Engine Unit: Reassembly

CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .

INSTALL STRAIGHT PIN

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

Fig 1: Identifying Straight Pin Dimension

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard protrusion

ITEM SPECIFICATION

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

INSTALL STUD BOLT
1. Using an E8 "torx" socket, install the stud bolts.
  
  Fig 2: Identifying Stud Bolts Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL TIGHT PLUG
NOTE: If water leaks from the tight plug or the plug is corroded, replace it.
1. Apply adhesive around the tight plugs.
  Adhesive:
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
  
  Fig 3: Applying Adhesive To Around Tight Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap in new tight plugs as shown in the illustration.
  
  Fig 4: Locating Cylinder Block Tight Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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)
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the oil nozzles.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 5: Locating Oil Nozzles Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD SMALL END BUSH
1. Align the oil holes of a new bush and the connecting rod.
  
  Fig 6: Identifying Oil Holes Of Bush And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the bush.
  SST 09222-30010
  
  Fig 7: Pressing Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Clearance Between Bush And Piston Pin
  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: Checking Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PISTON SUB-ASSEMBLY WITH PIN

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: Installing Piston Sub-Assembly With Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Gradually heat the piston to approximately 80°C (176°F).
Coat the piston pin with engine oil.

Fig 11: Heating Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Front Mark

ITEM SPECIFICATION

Item	Front Mark
Piston LH	1
Piston RH	2

HINT:

The piston and pin are a matched set.

Fig 12: Identifying Front Marks Of Piston And Connecting Rod

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 And Piston Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

INSTALL PISTON RING SET
1. Install the oil ring expander by hand.
  
  Fig 14: Installing Snap Ring Of Piston Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, install the oil ring rail and 2 compression rings as shown in the illustration.
  
  Fig 15: Installing Oil Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown in the illustration.
  NOTE: Do not align the ring ends.
  
  Fig 16: Identifying Position Of Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT BEARING
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 Crankshaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the upper bearing.
  1. Install the upper bearings to the cylinder block as shown in the illustration.
    NOTE:
    Do not apply engine oil to the bearings or 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 Bearing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 or the contact surfaces.
INSTALL CRANKSHAFT THRUST WASHER SET
1. Apply engine oil to the crankshaft thrust washer.
  
  Fig 19: Installing Lower Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.

INSTALL CRANKSHAFT

Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

Fig 20: Identifying Grooves
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
Temporarily install the 8 main bearing cap bolts to the inside positions.

Fig 21: Identifying Numbers Of Main Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
Bolt length:

100 to 102 mm (3.94 to 4.02 in.)

Fig 22: Identifying Bearing Cap Bolts Dimension
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Bolt length

BOLT LENGTH SPECIFICATION

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.)

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 Dimension
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Step 1
1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
  Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
  
  If any of the main bearing cap bolts does not meet the torque specified, replace it.
  
  Fig 25: Identifying Main Bearing Cap Bolts Tighten Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
3. Check that the painted mark is now at a 90° angle to the front.
  
  Fig 26: Identifying Bearing Cap Bolts Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

Bolt length

BOLT LENGTH SPECIFICATION

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

Check that the crankshaft turns smoothly.

Fig 27: Identifying Main Bearing Cap Bolts Tighten Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check the crankshaft thrust clearance (See INSPECTION ).

INSTALL CONNECTING ROD BEARING
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 or the contact surfaces.

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.

Fig 28: Installing Connecting Rod Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Position the piston rings so that the ring ends are as shown in the illustration.
NOTE: Do not align the ring ends.

Fig 29: Identifying Position Of Piston Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

FRONT MARK SPECIFICATION

Item	Front Mark
Piston LH	1
Piston RH	2

Fig 30: Pushing Connecting Rod

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

The connecting rod cap bolts are tightened in 2 progressive steps.

Fig 31: Checking Front Mark Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Step 1
1. Install and alternately tighten the connecting rod cap bolts in several steps.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 32: Installing Connecting Rod Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Step 2
1. Mark the front side of each connecting rod cap bolt with paint.
2. Retighten the cap bolts by 90° as shown in the illustration.
3. Check the painted mark is now at a 90° angle to the front.
Check that the crankshaft turns smoothly.
Check the connecting rod thrust clearance (See INSPECTION ).

Fig 33: Identifying Connecting Rod Cap Bolts Mark Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INTAKE VALVE GUIDE BUSH

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)

BUSH DIAMETER REFERENCE

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: Installing Intake Valve Guide Bush

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 an 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.

