Engine Unit Reassembly

Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

Standard Ring Pin:

Item	Protrusion Height	Height	Width
Ring Pin	3.0 mm (0.118 in.)	11 mm (0.433 in.)	8 mm (0.315 in.)

Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

Torque:

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

Apply seal packing in a continuous line as shown in the illustration.

Seal packing:

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

Standard Seal Packing Diameter:

Area	Specified Condition
Continuous Line	2.0 to 3.0 mm (0.0787 to 0.118 in.)
A	4.5 to 5.5 mm (0.177 to 0.217 in.)

Application Length A:

56 mm (2.20 in.)

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.
   

Install the stiffening crankcase with the 11 bolts in the sequence shown in the illustration.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Bolt Length:

Item	Specified Condition
Bolt A	138 mm (5.43 in.)
Bolt B	35 mm (1.38 in.)
Bolt C	70 mm (2.76 in.)

Recheck the torque for bolts 1 and 2.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Wipe off any excess seal packing with a clean piece of cloth.

Install the oil pump with the 3 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

Apply seal packing in a continuous line as shown in the illustration.

Application Specification:

Area	Seal Packing Diameter	Distance from Center of Bolt Hole to Center of Seal Packing
A - A	3.0 to 4.5 mm (0.118 to 0.177 in.)	6.0 mm (0.236 in.)
B - B		-

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the oil pan within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the No. 2 oil pan with the 10 bolts and 2 nuts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install a new gasket and the drain plug.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Apply MP grease to the lip of a new oil seal.

NOTICE:

1. Do not allow foreign matter to contact the lip of the oil seal.
   
2. Do not allow MP grease to contact the dust seal.
   

Using SST and a hammer, tap in the oil seal until its surface is flush with the edges of the cylinder block and crankcase.

SST

09223-15030
09950-70010(09951-07100)

NOTICE:

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

Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:

1. Install the plug within 3 minutes of applying adhesive.
   
2. Do not start the engine within 1 hour of installing the plug.
   

Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (B).

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

1. Install the plug within 3 minutes of applying adhesive.
   
2. Do not start the engine within 1 hour of installing the plug.
   

Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly.

Adhesive:

Toyota genuine adhesive 1324, three bond 1324 or equivalent

Using a 22 mm ball joint lock nut wrench, install the ventilation valve sub-assembly.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where ball joint lock nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

Apply seal packing to the cylinder block as shown in the illustration.

Seal packing:

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

Standard seal packing diameter:

4.0 mm (0.157 in.)

Application Specification:

Area	Seal Packing Application Length	Distance from Edge of Cylinder Block to Center of Seal Packing
A	-	2.0 to 4.0 mm (0.0787 to 0.157 in.)
B	10 to 15 mm (0.394 to 0.591 in.)	-

NOTICE:

Remove any oil from the cylinder block.

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

NOTICE:

Install the cylinder head gasket within 3 minutes after applying seal packing.

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

Seal packing:

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

Standard seal packing diameter:

4.0 mm (0.157 in.)

Application Specification:

Area	Seal Packing Application Length	Distance from Edge of Cylinder Head Gasket to Center of Seal Packing
A	-	2.0 to 4.0 mm (0.0787 to 0.157 in.)
B	10 to 15 mm (0.394 to 0.591 in.)	-

NOTICE:

1. Remove any oil from the cylinder head gasket and cylinder head.
   
2. Install the cylinder head within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
   

Place the cylinder head on the cylinder block.

NOTICE:

1. Make sure that no oil is on the mounting surface of the cylinder head.
   
2. Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.
   

Install the plate washers to the cylinder head bolts.

Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

Step 1:

1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.
   

   Torque:

   49 N*m{500 kgf*cm, 36 ft.*lbf}

   NOTICE:

   Do not drop the plate washers into the cylinder head.

Step 2:

1. Mark each cylinder head bolt head with paint as shown in the illustration.
   

2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.
   

Step 3:

1. Tighten the cylinder head bolts another 45° in the sequence shown in step 1.
   

Check that the paint mark is now at a 135° angle to the front.

After tightening the cylinder head bolts, wipe off the seal packing material that has seeped out from between the contact surfaces of the cylinder head and cylinder block.

Apply a light coat of engine oil to the valve stem ends.

Install the 16 valve stem caps to the cylinder head.

