Engine Unit: Reassembly: Reassembly

INSTALL STRAIGHT PIN

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

Fig 1: Identifying Straight Pin Installation Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard protrusion

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

INSTALL STUD BOLT
1. Using E8 and E10 "TORX" socket wrenches, install the stud bolt.
  
  Fig 2: Identifying Stud Bolt Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolt A
  
  Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
  
  for bolt B
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assembly.
  
  Fig 3: Identifying Bolt And Oil Nozzle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL PISTON SUB-ASSEMBLY WITH PIN
1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
  
  Fig 4: Identifying Snap Ring And Piston Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
2. Gradually heat the piston to approximately 80°C (176°F).
  
  Fig 5: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the piston pin with engine oil.
4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
  
  Fig 6: Aligning Front Marks Of Piston And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The piston and pin are a matched set.
5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
  
  Fig 7: Checking Fitting Condition Between Piston And Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.
  
  Fig 8: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
INSTALL PISTON RING SET
1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings as shown.
  
  Fig 9: Identifying Piston Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown.
  
  Fig 10: Identifying Piston Rings Gap Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not align the ring ends.
INSTALL CRANKSHAFT BEARING
1. Clean the main journal and both surfaces of the bearing.
  
  Fig 11: Identifying Journal Bearings Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
2. Install the upper bearing.
  
  Fig 12: Identifying Upper Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the upper bearings to the cylinder block as shown in the illustration.
    NOTE:
    Do not apply engine oil to the bearings and the contact surfaces.
    
    Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.
3. Install the lower bearing.
  
  Fig 13: Identifying Lower Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the lower bearings to the bearing caps.
  2. Using a vernier caliper, 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.
INSTALL CRANKSHAFT THRUST WASHER SET
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.
  
  Fig 14: Identifying Oil Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CRANKSHAFT

Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
Confirm the projections and numbers of the main bearing caps and install the bearing caps on the cylinder block.

Fig 15: Identifying Numbers Of Main Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

A number is marked on each main bearing cap to indicate the installation position.
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.
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 using the 2 internal bearing cap bolts as guides.

Fig 16: Identifying Bolt Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length

100 to 102 mm (3.94 to 4.02 in.)
Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.

Fig 17: Tapping Bearing Cap To Ensure Proper Fit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
Install the 8 main bearing cap bolts to the outside positions.

Fig 18: Identifying Main Bearing Cap Bolt Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the crankshaft bearing cap bolts.
HINT:

The main bearing cap bolts are tightened in 2 progressive steps.
Step 1
1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown.
  
  Fig 19: Identifying Main Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
  
  If any of the main bearing cap bolts does not meet the specified torque, replace it.
Step 2
1. Mark the front of the bearing cap bolts with paint.
  
  Fig 20: Identifying Paint Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Retighten the bearing cap bolts 90° in the order above.
3. Check that the painted mark is now at a 90° angle to the front.

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

Fig 21: Identifying Main Bearing Cap Bolt Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf)

Bolt length

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

Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance. See step 31.

INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearing to the connecting rod and bearing cap.
2. Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.
  
  Fig 22: Identifying Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Dimension (A - B)
  
  0.7 mm (0.0276 in.) or less
  
  NOTE: Do not apply engine oil to the bearings and the contact surfaces.
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
2. Position the piston rings so that the ring ends are as shown.
  
  Fig 23: Identifying Piston Rings Gap Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not align the ring ends.
3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
  
  Fig 24: Pushing Piston And Connecting Rod Assembly Into Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Match the numbered connecting rod cap with the connecting rod.
4. Check that the front mark of the connecting rod cap is facing forward.
  
  Fig 25: Identifying Front Mark Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
6. Install the connecting rod cap bolts.
  HINT:
  
  The connecting rod cap bolts are tightened in 2 progressive steps.
7. Step 1
  1. Install and alternately tighten the bolts of the connecting rod cap in several steps.
    
    Fig 26: Tightening Connecting Cap Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
8. Step 2
  1. Mark the front side of each connecting rod cap bolt with paint.
    
    Fig 27: Identifying Retightening Angle Of Connecting Rod Cap Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Retighten the cap bolts 90° as shown.
  3. Check that 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.

INSTALL INTAKE VALVE GUIDE BUSH

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

Fig 28: Measuring Bush Bore Diameter Of Cylinder Head Using Caliper Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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.

Fig 29: Tapping In New Valve Guide Bushes To Specified Protrusion Height Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09201-10000
  - 09201-01050
- SST: 09950-70010
  - 09951-07100
Protrusion height

9.30 to 9.70 mm (0.3661 to 0.3819 in.)
Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

Fig 30: Reaming Valve Guide Bushing Using A Reamer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.025 to 0.060 mm (0.0010 to 0.0023 in.)

