Partial Engine Assembly - 1ZZ-FE: Overhaul

1. Remove the oil filler cap from the cylinder head cover.
   Fig 1: Removing Oil Filler Cap From Cylinder Head Cover

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1. Using a screwdriver, remove the gasket from the oil filler cap.
   Fig 2: Removing Oil Gasket

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1. Remove the ventilation valve from the cylinder head cover.
   Fig 3: Removing Ventilation Valve

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1. Using a spark plug wrench, remove the spark plugs.
   Fig 4: Removing Spark Plugs

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1. Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder head cover.
   Fig 5: Removing Cylinder Head Cover Bolts & Head Cover

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1. Remove the gasket from the cylinder head cover.
   Fig 6: Removing Cylinder Head Cover Gasket

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1. Remove the 3 bolts and transverse engine mounting bracket.
   Fig 7: Removing Transverse Engine & Mounting Bracket

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1. Remove the 6 bolts and water pump.
   Fig 8: Removing Bolts & Water Pump

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1. Remove an O-ring from the timing chain cover.
   Fig 9: Removing Water Pump O-Ring

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1. Set No. 1 cylinder to TDC/compression.
   1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
   2. Check that the point marks of the camshaft timing gears are in straight line on the timing chain cover surface as shown in the illustration.
      NOTE: If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
      Fig 10: Removing Crankshaft Pulley

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

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

3. Remove the crankshaft pulley from the crankshaft.
   Fig 11: Disassembling Crankshaft Pulley Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 nuts and chain tensioner.
   Fig 12: Removing Nuts & Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 11 bolts and nut.
2. Remove the timing chain cover by prying the portions between the timing chain cover and cylinder head and cylinder block with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
   Fig 13: Removing Timing Chain Cover

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3. Using a Torx socket wrench E5, remove the 3 stud bolts.
   Fig 14: Removing Stud Bolts

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1. Place the timing chain cover on wooden blocks.
2. Using a screwdriver, remove the oil seal.
   Fig 15: Disassembling Timing Gear Cover Oil Seal

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1. Remove the crankshaft position sensor plate from the crankshaft.
   Fig 16: Remove Crankshaft Position Sensor Plate

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1. Remove the bolt and chain tensioner slipper.
   Fig 17: Remove Chain Tensioner Slipper

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1. Using the 2 screwdrivers, pry out the chain with the crankshaft timing gear as shown in the illustration.
   NOTE:

   • Put shop rag to protect the engine.
   • In case of revolving the camshafts with the chain off the gears, turn the crankshaft 1/4 revolution for valves not to touch the pistons.
   Fig 18: Removing Chain Sub Assy By Screwdrivers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and chain vibration damper.
   Fig 19: Removing Chain Vibration Damper

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1. Remove the 5 bolts and oil pump.
   Fig 20: Removing Oil Pump

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1. Remove the gasket from the cylinder block.
   Fig 21: Removing Gasket From Cylinder Block

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1. Remove the bolt and camshaft timing oil control valve.
   Fig 22: Removing Camshaft Timing Oil Control Valve

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1. Remove the bolt with gasket and oil control valve filter.
2. Remove the gasket and oil control valve filter from the bolt.
   Fig 23: Removing Bolt & Remove Oil Control

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Uniformly loosen and remove the 19 bolts, in several passes, in the sequence shown, and remove the 9 bearing caps.
2. Remove the 2 camshafts from the cylinder head.
   Fig 24: Removing Bolts & Camshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Grip the camshaft with a vice, and remove the bolt and camshaft timing gear.
   NOTE: Be careful not to damage the camshaft.
   Fig 25: Removing Camshaft Timing Gear

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Fig 26: Inspecting Camshaft Timing Gear

