RM38T0EC _51 Engine / Hybrid System _144958 M20F-FXS, M20G-FXS ENGINE MECHANICAL _0604254 ENGINE UNIT A

M20F-FXS, M20G-FXS ENGINE MECHANICAL  ENGINE UNIT  REASSEMBLY  


CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)
A464676N08
0.667,0.427 1.625,0.594 0.958,0.167 3.354,5.302 4.292,5.469 0.938,0.167 0.375,0.917 0.5,0.5 0.5,0.5 0.656,0.5 false 2.667,1.333 3.25,0.833 3.25,0.833 3.417,0.833 false 3.583,3.365 3.917,2.833 3.917,2.833 4.083,2.833 false 5.417,1.667 5.583,1.667 5.583,1.667 6.167,2.208 false 2.979,4.448 3.646,4.448 false 4.292,5.375 4.5,5.375 false 5.417,5.5 5.25,5.5 5.25,5.5 4.719,5.229 false 3.917,0.667 4.198,1.021 0.281,0.354 18 false 1 4.573,2.667 4.854,3.021 0.281,0.354 18 false 1 5.146,1.479 5.427,1.833 0.281,0.354 18 false 2 4.458,2.75 4.74,3.104 0.281,0.354 10 false ● 3.177,5.208 3.458,5.563 0.281,0.354 18 false 3 1.99,0.302 2.271,0.656 0.281,0.354 18 false 3 3.76,0.74 4.042,1.094 0.281,0.354 10 false ● 4.979,1.573 5.26,1.927 0.281,0.354 10 false ● 5.75,5.417 6.031,5.771 0.281,0.354 10 false ● 2.625,4.375 2.906,4.729 0.281,0.354 10 false ● 5.896,5.323 6.177,5.677 0.281,0.354 18 false 2 2.76,4.271 3.042,4.625 0.281,0.354 18 false 2 0.688,0.427 1.781,0.625 1.094,0.198 8 false 4.0 (41, 35 in.*lbf) 3.375,5.313 4.469,5.51 1.094,0.198 8 false 4.0 (41, 35 in.*lbf) 3.625,4.479 3.938,4.677 0.313,0.198 10 false x2 4.844,5.125 5.156,5.323 0.313,0.198 10 false x2 4.573,5.344 4.885,5.542 0.313,0.198 10 false x2 6.281,2.188 6.594,2.385 0.313,0.198 10 false x10 2.813,1.229 3.125,1.427 0.313,0.198 10 false x2 3.615,3.344 3.927,3.542 0.313,0.198 10 false x2

Procedure Part Name Code
Z101186

Z101188

Z101187

1 STRAIGHT PIN - (Click here) - -
2 RING PIN - (Click here) - -
3 STUD BOLT - (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

A549599N01
5.083,3.167 5.833,3.333 0.75,0.167 4.833,3.5 5.583,3.667 0.75,0.167 4.5,5.333 5.167,5.5 0.667,0.167 4.354,4.635 5.021,4.802 0.667,0.167 1.25,5.552 2.083,5.719 0.833,0.167 1.031,5.24 1.698,5.406 0.667,0.167 3.833,4 4.5,4.167 0.667,0.167 1.833,3.25 2.667,3.417 0.833,0.167 1.792,3.208 2.708,3.458 0.917,0.25 1.458,2.938 2.292,3.104 0.833,0.167 1.417,2.896 2.333,3.146 0.917,0.25 1.167,2.167 1.917,2.333 0.75,0.167 3.396,3.229 4.063,3.396 0.667,0.167 1.531,1.25 1.708,1.25 1.708,1.25 1.927,1.563 false 3,4.167 3.167,4.167 3.167,4.167 3.531,4.417 false 4.99,3.948 5.167,4.167 5.167,4.167 5.333,4.167 false 4.698,1.802 4.833,1.615 4.833,1.615 5.01,1.615 false 1.917,2.25 2.083,2.25 2.083,2.25 2.333,2.156 false 2,2.5 2.167,2.5 2.167,2.5 2.479,2.208 false 2.833,4.583 3,4.583 3,4.583 3.25,4.531 false 3.406,5.604 3.625,5.604 false 5.313,0.521 5.5,0.333 5.5,0.333 5.667,0.333 false 4.25,3.479 4.667,3.583 4.667,3.583 4.833,3.583 false 2.5,5 2.667,5 2.667,5 2.927,5.135 false 2.094,5.625 2.24,5.625 2.24,5.625 3.333,5.771 false 1.698,5.333 1.844,5.333 1.844,5.333 3.125,5.531 false 2.667,3.333 2.833,3.333 2.833,3.333 3.135,2.865 false 2.646,3.688 2.979,3.688 false 2.292,3.021 2.625,3.021 false 3.708,3.229 3.708,3.021 false 5.229,3.833 5.563,3.833 false 4.021,4.719 4.354,4.719 false 3.5,4.083 3.833,4.083 false 4.167,5.417 4.5,5.417 false 4.75,3.25 5.083,3.25 false 1.198,1.083 1.75,1.438 0.552,0.354 18 false 14 1.083,2.833 1.635,3.188 0.552,0.354 18 false 12 1.458,3.198 2.01,3.552 0.552,0.354 18 false 11 0.917,5.469 1.354,5.75 0.438,0.281 18 false 10 2.313,4.833 2.75,5.115 0.438,0.281 18 false 9 2.781,4.031 3.219,4.313 0.438,0.281 18 false 8 5.417,4.052 5.854,4.333 0.438,0.281 18 false 7 2.458,3.51 2.896,3.792 0.438,0.281 18 false 5 5.25,1.479 5.688,1.76 0.438,0.281 18 false 6 0.99,2.052 1.427,2.333 0.438,0.281 18 false 4 1.865,2.385 2.417,2.74 0.552,0.354 10 false ● 2.719,4.479 3.271,4.833 0.552,0.354 10 false ● 3.708,5.5 4.083,5.76 0.375,0.26 10 false ● 4.708,3.25 5.083,3.51 0.375,0.26 10 false x2 4.198,3.49 4.573,3.75 0.375,0.26 10 false x3 3.781,2.906 4.156,3.167 0.375,0.26 10 false x2 3.5,4.073 3.875,4.333 0.375,0.26 10 false x3 4.125,5.427 4.5,5.688 0.375,0.26 10 false x2 3.083,5.563 3.458,5.823 0.375,0.26 10 false x10 6.031,0.177 6.583,0.531 0.552,0.354 18 false 13 5.917,0.229 6.469,0.583 0.552,0.354 10 false ● 5.135,3.167 6.073,3.365 0.938,0.198 8 false 43 (438, 32) 4.885,3.5 5.823,3.698 0.938,0.198 8 false 43 (438, 32) 4.552,5.333 5.49,5.531 0.938,0.198 8 false 10 (102, 7) 4.417,4.635 5.354,4.833 0.938,0.198 8 false 10 (102, 7) 1.281,5.542 2.219,5.74 0.938,0.198 8 false 40 (408, 30) 1.073,5.24 2.01,5.438 0.938,0.198 8 false 10 (102, 7) 3.865,4 4.802,4.198 0.938,0.198 8 false 24 (245, 18) 1.896,3.25 2.833,3.448 0.938,0.198 8 false 29.5 (301, 22) 1.49,2.927 2.427,3.125 0.938,0.198 8 false 17.5 (178, 13) 0.969,2.917 1.521,3.271 0.552,0.354 10 false ● 1.219,2.167 2.156,2.365 0.938,0.198 8 false 44 (449, 32) 3.427,3.24 4.365,3.438 0.938,0.198 8 false 43 (438, 32) 5.635,3.729 6.188,4.083 0.552,0.354 10 false ●

Procedure Part Name Code
Z101186

Z101188

Z101187

4 STRAIGHT SCREW PLUG - (Click here) - -
5 OIL PUMP ASSEMBLY 15100 - - -
6 STIFFENING CRANKCASE ASSEMBLY 11420 (Click here) - -
7 CRANKCASE CAP ASSEMBLY 15520B - - -
8 OIL STRAINER SUB-ASSEMBLY 15104 (Click here) - -
9 OIL PAN SUB-ASSEMBLY 12101 (Click here) - -
10 OIL PAN DRAIN PLUG 12101A - - -
11 OIL FILTER UNION 15600A (Click here) - -
12 OIL FILTER SUB-ASSEMBLY 15601 - - -
13 REAR ENGINE OIL SEAL 11401L (Click here) - -
14 CYLINDER BLOCK WATER JACKET SPACER 11445 - - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
V100135

