Partial Engine: Overhaul

1. Using a spark plug wrench, remove the 4 spark plugs.

Fig 1: Removing Spark Plugs By Spark Plug Wrench

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1. Remove the oil filler cap from the cylinder head cover.

Fig 2: Removing Oil Filler Cap From Cylinder Head Cover

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1. Using a screwdriver with its tip wrapped in tape, remove the oil filler cap gasket.

Fig 3: Removing Oil Filler Cap Gasket

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1. Remove the bolt and camshaft position sensor.

Fig 4: Removing Bolt Of Camshaft Position Sensor

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1. Remove the bolt and camshaft timing oil control valve assembly.

Fig 5: Removing Bolt Of Camshaft Timing Oil Control Valve Assy

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1. Using SST, remove the oil filter. SST 09228-06501

Fig 6: Removing Oil Filter

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1. Remove the 2 nuts and water inlet.
   Fig 7: Removing 2 Nuts Of Water Inlet

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2. Remove the thermostat.
   Fig 8: Removing Thermostat

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3. Remove the water inlet housing gasket No. 1 from the thermostat.

Fig 9: Removing Water Inlet Housing Gasket No. 1 From Thermostat

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1. Remove the bolt and crank position sensor.

Fig 10: Removing Bolt Of Crank Position Sensor

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1. Using SST, hold the water pump pulley.
   1. SST 09960-10010 (09962-01000, 09963-01000)
2. Remove the 3 bolts and water pump pulley.

Fig 11: Holding Water Pump Pulley Remove 3 Bolts & Water Pump Pulley

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1. Remove the 3 bolts and 2 nuts, then remove the water pump assembly.
2. Remove the water pump gasket.

Fig 12: Removing 3 Bolts, 2 Nuts Of Water Pump Assy

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1. Remove the 4 bolts and transverse engine mounting bracket.

Fig 13: Removing 4 Bolts Of Transverse Engine Mounting Brackets

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1. Remove the ventilation valve from the cylinder head cover.

Fig 14: Removing Ventilation Valve From Cylinder Head Cover

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1. Remove the 9 bolts and 2 nuts, then remove the cylinder head cover.
2. Remove the cylinder head cover gasket from the cylinder head cover.

Fig 15: Removing 9 Bolts, 2 Nuts Of Cylinder Head Cover

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1. Set the No. 1 cylinder to the TDC/compression.
   1. Turn the crankshaft damper clockwise, then align its timing mark notch with the timing mark "0".
   2. Check that the timing marks of the camshaft timing gear are located as illustrated.

   HINT:

   If not, turn the crankshaft to align the marks.

   Fig 16: Setting No. 1 Cylinder To TDC, Turn Crankshaft Damper Clockwise Then Align Timing Mark Notch With Timing Mark 0

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2. Using SST, hold the crankshaft damper and loosen the crankshaft bolt.
   1. SST 09213-58013 (91111-50845), 09330-00021
   NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.
   Fig 17: Holding Crankshaft Damper Loosen Crankshaft Bolt

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3. Loosen the crankshaft bolt until the 2 to 3 threads of the bolt is tightened to the crankshaft.
4. Using SST, remove the crankshaft damper and crankshaft bolt.
   1. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
   Fig 18: Removing Crankshaft Damper & Crankshaft Bolt

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5. Remove the crankshaft straight pin.

Fig 19: Removing Crankshaft Straight Pin

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1. Remove the 15 bolts and nut.
   Fig 20: Removing 15 Bolts & Nut Of Oil Pump Assy

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2. Using a screwdriver with its tip wrapped in tape, remove the oil pump assembly by prying out between the cylinder head and cylinder block.
   NOTE: Be careful not to damage the contact surfaces of the oil pump assembly, cylinder head and cylinder block.
   Fig 21: Using Screwdriver With Its Tip Wrapped In Take Remove Oil Pump Assy

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3. Remove the 2 O-rings from the cylinder block and oil pan.
   Fig 22: Removing 2 O-Rings From Cylinder Block & Oil Pan

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4. Using an 8 mm socket hexagon wrench, remove the service hole screw plug.

Fig 23: Removing Service Hole Screw Plug

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1. Using a screwdriver with its tip wrapped in tape, remove the oil seal.

