Engine Unit - Reassembly

1. Install cylinder block water drain cock sub-assembly

2. Install straight pin

3. Install oil pump set ring pin

4. Install stud bolt

5. Install crankshaft bearing

6. Install crankshaft thrust washer upper

7. Install crankshaft

8. Inspect crankshaft thrust clearance

9. Inspect crankshaft oil clearance

10. Install with pin piston sub-assembly

11. Install connecting rod bearing

12. Install piston ring set

13. Install piston sub-assembly with connecting rod

14. Inspect connecting rod thrust clearance

15. Inspect connecting rod oil clearance

16. Install stud bolt

17. Install oil pan sub-assembly

18. Install oil strainer sub-assembly

19. Install oil pan sub-assembly no. 2

20. Install oil filter union

21. Install oil filter sub-assembly

22. Install cylinder head gasket

23. Install cylinder head sub-assembly

24. Install engine rear oil seal

25. Install camshaft timing gear assembly

26. Install camshaft

27. Install camshaft timing sprocket

28. Install no. 2 camshaft

29. Install camshaft position sensor

30. Install chain sub-assembly

31. Install chain tensioner slipper

32. Install chain tensioner assembly no. 1

33. Install oil pump seal

34. Install oil pump assembly

35. Install water pump assembly

36. Install transverse engine engine mounting bracket

37. Install crankshaft damper sub-assembly

38. Install water pump pulley

39. Inspect valve clearance

40. Adjust valve clearance

41. Install camshaft timing oil control valve assembly

42. Install fuel injector assembly

43. Install injector vibration insulator

44. Install delivery pipe no. 1 spacer

45. Install fuel delivery pipe sub-assembly

46. Install cylinder head cover sub-assembly

47. Install ventilation valve sub-assembly

48. Install oil level gauge guide

49. Install crankshaft position sensor

50. Install oil filler cap gasket

51. Install oil filler cap sub-assembly

52. Install thermostat

53. Install water inlet

54. Install engine coolant temperature sensor

55. Install engine oil pressure switch assembly

56. Install knock sensor

57. Install spark plug

​

1. Apply adhesive to the end 2 or 3 threads of the drain union and install the water drain cock within 3 minutes of applying adhesive.

2. After applying the specified torque, rotate the drain union clockwise until its drain port faces downward.

   Torque:

   35 N*m{357 kgf*cm, 26 ft.*lbf}

   NOTICE:

   1. Do not put into coolant within 1 hour of installation.
      
   2. Do not rotate the drain union more than 360° in step (b), and never loosen it after setting the union correctly.
      

1. Using a plastic-faced hammer, tap in the straight pin.

   Standard protrusion:

   Pin A:

   8.5 to 9.5 mm (0.335 to 0.374 in.)
   

   Pin B:

   8.5 to 9.5 mm (0.335 to 0.374 in.)
   

   Pin C:

   18.5 to 19.5 mm (0.728 to 0.768 in.)
   

   Pin D:

   11.5 to 12.5 mm (0.453 to 0.492 in.)
   

1. Using a plastic-faced hammer, tap in the ring pin.

   Standard protrusion:

   3.5 to 4.5 mm (0.138 to 0.177 in.)
   

1. Using "Torx" socket wrench E5, install the 7 stud bolts.

   Torque:

   5.0 N*m{51 kgf*cm, 44 in.*lbf}(for Stud bolt A, B and D)

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}(for Stud bolt C)

   NOTICE:

   The lower threads of the bolt are installed into the cylinder block.

1. Align the crankshaft bearing (upper) with the oil hole of the cylinder block and install the bearing.

   NOTICE:

   Do not apply engine oil to the bearing or its contact surface.

2. Align the crankshaft bearing (lower) with the bearing cap and install the crankshaft bearing cap.

   NOTICE:

   1. Install the bearing cap so that the gap between A and B is less than 0.7 mm (0.028 in.).
      
   2. Do not apply engine oil to the bearing or its contact surface.
      

1. Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.

2. Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.

1. Examine the front marks and numbers and install the bearing caps onto the cylinder block.

2. Apply a light coat of engine oil to the threads of the bearing cap bolts.

3. Using 12 mm socket wrench, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration (*1).

   Torque:

   22 N*m{224 kgf*cm, 16 ft.*lbf}

   NOTICE:

   Check that the crankshaft turns smoothly.