INSTALL EXHAUST VALVE GUIDE BUSH

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

Fig 31: Measuring Exhaust Valve Guide Bush Bore Diameter Of Cylinder Head

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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.

Fig 32: Tapping In Valve Guide Bushes To Specified Protrusion Height Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09201-10000
  - 09201-01050
- SST: 09950-70010
  - 09951-07100
Protrusion height

9.30 to 9.70 mm (0.3661 to 0.3819 in.)
Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

Fig 33: Reaming Valve Guide Bushing Using A Reamer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.030 to 0.065 mm (0.0012 to 0.0026 in.)

INSTALL RING PIN
1. Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.
  
  Fig 34: Identifying Ring Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Specified protrusion height
  
  2.5 to 3.5 mm (0.098 to 0.138 in.)
INSTALL NO. 1 STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs.
  
  Fig 35: Identifying No. 1 Straight Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
INSTALL NO. 2 STRAIGHT SCREW PLUG
1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs.
  
  Fig 36: Identifying Straight Screw Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
INSTALL STUD BOLT
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
1. Using E6 and E8 "TORX" socket wrenches, install the stud bolts.
  
  Fig 37: Identifying Stud Bolts Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolts A and B
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  for bolt C
INSTALL STRAIGHT PIN
1. Using a plastic hammer, tap in 4 new straight pins as shown.
  
  Fig 38: Identifying Straight Pin Position
  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 valve stem oil seals.
  
  Fig 39: Identifying Intake And Exhaust Valve Oil Seals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later.
  
  HINT:
  
  The intake valve stem oil seals are gray and the exhaust valve stem oil seals are black.
2. Using SST, push in the valve stem oil seals.
  
  Fig 40: Pushing In Oil Seals Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09201-41020
  NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
INSTALL EXHAUST VALVE
1. Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown.
  
  Fig 41: Identifying Intake Valve Tip Area Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.
  NOTE: Install the same parts in the same combination to the original locations.
3. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
  
  Fig 42: Identifying SST Exhaust Valve Inner Compression Spring & Valve Spring Retainer Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09202-70020
    - 09202-00010
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  
  Fig 43: Tapping Valve Stem Tip To Ensure Proper Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the retainer.
INSTALL INTAKE VALVE
1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown.
  
  Fig 44: Identifying Intake Valve Tip Area Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.
  NOTE: Install the same parts in the same combination to the original locations.
3. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.
  
  Fig 45: Identifying SST Inner Compression Spring & Valve Spring Retainer Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09202-70020
    - 09202-00010
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  
  Fig 46: Tapping Valve Stem Tip To Ensure Proper Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the retainer.
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the valve stem caps on the valves.
INSTALL ENGINE REAR OIL SEAL
1. Place the oil seal retainer on wooden blocks.
2. Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge.
  
  Fig 47: Identifying Engine Rear Oil Seal And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09223-15030
  - SST: 09950-70010
    - 09951-07100
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the engine rear oil seal at an angle.
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Apply seal packing in a continuous line as shown.
  
  Fig 48: Identifying Seal Packing Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal Diameter
  
  2.0 to 3.0 mm (0.079 to 0.118 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the engine rear oil seal retainer within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installation.
2. Install the engine rear oil seal retainer with the 6 bolts.
  
  Fig 49: Identifying Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
INSTALL WATER INLET PIPE
1. Install the water inlet pipe with the 2 bolts.
  
  Fig 50: Identifying Water Inlet Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install the No. 1 water by-pass hose.
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
1. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
  
  Fig 51: Identifying Cylinder Head Gasket And Lot No. Stamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder head.
2. Place the cylinder head on the cylinder block.
  NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
4. Step 1
  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.
    
    Fig 52: Identifying Cylinder Head Bolts Tightening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
5. Step 2
  
  Fig 53: Identifying Painted Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Mark the cylinder head bolt head with paint as shown.
  2. Tighten the cylinder head bolts another 90°.
6. Step 3
  1. Tighten the cylinder head bolts an additional 90°.
  2. Check that the painted mark is now facing rearward.
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
1. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
  
  Fig 54: Placing Cylinder Head Gasket On Cylinder Block Surface With Front Face
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder head.
2. Place the cylinder head on the cylinder block.
  NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
4. Step 1
  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.
    