MP grease ● Non-reusable part

A545645N02
2.688,0.031 3.354,0.198 0.667,0.167 2.333,2.5 3.167,2.667 0.833,0.167 1.49,2.75 1.823,2.917 0.333,0.167 1.448,2.708 1.865,2.958 0.417,0.25 1.333,3.25 1.667,3.417 0.333,0.167 1.292,3.208 1.708,3.458 0.417,0.25 2.167,5.083 2.833,5.25 0.667,0.167 4.406,0.365 5.24,0.531 0.833,0.167 4.823,0.583 5.656,0.75 0.833,0.167 3.5,0.438 3.802,0.438 false 4.917,2.688 5.229,2.688 false 5.146,4.115 5.438,4.115 false 2.135,1.104 3.74,1.104 false 2.375,1.573 2.375,1.104 false 2.635,1.375 2.635,1.104 false 3.021,1.333 3.021,1.104 false 3.427,1.229 3.427,1.115 false 2.281,2.052 2.479,2.052 false 4.51,1.938 4.76,1.938 false 4.802,3.094 5.125,3.094 false 4.719,3.313 4.865,3.563 4.865,3.563 5.052,3.563 false 5.021,4.656 5.25,4.656 false 4.844,3.271 5.604,3.344 5.604,3.344 5.792,3.344 false 3.354,0.125 3.656,0.125 false 3.167,2.583 3.333,2.583 3.333,2.583 3.635,2.458 false 1.823,2.823 1.99,2.823 1.99,2.823 2.333,2.958 false 1.667,3.333 2,3.333 false 1.854,5.021 1.854,4.688 false 4.073,0.448 4.406,0.448 false 4.49,0.667 4.823,0.667 false 3.156,0.281 3.708,0.635 0.552,0.354 18 false 25 5.51,2.5 6.063,2.854 0.552,0.354 18 false 24 1.792,0.99 2.344,1.344 0.552,0.354 18 false 23 5.052,1.74 5.604,2.094 0.552,0.354 18 false 22 1.958,1.896 2.51,2.25 0.552,0.354 18 false 21 5.396,2.896 5.948,3.25 0.552,0.354 18 false 20 5.313,3.438 5.865,3.792 0.552,0.354 18 false 19 6.01,3.167 6.563,3.521 0.552,0.354 18 false 18 1.833,5.063 2.385,5.417 0.552,0.354 18 false 17 5.573,4.49 6.125,4.844 0.552,0.354 18 false 15 5.479,4.552 6.031,4.906 0.552,0.354 10 false ● 4.125,0.615 4.677,0.969 0.552,0.354 10 false x9 4.563,0.74 5.115,1.094 0.552,0.354 10 false x14 3.75,0.042 4.302,0.396 0.552,0.354 10 false x2 3.74,2.385 4.292,2.74 0.552,0.354 10 false x3 2.448,3.135 3,3.49 0.552,0.354 10 false x6 2.531,3.542 3.083,3.896 0.552,0.354 10 false x6 2.125,3.365 2.677,3.719 0.552,0.354 10 false x4 4.417,3.229 4.969,3.583 0.552,0.354 10 false x16 4.823,3.292 5.375,3.646 0.552,0.354 10 false x16 4.417,3.031 4.969,3.385 0.552,0.354 10 false x16 5.656,3.948 6.208,4.302 0.552,0.354 18 false 16 2.708,0.031 3.646,0.271 0.938,0.24 8 false 10 (102, 7) 2.375,2.5 3.313,2.74 0.938,0.24 8 false 28.5 (291, 21) 1.531,2.74 1.938,2.958 0.406,0.219 10 false *T1 1.365,3.24 1.771,3.458 0.406,0.219 10 false *T1 2.188,5.083 3.125,5.323 0.938,0.24 8 false 44 (449, 32) 4.458,0.354 5.396,0.594 0.938,0.24 8 false 16 (163, 12) 4.865,0.583 5.802,0.823 0.938,0.24 8 false 28.5 (291, 21) 1.698,5.083 2.25,5.438 0.552,0.354 10 false ★

Procedure Part Name Code
Z101186

Z101188

Z101187

15 CYLINDER HEAD GASKET 11115 (Click here) - -
16 CYLINDER HEAD SUB-ASSEMBLY 11101 (Click here) - -
17 NO. 3 HEAD WITH STRAIGHT SCREW PLUG 11117G (Click here) - -
18 VALVE STEM CAP 13716 (Click here) - -
19 VALVE LASH ADJUSTER ASSEMBLY 13750 (Click here) - -
20 NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 13801 (Click here) - -
21 EXHAUST CAMSHAFT SUB-ASSEMBLY 13502B (Click here) - -
22 INTAKE CAMSHAFT SUB-ASSEMBLY 13501A (Click here) - -
23 CAMSHAFT BEARING CAP - (Click here) - -
24 CAMSHAFT HOUSING SUB-ASSEMBLY 11103 (Click here) - -
25 FUEL PUMP LIFTER GUIDE 23477 (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
● Non-reusable part
V100135

Adhesive 1324
★ Precoated part - -
*T1 1st: 50 (510, 37)
2nd: Turn 90°
3rd: Turn 90° 		- -

A535968N03
3.083,0.167 5,1.417 1.917,1.25 3.188,0.896 3.938,1.063 0.75,0.167 1.115,1.635 1.865,1.802 0.75,0.167 0.698,2.469 1.448,2.635 0.75,0.167 0.552,2.229 1.302,2.396 0.75,0.167 3.5,2.5 4.25,2.667 0.75,0.167 2.781,2.01 3.531,2.177 0.75,0.167 0.448,4.01 1.198,4.177 0.75,0.167 4.094,4.802 4.844,4.969 0.75,0.167 0.146,5 0.813,5.167 0.667,0.167 6.542,0.229 6.875,0.229 false 3.604,0.896 3.604,0.646 false 5,0.667 5.188,0.667 false 2.938,1.646 3.125,1.646 false 1.865,1.719 2.198,1.719 false 0.427,3.177 0.521,2.542 0.521,2.542 0.688,2.542 false 0.167,3.438 0.375,2.313 0.375,2.313 0.542,2.313 false 3.281,3.104 3.333,2.583 3.333,2.583 3.5,2.583 false 2.302,2.104 2.469,2.104 2.469,2.104 2.552,2.25 false 0.823,3.063 0.854,2.833 0.854,2.833 1.021,2.833 false 3.76,3.406 4.094,3.406 false 3.531,2.115 3.865,2.115 false 1.719,3.865 2.052,3.865 false 1.208,4.104 1.375,4.104 1.375,4.104 1.51,4.313 false 5.438,3.302 5.438,3.125 false 5.458,5.083 5.5,5.198 5.5,5.198 5.667,5.198 false 5.073,4.271 5.115,4.479 5.115,4.479 5.281,4.479 false 4.479,4.792 4.479,4.542 false 0.823,5.083 0.99,5.083 0.99,5.083 1.042,5.25 false 2.281,4.552 2.385,4.688 2.385,4.688 2.552,4.688 false 1.865,5.156 2.01,5.219 2.01,5.219 2.177,5.219 false 0.927,4.708 1.26,4.708 false 1.063,5.51 1.229,5.51 1.229,5.51 1.417,5.281 false 3.167,4.979 3.5,4.979 false 3.833,4.865 3.99,5.167 3.99,5.167 4.156,5.167 false 6.219,0.104 6.771,0.458 0.552,0.354 18 false 30 3.229,0.896 4.698,1.052 1.469,0.156 8 false 19 (194, 14) 3.677,0.594 3.917,0.75 0.24,0.156 10 false x3 5.479,0.5 6.031,0.854 0.552,0.354 18 false 29 3.354,1.479 3.906,1.833 0.552,0.354 18 false 35 1.167,1.635 2.635,1.792 1.469,0.156 8 false 86 (877, 63) 0.625,2.219 2.094,2.375 1.469,0.156 8 false 10 (102, 7) 0.781,2.469 2.25,2.625 1.469,0.156 8 false 10 (102, 7) 1.948,1.948 2.5,2.302 0.552,0.354 18 false 34 1.25,2.677 1.802,3.031 0.552,0.354 18 false 33 3.531,2.5 5,2.656 1.469,0.156 8 false 24 (245, 18) 3.958,2.094 4.198,2.25 0.24,0.156 10 false x9 4.125,3.24 4.677,3.594 0.552,0.354 18 false 31 3.281,3.188 3.521,3.344 0.24,0.156 10 false x2 2.823,2 4.292,2.156 1.469,0.156 8 false 27 (275, 20) 1.365,3.698 1.917,4.052 0.552,0.354 18 false 32 0.5,4.01 1.969,4.167 1.469,0.156 8 false 24 (245, 18) 5.313,3.281 5.865,3.635 0.552,0.354 18 false 27 5.521,4.313 6.073,4.667 0.552,0.354 18 false 28 5.896,5.01 6.448,5.365 0.552,0.354 18 false 26 4.135,4.792 5.604,4.948 1.469,0.156 8 false 27 (275, 20) 4.219,4.521 4.458,4.677 0.24,0.156 10 false x11 0.167,4.99 1.635,5.146 1.469,0.156 8 false 50 (510, 37) 2.438,5.083 2.99,5.438 0.552,0.354 18 false 36 2.625,4.615 2.938,4.844 0.313,0.229 10 false *1 5.552,4.979 5.792,5.135 0.24,0.156 10 false x2 0.75,4.625 1.063,4.854 0.313,0.229 10 false *2 0.896,5.427 1.208,5.656 0.313,0.229 10 false *3 2.99,4.896 3.302,5.125 0.313,0.229 10 false *4 4.198,5.094 4.51,5.323 0.313,0.229 10 false *5