NOTICE:

Do not drop the valve stem caps into the cylinder head.

Inspect each valve lash adjuster before installing it (RAV4_ACA30 RM000002XR2015X_01_0014.html).

Install the 16 valve lash adjusters to the cylinder head.

NOTICE:

Install the valve lash adjuster to the same place it was removed from.

Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.

Using a plastic-faced hammer, tap in a new straight pin to the specified protrusion height.

Standard Straight Pin:

Item	Protrusion Height	Height	Width
Straight Pin	6.5 to 7.5 mm (0.256 to 0.295 in.)	14 mm (0.551 in.)	6.0 mm (0.236 in.)

Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.

Torque:

9.5 N*m{97 kgf*cm, 84 in.*lbf}

Install a new O-ring to the continuously variable valve lift controller.

NOTICE:

1. Align the protrusion of the O-ring with the protrusion of the continuously variable valve lift controller.
   
2. Make sure that the O-ring is not protruding from the groove in the continuously variable valve lift controller.
   

Install the control actuator clip to the control actuator connector.

HINT:

When the continuously variable valve lift controller is new, a control actuator connector is attached to it. Remove the control actuator connector before performing these procedures.

NOTICE:

Be sure to insert the protrusions of the control actuator clip into the holes in the control actuator connector.

Install the control actuator connector to the valve rocker shaft and rotate the control actuator connector as shown in the illustration.

Insert the continuously variable valve lift controller into the camshaft housing.

Install the continuously variable valve lift controller to the camshaft housing with the bolt.

Torque:

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

NOTICE:

Do not let the O-ring become jammed between parts.

Using a screwdriver, slide the control actuator clip from the control actuator connector.

Slide only the upper part of the control actuator clip as the straight pin may fall if the control actuator clip is completely removed.

Using a screwdriver, lightly pry the control actuator connector and align the hole in the control actuator connector with the hole in the continuously variable valve lift controller.

NOTICE:

1. Do not forcefully pry the control actuator connector.
   
2. Do not damage the camshaft housing or camshaft bearing cap.
   

Insert the straight pin into the control actuator connector.

NOTICE:

Do not use a tool to insert the straight pin. Insert the straight pin by hand.

HINT:

If the straight pin is difficult to insert, insert the straight pin while lightly prying the control actuator connector.

Using a screwdriver, install the control actuator clip to the control actuator connector.

NOTICE:

Insert the protrusion of the control actuator clip into the hole in the control actuator connector.

Check that the valve rocker arms are installed as shown in the illustration.

Apply seal packing in a continuous line as shown in the illustration.

Seal packing:

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

Standard Seal Packing Diameter:

Area	Specified Condition
Continuous Line	3.5 to 4.5 mm (0.138 to 0.177 in.)
A	8.0 mm (0.315 in.)
B	7.0 mm (0.276 in.)

Application Length A and B:

15 mm (0.591 in.)

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installation.
   

Set the camshaft and No. 2 camshaft as shown in the illustration.

Install the camshaft housing with the 17 bolts and tighten them in the order shown in the illustration.

Torque:

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

NOTICE:

1. After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
   
2. If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
   
3. 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. After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and cylinder head.
   

Put the camshaft timing exhaust gear and camshaft together by aligning the pin hole and straight pin.

NOTICE:

Do not forcefully push in the camshaft timing exhaust gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing exhaust gear.

Lightly press the gear against the camshaft and turn the gear. Push further at the position where the pin enters the hole.

NOTICE:

Be sure not to turn the camshaft timing exhaust gear in the retard direction (clockwise).

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

Tighten the flange bolt with the camshaft timing exhaust gear secured in place.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

Check the camshaft timing exhaust gear lock.

1. Make sure that the camshaft timing exhaust gear is locked.
   

Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned as shown in the illustration.

NOTICE:

Do not forcefully push in the camshaft timing gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear.

Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

NOTICE:

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

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

Tighten the flange bolt with the camshaft timing gear secured in place.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

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

Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

HINT:

Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

Install the crankshaft position sensor plate with the "F" mark facing forward.

Temporarily install the crankshaft pulley bolt.

Set the crankshaft key as shown in the illustration.

Turn the drive shaft so that the cutout faces upward.

Remove the crankshaft pulley bolt.