4. Mark the front of the bearing cap bolts with paint.

5. Retighten the bearing cap bolts by 90° in the same sequence as step (*1).

6. Check that the painted mark is now at a 90° angle from the front.

1. Using a dial indicator, measure the thrust clearance while moving the crankshaft back and forth with a screwdriver.

   Standard thrust clearance:

   0.09 to 0.19 mm (0.0035 to 0.0075 in.)
   

   Maximum thrust clearance:

   0.30 mm (0.0118 in.)
   

   If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft and block for wear. Repair or replace the parts if necessary.
   

   HINT:

   Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.976 in.)

1. Clean each main journal and bearing.

2. Install the bearing onto the cylinder block and bearing cap. (Click here)

3. Place the crankshaft onto the cylinder block.

4. Lay a strip of Plastigage across each journal.

5. Examine the front marks and numbers and install the bearing cap onto the cylinder block.

6. Apply a light coat of engine oil to the threads of the bearing cap bolts.

7. Using 12 mm socket wrench, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration. (*1)

   Torque:

   22 N*m{224 kgf*cm, 16 ft.*lbf}

8. Mark the front of the bearing cap bolts with paint.

9. Retighten the bearing cap bolts by 90° in the same sequence as step (*1).

10. Check that the painted mark is now at a 90° angle from the front.

    NOTICE:

    Do not turn the crankshaft.

11. Remove the bearing cap sub-assembly.

12. Measure the plastigage at its widest point.

    Standard oil clearance:

    0.01 to 0.023 mm (0.0004 to 0.0009 in.)
    

    Maximum oil clearance:

    0.07 mm (0.0028 in.)
    

    NOTICE:

    Completely remove the plastigage after the measurement.

13. When replacing a standard bearing, replace it with one with the same number. If the number of the bearing cannot be found on the bearing shell, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then select the bearing with the same number as the total. There are 4 sizes of standard bearings, marked 1, 2, 3 and 4 accordingly.

    EXAMPLE: Cylinder Block 4 (A) + Crankshaft 3 (B) = Total No. 7 (Use Bearing 3)

    Cylinder Block (A) + Crankshaft (B)	0 to 2	3 to 5	6 to 8	9 to 11
    Use Bearing	1	2	3	4

    
    

    Item	Mark	mm (in.)
    Cylinder block main journal bore diameter (A)	0 1 2 3 4 5 6	50.000 to 50.003 (1.96850 to 1.96862) 50.003 to 50.005 (1.96862 to 1.96870) 50.005 to 50.007 (1.96870 to 1.96878) 50.007 to 50.010 (1.96878 to 1.96890) 50.010 to 50.012 (1.96890 to 1.96898) 50.012 to 50.014 (1.96898 to 1.96906) 50.014 to 50.016 (1.96906 to 1.96913)
    Crankshaft main journal diameter (B)	0 1 2 3 4 5	45.998 to 46.000 (1.81094 to 1.81102) 45.996 to 45.998 (1.81087 to 1.81094) 45.994 to 45.996 (1.81079 to 1.81087) 45.992 to 45.994 (1.81071 to 1.81079) 45.990 to 45.992 (1.81063 to 1.81071) 45.988 to 45.990 (1.81055 to 1.81063)
    Standard bearing center wall thickness	1 2 3 4	1.992 to 1.995 (0.07843 to 0.07854) 1.995 to 1.998 (0.07854 to 0.07866) 1.998 to 2.001 (0.07866 to 0.07878) 2.001 to 2.004 (0.07878 to 0.07890)

1. Coat the piston pin and pin holes in the piston with engine oil.

2. Align the cavity of the piston with the protruded portion on the connecting rod.

3. Using SST, press in the piston pin.

   SST

   09221-25026 (09221-00021, 09221-00030, 09221-00090, 09221-00150, 09221-00100)
   

   NOTICE:

   Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to the original location when reassembled.

1. Align the bearing claw with the groove of the connecting rod or connecting cap.

   NOTICE:

   Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oil.

HINT:

When reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly.

