Engine Unit Reassembly

Apply engine oil to each valve stem and valve lifter, and then install the valve lifters.

Check that the valve lifters rotate smoothly by hand.

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

SST

09223-78010

Apply MP grease to the lip of the oil seal.

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the rear engine oil seal retainer and cylinder block.

Apply a continuous line of seal packing to the rear engine oil seal retainer as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the rear engine oil seal retainer within 3 minutes after applying seal packing.
   

Install the rear engine oil seal retainer with the 5 bolts and 2 nuts.

Torque:

for bolt:

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

for nut:

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

Install the 2 knock sensors with the 2 bolts as shown in the illustration.

Torque:

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

Connect the 2 knock sensor connectors.

for Type A:
Install the No. 1 water outlet pipe with the 3 bolts.

Torque:

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

Torque:

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

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head LH or cylinder block.

Apply seal packing to a new No. 2 cylinder head gasket as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.5 to 3.0 mm (0.0984 to 0.118 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the No. 2 cylinder head gasket within 3 minutes after applying the seal packing.
   
3. Do not add engine oil within 2 hours of installation.
   

Place the No. 2 cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

Text in Illustration

*1	Lot No.
	Engine Front

NOTICE:

Make sure that the gasket is installed facing the proper direction.

Seal packing will seep out from the front side of engine. Thoroughly wipe off the seal packing that seeps out.

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head or cylinder block.

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

Seal packing:

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

Standard seal diameter:

2.5 to 3.0 mm (0.0984 to 0.118 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head gasket within 3 minutes after applying the seal packing.
   
3. Do not add engine oil within 2 hours of installation.
   

Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

Text in Illustration

*1	Lot No.
	Engine Front

NOTICE:

Make sure that the gasket is installed facing the proper direction.

Place the cylinder head RH on the cylinder block.

NOTICE:

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

HINT:

The cylinder head bolts are tightened in 2 progressive steps.

1. 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 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
   

   Torque:

   36 N*m{367 kgf*cm, 27 ft.*lbf}

   NOTICE:

   Do not drop the washers into the cylinder head.

Step 2:

1. Mark the front side of each cylinder head bolt head with paint.
   

2. Tighten the cylinder head bolts another 180°.
   

3. Check that the paint marks are now at a 180° angle to the front.
   

Seal packing will seep out from the front side of engine. Thoroughly wipe off the seal packing that seeps out.

Place the cylinder head LH on the cylinder block.

NOTICE:

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

HINT:

The cylinder head bolts are tightened in 2 progressive steps.

1. 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 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
   

   Torque:

   36 N*m{367 kgf*cm, 27 ft.*lbf}

   NOTICE:

   Do not drop the washers into the cylinder head LH.

Step 2:

1. Mark the front side of each cylinder head bolt head with paint.
   

2. Tighten the cylinder head bolts another 180°.
   

3. Check that the paint marks are now at a 180° angle to the front.
   

Install the 2 bolts in the order shown in the illustration.

Torque:

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

NOTICE:

Thoroughly wipe clean any seal packing.

Apply soapy water to a new O-ring and install it to the No. 1 water outlet pipe. Then install 2 new gaskets to the water ports LH and RH.

Install the rear water by-pass joint with the 2 bolts and 4 nuts.

Torque:

for bolt:

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

for nut:

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

Align the bearing claw with the groove of the No. 1 camshaft bearing cap and push in the camshaft bearing.

NOTICE:

1. Install the bearing while aligning it with the oil hole in the No. 1 camshaft bearing cap.
   
2. Clean the backside of the bearing and the bearing surface of the No. 1 camshaft bearing cap and do not allow any oil or grease to contact the parts.
   

Install the No. 2 camshaft bearing to the cylinder head.

NOTICE:

Clean the backside of the bearing and the bearing surface of the cylinder head and do not allow any oil or grease to contact the parts.

Set the crankshaft position.

1. Using the crankshaft pulley set bolt, turn the crankshaft and set the crankshaft set key to the left horizontal position.
   

   Text in Illustration

   *1	Set Key
   *a	Turn

   NOTICE:

   Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.

Apply new engine oil to the thrust portion and journals of the camshafts.

Place the 2 camshafts onto the cylinder head with the cam lobes of the No. 1 cylinder oriented shown in the illustration.

Set the 8 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Uniformly install the 16 bolts in several steps in the order shown in the illustration.