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1. Check the lock of camshaft timing gear.
   1. Grip the camshaft with a vice, and confirm the camshaft timing gear is locked.
      NOTE: Be careful not to damage the camshaft.
2. Release lock pin.
   1. Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.
      NOTE: Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece.
   2. Break through the tapes of the advance side path and the retard side path on the opposite side of the groove.
   3. Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1.5 kgf.cm² }.
      CAUTION: Cover the paths with shop rag to avoid oil splashing.
      Fig 27: Checking Advanced & Retard Side Path Of Timing Gear

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path.
      NOTE: The lock pin is released, and camshaft timing gear, revolves in the advance direction.
   Fig 28: Removing Retard Side Path
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, take out that of timing advance side path.
      CAUTION: Camshaft timing assembly gear occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side path. It often causes the breakage of the lock pin.
3. Check smooth revolution
   1. Revolve the camshaft timing gear assembly within the movable range except for the most retarded position several times, and check the smooth revolution.
      CAUTION: Be sure to perform this check by hand, instead of air pressure.
4. Check the lock in the most retarded position.
   1. Confirm that the camshaft timing gear assembly is locked at the most retarded position.

Fig 29: Removing Camshaft Timing Gear Assembling

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Grip the camshaft with a vice, and confirm that the gear is locked.
   CAUTION: Be careful not to damage the camshaft.
2. Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.
   NOTE: Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece.
3. Break through the tapes of the advance side path and the retard side path on the opposite side of the groove.
4. Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1.5 kgf/cm² }.
   CAUTION: Cover the paths with shop rag to avoid oil splashing.
   Fig 30: Checking Retard & Advanced Side Path

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path.
   Fig 31: Checking Decompress & Hold Pressure

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: The lock pin is released, and camshaft timing gear revolves in the advance direction.
6. When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, takeout that of timing advance side path.
   CAUTION: Camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side paths. It often causes the breakage of the lock pin.
7. Remove the fringe bolt and camshaft timing gear.
   Fig 32: Removing Fringe Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Be sure not to remove the other 4 bolts.
   • In case of reusing the camshaft timing gear, release the strait pin locking first, and then install the gear.

Fig 33: Removing Cylinder Head Cover Bolts In Sequence

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1. Using a bi-hexagon wrench 10, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown, and remove the 10 cylinder head bolts and 10 plate washers.
   NOTE:

   • Be careful not to drop plate washers into the cylinder head.
   • Head warpage or cracking could result from removing bolts in an incorrect order.
2. Remove the cylinder head from the cylinder block.
   Fig 34: Removing Cylinder Head Cover

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1. Remove the cylinder head gasket from the cylinder block.
   Fig 35: Removing Cylinder Head Gasket

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1. Using SST, remove the oil filter.

   SST 09228-06501

   Fig 36: Removing Oil Filter Sub Assy

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1. Using a socket hexagon wrench 12, remove the oil filter union.
   Fig 37: Removing Oil Filter Union

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a knife, cut off the oil seal lip.
2. Using a screwdriver with its tip taped, pry out the oil seal.
   NOTE: After the removal, check if the crankshaft is not damaged. If there is, mend it with a sandpaper (# 400).
   Fig 38: Removing Rear Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the oil pan drain plug and gasket from the oil pan.
   Fig 39: Removing Oil Pan Drain Plug & Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 14 bolts and 2 nuts.
   Fig 40: Removing Oil Pan Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the blade of SST between the bearing cap and oil pan, and cut off applied sealer and remove the oil pan.

   SST 09032-00100

   NOTE: Be careful not to damage the oil pan contact surface of the bearing cap and the oil pan.
   Fig 41: Removing Bearing Cap From Oil Pan

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt, 2 nuts and oil strainer.
   Fig 42: Removing Oil Strainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the gasket from the bearing cap.
   Fig 43: Removing Oil Strainer Flange Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
2. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
   Fig 44: Inspecting Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a spring tension gauge and vernier calipers, pull the timing chain with 140 N (4.3 kgf, 315 lb) and measure the length of it.

   Maximum chain elongation: 122.6 mm (4.827 in.) 