    Fig 55: Identifying Cylinder Head Bolt Tightening Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
5. Step 2
  
  Fig 56: Identifying Painted Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Mark the cylinder head bolt head with paint as shown.
  2. Tighten the cylinder head bolts another 90°.
6. Step 3
  1. Tighten the cylinder head bolts an additional 90°.
  2. Check that the painted mark is now facing rearward.
7. Tighten the 2 bolts in the order shown.
  
  Fig 57: Identifying Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
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.
2. Insert the tip of SST into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
  
  Fig 58: Identifying SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09276-75010
3. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed air.
  OK
  
  Plunger moves up and down.
  
  NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown. If the check ball is not pressed, air will not bleed.
5. After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly with a finger.
  OK
  
  Plunger is very difficult to move.
  
  If the result is not as specified, replace the lash adjuster.
6. Install the lash adjusters.
  NOTE: Install the lash adjuster to the same place where it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Apply engine oil to the lash adjuster tip and valve stem cap end.
2. Make sure that the 24 No. 1 valve rocker arms are installed as shown.
  
  Fig 59: Identifying Valve Rocker Arm, Lash Adjuster And Valve Stem Cap Ends
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP (for RH Side)
1. Apply engine oil to the camshaft journals, camshaft housing, and bearing caps.
2. Install the camshaft and No. 2 camshaft 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 60: Identifying Marks And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 8 bolts in the order shown.
  
  Fig 61: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
1. Make sure that the valve rocker arm is installed as shown.
  
  Fig 62: Identifying Valve Rocker Arm, Lash Adjuster And Valve Stem Cap Ends
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown.
  
  Fig 63: Identifying Camshaft Housing Sub-Assembly Seal Packing Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.5 to 4.5 mm (0.138 to 0.177 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing sub-assembly RH within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing the camshaft housing sub-assembly RH.
3. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown.
  
  Fig 64: Identifying Camshaft Housing Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing sub-assembly RH, it is necessary to correctly position the camshafts as shown. 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.
4. Tighten the 8 bolts in the order shown.
  
  Fig 65: Identifying Camshaft Housing Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
INSTALL CAMSHAFT BEARING CAP (for LH Side)
1. Apply engine oil to the camshaft journals, camshaft housing, and bearing caps.
2. Install the No. 3 camshaft and No. 4 camshaft 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 66: Identifying Marks And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 8 bolts in the order shown.
  
  Fig 67: Identifying Camshaft Bearing Cap Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
1. Make sure that the valve rocker arm is installed as shown.
  
  Fig 68: Identifying Valve Rocker Arm, Lash Adjuster And Valve Stem Cap Ends
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown.
  
  Fig 69: Identifying Camshaft Housing Sub-Assembly Seal Packing Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.5 to 4.5 mm (0.138 to 0.177 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing sub-assembly LH within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing the camshaft housing sub-assembly LH.
3. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown.
  
  Fig 70: Identifying Camshaft Housing Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
  - If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
4. Tighten the 8 bolts in the order shown.
  
  Fig 71: Identifying Camshaft Housing Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
1. Install the No. 2 chain tensioner assembly with the bolt.
  
  Fig 72: Identifying No. 2 Chain Tensioner Assembly And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for RH Side)
1. Align the mark plates (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown.
  
  Fig 73: Identifying Mark Plate (Yellow) With Timing Marks (1-Dot Mark) Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.
4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
  
  Fig 74: Identifying Flange Bolts Of Camshaft Timing Gear Assembly And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
5. Remove the pin from the No. 2 chain tensioner assembly.
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
1. Install the No. 3 chain tensioner assembly with the bolt.
  
  Fig 75: Identifying No. 3 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to hold it.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for LH Side)
1. Align the mark plates (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown.
  
  Fig 76: Aligning Mark Plate (Yellow) With Timing Marks (2-Dot Mark) Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.
4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
  
  Fig 77: Identifying SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
5. Remove the pin from the No. 3 chain tensioner assembly.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the No. 1 chain vibration damper with the 2 bolts.
  
  Fig 78: Identifying No. 1 Chain Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
INSTALL NO. 2 CHAIN VIBRATION DAMPER
1. Install the 2 No. 2 chain vibration dampers.
INSTALL CRANKSHAFT TIMING SPROCKET
1. Install the 2 timing gear set keys and timing sprocket as shown.
  
  Fig 79: 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.
  
  Fig 80: Identifying Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 sure to install the idle gear shaft in the correct direction.
  
  HINT:
  
  Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.
3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
  
  HINT:
  
  After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
INSTALL CHAIN SUB-ASSEMBLY
1. Align the mark plates with the timing marks as shown and install the chain.
  