Align the yellow mark plates with the timing mark of each gear as shown in the illustration.

Install the gears onto the crankshaft and oil pump shaft with the chain on the gears.

Temporarily install the oil pump drive shaft gear with the nut.

Install the spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Temporarily install the crankshaft pulley with the pulley bolt.

Using SST, hold the crankshaft. Then tighten the drive shaft gear nut.

SST

09213-58014(91551-80840)
09330-00021

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Remove SST, the crankshaft pulley bolt and crankshaft pulley.

Install the crankshaft timing sprocket as shown in the illustration.

Install the chain vibration damper with the 2 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Temporarily install the crankshaft pulley bolt.

Turn the crankshaft counterclockwise to position the timing gear key at the top.

Check that the timing marks on the camshaft timing gears are aligned as shown in the illustration.

Remove the crankshaft pulley bolt.

Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

HINT:

1. Be sure to position the mark plate at the front of the engine.
   
2. The mark plate on the camshaft side is colored orange.
   
3. Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.
   
4. Pass the chain through the No. 1 vibration damper.
   

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain.

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.

HINT:

To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.

Align the mark plates (yellow) and timing marks and install the chain to the crankshaft timing gear.

HINT:

The mark plates on the crankshaft side are colored yellow.

Install the chain tensioner slipper to the cylinder block.

Check each timing mark at TDC/compression.

Install the generator bracket with the 4 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration.

Torque:

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

Install a new gasket and the water inlet housing with the 3 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Install a new gasket.

NOTICE:

Remove any oil from the contact surface.

for Type A:
Install the water pump with the 3 bolts.

Torque:

24 N*m{241 kgf*cm, 17 ft.*lbf}

for Type B:
Install the water pump with the 3 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, camshaft housing, stiffening crankcase and cylinder block.

Install 3 new O-rings.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal packing diameter:

5.0 mm (0.197 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installing the timing chain cover sub-assembly.
   

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

Seal Packing:

Item	Seal Packing
Dashed line	Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Continuous line
Alternate long and short dashed line	Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

Application Specification:

Area	Seal Packing Diameter	Distance from Edge of Cover to:	Seal Packing Application Length	Distance from Top of Cover to Top of Seal Packing
Dashed line	2.5 to 3.0 mm (0.0984 to 0.118 in.)	Center of seal packing 2.5 mm (0.0984 in.)	-	-
Continuous line	4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.)	-	-	-
Alternate long and short dashed line	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-
A - A	2.5 to 3.0 mm (0.0984 to 0.118 in.)	Center of seal packing 2.5 mm (0.0984 in.)	-	-
B - B	4.5 to 5.5 mm (0.177 to 0.217 in.)	Opposite edge of seal packing 5.0 mm (0.197 in.)	-	-
C - C	7.0 to 8.0 mm (0.276 to 0.315 in.)	Opposite edge of seal packing 7.5 mm (0.295 in.)	-	-
F	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	15.8 mm (0.622 in.)	50.1 mm (1.97 in.)
G	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	10.3 mm (0.406 in.)	155.1 mm (6.11 in.)
H	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	19.5 mm (0.768 in.)	165.4 mm (6.51 in.)
I	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	14.6 mm (0.575 in.)	397.8 mm (1.31 ft.)
J	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	18.6 mm (0.732 in.)	51.4 mm (2.02 in.)
K	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	25.3 mm (0.996 in.)	133.9 mm (5.27 in.)
L	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	25.8 mm (1.02 in.)	159.2 mm (6.28 in.)
M	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	5.0 mm (0.197 in.)	185.0 mm (7.28 in.)
N	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	14.6 mm (0.575 in.)	397.8 mm (1.31 ft.)
O	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-

NOTICE:

1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
   
2. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.
   
4. Do not add engine oil for at least 2 hours after installation.
   

Clean the bolts and their installation holes.

Install the timing chain cover.

Temporarily install the engine mounting bracket with the 3 bolts.

NOTICE:

1. Install the mounting bracket within 10 minutes after installing the timing chain cover.
   
2. Do not add engine oil for at least 2 hours after installation.
   

Install 2 new O-rings.

Temporarily install the oil filter bracket with the 4 bolts.