Fig 24: Removing Oil Pump Seal

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1. Lift up the stopper plate, then unlock the plunger.
2. Push in the plunger to the end with the plunger unlocked.
   Fig 25: Lifting Up Stopper Plate Then Unlock Plunger

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3. Lift down the stopper plate with the plunger pushed to the end, then lock the plunger.
   Fig 26: Lifting Down Stopper Plate With Plunger Pushed To End Then Lock Plunger

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4. Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked.

   HINT:

   If the stopper plate is not completely lifted down and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. The stopper plate will be completely lifted down and a 3.0 mm (0.118 in.) diameter bar can be inserted easily.

   Fig 27: Inserting 3.0 mm Diameter Bar Into Hole Of Stopper Plate With Plunger Locked

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5. Remove the 2 bolts and chain tensioner No. 1.

Fig 28: Removing 2 Bolts & Chain Tensioner No.1

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1. Remove the chain tensioner slipper from cylinder block.

Fig 29: Removing Chain Tensioner Slipper From Cylinder Block

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1. Remove the 2 bolts and chain vibration damper No. 1.

Fig 30: Removing 2 Bolts & Chain Vibration Damper No. 1

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1. Remove the chain.

Fig 31: Removing Chain Sub-Assy

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1. Remove the 3 bolts and fuel delivery pipe with fuel injector assembly.
   Fig 32: Removing 3 Bolts Of Fuel Delivery Pipe With Fuel Injector Assy

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2. Remove the delivery pipe spacer No. 1 from the cylinder head.

Fig 33: Removing Delivery Pipe Spacer No. 1 From Cylinder Head

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1. Remove the fuel injector assembly from the fuel delivery pipe.

Fig 34: Removing Fuel Injector Assy From Fuel Delivery Pipe

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Fig 35: Rotating Crankshaft Counter Clockwise By 40° From TDC/Compression

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1. Remove the camshaft bearing caps No. 1 and No. 2 in the sequence shown in the illustration, then remove the camshaft No. 2.

Fig 36: Removing Camshaft Bearing Caps No. 1 & No. 2 Then Remove Camshaft No. 2

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1. Clamp the camshaft in a vise (using an aluminum protector).
2. Remove the bolt and camshaft timing gear.

Fig 37: Removing Bolt & Camshaft Timing Gear

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1. Remove the camshaft bearing caps No. 2 in the sequence shown in the illustration, then remove the camshaft.

1. Check the lock of the camshaft timing gear.
   1. Clamp the hexagonal lobe of the camshaft in a vise (using an aluminum protector).
   2. Check that the camshaft timing gear is locked.
   Fig 38: Removing Camshaft Bearing Caps No. 2 Then Remove Camshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the camshaft.
2. Release the lock pin.
   1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

      HINT:

      One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the 2 oil paths for each groove with rubber pieces before wrapping the cam journal with the tape.

   2. Punctuate the tape which covers the advance side path and retard side path on the opposite side.
      Fig 39: Covering 4 Oil Paths Of Cam Journal With Vinyl/Tape

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   3. Apply approximately 150 kPa (1.5 kgf/cm² ) of air pressure into the 2 punctuated paths (the advance side path and retard side path).
      NOTE: When applying air pressure, cover the paths with a shop rag to prevent oil splash.
      Fig 40: Applying Approximately 150 kPa Of Air Pressure Into 2 Punctuated Paths

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Confirm that the camshaft timing gear assembly revolves in the advance direction when reducing the air pressure of the retard side path.

      HINT:

      The lock pin is released and the camshaft timing gear revolves in the advance direction.

   5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure of the retard side path, then release the air pressure of the advance side path.
   Fig 41: Confirming Camshaft Timing Gear Assy Revolves In Advance Direction

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: If the air pressure of the advance side path is released first, the camshaft timing gear assembly occasionally shifts in the retard direction abruptly, which may damage the lock pin. Be sure to release the air pressure of the retard side path first.
3. Check the smooth revolution.
   1. Let the camshaft timing gear assembly rotate by 2 or 3 revolutions in the movable range (22.5°) except the most retarded position. Check that it rotates smoothly.
   NOTE: Do the check by hand, and do not use air pressure.
4. Check the lock at the most retarded position.
   1. Confirm that the camshaft timing gear assembly is locked at the most retarded position (at the end of the movable range).

1. Turn the camshaft timing gear assembly at the most advanced position.
2. Remove the bolt and camshaft timing gear assembly.

Fig 42: Removing Bolt & Camshaft Timing Gear Assy

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1. Using several steps, loosen the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Then remove the 10 bolts and 10 washers.

