.
3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
   Fig 80: Identifying Marks & Numbers On Camshaft Bearing Caps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 8 bolts in the order shown.

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

Fig 81: Identifying Tightening Sequence Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Make sure that the valve rocker arm is installed.
   Fig 82: Installing Valve Rocker Arm

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown in Fig 83 .

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal diameter: 

   3.5 to 4.0 mm (0.138 to 0.158 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the camshaft housing sub-assembly LH within 3 minutes.
   • Do not start the engine for at least 2 hours after installing.
   Fig 83: Applying Seal Packing In Continuous Line

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the camshaft housing LH and tighten the 13 bolts in the order shown in Fig 84 .

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

   NOTE:

   • When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in Fig 84. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
   • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
   • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
   Fig 84: Identifying Tightening Sequence Of Camshaft Housing LH Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 8 bolts in the order shown.

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

Fig 85: Identifying Tightening Sequence Of Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 2 chain tensioner with the bolt.

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

2. While pushing in the tensioner, insert a pin of a diameter of 1.0 mm (0.039 in.) into the hole to fix it.

Fig 86: Identifying No. 2 Chain Tensioner

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in Fig 87 .
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed.
   Fig 87: Aligning Mark Plate With Timing Marks Of Camshaft Timing Gears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

   Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) 

5. Remove the pin from the chain tensioner.

Fig 88: Tightening Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the chain tensioner with the bolt.

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

2. While pushing in the tensioner, insert a pin with a diameter of 1.0 mm (0.039 in.) into the hole to hold it.

Fig 89: Installing No. 3 Chain Tensioner

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in Fig 90 .
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed.
   Fig 90: Aligning Mark Plate With Timing Marks Of Camshaft Timing Gears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

   Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) 

5. Remove the pin from the chain tensioner.

Fig 91: Tightening Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the chain vibration damper with the 2 bolts.

   Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf) 

Fig 92: Identifying No. 1 Chain Vibration Damper

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 chain vibration dampers.

Fig 93: Identifying No. 2 Chain Vibration Dampers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 timing gear set keys and timing gear.

Fig 94: Identifying Timing Gear Set Keys & Timing Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
2. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.
   NOTE: Be careful of the idle gear direction.

   HINT:

   Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.

3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

   Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

   HINT:

   After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.

Fig 95: Installing Idle Sprocket Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the mark plate and timing mark and install the chain.

   HINT:

   The camshaft mark plate is orange.

   Fig 96: Aligning Mark Plate & Timing Mark

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Do not pass the chain over the crankshaft, just put it on it.
   Fig 97: Putting Chain On Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.
   NOTE: When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.
   Fig 98: Tightening Chain Between Banks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the mark plate and timing mark as shown in Fig 99 and install the chain onto the crankshaft timing sprocket.

   HINT:

   The crankshaft mark plate is yellow.

5. Temporarily tighten the pulley set bolt.
   Fig 99: Aligning Mark Plate & Timing Mark

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).

1. Install the chain tensioner slipper.

Fig 100: Setting Crankshaft To RH Block Bore Center Line (TDC/Compression)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
   Fig 101: Pushing Plunger Deep Into Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the chain tensioner with the 2 bolts.

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

   Fig 102: Identifying Chain Tensioner With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the lock pin of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression.
5. Remove the pulley set bolt.

Fig 103: Aligning Each Timing Mark With Crankshaft At TDC/Compression

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

   SST 09223-22010, 09506-35010 

   NOTE:

   • Keep the lip free of foreign matter.
   • Do not tap on the oil seal at an angle.
   • Make sure that the oil seal edge does not stick out of the timing chain case.

Fig 104: Tapping In New Timing Chain Case Oil Seal Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket and the water pump with the 16 bolts.

   Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 

   NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

Fig 105: Identifying Water Pump Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply seal packing in a continuous line to the engine unit.
   Fig 106: Applying Seal Packing In Continuous Line To Engine Unit

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal diameter: 

   5.0 to 5.5 mm (0.197 to 0.217 in.) 