1. Install the oil ring expander and 2 side rails by hand.

2. Using a piston ring expander, install the 2 compression rings.

3. Position the piston rings so that the ring ends are as shown.

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

2. Check the position of the piston ring ends.

3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark on the piston facing forward.

   NOTICE:

   1. Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oil.
      
   2. Match the numbered connecting rod cap with the connecting rod.
      

4. Make sure that the connecting rod and its cap are in the correct combination and that the front mark of the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod.

5. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

6. Using SST, tighten the bolts in several steps to the specified torque.

   SST

   09205-16011
   

   Torque:

   15 N*m{153 kgf*cm, 11 ft.*lbf}

7. Mark the front of the connecting cap bolts with paint.

8. Retighten the cap bolts by 90° as shown.

9. Check that the crankshaft turns smoothly.

1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

   Standard thrust clearance:

   0.16 to 0.36 mm (0.0063 to 0.0142 in.)
   

   Maximum thrust clearance:

   0.36 mm (0.0142 in.)
   

1. Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

2. Using SST, remove the 2 connecting rod cap bolts.

   SST

   09205-16011
   

3. Clean the crank pin and bearing.

4. Check the crank pin and bearing for pitting and scratches.

5. Lay a strip of Plastigage across the crank pin.

6. Make sure that the connecting rod and its cap are in the correct combination and that the front mark of the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod.

7. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

8. Using SST, tighten the bolts in several steps to the specified torque.

   Torque:

   15 N*m{153 kgf*cm, 11 ft.*lbf}

   SST

   09205-16011
   

9. Mark the front of the connecting cap bolts with paint.

10. Retighten the cap bolts by 90° as shown in the illustration.

    NOTICE:

    Do not turn the crankshaft.

11. Remove the 2 bolts, connecting rod cap and lower bearing.

12. Measure the plastigage at its widest point.

    Standard oil clearance:

    0.012 to 0.038 mm (0.00047 to 0.0015 in.)
    

    Maximum oil clearance:

    0.058 mm (0.0028in.)
    

    NOTICE:

    Completely remove the plastigage after the measurement.

13. When replacing a bearing, replace it with one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly.

    Standard bearing center wall thickness

    Mark	mm (in.)
    1	1.491 to 1.494 (0.0587 to 0.0588)
    2	1.494 to 1.497 (0.0588 to 0.0589)
    3	1.497 to 1.500 (0.0589 to 0.0591)

1. Using "Trox" socket wrench E5, install the 4 stud bolts.

   Torque:

   5.0 N*m{51 kgf*cm, 44 in.*lbf}

   
   
   
   
   
   

1. Remove any old packing material from the contact surface.

2. Apply a continuous bead of seal packing (Diameter 2.0 mm to 3.0 mm (0.079 to 0.118 in.)) to the oil pan mating surface as shown in the illustration.

   Seal packing:

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

   NOTICE:

   1. Remove any oil from the contact surface.
      
   2. Install the oil pan within 3 minutes of applying seal packing.
      
   3. Do not expose the seal to engine oil for at least 2 hours after the installation.
      

3. Install 2 new O-rings onto the cylinder block.

4. Using several steps, install and tighten the 13 bolts uniformly in the sequence shown in the illustration.

   Torque:

   24 N*m{245 kgf*cm, 18 ft.*lbf}

   HINT:

   Each bolt length is as follows:

   Bolt A 49 mm (1.93 in.)

   Bolt B 88 mm (3.47 in.)

   Bolt C 144 mm (5.67 in.)

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

   Torque:

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}

1. Remove any old packing material from the contact surface.

2. Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan mating surface as shown in the illustration.

   Seal packing:

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

   NOTICE:

   1. Remove any oil from the contact surface.
      
   2. Install the oil pan within 3 minutes of applying seal packing.
      
   3. Do not expose the seal to engine oil within 2 hours of installation.
      
   4. Do not start the engine for at least 2 hours after the installation.
      

3. Install oil pan No. 2 with the 9 bolts and the 2 nuts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

4. Install the drain plug with a new gasket.

   Torque:

   38 N*m{382 kgf*cm, 28 ft.*lbf}

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

   Torque:

   30 N*m{306 kgf*cm, 22 ft.*lbf}

1. Check and clean the oil filter installation surface.

2. Apply clean engine oil to the gasket of the new oil filter.

3. Gently screw the oil filter into place, and tighten it until the gasket comes into contact with the seat.

4. Using SST, tighten it an additional 3/4 turn.

   SST

   09228-06501
   

   HINT:

   When using a torque wrench, tighten it to the specified torque.