Heat the cylinder head to 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
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: Tapping Valve Guide Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the valve guide bushes 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 Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL EXHAUST VALVE GUIDE BUSH

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)

BUSH DIAMETER REFERENCE

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: Measuring Bush Bore Diameter Of Cylinder Head

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

Heat the cylinder head to 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
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: Tapping Valve Guide Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the valve guide bushes 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 Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL RING PIN
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: Locating Ring Pin Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 STRAIGHT SCREW PLUG
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: Locating No. 1 Straight Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 STRAIGHT SCREW PLUG
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: Locating No. 2 Straight Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STUD BOLT
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
1. Using E6 and E8 "torx" sockets, install the stud bolts.
  
  Fig 43: Stud Bolt Dimension Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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
INSTALL UNION
1. Apply adhesive to the union of the cylinder head.
  Adhesive:
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Using SST, install the union to the cylinder head as shown in the illustration.
  
  Fig 44: Applying Adhesive To Union Of Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 45: Identifying Union Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09023-38201
  
  Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
INSTALL STRAIGHT PIN
1. Using a plastic hammer, tap in new straight pins as shown in the illustration.
  
  Fig 46: Identifying Straight Pin Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Protrusion height:
  
  17.5 to 19.5 mm (0.689 to 0.768 in.)
INSTALL VALVE SPRING SEAT
1. Install the valve spring seats to the cylinder head.
INSTALL VALVE STEM OIL SEAL
1. Apply a light coat of engine oil to new 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 Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Oil Seals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST VALVE
1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
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 Exhaust Valve Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, compress the spring and install the 2 retainer locks.
  SST 09202-70020 (09202-00010)
  
  Fig 50: Compressing Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Installing Valve Steam
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE VALVE
1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
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 Intake Valve Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, compress the spring and install the 2 retainer locks.
  SST 09202-70020 (09202-00010)
  
  Fig 53: Compressing Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  NOTE: Be careful not to damage the retainer.
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the valve stem caps on the valves.
  
  Fig 54: Tapping Valve Stem Tip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE REAR OIL SEAL
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: Installing Engine Rear Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Apply seal packing in a continuous line as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter:
  
  2.0 to 3.0 mm (0.079 to 0.118 in.)
  
  Fig 56: Identifying Engine Rear Oil Seal Retainer
  Courtesy 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 start the engine for at least 2 hours after installation.
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:
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  
  Fig 57: Locating Oil Seal Retainer With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER OUTLET PIPE SUB-ASSEMBLY
1. Install the water outlet pipe with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 58: Locating Water Outlet Pipe With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL KNOCK SENSOR
1. Install the 2 knock sensors with the 2 bolts as shown in the illustration.
  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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER JACKET SPACER RH
1. Install the water jacket spacer as shown in the illustration.
  HINT:
  
  Be sure to face the slope to the front of the engine.
INSTALL CYLINDER BLOCK WATER JACKET SPACER LH
1. Install the water jacket spacer as shown in the illustration.
  HINT:
  
  Be sure to face the slope to the front of the engine.
  
  Fig 60: Identifying Water Jacket Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
1. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B 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: Locating Cylinder Head Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 62: Identifying Cylinder Head Gasket With Lot No. Stamp Upward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 and in the sequence shown in the illustration.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
    
    Fig 63: Identifying Cylinder Head Bolts Tightening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Step 2
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  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 Cylinder Head Bolts Paints Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
  
  Fig 65: Identifying Wipe Off Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
1. Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B 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 start the engine for at least 2 hours after installing.
    
    Fig 66: Locating Cylinder Head Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 67: Identifying Cylinder Head Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 the illustration.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
    
    Fig 68: Identifying Cylinder Head Bolts Tightening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Step 2
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  2. Tighten the cylinder head bolts by 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 69: Identifying Cylinder Head Bolts Paint Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Tighten the 2 bolts in the order shown in the illustration.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  Fig 70: Locating Cylinder Head Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.
1. Place the lash adjuster into a container filled with engine oil.
  
  Fig 71: Identifying Wipe Off Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
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 position it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Apply engine oil to the lash adjuster tip and valve stem cap end.
  
  Fig 72: Checking Plunger Movement
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Make sure that the valve rocker arms are installed as shown in the illustration.
Fig 73: Identifying Valve Rocker Arms
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP (for Bank 1)
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. Check the marks and numbers on the camshaft bearing caps and place each of them in the proper position and direction.
  
  Fig 74: Checking Marks And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 9 bolts in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 75: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
1. Make sure that the valve rocker arm is installed as shown in the illustration.
  