Fig 43: Removing Cylinder Head Sub-Assy

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

Fig 44: Removing Oil Filter Union

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1. Remove the oil pan drain plug and gasket.
2. Remove the 9 bolts and 2 nuts.
   Fig 45: Removing Oil Pan Drain Plug, Gasket, 9 Bolts & 2 Nuts

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3. Insert the blade of SST between the oil pan and oil pan No.2, and cut off the applied sealer and remove the oil pan No.2.
   1. SST 09032-00100

Fig 46: Cutting Off Applied Sealer & Removing Oil Pan No. 2

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1. Remove the bolt and 2 nuts, then remove the oil strainer and gasket.

Fig 47: Removing Oil Strainer & Gasket

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1. Remove the 13 bolts.
   Fig 48: Removing Oil Pan Sub-Assy

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2. Using a screwdriver with its tip wrapped in tape, remove the oil pan by prying out between the cylinder block and oil pan as illustrated.
   NOTE: Do not forcibly pry out between the cylinder block and oil pan.
   Fig 49: Removing Oil Pan By Prying Out Between Cylinder Block & Oil Pan

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3. Remove the 2 O-rings from the cylinder block.
   Fig 50: Removing 2 O-Rings From Cylinder Block

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4. Using a Torx socket wrench E5, remove the 4 stud bolts.

Fig 51: Removing 4 Stud Bolts

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1. Remove the engine rear oil seal.

Fig 52: Removing Engine Rear Oil Seal

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1. Using a spring scale, measure the length of the timing chain when it was pulled with 140 N (14.3 kgf, 31 lb).
   1. Maximum chain length: 124.2 mm (4.890 in.) 

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

HINT:

Measure the length at least at 3 places to obtain the average length.

Fig 53: Inspecting Chain Sub-Assy

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1. Check that the plunger moves smoothly when the cam is raised with your finger.
2. Release the cam. Check that the plunger is locked by the cam and does not move when it is pushed by your finger.

Fig 54: Inspecting Chain Tensioner Assy. No. 1

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1. Wrap the chain around the timing gear.
2. Using vernier calipers, measure the diameter of the timing gear with the chain wrapped.
   1. Minimum gear diameter (w/ chain): 96.2 mm (3.787 in.) 

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

Fig 55: Inspecting Camshaft Timing Gear Assy

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

   Minimum gear diameter (w/ chain): 96.2 mm (3.787 in.) 

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

Fig 56: Inspecting Camshaft Timing Gear Or Sprocket

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1. Using vernier calipers, measure the thickness of the chain tensioner slipper.

   Maximum wear: 1.0 mm (0.039 in.) 

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

Fig 57: Inspecting Chain Tensioner Slipper

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1. Using vernier calipers, measure the thickness of the chain vibration damper.

   Maximum wear: 1.0 mm (0.039 in.) 

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

Fig 58: Inspecting Chain Vibration Damper No. 1

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1. Using vernier calipers, measure the length of the head bolts from the seating to the end.
   1. Standard bolt length: 
   2. 142.8 to 144.2 mm (5.622 to 5.677 in.) 
   3. Maximum bolt length: 147.1 mm (5.791 in.) 

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

Fig 59: Inspecting Cylinder Head Set Bolt

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1. Using a Torx socket wrench E5, install the 4 stud bolts.
   1. Torque: 5.0 N.m (51 kgf.cm, 44 in. lbf) 
   Fig 60: Using Torx Socked Wrench E5 Install 4 Stud Bolts

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2. Apply a continuous bead of seal packing (Diameter 2.0 to 3.0 mm (0.079 to 0.118 in.)) to the oil pan as illustrated.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes, and tighten the bolts within 15 minutes after applying seal packing.
   • Do not expose the seal packing to engine oil within 2 hours of installation.
   Fig 61: Applying Continuous Bead Of Seal Packaging To Oil Pan

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install 2 new O-rings to the cylinder block, then install the oil pan.
   NOTE:

   • Clean the contact surface of the new O-rings.
   • Be careful that the O-rings are not jammed when installing the oil pan.
   Fig 62: Installing 2 New O-Rings To Cylinder Block

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4. Using several steps, temporarily tighten the 13 bolts in the sequence shown in the illustration, then tighten the bolts with the specified torque.
   1. Torque: 24 N.m (245 kgf.cm, 18 ft.lbf) 

HINT:

The bolt length is as follows.

Bolt A 46 mm (1.81 in.)

Bolt B 85 mm (3.35 in.)

Bolt C 140.7 mm (5.54 in.)