Procedure Part Name Code
Z101186

Z101188

Z101187

26 CRANKSHAFT TIMING GEAR KEY 13471A (Click here) - -
27 OIL NOZZLE VALVE SUB-ASSEMBLY 15703A - - -
28 TIMING CHAIN COVER ASSEMBLY 11310 (Click here) - -
29 CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 13070A (Click here) - -
30 NO. 1 CYLINDER TO TDC (COMPRESSION) - (Click here) - -
31 NO. 1 CHAIN VIBRATION DAMPER 13561 - - -
32 CHAIN TENSIONER SLIPPER 13559 - - -
33 NO. 1 CHAIN TENSIONER ASSEMBLY 13540 (Click here) - -
34 CHAIN SUB-ASSEMBLY 13506 (Click here) - -
35 CAMSHAFT TIMING GEAR ASSEMBLY 13050 (Click here) - -
36 OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 13507A (Click here) - -

*1 CRANKSHAFT TIMING SPROCKET *2 OIL PUMP DRIVE SPROCKET
*3 OIL PUMP DRIVE SHAFT SPROCKET *4 CHAIN TENSIONER PLATE
*5 CHAIN DAMPER SPRING - -
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
V103638

Do not apply lubrications to the threaded parts

A535969N03
2.104,0.104 2.854,0.271 0.75,0.167 0.802,0.198 1.635,0.448 0.833,0.25 0.844,0.24 1.594,0.406 0.75,0.167 0.094,3.75 1,3.917 0.906,0.167 5.813,0.417 6.813,0.583 1,0.167 4.844,0.094 5.844,0.26 1,0.167 2.323,0.521 3.073,0.688 0.75,0.167 0.042,3.708 1.042,3.958 1,0.25 5.927,4.208 5.927,4.5 false 5.625,2.396 5.958,2.396 false 5.854,1.615 6.219,1.615 false 6.531,0.219 6.865,0.219 false 5.385,0.844 5.719,0.844 false 2.292,1.406 2.583,1 2.583,1 2.75,1 false 1.542,1.083 1.938,0.177 1.938,0.177 2.104,0.177 false 0.385,0.927 0.677,0.323 0.677,0.323 0.844,0.323 false 2.677,3.906 3.01,3.906 false 5.74,3.792 5.979,3.792 false 6.781,3.146 6.781,3.479 false 6.656,5.083 6.656,5.417 false 4.354,2.479 4.688,2.479 false 4.375,1.698 4.708,1.698 false 5.135,0.521 5.5,0.521 false 4.344,0.448 4.677,0.167 4.677,0.167 4.844,0.167 false 1.313,1.896 2.156,0.615 2.156,0.615 2.323,0.615 false 0.677,1.448 0.854,1.448 false 1.323,2.75 1.323,3.323 false 0.813,2.656 0.813,2.948 false 0.292,2.083 0.542,3.573 0.542,3.573 0.542,3.74 false 0.854,2.938 1.406,3.292 0.552,0.354 18 false 47 6.646,3.479 6.979,3.896 0.333,0.417 18 false 46 6.531,5.427 7,5.823 0.469,0.396 18 false 45 5.885,4.521 6.281,4.948 0.396,0.427 18 false 43 2.354,3.74 2.75,4.167 0.396,0.427 18 false 44 6.031,3.688 6.427,4.115 0.396,0.427 10 false ● 6.021,2.292 6.417,2.719 0.396,0.427 10 false ● 4.25,1.594 4.646,2.021 0.396,0.427 10 false ● 4.24,2.375 4.635,2.802 0.396,0.427 10 false ● 6.479,1.458 6.875,1.885 0.396,0.427 18 false 42 5.917,0.698 6.313,1.125 0.396,0.427 18 false 41 0.5,1.365 0.906,1.781 0.406,0.417 10 false *1 3.354,0.052 3.75,0.479 0.396,0.427 18 false 39 2.979,0.865 3.375,1.292 0.396,0.427 18 false 38 1.354,3.365 1.75,3.792 0.396,0.427 18 false 40 6.229,0.052 6.625,0.479 0.396,0.427 18 false 37 0.542,0.854 0.938,1.281 0.396,0.427 10 false x3 5.781,0.76 6.177,1.188 0.396,0.427 10 false ● 4.344,0.531 4.74,0.958 0.396,0.427 10 false x12 5.115,0.583 5.51,1.01 0.396,0.427 10 false x4 4.833,2.438 5.229,2.865 0.396,0.427 10 false x6 1.396,1.813 1.792,2.24 0.396,0.427 10 false x20 5.385,0.854 5.781,1.281 0.396,0.427 10 false x4 3.198,0.115 3.594,0.542 0.396,0.427 10 false ★ 2.188,0.115 3.656,0.271 1.469,0.156 8 false 40 (408, 30) 0.906,0.25 2.375,0.406 1.469,0.156 8 false 43 (438, 32) 1.24,3.396 1.635,3.823 0.396,0.427 10 false ● 0.146,3.76 1.615,3.917 1.469,0.156 8 false 260 (2651, 192) 5.531,0.417 5.927,0.844 0.396,0.427 10 false ● ★ 5.854,0.417 7.115,0.625 1.26,0.208 8 false 7.5 (76, 66 in.*lbf) 4.896,0.104 6.156,0.313 1.26,0.208 8 false 7.5 (76, 66 in.*lbf) 2.396,0.521 3.865,0.677 1.469,0.156 8 false 24 (245, 18)

Procedure Part Name Code
Z101186

Z101188

Z101187

37 NO. 1 CYLINDER TO TDC (COMPRESSION) - (Click here) - -
38 NO. 2 TIMING CHAIN COVER ASSEMBLY 11320B (Click here) - -
39 STRAIGHT SCREW PLUG - (Click here) - -
40 TIMING CHAIN COVER OIL SEAL 11301C (Click here) - -
41 SPARK PLUG TUBE GASKET 11193 - - -
42 CYLINDER HEAD COVER SUB-ASSEMBLY 11201 (Click here) - -
43 WATER BY-PASS OUTLET 16351 (Click here) - -
44 WATER OUTLET SUB-ASSEMBLY 16304 - - -
45 OUTLET HEATER WATER HOSE - - - -
46 INLET HEATER WATER HOSE - - - -
47 CRANKSHAFT PULLEY ASSEMBLY 13470 (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
● Non-reusable part ★ Precoated part