Torque:

for 10 mm head bolt:

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

for 12 mm head bolt:

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

Text in Illustration

*A	for Bank 1
	10 mm Head Bolt
	12 mm Head Bolt

Using a wrench, turn the camshafts clockwise until the camshaft knock pin is at a position 90° to the cylinder head.

Place the 2 camshafts onto the cylinder head with the cam lobes of the No. 2 cylinder oriented as shown in the illustration.

Set the 8 bearing caps in their proper locations.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Uniformly install the 16 bolts in several steps in the order shown in the illustration.

Torque:

for 10 mm head bolt:

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

for 12 mm head bolt:

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

Text in Illustration

*A	for Bank 2
	10 mm Head Bolt
	12 mm Head Bolt

While pushing in the tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

Install the No. 2 chain tensioner with the bolt.

Torque:

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

Align the mark links of the No. 2 chain with the timing marks (1-dot mark) of the camshaft timing gear and sprocket as shown in the illustration.

Align the timing marks on the camshaft timing gear and sprocket with the timing marks on the bearing caps and install the camshaft timing gear and sprocket together with the No. 2 chain to the camshafts.

Temporarily install the 2 camshaft timing gear bolts.

NOTICE:

Do not forcibly push the camshaft timing gear assembly onto the camshaft when installing it.

Hold the hexagonal portion of the camshaft with a wrench and tighten the 2 bolts.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Remove the pin from the No. 2 chain tensioner.

While pushing in the tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

Install the No. 3 chain tensioner with the bolt.

Torque:

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

Align the mark links of the No. 2 chain with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gear and sprocket as shown in the illustration.

Align the timing marks on the camshaft timing gear and sprocket with the timing marks on the bearing caps and install the camshaft timing gear and sprocket together with the No. 2 chain to the camshafts.

Temporarily install the 2 camshaft timing gear bolts.

NOTICE:

Do not forcibly push the camshaft timing gear assembly onto the camshaft when installing it.

Hold the hexagonal portion of the camshaft with a wrench and tighten the 2 bolts.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Remove the pin from the No. 3 chain tensioner.

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

Torque:

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

Align the timing gear set key with the key groove of the timing gear.

Install the timing gear to the crankshaft, facing the gear side inward.

While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

While turning the stopper plate of the tensioner counterclockwise, insert a bar with a diameter of 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate in place.

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

Torque:

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

Set the No. 1 cylinder to TDC/compression.

1. Align the timing marks of the camshaft timing gears and sprockets with the timing marks of the bearing caps.
   

   Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *1	Timing Mark





2. Install the crankshaft pulley set bolt and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.
   

   Text in Illustration

   *1	Timing Line
   *2	Set Key

Align the mark link with the timing mark of the crankshaft timing gear.

Align the mark links with the timing marks of the camshaft timing gears and install the chain.

Install the 2 No. 2 chain vibration dampers.

Apply a light coat of engine oil to the sliding surface of the No. 1 idle gear shaft.

Temporarily install the No. 1 idle gear shaft and idle gear together with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

Text in Illustration

*1	Knock Pin
	Forward

NOTICE:

Make sure that the idle gear is installed facing the proper direction.

Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

Torque:

60 N*m{612 kgf*cm, 44 ft.*lbf}

Remove the bar from the No. 1 chain tensioner.

Install a new gasket and the engine water pump with the 8 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*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 and cylinder block.

Install a new O-ring to the cylinder head for bank 2.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

3.5 to 4.5 mm (0.138 to 0.177 in.)

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

Seal Packing:

Item	Seal Packing
Continuous Line Area	Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Dashed Line Area	Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

Application Specification:

Seal Packing Diameter	Application Position from Inside Seal Line
3.5 to 4.5 mm (0.138 to 0.177 in.)	3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

1. Install the timing chain cover within 3 minutes after applying seal packing. After installing it, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
   
2. Do not apply seal packing to "A" shown in the illustration.
   

Align the keyway of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear and slide the timing chain cover into place.

Install the timing chain cover with the 24 bolts labeled A and B, and the 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Standard Bolt:

Item	Length
Bolt A	25 mm (0.984 in.)
Bolt B	55 mm (2.17 in.)

Text in Illustration

	Bolt A
	Bolt B
	Nut

NOTICE:

1. Make sure not to wrap the chain and slipper over the timing chain cover seal line.
   
2. Make sure that there is no oil on the bolt threads.
   

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

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

SST

09226-10010

NOTICE:

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

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

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

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 diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan within 3 minutes after applying seal packing. After installing the oil pan, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
   
3. Do not start the engine for at least 2 hours after installing.
   

Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

for bolt A and B, and nut:

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

for bolt C:

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

Standard Bolt:

Item	Length
Bolt A	25 mm (0.98 in.)
Bolt B	45 mm (1.77 in.)
Bolt C	14 mm (0.55 in.)