  Fig 76: Identifying Valve Lash Adjuster
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B 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 Of Contact Surface
    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 the illustration.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
  - If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
    
    Fig 78: Locating Camshafts Housing Bolts Tighten Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 9 bolts in the order shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
INSTALL CAMSHAFT BEARING CAP (for Bank 2)
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.
  
  Fig 79: Locating Camshafts Bearing Bolts With Tighten Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the marks and numbers on the camshaft bearing caps and place each of them in the proper position and direction.
  
  Fig 80: Identifying Camshaft Bearing Caps In Proper Position And Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 8 bolts in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 81: Identifying Camshaft Bearing Caps Bolts With Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
1. Make sure that the valve rocker arm is installed as shown in the illustration.
  
  Fig 82: Identifying Valve Lash Adjuster
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B 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: Identifying Seal Packing Area 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 the illustration.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
    
    Fig 84: Identifying Camshaft Housing Bolts With Tightening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
4. Tighten the 8 bolts in the order shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 85: Identifying Camshaft Housing Bolts With Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
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 1.0 mm (0.039 in.) into the hole to fix it.
  
  Fig 86: Installing No. 2 Chain Tensioner With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .
1. Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.
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: Identifying Mark Plate With Timing Marks
  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: Holding Hexagonal Portion Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
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 of 1.0 mm (0.039 in.) into the hole to hold it.
  
  Fig 89: Installing Chain Tensioner With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .
1. Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration.
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: Identifying Mark Plate With Timing Marks
  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: Holding Hexagonal Portion Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper with the 2 bolts.
  Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
  
  Fig 92: Locating Chain Vibration Damper With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN VIBRATION DAMPER
1. Install the 2 chain vibration dampers.
  
  Fig 93: Locating Chain Vibration Dampers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING SPROCKET
1. Install the 2 timing gear set keys and timing gear as shown in the illustration.
  
  Fig 94: Identifying Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL IDLE SPROCKET ASSEMBLY
1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
2. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.
  NOTE: Make sure that the idle gear is facing the correct direction.
  
  HINT:
  
  Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.
  
  Fig 95: Identifying Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
  
  HINT:
  
  After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
INSTALL CHAIN SUB-ASSEMBLY
1. Align the mark plate and timing mark as shown in the illustration and install the chain.
  HINT:
  
  The camshaft mark plate is orange.
  
  Fig 96: Aligning Mark Plate And Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Rest the chain on top of the crankshaft.
  
  Fig 97: Identifying Crankshaft Timing Sprocket
  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: Turning Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the mark plate and timing mark as shown in the illustration 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 And 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).
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper.
  
  Fig 100: Turning Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
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: Identifying Stopper Plate
  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: Locating Chain Tensioner And 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: Identifying Timing Mark Of Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING CHAIN CASE OIL SEAL
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: Installing Timing Chain Case Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER PUMP ASSEMBLY
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: Locating Water Pump With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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

Fig 106: Identifying Timing Chain Cover Sub-Assembly Seal Location
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Seal packing:

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

Seal diameter:

A: 3.0 to 4.0 mm (0.118 to 0.158 in.)

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

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

Fig 107: Identifying Timing Chain Cover Seal Packing Area

Seal packing:

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

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

NOTE:

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

Seal Packing Application Chart

SEAL PACKING APPLICATION CHART

Area	Seal Packing Diameter	Application Position from Inside Seal Line
Continuous Line Area	4.5 mm (0.177 In.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area	6.0 mm (0.236 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 In.)
Alternate Long and Dashed Line Area	3.5 mm (0.138 In.) or more	2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area	3.5 mm (0.138 In.) or more	1.0 to 2.0 mm (0.039 to 0.079 In.)

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

Fig 109: Identifying Chain Cover To Crankshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

Bolt length

BOLT LENGTH SPECIFICATION

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: Locating Timing Chain Cover Bolts And Nuts

Fully tighten the 3 bolts as shown in the illustration.
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: Locating Timing Chain Cover Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fully tighten the 3 bolts as shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

Fig 112: Locating Timing Chain Cover Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fully tighten the 7 bolts and 2 nuts as shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

HINT:

Tighten the bolts and nuts in the order from upper to lower as shown in the illustration.