   Torque:

   13 N*m{133 kgf*cm, 9.5 ft.*lbf}

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

   NOTICE:

   1. Remove any oil from the contact surface.
      
   2. Pay attention to the mounting orientation of the cylinder head gasket.
      
   3. Do not damage the cylinder gasket when installing the cylinder head onto the cylinder block.
      

HINT:

The cylinder head bolts are tightened in 2 successive steps.

1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

2. Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.

   Torque:

   29 N*m{300 kgf*cm, 22 ft.*lbf}

3. Mark the front of the cylinder head bolt with paint.

4. Retighten the cylinder head bolts by additional 90° and one more additional 90° as shown in the illustration.

5. Check that the paint mark is now at a 180° angle from the front.

6. Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as shown in the illustration.

   Seal Packing:

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

   NOTICE:

   1. Remove any oil from the contact surface.
      
   2. Install the oil pump assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      

1. Apply MP grease to a new oil seal lip.

   NOTICE:

   Keep the lip free of foreign matter.

2. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

   SST

   09223-56010
   

   NOTICE:

   1. Do not tap the oil seal at an angle.
      
   2. Wipe any extra grease off the crankshaft.
      

NOTICE:

Install the camshaft timing gear assembly onto the camshaft with the lock pin of the camshaft timing gear assembly released.

1. Put the camshaft timing gear assembly and camshaft together with the straight pin of the groove.

2. Turn the camshaft timing gear assembly clockwise while pushing it gently towards the camshaft. When the pin fits into the groove, push to ensure a good fit.

   NOTICE:

   Do not turn the camshaft timing gear in the retard direction (to the right).

3. Check that there is no clearance between the gear flange and the camshaft.

4. Tighten the flange bolt with the camshaft timing gear fixed.

   Torque:

   64 N*m{653 kgf*cm, 47 ft.*lbf}

   NOTICE:

   1. Do not lock the camshaft timing gear assembly when tightening the bolt.
      
   2. Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position.
      
   3. Tightening the bolts with the lock pin locked could cause breakage of the lock pin.
      

5. Check that the camshaft timing gear assembly can move in the retard direction (to the right) and is locked in the most retarded position.

1. Apply a light coat of engine oil to the camshaft journals.

2. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.

3. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.

   Torque:

   13 N*m{129 kgf*cm, 9.4 ft.*lbf}

   NOTICE:

   Tighten each bolt uniformly while keeping the camshaft level.

1. Clamp the camshaft in a vice.

2. Align the knock pin hole the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket.

   Torque:

   64 N*m{653 kgf*cm, 47 ft.*lbf}

   NOTICE:

   Do not damage the camshaft.

1. Apply a light coat of engine oil to the camshaft journals.

2. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.

3. Examine the front marks and numbers on camshaft bearing cap No. 1and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.

   Torque:

   13 N*m{129 kgf*cm, 9.4 ft.*lbf} for bearing cap No. 2

   23 N*m{235 kgf*cm, 17 ft.*lbf} for bearing cap No. 1

   NOTICE:

   Tighten each bolt uniformly while keeping the camshaft level.

1. Apply engine oil to the O-ring.

   NOTICE:

   If the O-ring is damaged, replace the camshaft position sensor.

2. Install the camshaft position sensor with the bolt.

   Torque:

   8.0 N*m{82 kgf*cm, 71 in.*lbf}

1. Make sure that all the timing marks are in the positions (TDC) shown in the illustration.

   HINT:

   The positions of the timing marks may differ the predetermined positions due to the force of the valve spring.

2. Set the timing mark of the crankshaft in a position between ATDC 40 and 140° from the TDC, as illustrated.

3. Set the camshaft timing gear and the camshaft timing sprocket in the positions (ATDC 20°) shown in the illustration.

4. Set the crankshaft in the position (ATDC 20°) shown in the illustration.

5. Install chain vibration damper No. 1 with the 2 bolts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

6. Align the timing marks of the camshaft with the mark plates of the timing chain and install the timing chain.

   HINT:

   Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench.