Fig 63: Tightening 13 Bolts

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1. Apply a light coat of multipurpose grease No. 2 to the lip of a new oil seal.
   NOTE: Keep the lip free of foreign objects.
2. Using SST, uniformly tap in the oil seal until its surface is flush with the cylinder block edge.
   1. SST 09223-56010

Fig 64: Tapping In Oil Seal Until Its Surface Flush With Cylinder Block Edge

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1. Install a new gasket, then install the oil strainer with the bolt and 2 nuts.
   1. Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

Fig 65: Installing Oil Strainer Sub-Assy

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1. Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan as illustrated.

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes, and tighten the bolts within 15 minutes after applying seal packing.
   • Do not expose the seal packing to engine oil within 2 hours of installation.
   Fig 66: Applying Continuous Bead Of Seal Packing To Oil Pan

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil pan No. 2 with the 9 bolts and 2 nuts.
   1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 
3. Install a new gasket and oil pan drain plug.
   1. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 

Fig 67: Installing Oil Pan No.2

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1. Using a 12 mm socket hexagon wrench, install the oil filter union.
   1. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) 

Fig 68: Installing Oil Filter Union

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1. Clean the oil filter installation surface of the engine.
2. Apply a light coat of engine oil to the O-ring of a new oil filter.
3. Install the O-ring by hand until it contacts the seat.
4. Using SST, tighten it by an additional 3/4 turn.
   1. SST 09228-06501

Fig 69: Installing Oil Filter Sub-Assy

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

   Seal packing: Part No. 08826-00080 or equivalent 

Fig 70: Placing New Head Gasket On Cylinder Block With Lot No. Facing Upward

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HINT:

The cylinder head bolts are tightened in 2 successive steps.

1. Install the cylinder head to the cylinder block.
   NOTE: Do not damage the cylinder head gasket at the bottom of the cylinder head.
2. Apply a light coat of engine oil to the threads and seating of the cylinder head bolts.
3. Using several steps, temporarily install the cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration, then tighten the bolts with the specified torque.
   1. Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) 
   Fig 71: Installing Cylinder Head Bolts

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4. Mark the front of the cylinder head bolts with paint.
5. Retighten the bolts by additional 90° in the same sequence as step (c), then retighten them by one more additional 90°.
6. Check that each paint mark is now at the 180° angle to the front.

Fig 72: Retightening Bolts By Additional 90° Then Retighten Them By One More Additional 90°

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1. Put the camshaft timing gear assembly and camshaft together with the straight pin off the groove as illustrated.
2. Turn the camshaft timing gear assembly in the direction shown (to the left) while pushing it lightly into the camshaft. Push further at the position where the pin fits into the groove.
   Fig 73: Installing Camshaft Timing Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Do not turn the camshaft timing gear to the retard direction (to the right).
3. Check that there is no clearance between the camshaft timing gear assembly and fringe.
4. Tighten the bolt with the camshaft timing gear fixed.
   1. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 
   NOTE: If the camshaft timing gear is locked at the most retarded position, unlock the lock pin inside the timing gear, then tighten the bolts.
5. Check that the camshaft timing gear moves to the retard direction (to the right) and it is locked at the most retarded position.

1. Turn the crankshaft by 40° counterclockwise from the TDC/compression.
   Fig 74: Turning Crankshaft By 40° Counter Clockwise From TDC/Compression

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2. Apply engine oil to the cam and cylinder head journal.
3. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
4. Check the front marks and numbers on the bearing cap No. 2, then tighten the bolts uniformly in several steps in the sequence shown in the illustration.
   1. Torque: 13 N.m (130 kgf.cm, 9.6 ft.lbf) 

Fig 75: Checking Front Marks & Numbers On Bearing Cap No. 2 Then Tighten Bolts Uniformly In Several Steps

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1. Clamp the hexagonal lobe of the camshaft in a vise (using an aluminum protector).
2. Align the knock pin of the camshaft No. 2 and the pin groove of the camshaft timing gear, then install the camshaft timing gear with the bolt.
   1. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 

Fig 76: Installing Camshaft Timing Gear Or Sprocket

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1. Apply engine oil to the cam and cylinder head journal.
2. Place the camshaft No. 2 on the cylinder head with the timing mark on the camshaft timing gear facing upward.
3. Check the front marks and numbers on the bearing cap No. 2, then tighten the bolts uniformly in several steps in the sequence shown in the illustration.