Text in Illustration

	Bolt A
	Bolt B
	Bolt C
	Nut

NOTICE:

The bolts indicated by stars in the illustration are precoated parts. When reusing these bolts, apply adhesive to 2 or 3 threads before installation.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Torque:

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

Remove any old seal packing (FIPG) and be careful not to drop any oil on the contact surfaces of the oil pan and No. 2 oil pan.

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 diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the No. 2 oil pan within 3 minutes after applying seal packing. After installing the oil pan, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
   
3. Do not start the engine for at least 4 hours after the installation.
   

Install the No. 2 oil pan with the 14 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

for bolt:

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

for nut:

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

Install the drain plug with a new gasket.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Using SST, install the crankshaft pulley with the pulley set bolt.

SST

09213-54015(91651-60855)
09330-00021

Torque:

250 N*m{2549 kgf*cm, 184 ft.*lbf}

Turn the crankshaft pulley and align its groove with the "0" timing mark of the timing chain cover.

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

Check the valves indicated in the illustration.

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

   Standard Valve Clearance (Cold):

   Item	Specified Condition
   Intake	0.15 to 0.25 mm (0.00591 to 0.00984 in.)
   Exhaust	0.29 to 0.39 mm (0.0114 to 0.0154 in.)

   Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *a	Exhaust Side
   *b	Intake Side
   	Engine Front

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

Turn the crankshaft 2/3 of a revolution (240°).

Check the valves indicated in the illustration.

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

   Standard Valve Clearance (Cold):

   Item	Specified Condition
   Intake	0.15 to 0.25 mm (0.00591 to 0.00984 in.)
   Exhaust	0.29 to 0.39 mm (0.0114 to 0.0154 in.)

   Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *a	Exhaust Side
   *b	Intake Side
   	Engine Front

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

Turn the crankshaft 2/3 of a revolution (240°).

Check the valves indicated in the illustration.

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

   Standard Valve Clearance (Cold):

   Item	Specified Condition
   Intake	0.15 to 0.25 mm (0.00591 to 0.00984 in.)
   Exhaust	0.29 to 0.39 mm (0.0114 to 0.0154 in.)

   Text in Illustration

   *A	for Bank 1
   *B	for Bank 2
   *a	Exhaust Side
   *b	Intake Side
   	Engine Front

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

Remove the camshaft (HILUX_TGN26 RM0000015D100CX.html).

Remove the 24 valve lifters from the cylinder head and cylinder head LH.

Determine the size of the valve lifter to be installed according to the following formulas or charts.

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

2. Calculate the thickness of a new lifter so that the valve clearance is within the specified range.
   

   T:

   Thickness of removed lifter
   

   A:

   Measured valve clearance
   

   N:

   Thickness of new lifter
   

   Intake:

   N = T + (A - 0.20 mm (0.00787 in.))
   

   Exhaust:

   N = T + (A - 0.34 mm (0.0131 in.))
   





3. Select a new lifter with a thickness as close as possible to the calculated value.
   

   HINT:

   Lifters are available in 35 sizes in increments of 0.020 mm (0.000787 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

   
   
   
   
   
   
   

   Text in Illustration

   *1	Valve Lifter Selection Chart (Intake)	*2	Measured Clearance mm (in.)
   *3	Installed Lifter Thickness mm (in.)	-	-

   Intake valve clearance (Cold):

   0.15 to 0.25 mm (0.00591 to 0.00984 in.)
   

   EXAMPLE:

   The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a No. 46 lifter.
   

   
   

   New Lifter Thickness:

   
   

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

   
   
   
   
   
   
   

   Text in Illustration

   *1	Valve Lifter Selection Chart (Exhaust)	*2	Measured Clearance mm (in.)
   *3	Installed Lifter Thickness mm (in.)	-	-

   Exhaust valve clearance (Cold):

   0.29 to 0.39 mm (0.0114 to 0.0154 in.)
   

   EXAMPLE:

   The 5.340 mm (0.210 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.210 in.) lifter with a No. 48 lifter.
   

   
   

   New Lifter Thickness:

   
   

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

Install the camshaft (HILUX_TGN26 RM0000015CY00FX.html).

Check the valve clearance again.
If the result is not as specified, adjust the valve clearance.