If the chain elongation is greater than maximum, replace the chain.

Fig 45: Checking Length Of Chain By Vernier Calipers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Wrap the chain around the camshaft timing gear.
2. Using a vernier calipers, measure the camshaft timing gear diameter with the chain.

   Minimum gear diameter (w/ chain): 97.3 mm (3.831 in.) 

   NOTE: Vernier calipers must contact the chain rollers for measuring.
   Fig 46: Measuring Camshaft Timing Gear Diameter With The Chain

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the gear diameter is less than minimum, replace the chain and camshaft timing gear.

1. Wrap the chain around the crankshaft timing gear.
2. Using a vernier calipers, measure the crankshaft timing gear diameter with the chain.

   Minimum gear diameter (w/ chain): 51.6 mm (2.032 in.) 

   NOTE: Vernier calipers must contact the chain rollers for the measuring.

   If the gear diameter is less than minimum, replace the chain and crankshaft timing gear.

   Fig 47: Checking Sprocket & Timing Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a vernier calipers, measure the chain tensioner slipper wears.

   Maximum wear: 1.0 mm (0.039 in.) 

   If the wear is greater than maximum, replace the chain tensioner slipper.

   Fig 48: Inspecting Chain Tensioner Slipper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a vernier calipers, measure the vibration damper wears.

   Maximum wear: 1.0 mm (0.039 in.) 

If the wear is greater than maximum, replace the chain vibration damper.

Fig 49: Measuring Vibration Damper Wears

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a vernier calipers, measure the length of cylinder head bolts from the seat to the end.

   Standard bolt length: 

   146.8 - 148.2 mm (5.780 - 5.835 in.) 

   Maximum bolt length: 148.5 mm (5.846 in.) 

If the bolt length is greater than maximum, replace the cylinder head set bolt.

Fig 50: Inspecting Length Of Cylinder Seat Bolt

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1. Inspect camshaft for runout.
   1. Place the camshaft on V-blocks.
   2. Using a dial indicator, measure the circle runout at the center journal.

      Maximum circle runout: 0.03 mm (0.0012 in.) 

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

   Fig 51: Inspecting Circle Runout At Center Journal Of Cam Staff

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect cam lobes.
   1. Using a micrometer, measure the cam lobe height.

      Standard cam lobe height: 

      Intake 44.333 - 44.433 mm (1.7454 - 1.7493 in.) 

      Exhaust 43.761 - 43.861 mm (1.7229 - 1.7268 in.) 

      Minimum cam lobe height: 

      Intake 44.18 mm (1.7394 in.) 

      Exhaust 43.61 mm (1.7169 in.) 

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

   Fig 52: Measuring Camshaft Lobe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect camshaft journals.
   1. Using a micrometer, measure the journal diameter.

      No. 1 journal diameter: 

      34.449 - 34.465 mm (1.3563 - 1.3569 in.) 

      Others journal diameter: 

      22.949 - 22.965 mm (0.9035 - 0.9041 in.) 

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

   Fig 53: Inspecting Camshaft Journal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket to the bearing cap.
   Fig 54: Installing New Gasket To Bearing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the oil strainer with the 2 nuts and bolt.

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

   Fig 55: Installing Oil Strainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing material from the contact surface and thread holes.
2. Apply seal packing in the shape of bead (Diameter 3.5 mm - 4.5 mm (0.138 - 0.177 in.)) consequently as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes after applying seal packing.
   • Do not put into engine oil within 2 hours after installing.
     Fig 56: Installing New Packing

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

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

   Fig 57: Installing Oil Pan With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place a new gasket on the oil pan drain plug, and install it.

   Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) 

   Fig 58: Installing Oil Pan Drain Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of MP grease to a new oil seal lip.
   Fig 59: Installing Engine Rear Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Keep the lip off foreign materials.
2. Using SST, tap in the oil seal until its surface is flush with the oil seal retainer edge.