NOTICE:

1. Install the oil filter bracket within 10 minutes after installing the timing chain cover.
   
2. Do not add engine oil for at least 2 hours after installation.
   

Apply adhesive to 5 and a half threads or more of the end of bolt E.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the timing chain cover with the 26 bolts and new seal washer in the order shown in the illustration.

Torque:

for bolt A, E:

26 N*m{260 kgf*cm, 19 ft.*lbf}

for bolt B:

51 N*m{520 kgf*cm, 38 ft.*lbf}

for bolt C:

51 N*m{520 kgf*cm, 38 ft.*lbf}

for bolt D:

10 N*m{102 kgf*cm, 7 ft.*lbf}

NOTICE:

1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
   
2. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying the seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   

Bolt Length:

Item	Length	Thread Diameter
Bolt A, E	35 mm (1.38 in.)	8 mm (0.315 in.)
Bolt B	55 mm (2.17 in.)	10 mm (0.394 in.)
Bolt C	80 mm (3.15 in.)	10 mm (0.394 in.)
Bolt D	40 mm (1.57 in.)	6 mm (0.236 in.)

HINT:

Apply adhesive to bolt E before installing it.

Apply MP grease to the lip of a new oil seal.

NOTICE:

1. Do not allow foreign matter to contact the lip of the oil seal.
   
2. Do not allow MP grease to contact the dust seal.
   

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

SST

09223-22010

NOTICE:

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

Install the stud bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Align the key groove of the pulley with the pulley set key.

Temporarily install the pulley with the pulley bolt.

Using SST, hold the pulley in place and tighten the pulley bolt.

SST

09330-00021
09213-58014(91551-80840)

Torque:

190 N*m{1940 kgf*cm, 140 ft.*lbf}

Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

NOTICE:

Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

Install a new gasket, the chain tensioner and bracket with the 2 nuts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

NOTICE:

If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.

Turn the crankshaft clockwise and check that the plunger is extended.

Clean the inside of the oil filter cap, its threads and O-ring groove.

Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

Set a new oil filter element in the oil filter cap.

Remove any dirt or foreign matter from the installation surface and inside of the engine.

Reapply a small amount of engine oil to the O-ring of the oil filter cap. Align the oil filter cap with the oil filter bracket so that the cutout portion of the cap threads is in a position 90° from the groove in the bracket, and then temporarily install the cap.

NOTICE:

Make sure that the O-ring does not get caught between the parts.

Using SST, tighten the oil filter cap.

SST

09228-06501

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

NOTICE:

1. After tightening the oil filter cap, check for gaps between the installation surfaces.
   
2. Do not remove the oil filter bracket clip when installing the oil filter cap.
   
3. Do not cross thread the oil filter cap.
   

Using a cutter knife, cut off the seal part of the removed gasket.

Using a hammer and a plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.

HINT:

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

NOTICE:

1. Keep the lip free of foreign matter.
   
2. Do not tap in the plug tube gasket at an angle.
   

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

Install a new cylinder head cover gasket to the cylinder head cover.

NOTICE:

Remove any oil from the contact surfaces.

Install 3 new gaskets to the camshaft bearing cap.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard diameter:

4.0 mm (0.157 in.)

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after the installation.
   

Install the cylinder head cover with a new seal washer and the 13 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

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

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:

Do not let adhesive adhere to the oil hole.

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

Torque:

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

NOTICE:

Do not start the engine for at least 1 hour after installation.

Connect the oil pressure switch connector.

Using SST, install a new gasket and the engine coolant temperature sensor.

SST

09817-33190

Torque:

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

Install the knock sensor with the bolt.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

NOTICE:

Make sure that the knock sensor is in the correct position.

Apply a light coat of engine oil to the O-rings of the sensors.

Install the crankshaft position sensor with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Apply a light coat of engine oil to 2 new O-rings and install them to the camshaft timing oil control valves.

Install the 2 camshaft timing oil control valves and bracket with the 2 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

NOTICE:

1. Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover).
   
2. Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.
   

Apply a light coat of engine oil to the O-rings of the sensors.

Install the 2 camshaft position sensors with the 2 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

NOTICE:

Make sure that the O-ring is not cracked or jammed when installing the sensor.

Using a 14 mm spark plug wrench and 100 mm extension bar, install the 4 spark plugs.

Torque:

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

Install the 2 engine cover joints.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the gasket to the oil filler cap.

Install the oil filler cap.