1. Install the chain tensioner slipper.

1. Install chain tensioner assembly No. 1 with the 2 bolts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

2. Remove the bar from chain tensioner assembly No. 1.

1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

   SST

   09950-60010 (09951-00250, 09951-00380, 09952-06010)
   09950-70010 (09951-07100)
   

   NOTICE:

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

2. Apply MP grease to the oil seal lip.

1. Install 2 new O-rings onto the 2 locations shown in the illustration.

2. Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration.

   Seal packing:

   Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Other part Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent
   

   NOTICE:

   1. Remove any oil from the contact surface.
      
   2. Install the oil pump assembly within 3 minutes and tighten the bolts and nut within 15 minutes of applying seal packing.
      
   3. Do not expose the seal to engine oil for at least 2 hours after the installation.
      
   
   
   
   
   
   

3. Align the keyway of the oil pump rotor with the rectangular portion of the crankshaft, and slide the oil pump into place.

4. Install the oil pump assembly with the 15 bolts and nut. Tighten the bolts and nut uniformly in several steps.

   Torque:

   32 N*m{326 kgf*cm, 24 ft.*lbf}for bolt A

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}for bolt B

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}for bolt C

   24 N*m{245 kgf*cm, 18 ft.*lbf}for nut D

   24 N*m{245 kgf*cm, 18 ft.*lbf}for bolt E

   NOTICE:

   Install the mounting bracket and water pump within 15 minutes of installing the oil pump assembly.

   HINT:

   Each bolt length is as follows.

   A: 30 mm (1.181 in.)

   B: 35 mm (1.378 in.)

   C: 20 mm (0.787 in.)

   E: 20 to 14 mm (0.787 to 0.551 in.) Double ended bolt

1. Install the water pump and a new gasket with the 3 bolts and 2 nuts.

   Torque:

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}

1. Install the transverse engine mounting bracket with the 4 bolts.

   Torque:

   55 N*m{561 kgf*cm, 41 ft.*lbf}

1. Align the pin hole in the crankshaft damper with the pin position and install the crankshaft damper sub-assembly.

2. Provisionally install the bolt.

3. Using 2 SSTs, tighten the bolt while holding the crankshaft damper sub-assembly.

   SST

   09213-14010 (91651-60865)
   09330-00021
   

   Torque:

   128 N*m{1305 kgf*cm, 95 ft.*lbf}

   NOTICE:

   Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.

1. Using SST, install the water pump pulley with the 3 bolts.

   Torque:

   15 N*m{153 kgf*cm, 11 ft.*lbf}

   SST

   09960-10010 (09962-01000, 09963-00700)
   

1. Set No. 1 cylinder to TDC/compression.
   

   1. Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump.

   3. Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward, as shown in the illustration.

      HINT:

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

2. Check the valves indicated in the illustration.
   

   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (cold):

      for intake:

      0.15 to 0.25 mm (0.006 to 0.010 in.)
      

      for exhaust:

      0.25 to 0.35 mm (0.010 to 0.014 in.)
      

   2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

3. Turn the crankshaft 1 complete revolution (360°) and align its timing notch with timing mark "0" of the oil pump.

4. Check the valves indicated in the illustration.
   

   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (cold):

      for Intake:

      0.15 to 0.25 mm (0.006 to 0.010 in.)
      

      for Exhaust:

      0.25 to 0.35 mm (0.010 to 0.014 in.)
      

   2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

NOTICE:

When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves.

1. Set No. 1 cylinder to TDC/compression.
   

   1. Turn the crankshaft damper, and align its timing notch with timing mark "0" of the oil pump.

   3. Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward, as shown in the illustration.

      HINT:

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

2. Put paint marks on the chain in place where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.

3. Using an 8 mm hexagon wrench, remove the screw plug.

4. Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.

5. Using a wrench, rotate No. 2 camshaft clockwise to push in the plunger of the chain tensioner.

6. Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and insert a 3 mm (0.12 in.) diameter bar into the holes to hold the stopper plate.

   HINT:

   1. Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
      
   2. Hold the bar with tape so that it does not come off.
      

7. Using a wrench, hold the hexagonal lobe of No. 2 camshaft and remove the flange bolt.

8. Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2.