  Fig 81: Identifying Timing Mark On Marking Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The camshaft mark plate is orange.
2. Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.
  
  Fig 82: Identifying Chain Set
  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.
  
  Fig 83: Identifying Camshaft Timing Gear Assembly Components
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
4. Align the mark plate and timing marks as shown and install the chain onto the crankshaft timing sprocket.
  
  Fig 84: Identifying Aligning Mark Plate And Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The crankshaft mark plate is yellow.
5. Temporarily tighten the pulley set bolt.
6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).
  
  Fig 85: Identifying Turning Crankshaft Component Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
  
  Fig 86: Identifying Stopper Plate And Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
3. Install the No. 1 chain tensioner assembly with the 2 bolts.
  
  Fig 87: Identifying No. 1 Chain Tensioner Assembly & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.
INSPECT VALVE TIMING
1. Check the camshaft timing marks.
  WARNING:
  - Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.
  - If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
2. Check that each camshaft timing mark is positioned as shown.
  
  Fig 88: Identifying Camshaft Timing Mark Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 89: Identifying Camshaft Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  For the intake camshaft:
  
  Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.
3. If the valve timing is misaligned, reinstall the timing chain.
4. Remove the pulley set bolt.
INSTALL TIMING CHAIN CASE OIL SEAL
1. Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge.
  
  Fig 90: Identifying Timing Chain Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09223-22010
  - SST: 09506-35010
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the timing chain case oil seal at an angle.
  - Make sure that the timing chain case oil seal edge does not stick out of the timing chain case.
INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket and the water pump assembly with the 8 bolts.
  
  Fig 91: Identifying Water Pump Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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

Fig 92: Applying Seal Packing To Engine Unit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Seal packing

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

Seal diameter

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

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

Fig 93: Applying Seal Packing To Timing Chain Cover

Seal packing

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

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

NOTE:

If 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 installation.

Apply seal packing as follows

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

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

Fig 95: Identifying Alignment Of Oil Pump Drive Rotor Spline & Crankshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 96: Identifying Timing Chain Cover With Bolts

Bolt length

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

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

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

HINT:

Tighten the bolts and nuts in the order of upper to lower as shown.
Fully tighten the bolts in Area 4.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

for bolt A

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

for bolts except bolt A

HINT:

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

INSTALL WATER INLET HOUSING
1. Install 2 new O-rings.
  
  Fig 97: Identifying Water Inlet Housing O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply a small amount of water or soapy water to O-ring (A) before installing it.
2. Install the stud bolts.
  
  Fig 98: Identifying Stud Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
3. Install the water inlet with the 2 bolts and nut.
  
  Fig 99: Identifying Water Inlet Housing Bolts & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE: Be careful that the O-ring does not get caught between the parts.
4. Connect the No. 1 water by-pass hose.
5. Apply adhesive around the drain cock.
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
6. Install the drain cock to the water inlet housing.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
7. Install the drain cock plug to the water drain cock.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
8. Install a new gasket to the thermostat.
9. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.
  
  Fig 100: Identifying Jiggle Valve Angles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The jiggle valve may be set within 10° of either side of the prescribed position.
10. Install the water inlet with the 2 nuts.
  
  Fig 101: Identifying Water Inlet, Thermostat & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Install the No. 1 front engine mounting bracket LH with the 6 bolts.
  
  Fig 102: Identifying Stud Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
  NOTE:
  - Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
  - Do not start the engine for at least 2 hours after installation.
2. When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 1 OIL PAN BAFFLE PLATE
1. Install the No. 1 oil pan baffle plate with the 7 bolts.
  
  Fig 103: Identifying Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  HINT:
  
  Temporarily tighten the 7 bolts. Fully tighten 2 bolts A shown before tightening the other bolts.
INSTALL OIL PAN SUB-ASSEMBLY
1. When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.
  
  Fig 104: Identifying Lower Cylinder Block And Timing Chain Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install 2 new O-rings.
  
  Fig 105: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing in a continuous line as shown.
  
  Fig 106: Applying Seal Packing To Oil Pan Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.0 to 4.0 mm (0.118 to 0.156 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installation.
4. Install the oil pan with the 16 bolts and 2 nuts.
  
  Fig 107: Identifying Oil Pan, Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolt A
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for bolts except A
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Using an E6 "TORX" socket, install the stud bolts as shown.
  
  Fig 108: Identifying Stud Bolts And Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
2. Install a new gasket and the oil strainer subassembly with the bolt and 2 nuts.
  
