INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

INSTALL WATER PUMP ASSEMBLY

INSTALL CRANKSHAFT PULLEY

INSTALL OIL STRAINER SUB-ASSEMBLY

INSTALL OIL FILTER BRACKET

INSTALL OIL PAN SUB-ASSEMBLY

INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

INSTALL OIL FILLER CAP SUB-ASSEMBLY

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

INSTALL CRANK POSITION SENSOR

INSTALL CAM POSITION SENSOR

INSTALL INJECTOR ASSEMBLY

INSTALL ENGINE STAND

INSTALL ENGINE ASSEMBLY

Place the timing chain cover on wooden blocks.

Using SST, tap in a new oil seal to the timing chain or belt cover sub-assembly.

• SST
• 09223-50010

• Installation depth:
• 0 to 0.6 mm (0 to 0.024 in.)

• NOTICE:

Install a new gasket and O-ring to the timing chain cover as shown in the illustration.

Apply seal packing in a continuous bead to the timing chain cover as shown in the following illustration:

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

• Seal width:

• Position	Specified Condition
  A - A	2.0 to 4.0 mm (0.079 to 0.157 in.)
  B - B	8.0 to 10.0 mm (0.315 to 0.394 in.)
  C - C	Width: 13.0 mm (0.512 in.) Height: 6.0 mm (0.236 in.)

• NOTICE:

Apply adhesive to the 4 bolts.

• Adhesive:
• Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

• HINT:

• Bolt length: 37.5 mm (1.476 in.)

Temporarily install the timing chain cover with the 4 bolts.

Temporarily install a new seal washer and bolt A.

• HINT:

• Bolt length: 67.5 mm (2.657 in.)

Temporarily install the 8 bolts.

• HINT:

• Bolt length: 37.5 mm (1.476 in.)

Using several steps, install the 13 bolts.

• Torque:
• 32 N*m{ 321 kgf*cm, 23 ft.*lbf}Bolts except A
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}A bolt

Using a 10 mm socket hexagon wrench, install the timing chain cover tight plug and a new gasket.

• Torque:
• 19 N*m{ 194 kgf*cm, 14 ft.*lbf}

Align the protrusions and install a new gasket onto the timing chain cover.

Apply adhesive to the bolt (A) shown in the illustration.

Install the 2 bolts (*1), then tighten the other bolts.

• Torque:
• 32 N*m{ 326 kgf*cm, 24 ft.*lbf}

Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place.

Using SST, install a new pulley bolt.

• SST
• 09213-58013
  09330-00021

• Torque:
• 250 N*m{ 2,550 kgf*cm, 184 ft.*lbf}

Install a new O-ring and the oil strainer with the 4 bolts.

• Torque:
• 32 N*m{ 321 kgf*cm, 23 ft.*lbf}

Install a new gasket and the oil filter bracket with the 4 bolts.

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

If replacing a stud bolt, install the stud bolt.

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

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

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

• Seal width:
• 4.0 to 7.0 mm (0.157 to 0.276 in.)

• NOTICE:

Temporarily install the oil pan with the 20 bolts and nut.

Uniformly tighten the 20 bolts and nut.

• Torque:
• Bolt A:
• 43 N*m{ 439 kgf*cm, 31 ft.*lbf}
• Except bolt A:
• 11 N*m{ 112 kgf*cm, 8 ft.*lbf}
• Nut:
• 11 N*m{ 112 kgf*cm, 8 ft.*lbf}

• NOTICE:

• Be sure to replace the bolts indicated by B with new ones or reuse them after applying adhesive 1324.

If replacing the stud bolts, install the stud bolts.

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

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

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

• Seal width:
• 4.0 to 7.0 mm (0.157 to 0.276 in.)

• NOTICE:

Temporarily install the oil pan with the 16 bolts and 2 nuts.

Uniformly tighten the 16 bolts and 2 nuts.

• Torque:
• 11 N*m{ 112 kgf*cm, 8 ft.*lbf}

Install a new gasket and the drain plug.

• Torque:
• 38 N*m{ 388 kgf*cm, 28 ft.*lbf}

Install a new gasket.

Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

Clean the contact surfaces of the cylinder head cover, cylinder head assembly and timing chain cover assembly.

Fit a new cylinder head cover gasket and a new No. 2 gasket into the gasket groove on the cover.

Apply a continuous bead of seal gasket (diameter: 8 mm (0.31 in.)) to the contact surface between the cylinder head assembly and cylinder head cover assembly as shown in the illustration.

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

• NOTICE:

Install the cylinder head cover sub-assembly with the 13 bolts, 4 nozzle holder clamp seats, 2 washers and 2 nuts.

• Torque:
• for bolt A (Nozzle holder clamp seat):
• 16 N*m{ 167 kgf*cm, 12 ft.*lbf}
• for other bolts:
• 11 N*m{ 112 kgf*cm, 8 ft.*lbf}
• for nut:
• 11 N*m{ 112 kgf*cm, 8 ft.*lbf}

Install the 2 engine cover joints.

• Torque:
• 8.0 N*m{ 81 kgf*cm, 71 in.*lbf}

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

Install the crank position sensor with the 2 bolts and clamp.

• Torque:
• 8.8 N*m{ 90 kgf*cm, 78 in.*lbf}

Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

Install the cam position sensor with the bolt.

• Torque:
• 8.8 N*m{ 90 kgf*cm, 78 in.*lbf}