   NOTICE:

   Loosen each bolt uniformly while keeping the camshaft level.

9. Remove the flange bolt and remove the camshaft timing sprocket.

10. Remove No. 2 camshaft.

11. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2.

    NOTICE:

    Loosen each bolt uniformly while keeping the camshaft level.

12. Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly.

13. Tie the chain with a piece of string as shown in the illustration.

14. Remove the valve lifters.

15. Using a micrometer, measure the thickness of the removed lifter.

16. Calculate the thickness of a new lifter so that the valve clearance comes to within the specified values.

    A	Thickness of new lifter
    B	Thickness of used lifter
    C	Measured valve clearance

    Valve clearance:

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

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

17. Select a new lifter with the thickness as close to the calculated values as possible.

    HINT:

    Lifters 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.).

    
    
    
    
    
    

    Intake valve clearance (cold):

    0.15 to 0.25 mm (0.006 to 0.010 in.)
    

    EXAMPLE:

    A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.
    

    
    

    New Shim Thickness:

    
    

    Shim No.	Thickness	Shim No.	Thickness	Shim No.	Thickness
    06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)
    08	5.080 (0.2000)	32	5.320 (0.2094)	56	5.560 (0.2189)
    10	5.100 (0.2008)	34	5.340 (0.2102)	58	5.580 (0.2197)
    12	5.120 (0.2016)	36	5.360 (0.2110)	60	5.600 (0.2205)
    14	5.140 (0.2024)	38	5.380 (0.2118)	62	5.620 (0.2213)
    16	5.160 (0.2031)	40	5.400 (0.2126)	64	5.640 (0.2220)
    18	5.180 (0.2039)	42	5.420 (0.2134)	66	5.660 (0.2228)
    20	5.200 (0.2047)	44	5.440 (0.2142)	68	5.680 (0.2236)
    22	5.220 (0.2055)	46	5.460 (0.2150)	70	5.700 (0.2244)
    24	5.240 (0.2063)	48	5.480 (0.2157)	72	5.720 (0.2252)
    26	5.260 (0.2071)	50	5.500 (0.2165)	74	5.740 (0.2260)
    28	5.280 (0.2079)	52	5.520 (0.2173)

    
    
    
    
    
    

    Exhaust valve clearance (cold):

    0.25 to 0.35 mm (0.010 to 0.014 in.)
    

    EXAMPLE:

    A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.
    

    
    

    New Shim Thickness:

    
    

    Shim No.	Thickness	Shim No.	Thickness	Shim No.	Thickness
    06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)
    08	5.080 (0.2000)	32	5.320 (0.2094)	56	5.560 (0.2189)
    10	5.100 (0.2008)	34	5.340 (0.2102)	58	5.580 (0.2197)
    12	5.120 (0.2016)	36	5.360 (0.2110)	60	5.600 (0.2205)
    14	5.140 (0.2024)	38	5.380 (0.2118)	62	5.620 (0.2213)
    16	5.160 (0.2031)	40	5.400 (0.2126)	64	5.640 (0.2220)
    18	5.180 (0.2039)	42	5.420 (0.2134)	66	5.660 (0.2228)
    20	5.200 (0.2047)	44	5.440 (0.2142)	68	5.680 (0.2236)
    22	5.220 (0.2055)	46	5.460 (0.2150)	70	5.700 (0.2244)
    24	5.240 (0.2063)	48	5.480 (0.2157)	72	5.720 (0.2252)
    26	5.260 (0.2071)	50	5.500 (0.2165)	74	5.740 (0.2260)
    28	5.280 (0.2079)	52	5.520 (0.2173)

18. Install the selected valve lifter.

19. Apply a light coat of engine oil to the camshaft and camshaft journals.

20. Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned, as shown in the illustration.

21. Examine the front marks and the numbers on camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration.

    Torque:

    13 N*m{129 kgf*cm, 9.4 ft.*lbf}

    NOTICE:

    Tighten each bolt uniformly while keeping the camshaft level.

22. Install camshaft No. 2.

23. Hold the chain, and align the timing mark on the camshaft timing sprocket with paint mark of the chain.

24. Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft.

25. Provisionally install the flange bolt.

26. Examine the front marks and the numbers of camshaft bearing cap No. 1 and camshaft bearing cap No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.