   NOTE:

   • Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in Fig 106.
   • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   • Install the chain cover within 3 minutes.
   • Do not start the engine for at least 2 hours after installing.
2. Apply seal packing in a continuous line to the timing chain cover.
   Fig 107: Applying Seal Packing In Continuous Line To Timing Chain Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing: 

   08826-00080 or equivalent 

   08826-00100, THREE BOND 1282B or 

   equivalent 

   NOTE:

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

   Apply seal packing as follows 

   SEAL PACKING APPLICATION REFERENCE
   
   

   Area	Seal Packing Diameter	Application Position from Inside Seal Line
   Continuous Line Area	3.5 to 4.0 mm (0.138 to 0.158 in.)	3.0 to 4.0 mm (0.118 to 0.158 in.)
   Alternate Long and Dashed Line Area	3.5 to 4.0 mm (0.138 to 0.158 in.)	2.0 to 3.0 mm (0.079 to 0.118 in.)
   Dashed Line Area	6.0 mm (0.236 in.)	-

3. Install a new gasket.
   Fig 108: Locating New Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the oil pump's drive rotor spline and the crankshaft. Install the spline and chain cover to the crankshaft.
   Fig 109: Aligning Oil Pump's Drive Rotor Spline & Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

   Bolt length 

   BOLT LENGTH SPECIFICATIONS
   
   

   Item	Length
   Bolt A	50 mm (1.97 in.)
   Bolt B	25 mm (0.98 in.)
   Bolt C	55 mm (2.17 in.)

   NOTE: Make sure that there is no oil on the bolt threads.
   Fig 110: Tightening Timing Chain Cover Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Fully tighten the 3 bolts.

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

   21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A 

   Fig 111: Tightening Bolts (1 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Fully tighten the 3 bolts.

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

   Fig 112: Tightening Bolts (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Fully tighten the 7 bolts and 2 nuts as shown in Fig 113 .

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

   HINT:

   Tighten the bolts and nuts in the order of upper to lower.

   Fig 113: Tightening Bolts & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Fully tighten the 12 bolts as shown in Fig 114 .

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

   HINT:

   Tighten the bolts in the order of lower to upper as shown in Fig 114 .

10. Install a new gasket and the chain cover plate with the 4 bolts.

    Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 

Fig 114: Tightening Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. For 2WD:
   1. Using an E6 "torx" socket, install the stud bolts.
      Fig 115: Identifying Stud Bolts (2WD)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

   2. Install the baffle plate with the 8 bolts.

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

      HINT:

      Temporarily tighten the 8 bolts. Fully tighten 2 bolts A before tightening the other bolts.

      Fig 116: Identifying Baffle Plate

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Install a new gasket and the oil strainer with the 3 nuts.

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

2. For 4WD:
   1. Using an E6 "torx" socket, install the stud bolts.
      Fig 117: Identifying Oil Strainer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 118: Identifying Stud Bolts (4WD)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

   2. Install the baffle plate with the 7 bolts.

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

      HINT:

      Temporarily tighten the 7 bolts. Fully tighten 2 bolts A before tightening the other bolts.

      Fig 119: Identifying Baffle Plate

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Install a new gasket and the oil strainer with the bolt and 2 nuts.

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

      Fig 120: Identifying New Gasket & Oil Strainer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install 2 new O-rings.

1. When replacing a stud bolt, install it by using an E6 "torx" socket wrench.
   Fig 121: Identifying O-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 122: Identifying Stud Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

2. Apply seal packing in a continuous line as shown in Fig 123 .

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal diameter: 

   3.0 to 4.0 mm (0.118 to 0.156 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
   Fig 123: Applying Seal Packing In Continuous Line

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil pan with the 16 bolts and 2 nuts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 

   21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A 

Fig 124: Identifying Oil Pan

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket and the oil with strainer pipe with the 3 nuts.

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

Fig 125: Identifying New Gasket & Oil With Strainer Pipe

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply seal packing in a continuous line as shown in Fig 126 .

   Seal packing: 

   Part No. 08826-00080 or equivalent 

   Seal diameter: 

   3.0 to 4.0 mm (0.118 to 0.156 in.) 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan No. 2 within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
   Fig 126: Applying Seal Packing In Continuous Line

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. For 2WD:
   1. Install the oil pan with the 15 bolts and 2 nuts.

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

   Fig 127: Identifying Oil Pan (For 2WD)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. For 4WD:
   1. Install the oil pan with the 14 bolts and 2 nuts.

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

1. Install a new gasket and the drain plug.

   Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

Fig 128: Identifying Oil Pan (For 4WD)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a cutter, cut off the sealing part of the removed plug tube gasket.
   Fig 129: Identifying Spark Plug Tube Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.
   NOTE:

   • Keep the lip free of foreign matter.
   • Do not tap on the oil seal at an angle.

   HINT:

   If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

3. Return the claws of the ventilation baffle plate to their original positions.

Fig 130: Installing Spark Plug Tube Gasket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply seal packing as shown in Fig 131 .

   Seal packing: 

   08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the head cover within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
   Fig 131: Applying Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 3 new gaskets.
3. Install a new gasket to the head cover.
   Fig 132: Installing New Gaskets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a head cover with the 14 bolts.