  Fig 109: Identifying Oil Strainer Bolt & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
1. Using an E6 "TORX" socket, install the stud bolts as shown.
  
  Fig 110: Identifying No. 2 Oil Pan Sub-Assembly Stud Bolts Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
2. Apply seal packing in a continuous line as shown.
  
  Fig 111: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.0 to 4.0 mm (0.118 to 0.156 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the No. 2 oil pan within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installation.
3. Install the No. 2 oil pan with the 16 bolts and 2 nuts.
  
  Fig 112: Identifying Oil Pan With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL OIL PAN DRAIN PLUG
1. Install a new oil pan drain plug gasket and the oil pan drain plug.
  
  Fig 113: Identifying Oil Pan Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for RH Side)
1. Apply seal packing as shown.
  
  Fig 114: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install 3 new gaskets as shown.
  
  Fig 115: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
4. Install the cylinder head cover with the 12 bolts and a new washer.
  
  Fig 116: Identifying Head Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for bolt A
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolts except A
  
  HINT:
  
  After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for LH Side)
1. Apply seal packing as shown.
  
  Fig 117: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install 3 new gaskets as shown.
  
  Fig 118: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
4. Install the cylinder head cover with the 12 bolts and a new washer.
  
  Fig 119: Identifying Head Cover With Bolts Tightening Sequence And Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for bolt A
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolts except A
  
  HINT:
  
  After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
INSTALL WATER OUTLET
1. Install 2 new gaskets and a new O-ring.
  
  Fig 120: Identifying Gaskets & O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply soapy water to the O-ring.
2. Install the water outlet with the 2 bolts and 4 nuts.
  
  Fig 121: Identifying Bolts, Nuts And Water Outlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  for bolts
  
  Torque: 10 N*m (103 kgf*cm, 7 ft.*lbf)
  
  for nuts
  
  NOTE: Be careful that the O-ring does not get caught between the parts.
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide it on the pulley.
2. Using SST, install the pulley bolt.
  
  Fig 122: Identifying Crankshaft Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09213-70011
    - 09213-70020
  - SST: 09330-00021
  Torque: 250 N*m (2550 kgf*cm, 184 ft.*lbf)
INSTALL OIL FILTER ELEMENT
1. Clean the inside of the oil filter cap sub-assembly, the threads and O-ring groove.
  
  Fig 123: Identifying Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap sub-assembly.
3. Set a new oil filter element to the oil filter cap.
4. Remove dirt or foreign matter from the installation surface of the engine.
5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap sub-assembly.
  NOTE:
  - Be careful that the O-ring does not get caught between the parts.
  - The O-ring must not be twisted on the groove.
6. Using SST, tighten the oil filter cap.
  
  Fig 124: Tightening Oil Filter Cap Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09228-06501
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  NOTE: Make sure that the oil filter is installed securely as shown.
7. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
  
  Fig 125: Identifying Oil Filter Drain Plug, O-Ring And Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Remove all dirt and foreign matter from the installation surface.
8. Install the oil filter drain plug to the oil filter cap.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  NOTE: Make sure that the O-ring does not get caught between the parts.
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive around the drain cocks.
  
  Fig 126: Identifying Adhesive Around Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the water drain cocks as shown.
  
  Fig 127: Identifying Water Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks 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.
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) with the oil pipe union.
  
  Fig 128: Identifying No. 1 Oil Pipe Unions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.
4. Tighten the oil pipe union (on the head cover side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
5. Tighten the oil pipe union (on the cylinder head side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
  
  NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
INSTALL OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
  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) with the oil pipe union.
  
  Fig 129: Identifying Oil Pipe Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.
4. Install the bolt (A) to the cylinder head.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
5. Tighten the oil pipe union (on the head cover side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
6. Tighten the oil pipe union (on the cylinder head side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
  
  NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the crankshaft position sensor with the bolt.
  
  Fig 130: Identifying Crankshaft Position Sensor And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Install the 4 camshaft timing oil control valves with the 4 bolts.
  
  Fig 131: Identifying Camshaft Timing Oil Control Valves And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL CAMSHAFT POSITION SENSOR
1. Install the 4 camshaft position sensors with the 4 bolts.
  
  Fig 132: Identifying Camshaft Position Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL VENTILATION VALVE SUB-ASSEMBLY
1. Apply adhesive around the ventilation valve subassembly.
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the ventilation valve sub-assembly.
  
  Fig 133: Identifying Ventilation Valve Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
INSTALL SPARK PLUG
1. Install the 6 spark plugs.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install the oil filler gasket.
2. Install the oil filler cap sub-assembly.