    Torque:

    13 N*m{129 kgf*cm, 9.4 ft.*lbf}for bearing cap No. 2

    23 N*m{235 kgf*cm, 17 ft.*lbf}for bearing cap No. 1

    NOTICE:

    Tighten each bolt uniformly while keeping the camshaft level.

27. Using a union nut wrench, hold the hexagonal lobe of camshaft No. 2, and install the flange bolt.

    Torque:

    64 N*m{653 kgf*cm, 47 ft.*lbf}

28. Remove the bar from the timing chain tensioner.

29. Turn the crankshaft damper, and align its timing notch with timing mark "0" of the oil pump.

30. Check that all the pairs of timing marks are aligned.

31. Apply adhesive to the end 2 or 3 threads of the screw plug.

    Adhesive:

    Toyota Genuine Adhesive 1324, Three bond 1324 or equivalent
    

32. Using an 8 mm hexagon wrench, install the screw plug.

    Torque:

    15 N*m{153 kgf*cm, 11 ft.*lbf}

1. Apply a light coat of engine oil to a new O-ring, and install it onto the camshaft timing oil control valve.

2. Install the camshaft timing oil control valve with the bolt.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

   NOTICE:

   Do not twist the O-ring.

1. Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each fuel injector.

2. Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the O-ring of the fuel injector.

3. While turning the fuel injector left and right, install it onto the fuel delivery pipe.

   NOTICE:

   1. Do not twist the O-ring.
      
   2. After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring with a new one.
      

1. Install 4 new injector vibration insulators onto the cylinder head.

1. Install the 2 delivery pipe No. 1 spacers onto the cylinder head.

   NOTICE:

   Install the delivery pipe No. 1 spacer in the correct direction.

1. Provisionally install the fuel delivery pipe sub-assembly with the 4 fuel injectors using the 3 bolts.

   NOTICE:

   1. Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
      
   2. Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub-assembly.
      

2. Tighten the 3 bolts to the specified torque.

   Torque:

   19 N*m{194 kgf*cm, 14 ft.*lbf}for bolt A

   9.0 N*m{92 kgf*cm, 80 in.*lbf}for bolt B

1. Install the gasket onto the cylinder head cover.

2. Apply seal packing to the cylinder head, as shown in the illustration.

   Seal Packing:

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

   NOTICE:

   1. Remove any oil from the contact surface.
      
   2. Install the cylinder head cover sub-assembly within 3 minutes of applying seal packing.
      
   3. Do not start engine for at least 2 hours after the installation.
      

3. Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.

4. Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.

   Torque:

   10 N*m{102 kgf*cm, 7.0 ft.*lbf}

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

   Torque:

   27 N*m{275 kgf*cm, 20 ft.*lbf}

1. Apply engine oil to a new O-ring.

2. Install the oil level gauge guide with the bolt.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

1. Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.

   NOTICE:

   If the O-ring is damaged, replace the crankshaft position sensor.

2. Install the crankshaft position sensor with the bolt.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

1. Install the oil filler cap gasket onto the oil filler cap.

1. Install the oil filler cap onto the cylinder head cover.

1. Install a new gasket onto the thermostat.

2. Install the thermostat with the jiggle valve facing upward.

   HINT:

   The jiggle valve may be set within 10° of either side as shown in the illustration.

1. Install the water inlet with radiator hose using the 2 nuts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

1. Provisionally install the engine coolant temperature sensor through a new gasket.

2. Using SST, tighten the engine coolant temperature sensor.

   SST

   09817-33190
   

   Torque:

   20 N*m{204 kgf*cm, 15 ft.*lbf}

1. Apply adhesive to the end 2 or 3 threads of the oil pressure switch.

   Adhesive:

   Toyota Genuine Adhesive 1324, Three bond 1324 or equivalent
   

2. Using a 24 mm deep socket wrench, install the oil pressure switch.

   Torque:

   15 N*m{153 kgf*cm, 11 ft.*lbf}

1. Install the knock sensor with the nut as shown in the illustration.

   Torque:

   20 N*m{204 kgf*cm, 15 ft.*lbf}

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

   Torque:

   18 N*m{184 kgf*cm, 13 ft.*lbf}