   Torque: 13 N.m (130 kgf.cm, 9.6 ft.lbf) 

   Fig 77: Placing Camshaft No.2 On Cylinder Head With Timing Mark On Camshaft Timing Gear Facing Upward

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Tighten the bolts uniformly keeping the camshaft level.
4. Install the camshaft bearing cap No. 1.
   1. Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) 

1. Check that the timing marks are located as illustrated.
   Fig 78: Checking Timing Marks Locates

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2. Install the chain so the timing mark and the mark plate of the chain are aligned.

   HINT:

   • The camshaft side Orange
   • The crankshaft side Yellow
   Fig 79: Installing Chain So Timing Mark & Mark Plate Of Chain Aligned

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. To prevent misalignment of the mark plate and timing mark, tie the chain around the crankshaft timing sprocket with a string.

   HINT:

   Tie the chain to prevent misalignment of the timing marks.

   Fig 80: Preventing Misalignment Of Mark Plate & Timing Mark, Tie Chain Around Crankshaft Timing Sprocket With String

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the chain vibration damper with the 2 bolts.
   1. Torque: 9.0 N.m (92 kgf.cm, 80 in. lbf) 
   Fig 81: Installing Chain Vibration Damper With 2 Bolts

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5. Remove the string, then install the chain tensioner stopper.
   Fig 82: Installing Chain Tensioner Stopper

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6. Install the chain tensioner.
   1. Lift up the stopper plate, then unlock the plunger.
   2. Push in the plunger to the end with the plunger unlocked.
      Fig 83: Pushing Plunger To End With Plunger Unlocked

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   3. Lift down the stopper plate with the plunger pushed to the end, then lock the plunger.
      Fig 84: Lifting Down Stopper Plate With Plunger Pushed To End Then Lock Plunger

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked.

      HINT:

      If the stopper plate is not completely lifted down and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. The stopper plate will be completely lifted down and a 3.0 mm (0.118 in.) diameter bar can be inserted easily.

      Fig 85: Inserting 3.0 mm Diameter Bar Into Hole Of Stopper Plate With Plunger Locked

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Install the chain tensioner with the 2 bolts.
      1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 
   6. Remove the 3.0 mm (0.118 in.) diameter bar from the chain tensioner.
   Fig 86: Installing Chain Tensioner With 2 Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, uniformly tap in a new oil seal until its surface is flush with the oil pump edge.
   1. SST 09950-60010 (09951-00250, 09951-00380, 09952-06010), 09950-70010 (09951-07100)
   NOTE: Be careful not to tap the oil seal at an angle.
   Fig 87: Tapping New Old Seal Until Its Surface Flush With Oil Pump Edge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of multipurpose grease No. 2 to the lip of the new oil seal.

1. Install 2 new O-rings to the 2 locations as shown in the illustration.
2. Apply seal packing to the engine body and oil pump as shown in the illustration below.
   1. Seal packing: 
   2. Water pump part No. 08826-00100 or equivalent Other part No. 08826-00080 or equivalent 
   Fig 88: Installing 2 New O-Rings To 2 Locations

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes, and tighten the bolts within 15 minutes after applying seal packing.
   • Do not expose the seal packing to engine oil within 2 hours of installation.
   Fig 89: Applying Seal Packing To Engine Body & Oil Pump

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the keyway of the oil pump drive rotor with the rectangular portion of the crankshaft, then slide the oil pump assembly into place.
   Fig 90: Align Key Way Of Oil Pump Drive Rotor With Rectangular Portion Of Crankshaft

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4. Install the oil pump assembly with the 15 bolts and nut as illustrated.
   1. Torque: 
   2. 32 N.m (326 kgf.cm, 24 ft.lbf) for Bolt A 
   3. 11 N.m (112 kgf.cm, 8.1 ft.lbf) for Bolt B 
   4. 11 N.m (112 kgf.cm, 8.1 ft.lbf) for Bolt C 
   5. 24 N.m (245 kgf.cm, 18 ft.lbf) for Nut D 
   6. 24 N.m (245 kgf.cm, 18 ft.lbf) for Bolt E 
   Fig 91: Installing Oil Pump Assy With 15 Bolts & Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

The bolt length is as follows.

Bolt A 30 mm (1.18 in.)

Bolt B 35 mm (1.38 in.)

Bolt C 20 mm (0.79 in.)