   SST 09223-15020, 09950-70010 (09951-07100)

Fig 60: Installing Oil Fitter Union

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a socket hexagon wrench 12, install the oil filter union.

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

Fig 61: Installing Oil Filter Sub Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of a new oil filter.
3. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
4. Using SST, tighten it an additional 3/4 turn.

   SST 09228-06501

Fig 62: Installing New Cylinder Head Gasket

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1. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

Fig 63: Assembling Cylinder Head On Cylinder Block

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1. Place the cylinder head on the cylinder block.
2. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
3. Using a bi-hexagon wrench 10, install and uniformly tighten the 10 cylinder head bolts with plate washers, in several passes, in the sequence shown.
   Fig 64: Tightening Cylinder Head Bolts In Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

4. Mark the front of the cylinder head bolt with paint.
5. Retighten the cylinder head bolts 90° in the numerical order shown.
6. Check that the point marked bolts are moved at 90° angle.
   Fig 65: Checking Point Marked Bolt, Moved At 90° Angle

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Fig 66: Installing Camshaft With Straight Pin Off Key Groove

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1. Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove.
2. Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) with pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove.
   CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle).
3. Check that there is no clearance between the gear's fringe and the camshaft.
4. Tighten the fringe bolt with the camshaft timing gear fixed.

   Torque: 54 N.m (551 kgf.cm 40 ft.lbf) 

5. Check that the camshaft timing gear assembly can move to the retard angle side (the right angle), and is locked at the most retarded position.

Fig 67: Installing Camshaft Timing Gear

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1. Grip the camshaft with a vice, and install the camshaft timing gear with bolt.

   Torque: 54 N.m (551 kgf.cm 40 ft.lbf) 

Fig 68: Installing Camshaft

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1. Apply a light coat of engine oil on the camshaft journals.
2. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.
3. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
   Fig 69: Tightening Bolts In Given Order

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 

   Bearing cap No. 1 23 N.m (235 kgf.cm, 17 ft.lbf) 

   Bearing cap No. 3 13 N.m (133 kgf.cm, 10 ft.lbf) 

Fig 70: Installing Oil Control Value

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1. Check that no foreign substance on the mesh part of the oil control valve filter.
2. Install a new gasket and the oil control valve filter on the bolt, and install it.

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

Fig 71: Installing Camshaft Timing Oil Control Value

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1. Apply a light coat of a new O-ring, and install it to the camshaft timing oil control valve.
2. Install the camshaft timing oil control valve with the bolt.

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

1. Install a new gasket to the cylinder block.
   Fig 72: Installing Oil Pump Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft, and side the oil pump.
   Fig 73: Installing Oil Pump Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil pump with the 5 bolts.

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

   Fig 74: Installing Oil Pump With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   Fig 75: Installing Chain Vibration Damper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set No. 1 cylinder to TDC/compression.
   1. Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing gears.
      Fig 76: Installing Chain Sub Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a crankshaft pulley bolt, turn the crankshaft, and the timing gear key aligned with the point mark on the oil pump.
      Fig 77: Checking Point Mark & Timing Gear Key

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the chain on the crankshaft timing gear with the yellow color mark link aligned with the timing mark on the crankshaft timing gear.
   Fig 78: Installing Chain On Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, install the crankshaft timing gear.

   SST 09223-22010

   Fig 79: Tightening Crankshaft Timing Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the chain on the camshaft timing gears with the yellow color mark links aligned with the timing marks on the camshaft timing gears.
   Fig 80: Installing Timing Marks On Camshaft Timing Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the chain tensioner slipper with the bolt.

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

   Fig 81: Installing The Chain Tensioner Slipper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the crankshaft position sensor plate with the "F" mark facing forward.
   Fig 82: Installing Crank Shaft Position Sensor Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light coat of MP grease to a new oil seal lip.
2. Place the timing chain cover on wooden blocks.
3. Using SST, tap in the oil seal until its surface is flush with the timing chain cover edge.