A535966N03
3.604,0.156 4.354,0.323 0.75,0.167 1.521,4.604 2.354,4.854 0.833,0.25 5.656,0.25 6.656,0.417 1,0.167 5.615,0.208 6.698,0.458 1.083,0.25 1,0.396 1.75,0.563 0.75,0.167 0.438,0.781 1.188,0.948 0.75,0.167 1.031,3.958 1.781,4.125 0.75,0.167 1.563,4.646 2.313,4.813 0.75,0.167 6.354,3.208 7.104,3.375 0.75,0.167 5.833,1.271 6.833,1.438 1,0.167 5.792,1.229 6.875,1.479 1.083,0.25 2.719,0.344 2.844,0.344 2.844,0.344 2.885,0.844 false 4.76,1.177 5.49,0.75 5.49,0.75 5.656,0.75 false 5.115,1.802 5.448,1.802 false 6.125,2.583 6.229,2.583 6.229,2.583 6.24,3.063 false 2.448,2.417 2.615,2.417 2.615,2.417 2.74,2.188 false 3.135,4.938 3.302,5.146 3.302,5.146 3.302,5.302 false 3.615,1.792 3.948,1.792 false 3.677,1.385 4.01,1.385 false 2.719,1.542 2.719,1.75 false 1.875,1.333 2.177,1.333 false 1.552,3.313 1.854,3.313 false 2.156,4.385 2.323,4.385 2.323,4.385 2.781,4.104 false 3.188,1.031 3.521,1.031 false 4.354,0.25 4.521,0.25 4.521,0.25 4.552,0.49 false 4.854,0.531 5.135,0.344 5.135,0.344 5.302,0.344 false 1.75,0.49 1.917,0.49 1.917,0.49 2.156,0.615 false 1.188,0.865 1.521,0.865 false 1.792,4.052 2.125,4.052 false 2.323,4.729 2.656,4.729 false 6.125,3.146 6.177,3.292 6.177,3.292 6.344,3.292 false 5.156,1.375 5.49,1.375 false 3.281,0.063 3.646,0.396 0.365,0.333 18 false 60 1.813,4.229 2.229,4.573 0.417,0.344 18 false 59 5.844,2.417 6.24,2.708 0.396,0.292 18 false 58 5.875,0.594 6.281,0.906 0.406,0.313 18 false 55 2.406,0.125 2.708,0.458 0.302,0.333 18 false 54 1.563,1.125 1.865,1.458 0.302,0.333 18 false 53 2.792,1.729 3.094,2.063 0.302,0.333 18 false 52 3.354,1.208 3.698,1.542 0.344,0.333 18 false 51 3.292,1.615 3.635,1.948 0.344,0.333 18 false 50 3.323,5.302 3.667,5.635 0.344,0.333 18 false 49 2.104,2.229 2.448,2.563 0.344,0.333 18 false 48 1.688,0.74 1.99,1.073 0.302,0.333 10 false x3 2.302,0.521 2.604,0.854 0.302,0.333 10 false x2 4.563,0.656 4.865,0.99 0.302,0.333 10 false x4 2.688,1.76 2.99,2.094 0.302,0.333 10 false ● 0.719,0.385 1.021,0.719 0.302,0.333 10 false ● ★ 3.563,0.938 3.865,1.271 0.302,0.333 10 false ● 5.698,1.604 6.094,1.896 0.396,0.292 18 false 56 1.25,3.115 1.646,3.406 0.396,0.292 18 false 57 5.688,2.417 5.896,2.646 0.208,0.229 10 false ★ 3.635,0.146 5.104,0.302 1.469,0.156 8 false 20 (204, 15) 5.344,0.24 5.646,0.573 0.302,0.333 10 false ● ★ 5.688,0.25 7.156,0.406 1.469,0.156 8 false 7.5 (76, 66 in.*lbf) 1.094,0.396 2.563,0.552 1.469,0.156 8 false 10 (102, 7) 0.5,0.781 1.969,0.938 1.469,0.156 8 false 21 (214, 15) 1.104,3.969 2.573,4.125 1.469,0.156 8 false 20 (204, 15) 1.667,4.656 3.135,4.813 1.469,0.156 8 false 10 (102, 7) 6.417,3.208 7.104,3.469 0.688,0.26 8 false 15 (153, 11) 5.531,1.271 5.833,1.604 0.302,0.333 10 false ● ★ 5.875,1.271 7.125,1.49 1.25,0.219 8 false 7.5 (76, 66 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

48 PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 12204C (Click here) - -
49 CRANKSHAFT POSITION SENSOR 11401G (Click here) - -
50 OIL FILLER CAP GASKET 12108A - - -
51 OIL FILLER CAP ASSEMBLY 12180E - - -
52 CAM TIMING CONTROL MOTOR O-RING 13090E - - -
53 CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 13090D (Click here) - -
54 CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 15370 (Click here) - -
55 CAMSHAFT POSITION SENSOR (for Exhaust Side) 11102A (Click here) - -
56 CAMSHAFT POSITION SENSOR (for Intake Side) 11102A (Click here) - -
57 OIL PRESSURE CONTROL VALVE ASSEMBLY 15250 (Click here) - -
58 OIL PRESSURE AND TEMPERATURE SENSOR 89448D (Click here) - -
59 KNOCK CONTROL SENSOR 89615 (Click here) - -
60 SPARK PLUG 19100P (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
● Non-reusable part ★ Precoated part

PROCEDURE

Hide 1.INSTALL STRAIGHT PIN

Z101186

NOTICE:

It is not necessary to remove the straight pins unless they are being replaced.



a.
A528748C03
2.865,2.927 3.177,3.083 0.313,0.156 10 false *a 5.573,2.917 5.885,3.073 0.313,0.156 10 false *a 1.917,0.115 2.063,0.292 0.146,0.177 10 false A 3.083,0.625 3.229,0.802 0.146,0.177 10 false A 4.167,1.208 4.313,1.385 0.146,0.177 10 false B 5.792,1.719 5.938,1.896 0.146,0.177 10 false B 2.125,2.688 2.271,2.865 0.146,0.177 10 false A 4.854,2.698 5,2.875 0.146,0.177 10 false B 0.458,0.135 0.74,0.49 0.281,0.354 18 false i
*a Protrusion Height - -


i.

Using a plastic hammer, tap in 4 new straight pins to the No. 2 timing chain cover assembly.

Standard Protrusion Height:
Straight Pin (A):

3.0 to 5.0 mm (0.118 to 0.197 in.)

Straight Pin (B):

5.0 to 7.0 mm (0.197 to 0.276 in.)




Hide 2.INSTALL RING PIN

Z101186

NOTICE:

It is not necessary to remove the ring pins unless they are being replaced.



a.
A545650C01
1.083,0.885 1.24,1.083 0.156,0.198 10 true A 1.583,0.698 1.729,0.854 0.146,0.156 10 true A 2.188,1.979 2.344,2.177 0.156,0.198 10 false A 2.51,1.469 2.667,1.667 0.156,0.198 10 false A 2.792,0.917 2.948,1.115 0.156,0.198 10 false B 2.802,1.708 2.958,1.906 0.156,0.198 10 false B 3.5,2.042 3.656,2.24 0.156,0.198 10 false B 3.854,2.042 4.01,2.24 0.156,0.198 10 false B 4.229,2.042 4.385,2.24 0.156,0.198 10 false B 4.917,1.406 5.073,1.604 0.156,0.198 10 false B 4.51,0.646 4.667,0.844 0.156,0.198 10 false B 3.521,0.656 3.677,0.854 0.156,0.198 10 false B 3.865,0.677 4.021,0.875 0.156,0.198 10 false B 4.219,0.667 4.375,0.865 0.156,0.198 10 false B 6.646,1.188 6.802,1.385 0.156,0.198 10 false *a 0.354,0.031 0.583,0.333 0.229,0.302 18 false i
*a Protrusion Height - -


i.

Using a plastic hammer, tap in 14 new ring pins to the stiffening crankcase assembly.

Standard Protrusion Height:
Ring Pin (A):

3.5 to 4.5 mm (0.138 to 0.177 in.)

Ring Pin (B):

3.2 to 4.3 mm (0.126 to 0.169 in.)




Hide 3.INSTALL STUD BOLT

Z101186

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.



a.
A482656C01
5.281,0.667 5.594,0.823 0.313,0.156 10 false *a 5.865,0.792 6.177,0.948 0.313,0.156 10 false *b 5.167,2.427 5.479,2.583 0.313,0.156 10 false *c 5.281,0.938 5.594,1.094 0.313,0.156 10 false *a 5.135,2.823 5.448,2.979 0.313,0.156 10 false *d 6.031,2.635 6.344,2.792 0.313,0.156 10 false *e 0.51,0.094 0.792,0.448 0.281,0.354 18 true i 0.625,1.917 0.906,2.271 0.281,0.354 18 true ii
*a 9 mm (0.354 in.) *b 19 mm (0.748 in.)
*c 21 mm (0.827 in.) *d 9 mm (0.354 in.)
*e 34 mm (1.34 in.) - -


i.

Using an E6 "TORX" socket wrench, install the 2 stud bolts to the stiffening crankcase assembly.

Torque:
4.0 N*m (41 kgf*cm, 35 in.*lbf)


ii.

Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

Torque:
4.0 N*m (41 kgf*cm, 35 in.*lbf)



Hide 4.INSTALL STRAIGHT SCREW PLUG

a.
A484415N02
0.427,0.042 0.708,0.396 0.281,0.354 18 false i

i.

Using a 10 mm hexagon socket wrench, install the straight screw plug and a new gasket to the stiffening crankcase assembly.