Bolt E 20 and 14 mm (0.79 and 0.55 in.) double ended bolt

1. Install the crankshaft straight pin to the crankshaft.
2. Align the hole of the crankshaft damper with the straight pin, then install the crankshaft damper.
   Fig 92: Install Crank Shaft Straight Pin To Crank Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, hold the crankshaft damper and tighten the crankshaft bolt.
   1. SST 09213-58013 (91111-50845), 09330-00021
   1. Torque: 128 N.m (1305 kgf.cm, 95 ft.lbf) 

Fig 93: Holding Crank Shaft Damper & Tighten Crankshaft Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket, then install the water pump assembly with the 3 bolts and 2 nuts.
   1. Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

Fig 94: Installing Water Pump Assy

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1. Torque: 55 N.m (561 kgf.cm, 41 ft.lbf) 

Fig 95: Installing Transverse Engine Mounting Bracket

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1. Set the No. 1 cylinder to the TDC/compression.
   1. Turn the crankshaft damper clockwise, then align its timing mark notch with the timing mark "0" of the chain cover.
   2. Check that the timing marks of the camshaft timing gear are located as illustrated.

   HINT:

   If not, turn the crankshaft to align the marks.

   Fig 96: Checking Camshaft Timing Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the valves indicated in the illustration.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
      1. Valve clearance (Cold): 
      2. Intake 0.17 to 0.23 mm (0.007 to 0.009 in.) 
      3. Exhaust 0.27 to 0.33 mm (0.011 to 0.013 in.) 

   HINT:

   If the clearance is not as specified, record the out-of-specification measurement, then adjust the valve clearance.

3. Turn the crankshaft clockwise by 1 complete revolution (360°) and set the No. 4 cylinder to the TDC/compression.
   Fig 97: Measuring Clearance Between Value Lifter & Camshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the valves indicated in the illustration.
   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
      1. Valve clearance (Cold): 
      2. Intake 0.17 to 0.23 mm (0.007 to 0.009 in.) 
      3. Exhaust 0.27 to 0.33 mm (0.011 to 0.013 in.) 

HINT: 

If the clearance is not as specified, record the out-of-specification measurement, then adjust the valve clearance.

Fig 98: Measuring Clearance Between Value Lighter & Camshaft

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the No. 1 cylinder to the TDC/compression.
   1. Turn the crankshaft damper clockwise, then align its timing mark notch with the timing mark "0".
   2. Check that the timing marks of the camshaft timing gear are located as illustrated.

      HINT:

      If not, turn the crankshaft to align the marks.

      Fig 99: Turning Crankshaft Damper Clockwise Then Align Its Timing Mark Notch With Timing Mark 0

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Put the paint marks on the timing chain plates which align with timing marks of the camshaft timing gear.
   Fig 100: Put Paint Marks On Timing Chain Plates Which Align With Timing Marks Of Camshaft Timing Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using 8 mm socket hexagon wrench, remove the service hole screw plug.
   Fig 101: Removing Service Hole Screw Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate of the chain tensioner upward.

   HINT:

   Lifting up the stopper plate of the chain tensioner unlocks the plunger.

   Fig 102: Insert Screwdriver Into Service Hole Of Chain Tensioner To Hold Stopper Plate Of Chain Tensioner Upward

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Keeping the stopper plate of the chain tensioner lifted, slightly rotate the hexagonal lobe of the camshaft No. 2 to the right with an adjustable wrench so the plunger of the chain tensioner is pushed.

   HINT:

   When the camshaft No. 2 is slightly rotated to the right, the plunger is pushed.

   Fig 103: Keeping Stopper Plate Of Chain Tensioner Lifted, Slightly Rotate Hexagonal Lobe Of Camshaft No. 2 To Right With An Adjustable Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Keeping the adjustable wrench installed, remove the screwdriver with the plunger pushed.
   NOTE: Do not move the adjustable wrench.

   HINT:

   Removing the screwdriver lifts down the stopper plate and locks the plunger.

   Fig 104: Keeping Adjustable Wrench Installed, Remove Screwdriver With Plunger Pushed

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the stopper plate of the chain tensioner lifted down and locked.

   HINT:

   If a 3.0 mm (0.118 in.) diameter bar cannot be inserted into the hole of the stopper plate, rotate the camshaft No. 2 slightly to the left and right. Then a 3.0 mm (0.118 in.) diameter bar can be inserted easily.