   SST 09223-22010

Fig 83: Installing Timing Gear Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing material from the contact surface.
2. Using a Torx socket wrench E5, install the 3 stud bolts.

   Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) 

   Fig 84: Installing Timing Chain Belt Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing in the shape of bead (Diameter 3.5 mm - 4.5 mm (0.138 - 0.177 in.)) consequently as shown in the illustration.

   Seal packing: 

   Water pump Part No. 08826-00100 or equivalent Other Part No. 08826-00080 or equivalent 

   Fig 85: Installing Oil Pan Within 3 Minutes After Applying Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes after applying seal packing.
   • Do not put into engine oil within 2 hours after installing.
   Fig 86: Checking Water Pump Part

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the timing chain cover with the 12 bolts and nut.
   Fig 87: Installing Timing Chain Cover With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 

   A 13 N.m (133 kgf.cm, 10 ft.lbf) 

   B 19 N.m (189 kgf.cm, 14 ft.lbf) 

1. Check an O-ring is clean, and set the hook as shown in the illustration.
2. Apply a light coat of engine oil to an O-ring.
   Fig 88: Checking O-Ring Hook & Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the chain tensioner with the 2 nuts.
   Fig 89: Installing Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 90: Assembling Crank Shaft Pulley

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1. Align the pulley set key with the key groove of the crankshaft pulley, and slide on the crankshaft pulley.
2. Using SST, install the crankshaft pulley bolt.

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

   Torque: 138 N.m (1,407 kgf.cm, 102 ft.lbf) 

3. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
   Fig 91: Disconnecting Plunger Knock Pin From Hook

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

Fig 92: Checking Slipper Is Pushed By Plunger

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Fig 93: Installing New Water Pump O-Ring

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1. Install a new O-ring to the timing chain cover.

Fig 94: Installing Bolts In Water Pump

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1. Install the water pump with the 6 bolts.

   Torque: 

   Bolt A 9.0 N.m (92 kgf.cm, 80 in.lbf) 

   Bolt B 11 N.m (112 kgf.cm, 8 ft.lbf) 

Fig 95: Installing Engine Mounting Bracket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the transverse engine mounting bracket with the 3 bolts.

   Torque: 47 N.m (479 kgf.cm, 35 ft.lbf) 

1. Set No. 1 cylinder to TDC/compression.
   1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
   2. Check that the point marks of the camshaft timing gears are in straight line on the timing chain cover surface as shown in the illustration.
      Fig 96: Checking & Testing Value Clearance

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
2. Check only the valves indicated.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   Fig 97: Measuring Clearance Of Valve Filler & Camshaft (1 Of 2)
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.

      Valve clearance (Cold): 

      Intake 0.15 - 0.25 mm (0.0059 - 0.0098 in.) 

      Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 in.) 

3. Turn the crankshaft 1 revolution (360°) and set No. 4 cylinder to TDC/compression.
4. Check only the valves indicated.
   Fig 98: Measuring Clearance Of Valve Filler & Camshaft (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   2. Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.

      Valve clearance (Cold): 

      Intake 0.15 - 0.25 mm (0.0059 - 0.0098 in.) 

      Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 in.) 

1. Set the No. 1 cylinder to the TDC/compression.
2. Place painted marks on the chain and camshaft timing gears.
   Fig 99: Adjusting & Testing Valve Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 nuts and chain tensioner.
   Fig 100: Removing Chain Tensioner With & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Fix the camshaft with a spanner and so on, then loosen the camshaft timing gear set bolt.
   NOTE: Be careful not to damage the valve lifter.
   Fig 101: Adjusting Camshaft Loosening Camshaft Timing Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Loosen the bearing cap bolts on No. 2 camshaft in the order as shown in the illustration in several passes, and remove the bearing caps.
   Fig 102: Loosening Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the camshaft timing gear as shown in the illustration.
   Fig 103: Removing Camshaft Timing Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Loosen the bearing cap bolts on camshaft in the order as shown in the illustration in several passes, and remove the bearing caps.
   Fig 104: Loosening Camshaft Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the camshaft with holding the chain.
   Fig 105: Removing Camshaft With Holding Chain