Torque:
44 N*m (449 kgf*cm, 32 ft.*lbf)



Hide 11420 6.INSTALL STIFFENING CRANKCASE ASSEMBLY

a.
A482657C02
4.083,1.656 3.917,1.656 3.917,1.656 3.75,1.406 false 4.188,1.604 4.5,1.76 0.313,0.156 10 false *a 0.375,2.385 0.688,2.542 0.313,0.156 10 false *b 3.479,2.396 3.792,2.552 0.313,0.156 10 false *c 0.823,3.083 0.979,3.281 0.156,0.198 10 false C 0.833,2.333 0.99,2.531 0.156,0.198 10 false C 1.896,1.833 2.052,2.031 0.156,0.198 10 false C 2.333,3.583 2.49,3.781 0.156,0.198 10 false C 1.594,1.885 1.75,2.083 0.156,0.198 10 false A 2.729,3.583 2.885,3.781 0.156,0.198 10 false A 2.281,1.823 2.438,2.021 0.156,0.198 10 false B 2.615,1.885 2.771,2.083 0.156,0.198 10 false B 1.885,3.604 2.042,3.802 0.156,0.198 10 false B 1.5,3.604 1.656,3.802 0.156,0.198 10 false B 4.927,3.604 5.083,3.802 0.156,0.198 10 false 1 5.344,3.604 5.5,3.802 0.156,0.198 10 false 3 4.948,1.833 5.104,2.031 0.156,0.198 10 false 2 5.333,1.833 5.49,2.031 0.156,0.198 10 false 4 5.677,1.833 5.833,2.031 0.156,0.198 10 false 10 5.76,3.604 5.917,3.802 0.156,0.198 10 false 9 4.583,3.604 4.74,3.802 0.156,0.198 10 false 5 3.854,3.104 4.01,3.302 0.156,0.198 10 false 7 3.844,2.365 4,2.563 0.156,0.198 10 false 8 4.646,1.896 4.802,2.094 0.156,0.198 10 false 6 2.531,0.167 2.813,0.521 0.281,0.354 18 true i 0.646,1.938 0.927,2.292 0.281,0.354 18 true ii 3.771,1.979 4.052,2.333 0.281,0.354 18 true iii
*a Seal Packing *b Bolt Type
*c Tightening Order - -


i.

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 Dimension:
Area Specified Condition
Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)


NOTICE:
·

Remove any oil from the contact surfaces.

·

Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

·

Do not add engine oil for at least 2 hours after the installation.

·

Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).




ii.

Temporarily install the stiffening crankcase assembly with the 11 bolts.

Bolt Length :
Item Length
Bolt (A) 40 mm (1.57 in.)
Bolt (B) 90 mm (3.54 in.)
Bolt (C) 170 mm (6.69 in.)



iii.

Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.

Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf)



Hide 15520B 7.INSTALL CRANKCASE CAP ASSEMBLY

Hide 15104 8.INSTALL OIL STRAINER SUB-ASSEMBLY

a.
A484419N01
5.563,0.188 5.792,0.5 0.229,0.313 18 true i 2.385,1.26 2.625,1.573 0.24,0.313 18 true ii

i.

Apply a light coat of engine oil to a new oil strainer gasket.


ii.

Using an 8 mm socket wrench, install the oil strainer sub-assembly and oil strainer gasket to the stiffening crankcase assembly with the bolt.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 12101 9.INSTALL OIL PAN SUB-ASSEMBLY

a.
A482659C01
1.063,1.521 1.333,1.281 true 3.271,3.365 3.51,2.76 3.51,2.76 4,3 true 0.896,1.5 1.208,1.656 0.313,0.156 10 false *a 4.25,0.5 4.563,0.656 0.313,0.156 10 false *b 4.26,0.75 4.573,0.906 0.313,0.156 10 false *c 5.385,0.531 5.698,0.688 0.313,0.156 10 false *b 5.365,0.75 5.677,0.906 0.313,0.156 10 false *c 0.969,0.052 1.125,0.25 0.156,0.198 10 true A 0.969,0.375 1.125,0.573 0.156,0.198 10 true A 1.563,0.063 1.719,0.26 0.156,0.198 10 true B 1.542,0.396 1.698,0.594 0.156,0.198 10 true B 4.385,0.167 5.125,0.385 0.74,0.219 10 true A - A 5.656,0.177 6.396,0.396 0.74,0.219 10 true B - B 4.24,3.125 4.688,3.333 0.448,0.208 10 true 1, 9 4.083,3.552 4.531,3.76 0.448,0.208 10 true 10 3.208,3.594 3.656,3.802 0.448,0.208 10 false 11 2.865,3.542 3.115,3.792 0.25,0.25 10 false 12 2.698,2.969 2.896,3.156 0.198,0.188 10 true 13 2.5,2.531 2.885,2.771 0.385,0.24 10 true 2, 14 2.958,1.958 3.208,2.208 0.25,0.25 10 false 3 3.5,1.844 3.75,2.094 0.25,0.25 10 false 4 3.781,1.833 4.031,2.083 0.25,0.25 10 false 5 4.052,1.844 4.302,2.094 0.25,0.25 10 false 6 4.552,2.75 4.802,3 0.25,0.25 10 true 7 3.438,2.552 3.625,2.719 0.188,0.167 10 true *d 0.625,0.156 0.875,0.51 0.25,0.354 18 true i 2.188,2.396 2.438,2.75 0.25,0.354 18 true ii
*a Seal Packing *b 4.5 mm (0.177 in.)
*c 2.5 to 3.5 mm (0.0984 to 0.138 in.) *d Nut


i.

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:

2.5 to 3.5 mm (0.0984 to 0.138 in.)


NOTICE:
·

Remove any oil from the contact surfaces.

·

Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.

·

Do not start the engine for at least 2 hours after installation.

·

Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).




ii.

Install the oil pan sub-assembly with the 12 bolts and 2 nuts in several steps in the order shown in the illustration.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 12101A 10.INSTALL OIL PAN DRAIN PLUG

Torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)

Hide 15600A 11.INSTALL OIL FILTER UNION

a.
A484407N02
0.438,0.042 0.719,0.396 0.281,0.354 18 false i

i.

Using a 12 mm hexagon socket wrench, install the oil filter union to the stiffening crankcase assembly.

Torque:
29.5 N*m (301 kgf*cm, 22 ft.*lbf)



Hide 11401L 13.INSTALL REAR ENGINE OIL SEAL

Z101186

Click here(Click here)

Hide 11445 14.INSTALL CYLINDER BLOCK WATER JACKET SPACER

Hide 11115 15.INSTALL CYLINDER HEAD GASKET

Z101186

Click here(Click here)

Hide 11101 16.INSTALL CYLINDER HEAD SUB-ASSEMBLY

Z101186

HINT:

The cylinder head set bolts are tightened in 3 progressive steps.



a.
A528757C02
3.188,3.271 3.427,2.958 false 3.063,3.271 3.375,3.469 0.313,0.198 10 false *a 3.135,2.25 3.448,2.448 0.313,0.198 10 false 90° 4.229,2.24 4.542,2.438 0.313,0.198 10 false 90° 4.563,0.24 4.948,0.427 0.385,0.188 10 true 7, 17 5.042,0.24 5.427,0.427 0.385,0.188 10 true 5, 15 5.552,0.24 5.938,0.427 0.385,0.188 10 true 2, 12 6.021,0.24 6.406,0.427 0.385,0.188 10 true 4, 14 6.531,0.25 6.969,0.438 0.438,0.188 10 true 10, 20 6.552,1.635 6.99,1.823 0.438,0.188 10 true 8, 18 6.042,1.625 6.406,1.813 0.365,0.188 10 true 6, 16 4.573,1.615 4.958,1.802 0.385,0.188 10 true 9, 19 5.042,1.625 5.427,1.813 0.385,0.188 10 true 3, 13 5.563,1.625 5.948,1.813 0.385,0.188 10 true 1, 11 1.115,0.24 1.24,0.427 0.125,0.188 10 true A 1.594,0.25 1.719,0.438 0.125,0.188 10 true B 2.083,0.24 2.208,0.427 0.125,0.188 10 true B 2.573,0.25 2.698,0.438 0.125,0.188 10 true B 3.052,0.229 3.177,0.417 0.125,0.188 10 true A 1.135,1.625 1.26,1.813 0.125,0.188 10 true A 3.073,1.635 3.198,1.823 0.125,0.188 10 true A 2.573,1.635 2.698,1.823 0.125,0.188 10 true B 2.104,1.625 2.229,1.813 0.125,0.188 10 true B 1.594,1.625 1.719,1.813 0.125,0.188 10 true B 0.135,0.385 0.594,0.677 0.458,0.292 18 false i, ii 3.667,0.354 4.26,0.635 0.594,0.281 18 false iii, iv 2.635,1.99 3.229,2.271 0.594,0.281 18 false v, vi
*a Paint Mark - -
V100136

Front of Engine - -


i.