7. Secure the 3.0 mm (0.118 in.) diameter bar with tape.
   Fig 105: Inserting 3.0 mm Diameter Bar Into Hole Of Stopper Plate With Stopper Plate Of Chain Tensioner Lifted Down & Locked

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Hold the hexagonal lobe of the camshaft No. 2 with the adjustable wrench.
9. Using SST, loosen the bolt.
   1. SST 09023-38400
   Fig 106: Loosening Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Remove the camshaft bearing caps No. 1 and No. 2 in the sequence shown in the illustration.
    NOTE: Uniformly loosen the bolts keeping the camshaft No. 2 level.
    Fig 107: Removing Camshaft Bearing Caps No. 1 And No. 2

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Remove the bolt when the camshaft No. 2 is lifted slightly, then remove the camshaft No. 2 and camshaft timing gear.
    Fig 108: Removing Bolt When Camshaft No. 2 Is Lifted Slightly

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Remove the camshaft bearing caps No. 2 in the sequence shown in the illustration.
    NOTE: Uniformly loosen the bolts keeping the camshaft level.
    Fig 109: Removing Camshaft Bearing Caps No. 2

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Hold the timing chain by hand, then remove the camshaft.
    Fig 110: Holding Timing Chain By Hand Then Remove Camshaft

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Tie the timing chain with a string or wire.
    NOTE: Prevent foreign object from getting into the engine compartment with a shop rag.
    Fig 111: Tying Timing Chain With String Or Wire

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Using a micrometer, measure the thickness of the removed valve lifter.
16. Calculate the thickness of the valve lifter so that the valve clearance comes within the specified value.
    SPECIFIED VALUE
    
    

    Calculation Value	Measurement
    A	Thickness of new lifter
    B	Thickness of used lifter
    C	Measured valve clearance

    1. Specified value (Cold): 
    2. Intake A = B + (C - 0.20 mm (0.008 in.)) 
    3. Exhaust A = B + (C - 0.30 mm (0.012 in.)) 
    Fig 112: Measuring Thickness Of Removed Value Lifter

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Select a new lifter with a thickness as close to the calculated values as possible.

    EXAMPLE (Intake):

    Measured valve clearance = 0.40 mm (0.0158 in.)

    0.40 mm (0.0158 in.) - 0.20 mm (0.0079 in.) = 0.20 mm (0.0079 in.)

    (Measured - Specification = Excess clearance)

    Used lifter measurement = 5.25 mm (0.2067 in.)

    0.20 mm (0.0079 in.) + 5.25 mm (0.2067 in.) = 5.45 mm (0.2146 in.)

    (Excess clearance + Used lifter = Ideal new lifter)

    Closest new lifter = 5.45 mm (0.2146 in.)

    Select No. 46 lifter (5.46 mm (0.2150 in.))

    HINT:

    • The 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.)
    • Refer to the New Lifter Thickness table on the next 2 pages.
    Fig 113: Valve Lifter Selection Chart (Intake)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 114: Valve Lifter Selection Chart (Exhaust)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. Install the selected valve lifter.
19. Apply engine oil to the cam and cylinder head journal.
20. Hold the chain as illustrated, then install the camshaft and camshaft timing gear assembly so that the pain mark of the chain and the timing mark of the camshaft timing gear assembly are aligned.
    Fig 115: Installing Camshaft & Camshaft Timing Gear Assembly So That Paint Mark Of Chain & Timing Mark Of Camshaft Timing Gear Assembly Are Aligned

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. Check the front marks and numbers on the bearing cap No. 2, then tighten the bolts uniformly in several steps in the sequence shown in the illustration.
    1. Torque: 13 N.m (130 kgf.cm, 9.6 ft.lbf) 
    NOTE: Tighten the bolts uniformly keeping the camshaft level.
    Fig 116: Tightening Bolts Uniformly In Several Steps

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. Hold the chain as illustrated, then install the camshaft No. 2 and camshaft timing gear so that the pain mark of the chain and the timing mark of the camshaft timing gear are aligned.
23. Align the knock pin of the camshaft No. 2 with the pin groove of the camshaft timing gear.
    Fig 117: Aligning Knock Pin Of Camshaft No. 2 With Pin Groove Of Camshaft Timing Gear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. Temporarily tighten the camshaft timing chain with the bolt.
    Fig 118: Tightening Camshaft Timing Chain With Bolt

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. Check the front marks and numbers on the bearing caps No. 1 and No. 2, then tighten the bolts uniformly in several steps in the sequence shown in the illustration.
    1. Torque: 
    2. 23 N.m (235 kgf.cm, 17 ft.lbf) for Bearing Cap No. 1 
    3. 13 N.m (130 kgf.cm, 9.6 ft.lbf) for Bearing Cap No. 2 
    NOTE: Tighten the bolts uniformly keeping the camshaft level.
    Fig 119: Checking Front Marks & Numbers On Bearing Caps No.1 & No.2