Fig 113: Locating Timing Chain Cover Bolts And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fully tighten the 12 bolts as shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

HINT:

Tighten the bolts in the order from lower to upper as shown in the illustration.
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: Locating Timing Chain Cover Nuts Tighten Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OIL STRAINER SUB-ASSEMBLY
1. For 2WD:
  1. Using an E6 "torx" socket, install the stud bolts as shown in the illustration.
    
    Fig 115: Identifying Stud Bolts Dimension
    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 as shown in the illustration before tightening the other bolts.
    
    Fig 116: Locating Baffle Plate With Bolts
    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 as shown in the illustration.
    
    Fig 118: Identifying Stud Bolt Dimension
    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 as shown in the illustration before tightening the other bolts.
    
    Fig 119: Locating Baffle Plate With Bolts
    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: Locating Oil Strainer With Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install 2 new O-rings.
INSTALL OIL PAN SUB-ASSEMBLY
1. When replacing a stud bolt, install it by using an E6 "torx" socket wrench.
  
  Fig 121: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 122: Identifying Oil Pan Bolts Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
2. Apply seal packing in a continuous line as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter:
  
  3.0 to 4.0 mm (0.118 to 0.156 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
    
    Fig 123: Identifying 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: Locating Oil Pan With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL WITH STRAINER PIPE SUB-ASSEMBLY (for 4WD)
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: Locating Oil Strainer With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
1. Apply seal packing in a continuous line as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter:
  
  3.0 to 4.0 mm (0.118 to 0.156 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan No. 2 within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
    
    Fig 126: Identifying 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: Locating Oil Pan Bolts And Nuts (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)
    
    Fig 128: Locating Oil Pan Bolts And Nuts (For 4WD)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN DRAIN PLUG
1. Install a new gasket and the drain plug.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
INSTALL SPARK PLUG TUBE GASKET
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: Tapping Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Apply seal packing as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
    
    Fig 131: Applying Seal Packing In Cylinder Head Cover Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 3 new gaskets as shown in the illustration.
3. Install a new gasket to the head cover.
  
  Fig 132: Locating Cylinder Head Cover And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 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: Locating Head Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Apply seal packing as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
    
    Fig 134: Applying Seal Packing In Cylinder Head Cover Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 3 new gaskets as shown in the illustration.
3. Install a new gasket to the head cover.
  
  Fig 135: Locating Cylinder Head Cover Gasket
  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: Locating Head Cover With Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR WATER BY-PASS JOINT
1. Install 2 new gaskets and a new O-ring.
  HINT:
  
  Apply soapy water to the O-ring.
  
  Fig 137: Locating Gaskets And 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: Locating Water By-Pass Joint, Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
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: Locating Water Inlet With Thermostat Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER INLET SUB-ASSEMBLY
1. Install the 3 water by-pass hoses.
  
  Fig 140: Locating 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) shown in the illustration before installing it.
  
  Fig 141: Locating 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: Locating Water Inlet, Bolts And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 3 water by-pass hoses.
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
  
  Fig 143: Locating 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER ELEMENT (for 2WD)
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.
  NOTE: Be careful that the O-ring does not get caught between the parts.
  
  Fig 145: Identifying Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 as shown in the illustration.
  
  Fig 146: Tightening Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD)
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: Locating Oil Filter Bracket Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER ELEMENT (for 4WD)
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.
  NOTE: Be careful that the O-ring does not get caught between the parts.
  
  Fig 148: Identifying Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 as shown in the illustration.
  - 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: Locating Oil Filter Drain Plug
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive around the drain cocks.
  Adhesive:
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  
  Fig 151: Applying Adhesive To Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water drain cocks as shown in the illustration.
  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 to 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)
INSTALL NO. 1 OIL PIPE
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: Identifying Water Drain Cock Plugs To 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)
  
  Fig 153: Locating No. 1 Oil Pipe And Bolts
  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.
INSTALL NO. 2 OIL PIPE
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)
  
  NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
  
  Fig 154: Locating Oil Pipe Union And Oil Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the sensor with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 155: Locating Sensor With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Install the 4 oil control valves with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 156: Locating Oil Control Valves Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT POSITION SENSOR
1. Install the 4 sensors with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL VENTILATION VALVE SUB-ASSEMBLY
1. Apply adhesive around the ventilation valve.
  Adhesive:
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  
  Fig 157: Locating Camshaft Position Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the ventilation valve.
  Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
INSTALL SPARK PLUG
1. Install the spark plugs.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
INSTALL RADIATOR CAP SUB-ASSEMBLY
1. Install the radiator cap.
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install a new gasket.
2. Install the oil filler cap.
  
  Fig 158: Locating Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002