Place the cylinder head sub-assembly on the cylinder block sub-assembly.

NOTICE:
·

Ensure that the contact surface of the cylinder head sub-assembly is free of oil.

·

Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the cylinder head gasket with the bottom of the cylinder head sub-assembly.




ii.

Install the 6 plate washers to the 10 cylinder head set bolts.

Bolt Length :
Item Length
Bolt (A) 129.1 to 130.9 mm (5.08 to 5.15 in.)
Bolt (B) 139.1 to 140.9 mm (5.48 to 5.55 in.)



iii.

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


iv.

Step 1:

1.

Using a 12 mm socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.


Torque:
50 N*m (510 kgf*cm, 37 ft.*lbf)

NOTICE:

Be careful not to drop the plate washers into the cylinder head sub-assembly.



v.

Step 2:

1.

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

2.

Tighten the cylinder head set bolts 90° in the order shown in step 1.



vi.

Step 3:

1.

Tighten the cylinder head set bolts another 90° in the order shown in step 1.

2.

Check that the paint marks are now facing rearward.

HINT:

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION





Hide 11117G 17.INSTALL NO. 3 HEAD WITH STRAIGHT SCREW PLUG

a.
A545647N01
0.688,0.01 0.969,0.365 0.281,0.354 18 false i 3.958,0.021 4.24,0.375 0.281,0.354 18 false ii

i.

Apply adhesive to the No. 3 head with straight screw plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent



ii.

Using a 10 mm hexagon wrench, install the No. 3 head with straight screw plug to the cylinder head sub-assembly.

Torque:
44 N*m (449 kgf*cm, 32 ft.*lbf)

NOTICE:
·

install the No. 3 head with straight screw plug within 3 minutes of applying adhesive.

·

Do not add engine oil for at least 1 hours after installation.





Hide 13716 18.INSTALL VALVE STEM CAP

a.
A528737N02
0.417,0.042 0.948,0.323 0.531,0.281 18 false i, ii

i.

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


ii.

Install the 16 valve stem caps to the cylinder head sub-assembly.

NOTICE:
·

Install the same parts in the same combination to their original locations.

·

Do not drop the valve stem caps into the cylinder head sub-assembly.





Hide 13750 19.INSTALL VALVE LASH ADJUSTER ASSEMBLY

a.
A468860N03
0.573,0.188 0.854,0.542 0.281,0.354 18 false i 2.375,3.021 2.656,3.375 0.281,0.354 18 false ii

i.

Inspect the 16 valve lash adjuster assemblies before installing them.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE MECHANICAL)>ENGINE UNIT>INSPECTION


ii.

Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

NOTICE:

Install the same parts in the same combination to their original locations.




Hide 13801 20.INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

a.
A528761C02
4.25,0.729 4.667,0.729 false 3.823,0.396 4.323,0.229 false 2.615,0.646 3.031,0.646 false 4.385,0.125 4.698,0.281 0.313,0.156 10 false *1 4.729,0.625 5.042,0.781 0.313,0.156 10 false *2 2.438,0.552 2.75,0.708 0.313,0.156 10 false *3 0.417,0.052 0.875,0.365 0.458,0.313 18 false i, ii
*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly
*3 Valve Stem Cap - -


i.

Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.


ii.

Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

NOTICE:

Install the same parts in the same combination to their original locations.




Hide 13502B 21.INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY

Z101186

HINT:

Perform "Inspection After Repair" after replacing the exhaust camshaft sub-assembly.

Click here(Click here)



a.
A528763N01
0.448,0.063 1.208,0.365 0.76,0.302 18 false i, ii, iii

i.

Clean the camshaft journals and camshaft housing sub-assembly.


ii.

Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.


iii.

Install the exhaust camshaft sub-assembly to the camshaft housing sub-assembly.



Hide 13501A 22.INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY

Z101186

HINT:

Perform "Inspection After Repair" after replacing the intake camshaft sub-assembly.

Click here(Click here)



a.
A528764N01
0.427,0.031 1.271,0.354 0.844,0.323 18 false i, ii, iii

i.

Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.


ii.

Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.


iii.

Install the intake camshaft sub-assembly to the camshaft housing sub-assembly.



Hide 23.INSTALL CAMSHAFT BEARING CAP

a.
A528765N02
1.479,1.583 1.635,1.781 0.156,0.198 10 false 2 1.885,1.583 2.042,1.781 0.156,0.198 10 false 3 2.281,1.583 2.438,1.781 0.156,0.198 10 false 4 4.333,0.865 4.49,1.063 0.156,0.198 10 false 9 5.438,0.354 5.594,0.552 0.156,0.198 10 true 6 5.906,0.313 6.063,0.51 0.156,0.198 10 true 2 6.333,0.313 6.49,0.51 0.156,0.198 10 true 4 6.729,1.198 6.885,1.396 0.156,0.198 10 true 7 6.094,1.5 6.25,1.698 0.156,0.198 10 true 8 5.76,1.219 5.917,1.417 0.156,0.198 10 true 3 5.323,1.219 5.479,1.417 0.156,0.198 10 true 1 4.885,1.229 5.042,1.427 0.156,0.198 10 true 5 0.385,0.052 0.667,0.406 0.281,0.354 18 false i 4.052,0.042 4.542,0.333 0.49,0.292 18 false ii, iii

i.

Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap in their correct locations.


ii.

Uniformly tighten the 9 bolts in the order shown in the illustration.


iii.

Check the torque of each bolt again.



Hide 11103 24.INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

a.
A528766C02
1.917,0.74 2.24,0.74 false 0.948,0.719 1.24,0.719 false 1.677,1.969 2.146,1.833 false 1.969,2.198 2.292,2.198 false 0.979,2.073 1.271,2.073 false 1.667,0.51 2.135,0.375 false 5.333,0.594 5.74,0.188 true 5.271,2.802 5.542,3.354 5.542,3.354 5.813,2.854 true 2.208,0.302 2.521,0.458 0.313,0.156 10 false *1 0.76,0.615 1.073,0.771 0.313,0.156 10 false *2 2.292,0.667 2.604,0.823 0.313,0.156 10 false *3 0.594,0.365 0.906,0.521 0.313,0.156 10 false *a 0.677,1.74 0.99,1.896 0.313,0.156 10 false *b 5.802,0.073 6.115,0.229 0.313,0.156 10 false *c 5.208,2.146 5.521,2.302 0.313,0.156 10 false *d 5.75,2.365 6.063,2.521 0.313,0.156 10 false *e 5.5,3.396 5.969,3.552 0.469,0.156 10 false *f 2.24,1.74 2.552,1.896 0.313,0.156 10 false *1 2.354,2.094 2.667,2.25 0.313,0.156 10 false *3 0.802,1.969 1.115,2.125 0.313,0.156 10 false *2 0.719,4.021 0.896,4.229 0.177,0.208 10 false B 0.729,4.938 0.906,5.146 0.177,0.208 10 false B 0.729,5.49 0.906,5.698 0.177,0.208 10 false B 1.385,3.958 1.563,4.167 0.177,0.208 10 false B 2.042,3.958 2.219,4.167 0.177,0.208 10 false B 2.552,3.958 2.729,4.167 0.177,0.208 10 false B 3.01,3.938 3.188,4.146 0.177,0.208 10 false B 3.406,4.083 3.583,4.292 0.177,0.208 10 false B 3.375,5.042 3.552,5.25 0.177,0.208 10 false B 3.229,5.531 3.406,5.74 0.177,0.208 10 false B 2.594,5.594 2.771,5.802 0.177,0.208 10 false B 1.906,5.594 2.083,5.802 0.177,0.208 10 false B 1.385,5.573 1.563,5.781 0.177,0.208 10 false B 2.625,4.438 2.771,4.656 0.146,0.219 10 true B 2.135,4.427 2.281,4.646 0.146,0.219 10 true A 1.635,4.479 1.781,4.698 0.146,0.219 10 true A 1.094,4.479 1.24,4.698 0.146,0.219 10 true A 4.26,4.156 4.479,4.365 0.219,0.208 10 false 12 4.229,4.896 4.458,5.104 0.229,0.208 10 false 10 4.24,5.479 4.49,5.677 0.25,0.198 10 false 11 4.958,3.969 5.177,4.177 0.219,0.208 10 false 6 5.521,3.948 5.917,4.125 0.396,0.177 10 false 3, 20 6.135,3.948 6.396,4.125 0.26,0.177 10 false 9 6.521,3.927 6.781,4.104 0.26,0.177 10 false 15 6.927,4.042 7.156,4.26 0.229,0.219 10 false 17 6.875,5.042 7.104,5.26 0.229,0.219 10 false 16 6.802,5.531 7.031,5.75 0.229,0.219 10 false 14 6.135,5.594 6.365,5.813 0.229,0.219 10 false 8 5.375,5.594 5.771,5.771 0.396,0.177 10 false 2, 19 4.979,5.583 5.146,5.771 0.167,0.188 10 false 5 6.115,4.458 6.313,4.677 0.198,0.219 10 true 13 5.698,4.448 5.833,4.667 0.135,0.219 10 true 7 4.958,4.479 5.354,4.677 0.396,0.198 10 true 1, 18 4.656,4.479 4.792,4.698 0.135,0.219 10 true 4 0.417,0.094 0.698,0.448 0.281,0.354 18 false i 4.26,0.073 4.542,0.427 0.281,0.354 18 false ii 4.25,1.99 4.531,2.344 0.281,0.354 18 false iii 0.354,4 0.635,4.354 0.281,0.354 18 false iv 3.958,4 4.24,4.354 0.281,0.354 18 false v
*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Stem Cap
*3 Valve Lash Adjuster Assembly - -
*a Incorrect *b Correct
*c Seal Packing *d 17° to 47°
*e 42° to 72° *f No. 1 Cylinder Cam Nose