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. Hold the hexagonal lobe of the camshaft No. 2 with the adjustable wrench.
27. Using SST, tighten the bolt.
    1. SST 09023-38400
    2. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 
    Fig 120: Holding Hexagonal Lobe Of Camshaft No.2 With Adjustable Wrench

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. Remove the 3.0 mm (0.118 in.) diameter bar from the chain tensioner.
    Fig 121: Removing 3.0 mm Diameter Bar From Chain Tensioner

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. Turn the crankshaft damper clockwise, then align its timing mark notch with the timing mark "0".
30. Check that the timing marks are located as illustrated.
    Fig 122: Turning Crankshaft Damper Clockwise, Then Align Its Timing Mark Notch With Timing Mark 0

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. Apply adhesive to 2 or 3 threads of the service hole screw plug bolt end.

    Adhesive: 

    Part No. 08833-00070, THREE BOND 1324, or equivalent 

    NOTE: Remove any oil from the bolts and bolt holes.
32. Using an 8 mm socket hexagon wrench, install the service hole screw plug.
    1. Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

Fig 123: Applying Adhesive To 2 Or 3 Threads Of Service Hole Screw Plug Bolt End

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring to the fuel injector.
2. Apply gasoline to the O-ring.
   Fig 124: Installing New O-Ring To Fuel Injector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. While turning the fuel injector clockwise and counterclockwise, push it to the fuel delivery pipe.

Fig 125: Turning Fuel Injector Clockwise & Counter Clockwise Push It To Fuel Delivery Pipe

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 4 new insulators to the cylinder head.
2. Install the 2 delivery pipe spacers to the cylinder head.
   Fig 126: Installing 4 New Insulators & 2 Delivery Pipe Spacers To Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the delivery pipe together with the injectors using the 3 bolts.
   1. Torque: 
   2. 19 N.m (194 kgf.cm, 14 ft.lbf) for Bolt A 
   3. 9.0 N in (92 kgf.cm, 80 in.lbf) for Bolt B 
   NOTE:

   • Do not drop the fuel injectors.
   • After installing the delivery pipe, check that it is installed securely by turning the fuel injectors.
   Fig 127: Installing Delivery Pipe Together With Injectors Using 3 Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the cylinder head gasket to the cylinder head cover.
2. Apply seal packing to the 2 locations as shown in the illustration, then install the cylinder head cover.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   Fig 128: Applying Seal Packing To 2 Locations

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily tighten the 9 bolts and 2 nuts on the cylinder head cover.
4. Using several steps, tighten the bolts and nuts with the specified torque in the sequence shown in the illustration.
   1. Torque: 10 N.m (102 kgf.cm, 7.4 ft.lbf) 

Fig 129: Tightening 9 Bolts & 2 Nuts On Cylinder Head Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) 

Fig 130: Installing Ventilation Valve Sub-Assy

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

1. Temporarily install the water pump pulley with the 3 bolts.
2. Using SST, secure the water pump pulley.
   1. SST 09960-10010 (09962-01000, 09963-00600)
3. Tighten the 3 bolts with the specified torque.
   1. Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

Fig 132: Installing Water Pump Pulley

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1. Apply a light coat of engine oil to the O-ring.
   NOTE: If the O-ring is damaged, replace the crank position sensor.
2. Install the crank position sensor with the bolt.
   1. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

Fig 133: Installing Crank Position Sensor

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1. Install a new gasket to the thermostat.
2. Install the thermostat with the jiggle valve facing upward.

   HINT:

3. The jiggle valve may be set within 10Ω at either side as illustrated.
   Fig 134: Installing Thermostat With Valve Facing Upward

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the water inlet with the 2 nuts.
   1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

Fig 135: Installing Water Inlet With 2 Nuts

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1. Apply a light coat of engine oil to the O-ring.
2. Install the camshaft timing oil control valve assembly with the bolt.
   1. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

Fig 136: Installing Camshaft Timing Oil Control Valve Assy

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1. Apply a light coat of engine oil to the O-ring.
   NOTE: If the O-ring is damaged, replace the camshaft position sensor.
2. Install the camshaft position sensor with the bolt.
   1. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

Fig 137: Installing Cam Position Sensor

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1. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

Fig 138: Installing Spark Plugs

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