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

   10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A 

Fig 133: Identifying Head Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply seal packing as shown in Fig 134 .

   Seal packing: 

   08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the head cover within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
   Fig 134: Applying Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 3 new gaskets.
3. Install a new gasket to the head cover.
   Fig 135: Identifying New Gaskets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the head cover with the 12 bolts.

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

   10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A 

5. For 4WD:
   1. Install the engine hanger with the 2 bolts.

   Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

Fig 136: Identifying Head Cover With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 new gaskets and a new O-ring.

   HINT:

   Apply soapy water to the O-ring.

   Fig 137: Identifying New Gaskets & New O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water by-pass joint with the 2 bolts and 4 nuts.

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

   NOTE: Be careful that the O-ring does not get caught between the parts.

Fig 138: Identifying Water By-Pass Joint

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket and water inlet with thermostat with the 3 nuts.

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

Fig 139: Identifying Water Inlet With Thermostat Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 3 water by-pass hoses.
   Fig 140: Identifying Water By-Pass Hoses

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 2 new O-rings.

   HINT:

   Apply a small amount of water or soapy water to O-ring (A) before installing it.

   Fig 141: Identifying O-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the water inlet with the 4 bolts and nut.

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

   NOTE: Be careful that the O-ring does not get caught between the parts.
   Fig 142: Installing Water Inlet

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 3 water by-pass hoses.

1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
   Fig 143: Identifying Water By-Pass Hoses

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

   SST 09213-70011 (09213-70020), 09330-00021 

   Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf) 

Fig 144: Installing Pulley Bolt Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clean the inside of the oil filter cap, the threads and O-ring groove.
2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
3. Set a new oil filter element to the oil filter cap.
4. Remove any dirt or foreign matter from the installation surface of the engine.
5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
   Fig 145: Identifying Oil Filter Element & O-Ring (For 2WD)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful that the O-ring does not get caught between the parts.
6. Using SST, tighten the oil filter cap.

   SST 09228-06501 

   Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

   NOTE: Make sure that the oil filter is installed securely.

Fig 146: Tightening Oil Filter Cap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

Fig 147: Identifying Oil Filter Bracket Sub-Assembly (For 4WD)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clean the inside of the oil filter cap, the threads and O-ring groove.
2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
3. Set a new oil filter element to the oil filter cap.
4. Remove any dirt or foreign matter from the installation surface of the engine.
5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
   Fig 148: Identifying Oil Filter Element & O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful that the O-ring does not get caught between the parts.
6. Using SST, tighten the oil filter cap.

   SST 09228-06501 

   Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

   NOTE:

   • Make sure that the oil filter is installed securely.
   • Be careful that the O-ring does not get caught between the parts.
   Fig 149: Tightening Oil Filter Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Apply a light coat of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

   Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

   NOTE:

   • Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.
   • Be careful that the O-ring does not get caught between the parts.

Fig 150: Installing Drain Plug O-Ring To Oil Filter Cap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply adhesive around the drain cocks.

   Adhesive: 

   Part No. 08833-00070, THREE BOND 1324 or equivalent 

   Fig 151: Applying Adhesive Around Drain Cocks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water drain cocks as shown in Fig 152 .

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

   NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
3. Install the water drain cock plugs to the water drain cocks.

   Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
   NOTE: Do not touch the mesh when installing the oil control valve filter.
   Fig 152: Installing Water Drain Cocks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
4. Tighten the oil pipe union (on the head cover side).

   Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

5. Tighten the oil check valve bolt (on the cylinder head side).

   Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

   NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

Fig 153: Tightening Oil Check Valve Bolt (On Cylinder Head Side)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
   NOTE: Do not touch the mesh when installing the oil control valve filter.
2. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
4. Tighten the oil pipe union (on the head cover side).

   Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

5. Tighten the oil check valve bolt (on the cylinder head side).

   Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

   Fig 154: Tightening Oil Check Valve Bolt (No 2 Oil Pipe)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

1. Install the sensor with the bolt.

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

Fig 155: Identifying Crankshaft Position Sensor

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1. Install the 4 oil control valves with the 4 bolts.

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

Fig 156: Installing Camshaft Timing Oil Control Valve Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 4 sensors with the 4 bolts.

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

   Fig 157: Installing Camshaft Position Sensor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply adhesive around the ventilation valve.

   Adhesive: 

   Part No. 08833-00070, THREE BOND 1324 or equivalent 

2. Install the ventilation valve.

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

1. Install the spark plugs.

   Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

1. Install the radiator cap.

1. Install a new gasket.
2. Install the oil filler cap.

Fig 158: Installing Ventilation Valve

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002