i.

Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.


ii.

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:

3.0 to 4.0 mm (0.118 to 0.157 in.)


NOTICE:
·

Remove any oil from the contact surfaces.

·

Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

·

Do not start the engine for at least 2 hours after installation.

·

Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).




iii.

Position the intake camshaft sub-assembly and exhaust camshaft sub-assembly as shown in the illustration.


iv.

Temporarily install the camshaft housing sub-assembly with the 17 bolts.

Bolt Length :
Item Length
Bolt (A) 40 mm (1.57 in.)
Bolt (B) 65 mm (2.56 in.)



v.

Install the camshaft housing sub-assembly, and then tighten the 17 bolts in several steps in the order shown in the illustration.

Torque:
28.5 N*m (291 kgf*cm, 21 ft.*lbf)

NOTICE:
·

Do not add engine oil for at least 2 hours after installation.

·

Do not start the engine for at least 2 hours after installation.

·

After installation, if the seal packing has seeped out, wipe it off.





Hide 23477 25.INSTALL FUEL PUMP LIFTER GUIDE

a.
A528730N02
0.406,0.042 0.688,0.396 0.281,0.354 18 false i

i.

Using an 8 mm socket wrench, install the fuel pump lifter guide to the No. 4 camshaft bearing cap with the 2 bolts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 13471A 26.INSTALL CRANKSHAFT TIMING GEAR KEY

a.
A528768N01
0.385,0.031 0.667,0.385 0.281,0.354 18 false i

i.

Using a plastic 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.




Hide 15703A 27.INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY

Hide 11310 28.INSTALL TIMING CHAIN COVER ASSEMBLY

a.
A434755C02
0.646,0.125 0.958,0.323 0.313,0.198 10 false *a 4.042,0.104 4.354,0.302 0.313,0.198 10 false *b 0.229,0.063 0.51,0.417 0.281,0.354 18 false i
*a Timing Chain Cover Assembly Side *b Engine Assembly Side


i.

Clean the contact surfaces of the timing chain cover assembly, cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.



b.
A528769C02
4.177,2.813 4.802,2.458 4.802,2.458 4.396,1.833 true 3.5,2.417 2.406,2.667 2.406,2.667 3,2.396 true 1.615,4.844 2.625,5.083 1.01,0.24 10 false A - A 2.656,4.135 2.833,4.302 0.177,0.167 10 true A 2.99,4.135 3.167,4.302 0.177,0.167 10 true A 4.854,2.365 5.167,2.563 0.313,0.198 10 false *a 2.208,2.583 2.521,2.781 0.313,0.198 10 false *b 1.531,0.615 1.844,0.813 0.313,0.198 10 false *c 5.375,0.625 5.688,0.823 0.313,0.198 10 false *c 2.052,3.542 2.365,3.74 0.313,0.198 10 false *d 5.01,0.177 5.323,0.375 0.313,0.198 10 false *c 5.115,3.531 5.427,3.729 0.313,0.198 10 false *d 0.844,2.417 1.156,2.615 0.313,0.198 10 false *e 6.438,2.406 6.75,2.604 0.313,0.198 10 false *e 2.313,5.177 2.625,5.375 0.313,0.198 10 false *f 1.302,5.948 1.615,6.146 0.313,0.198 10 false *g 2.927,3.75 3.115,3.927 0.188,0.177 10 true ★ 4.24,3.75 4.427,3.927 0.188,0.177 10 true ★ 2.625,0.792 2.813,0.969 0.188,0.177 10 true ★ 4.573,0.344 4.76,0.521 0.188,0.177 10 false ★ 4.365,0.833 4.552,1.01 0.188,0.177 10 false ★ 2,4.833 2.51,5.115 0.51,0.281 10 true (★) 0.458,0.135 0.74,0.49 0.281,0.354 18 false i
*a 2.5 to 3.5 mm (0.0984 to 0.138 in.) *b 2.0 to 6.0 mm (0.0787 to 0.236 in.)
*c 10 mm (0.394 in.) *d 20 mm (0.787 in.)
*e 344.2 mm (1.13 ft.) *f 4.0 to 6.0 mm (0.157 to 0.236 in.)
*g 3.0 to 4.0 mm (0.118 to 0.157 in.) - -
V100155

Seal Packing - -


i.

Apply seal packing to the timing chain cover assembly as shown in the illustration.

Seal Packing:

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


NOTICE:
·

Clean the surfaces with non-residue solvent before applying seal packing.

·

Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

·

Do not add oil for at least 2 hours after installation.

·

Do not start the engine for at least 2 hours after installation.

·

Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).





c.
A528770N02
0.958,0.042 1.115,0.24 0.156,0.198 10 false B 0.792,0.438 0.948,0.635 0.156,0.198 10 false B 0.896,0.625 1.052,0.823 0.156,0.198 10 false B 1.385,0.385 1.542,0.583 0.156,0.198 10 true B 1.698,0.219 1.854,0.417 0.156,0.198 10 true B 0.875,0.823 1.031,1.021 0.156,0.198 10 false B 2.375,0.063 2.531,0.26 0.156,0.198 10 false B 2.542,0.438 2.698,0.635 0.156,0.198 10 false B 2.438,0.792 2.594,0.99 0.156,0.198 10 false B 2.323,1.281 2.479,1.479 0.156,0.198 10 true A 2.417,1.583 2.573,1.781 0.156,0.198 10 true A 2.385,1.896 2.542,2.094 0.156,0.198 10 true A 1.865,2.469 2.021,2.667 0.156,0.198 10 true A 1.365,2.552 1.521,2.75 0.156,0.198 10 false A 0.854,2.219 1.01,2.417 0.156,0.198 10 false A 0.865,1.604 1.031,2.083 0.167,0.479 10 false A 0.844,1.948 1.042,2.25 0.198,0.302 10 false A 0.927,1.302 1.125,1.604 0.198,0.302 10 false A 1.167,1 1.302,1.219 0.135,0.219 10 true A 4.823,0.052 5.063,0.271 0.24,0.219 10 false 16 4.688,0.417 4.927,0.635 0.24,0.219 10 false 15 4.771,0.625 5.01,0.844 0.24,0.219 10 false 14 4.729,0.813 4.969,1.031 0.24,0.219 10 false 13 5.281,0.375 5.469,0.583 0.188,0.208 10 true 12 5.656,0.198 5.844,0.406 0.188,0.208 10 true 11 6.313,0.094 6.552,0.313 0.24,0.219 10 false 19 6.458,0.406 6.698,0.625 0.24,0.219 10 false 18 6.385,0.781 6.625,1 0.24,0.219 10 false 17 6.26,1.302 6.5,1.521 0.24,0.219 10 true 10 6.354,1.594 6.594,1.813 0.24,0.219 10 false 1 6.323,1.885 6.563,2.104 0.24,0.219 10 true 4 5.823,2.479 6.01,2.688 0.188,0.208 10 true 5 5.271,2.531 5.458,2.74 0.188,0.208 10 true 6 4.854,1.292 5.094,1.51 0.24,0.219 10 false 8 4.813,1.604 5.052,1.823 0.24,0.219 10 false 3 4.792,1.938 5.031,2.156 0.24,0.219 10 false 2 4.802,2.208 5.042,2.427 0.24,0.219 10 false 7 5.385,1.646 5.573,1.854 0.188,0.208 10 true 20 5.094,1.01 5.281,1.219 0.188,0.208 10 true 9 0.5,0.094 0.781,0.448 0.281,0.354 18 false i 4.323,0.073 4.604,0.427 0.281,0.354 18 false ii

i.