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Tie the chain with a string as shown in the illustration.
   NOTE: Be careful not to drop anything inside the timing chain cover.
10. Remove the valve lifters.
    Fig 106: Removing Valve Lifter

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Using a micrometer, measure the thickness of the removed valve lifters.
Fig 107: Measuring Valve Lifter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

    Specified valve: 

    Intake A = B + (C - 0.20 mm (0.0079 in.)) 

    Exhaust A = B + (C - 0.30 mm (0.0118 in.)) 

    Valve Thickness Table
    
    

    A	Thickness Of New Lifter
    B	Thickness Of Used Lifter
    C	Measured Valve Clearance

    NOTE:

    • Select a new lifter with a thickness as close as possible to the calculated values.
    • Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).
13. As shown in the illustration, install the chain on the camshaft timing gear, with the painted mark aligned with the timing mark on the camshaft timing gear.
    Fig 108: Installing Chain On Camshaft Timing Gear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.

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

    Fig 109: Tightening Cam Bolts In Given Diagram

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Put the camshaft No. 2 on the cylinder head with the painted mark of the chain aligned with the timing mark on the camshaft timing gear.
    Fig 110: Checking Painted Mark & Timing Mark

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. Raising the camshaft, tighten the set bolt temporarily.
    Fig 111: Tightening Set Bolt Temporarily

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
    Fig 112: Checking Front Mark Number

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: 

    Bearing cap No. 313 N.m (133 kgf.cm, 10 ft.lbf) 

    Bearing cap No. 123 N.m (235 kgf.cm, 17 ft.lbf) 

    NOTE:

    Bearing Cap Table

    
    

    Bearing Cap	Illustration Number
    No.1	5 To 7
    No.3	1 To 4

18. Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt.

    Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 

    NOTE: Be careful not to damage the valve lifter.
    Fig 113: Adjusting Camshaft With Spanner

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. Check the painted marks on the chain and camshaft timing gears, and then the alignment of the crankshaft pulley groove with timing mark of the timing chain cover as shown in the illustration.
    Fig 114: Checking Painted Mark On Chain & Camshaft Timing Gear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. Install chain tensioner.
    Fig 115: Installing Chain Tensioner

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check an O-ring is clean, and set the hook as shown in the illustration.
    2. Apply a light coat of engine oil to an O-ring.
    3. Install the chain tensioner with the 2 nuts.
       Fig 116: Installing Chain Tensioner With Nuts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

       NOTE:

       • Be careful not twist an O-ring.
       • When installing the tensioner, set the hook again if the hook releases the plunger.
    4. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
       Fig 117: Disconnecting Plunger Knock Pin From Hook

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
    NOTE: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunger springs out.
    Fig 118: Turning Crankshaft Clockwise & Checking Slipper Is Pushed By Plunger

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the gasket to the cylinder head cover.
   Fig 119: Installing Cylinder Head Cover Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing (FIPG) material.
2. Apply seal packing to 2 locations as shown in the illustration.
   Fig 120: Applying Seal Packing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   • Do not put into engine oil 2 hours after installing.
3. Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts.
   Fig 121: Installing Bolts & Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 

   A 11 N.m (112 kgf.cm, 8 ft.lbf) 

   B 9.0 N.m (92 kgf.cm, 80 in.lbf) 

1. Using a spark plug wrench, install the spark plugs.

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

   Fig 122: Assembling Spark Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the ventilation valve to the cylinder head cover.

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

   Fig 123: Installing Ventilation Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the gasket to the oil filler cap.
   Fig 124: Install Oil Filler Cap Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the oil filler cap to the cylinder head cover.
   Fig 125: Installing Oil Filler Cap Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002