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

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

NOTICE:

Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

Install a new gasket to the cylinder head cover.

Install a new seal washers to the bolts.

Temporarily install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

for bolt A:

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

for bolt B and nut:

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

Text in Illustration

	Bolt A
	Bolt B
	Nut

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

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

NOTICE:

Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

Install a new gasket to the cylinder head cover.

Install a new seal washers to the bolts.

Temporarily install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

for bolt A:

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

for bolt B and nut:

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

Text in Illustration

	Bolt A
	Bolt B
	Nut

Install a new O-ring to the water outlet pipe.

Install a new gasket to the water pump.

Apply soapy water to the O-ring.

Install the water inlet assembly to the 5 bolts.

Torque:

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

Connect the 5 water by-pass hoses.

Install the 2 radiator hoses to the water inlet assembly.

Install the 6 spark plugs.

Torque:

20 N*m{200 kgf*cm, 14 ft.*lbf}

Apply adhesive to 2 or 3 threads of the PCV valve.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the PCV valve.

Torque:

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

Connect the PCV hose to the PCV valve.

Secure the PCV hose with the clamp.

Install a new gasket and the oil filter bracket with the 3 bolts and 2 nuts.

Torque:

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

Clean the contact surfaces of the oil filter bracket and oil cooler.

Place a new O-ring on the oil cooler.

Apply a light coat of engine oil to the threads of the union bolt.

Align the protrusion of the oil filter bracket with the cutout of the oil cooler.

Install the oil cooler and plate washer with the union bolt.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Connect the 2 hoses to the oil cooler.

Check and clean the oil filter installation surface.

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

Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.

Using SST, tighten the oil filter.

SST

09228-07501

Text in Illustration

3/4 Turn

1. Depending on the work space available, choose from the following.
   If enough space is available, use a torque wrench to tighten the oil filter.
   

   Torque:

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

   If enough space is not available to use a torque wrench, tighten the oil filter a 3/4 turn by hand or use a common wrench.
   

Check that there are no foreign objects on the mesh part of the 2 filters.

Text in Illustration

*1	Mesh Part
*2	New Gasket
	Apply Adhesive

Install 2 new gaskets to 2 new plugs.

Insert the filters into the plugs.

Apply adhesive to 2 or 3 threads of the plugs.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the 2 plugs to the cylinder heads.

Torque:

62 N*m{632 kgf*cm, 46 ft.*lbf}

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

NOTICE:

1. When reusing the crankshaft position sensor, inspect the O-ring.
   
2. If the O-ring has scratches or cuts, replace the crankshaft position sensor.
   

Install the crankshaft position sensor with the bolt.

Torque:

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

Connect the crankshaft position sensor connector.

Apply a light coat of engine oil to a new O-ring of the camshaft timing oil control valve.

Install the camshaft timing oil control valve with the bolt.

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 camshaft timing oil control valve (surface which contacts the cylinder head).
   
2. Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.
   

Connect the camshaft timing oil control valve connector.

Apply a light coat of engine oil to a new O-ring of the camshaft timing oil control valve.

Install the camshaft timing oil control valve with the bolt.

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 camshaft timing oil control valve (surface which contacts the cylinder head).
   
2. Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.
   

Connect the camshaft timing oil control valve connector.

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

NOTICE:

1. When reusing the VVT sensor, inspect the O-ring.
   
2. If the O-ring has scratches or cuts, replace the VVT sensor.
   

Install the VVT sensor with the bolt.

Torque:

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

Connect the VVT sensor connector.

Connect the No. 4 and No. 5 water by-pass hoses.

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

NOTICE:

1. When reusing the VVT sensor, inspect the O-ring.
   
2. If the O-ring has scratches or cuts, replace the VVT sensor.
   

Install the VVT sensor with the bolt.

Torque:

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

Connect the VVT sensor connector.

Apply adhesive to 2 or 3 threads at the end of the cylinder block water drain cock.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the 2 cylinder block water drain cocks.

Torque:

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

NOTICE:

1. Install the cylinder block water drain cock within 3 minutes after applying adhesive.
   
2. Do not expose the cylinder block water drain cock to coolant within 1 hour after installation.
   

Rotate the cylinder block water drain cock clockwise as shown in the illustration.

NOTICE:

1. Do not rotate the cylinder block water drain cock by more than 1 revolution (360°) after tightening the cylinder block water drain cock to the specified torque.
   
2. Do not loosen the cylinder block water drain cock after installing it correctly.