Temporarily install the timing chain cover assembly with the 20 bolts.

Bolt Length:
Bolt Length
(A) 30 mm (1.18 in.)
(B) 45 mm (1.77 in.)


NOTICE:

Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.



ii.

Tighten the 20 bolts in the order shown in the illustration.

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



Hide 13070A 29.INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Z101186

HINT:

Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

Click here(Click here)



a.
A528771C02
0.635,0.813 1.25,0.51 true 1.667,1.365 2.073,1.125 true 0.448,0.771 0.76,0.969 0.313,0.198 10 false *a 1.479,1.333 1.792,1.531 0.313,0.198 10 false *b 0.365,0.031 0.646,0.385 0.281,0.354 18 false i 4.031,0.042 4.833,0.344 0.802,0.302 18 true ii, iii, iv
*a Knock Pin Hole *b Knock Pin


i.

Align and fit the knock pin of the exhaust camshaft sub-assembly to the knock pin hole of the camshaft timing exhaust gear assembly.


ii.

Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.

NOTICE:

Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.



iii.

Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly and camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly) with the 3 bolts.

Torque:
19 N*m (194 kgf*cm, 14 ft.*lbf)

NOTICE:

Make sure to fit the protrusion of the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly) into the cutout of the camshaft timing exhaust gear assembly.



iv.

Pull the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly) to confirm that is installed securely.



Hide 30.SET NO. 1 CYLINDER TO TDC (COMPRESSION)

a.
A528773C02
1.188,1.781 1.885,1.781 true 5,1 4.646,0.823 4.646,0.823 5.021,0.677 true 6.25,0.885 6.042,0.667 6.042,0.667 6.406,0.635 true 0.917,1.677 1.135,1.865 0.219,0.188 10 true *1 1.688,1.125 1.896,1.344 0.208,0.219 10 true *a 4.396,0.698 4.604,0.896 0.208,0.198 10 true *b 5.781,0.552 5.99,0.75 0.208,0.198 10 true *b 0.385,0.969 0.854,1.26 0.469,0.292 18 true i, ii 3.885,0.083 4.167,0.365 0.281,0.281 18 false iii
*1 Crankshaft Timing Gear Key - -
*a 44.2° *b Timing Mark


i.

Temporarily install the crankshaft pulley bolt.


ii.

Rotate the crankshaft 44.2° counterclockwise to position the crankshaft timing gear key as shown in the illustration.


iii.

Check that the timing marks of the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.



Hide 13561 31.INSTALL NO. 1 CHAIN VIBRATION DAMPER

Torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)

Hide 13559 32.INSTALL CHAIN TENSIONER SLIPPER

Torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)

Hide 13540 33.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Z101186

HINT:

After replacing or removing and installing the No. 1 chain tensioner assembly, an abnormal noise may occur at start up until the oil in the line has had time to replenish.



a.
A528774C02
1.354,0.615 1.521,0.24 true 1.646,1.063 1.438,0.833 true 1.927,0.51 2.385,0.167 true 2.156,0.521 2.5,0.438 true 2.021,0.771 1.813,0.563 true 2.01,0.781 2.198,1 0.188,0.219 10 true *a 2.458,0.073 2.771,0.229 0.313,0.156 10 false *b 1.552,0.115 1.781,0.313 0.229,0.198 10 true *c 2.573,0.354 2.885,0.51 0.313,0.156 10 false *d 1.677,1 1.875,1.188 0.198,0.188 10 true *e 0.417,0.063 0.698,0.417 0.281,0.354 18 false i 4.021,0.448 4.563,0.76 0.542,0.313 18 false ii, iii
*a End of the plunger *b Groove
*c Oil Hole *d No. 1 Chain Tensioner Slipper
*e Plunger - -


i.

While slightly pushing in the plunger of the No. 1 chain tensioner assembly, install the No. 1 chain tensioner assembly.

HINT:
·

Make sure that the end of the plunger is correctly seated in the groove of the No. 1 chain tensioner slipper.

·

Make sure that the oil hole of the plunger is facing up.




ii.

Using an 8 mm socket wrench, install the bolt.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


iii.

Install the nut.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 13506 34.INSTALL CHAIN SUB-ASSEMBLY

a.
A528775C02
1.927,0.802 2.406,0.604 true 1.844,4.021 1.76,4.333 1.76,4.333 1.677,4.333 true 1.875,3.823 1.917,3.51 1.917,3.51 2,3.51 true 4.573,4.885 4.594,4.625 4.594,4.625 4.677,4.625 true 4.573,5.042 4.573,5.271 4.573,5.271 4.49,5.271 true 2.458,0.521 2.667,0.719 0.208,0.198 10 true *1 2.031,3.406 2.208,3.604 0.177,0.198 10 true *b 1.469,4.24 1.646,4.438 0.177,0.198 10 true *a 4.719,4.521 4.896,4.719 0.177,0.198 10 true *c 4.281,5.177 4.458,5.375 0.177,0.198 10 true *b 0.396,0.104 0.844,0.375 0.448,0.271 18 true i, ii 3.781,0.135 4.083,0.406 0.302,0.271 18 true iii 0.438,2.625 0.74,2.896 0.302,0.271 18 true iv 4.229,2.104 4.531,2.375 0.302,0.271 18 true v
*1 Crankshaft Timing Gear Key - -
*a Paint Mark (Yellow) *b Timing Mark
*c Paint Mark (Orange) - -
V113147

Turn - -


i.

Set the crankshaft timing gear key as shown in the illustration.


ii.

Remove the crankshaft pulley bolt.


iii.

Install the crankshaft timing sprocket and chain sub-assembly.


iv.

Align the paint mark (yellow) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.


v.

Using the hexagonal portion of the exhaust camshaft sub-assembly, rotate the exhaust camshaft sub-assembly counterclockwise with a wrench, align the timing mark of the camshaft timing exhaust gear assembly with the paint mark (orange) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing exhaust gear assembly.



Hide 13050 35.INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

Z101186

HINT:

Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

Click here(Click here)



a.
A528776C02
1.875,0.99 2.406,0.854 true 5.792,0.833 6.281,0.667 true 5.594,1.375 5.74,1.115 true 1.563,3.583 1.969,3.125 true 2,3.875 2.302,3.49 true 2.479,0.771 2.792,0.927 0.313,0.156 10 false *a 5.458,1.406 5.667,1.594 0.208,0.188 10 true *b 6.323,0.563 6.531,0.75 0.208,0.188 10 true *c 2.031,3 2.344,3.156 0.313,0.156 10 false *d 2.344,3.417 2.656,3.573 0.313,0.156 10 false *e 5.281,3.26 5.594,3.417 0.313,0.156 10 false *f 0.469,0.104 0.75,0.458 0.281,0.354 18 false i 4.01,0.073 4.292,0.427 0.281,0.354 18 false ii 0.49,3.031 0.771,3.385 0.281,0.354 18 false iii 4.333,2.958 4.875,3.271 0.542,0.313 18 false iv, v
*a Loosen *b Paint Mark (Orange)
*c Timing Mark *d Knock Pin Hole
*e Knock Pin *f Hold
V113147

Turn - -


i.

Hold the hexagonal portion of the exhaust camshaft sub-assembly with a wrench and turn the camshaft timing exhaust gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and crankshaft timing sprocket as shown in the illustration.


ii.

Align the paint mark (orange) of the chain sub-assembly with the timing mark of the camshaft timing gear assembly and install the chain sub-assembly to the camshaft timing gear assembly.


iii.

Align and fit the knock pin of the intake camshaft sub-assembly to the knock pin hole of the camshaft timing gear assembly.


iv.

Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.

NOTICE:
·

Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.

·

Do not disassemble the camshaft timing gear assembly.




v.

Using a 10 mm bi-hexagonal wrench, install the camshaft timing gear assembly with the bolt.

Torque:
86 N*m (877 kgf*cm, 63 ft.*lbf)



Hide 13507A 36.INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

a.
A528777C02
2.125,0.635 2.354,0.51 false 4.135,0.448 4.531,0.406 false 4.042,0.542 4.458,0.896 true 4.021,0.948 4.313,1.198 true 3.313,1.833 3.76,2.052 true 3.333,2.156 3.781,2.375 true 3.375,2.688 3.688,2.469 false 5.333,2.385 5.51,2.208 false 0.594,4.156 0.813,4.302 false 1.583,3.958 1.844,4.115 true 5.354,4.146 5.813,4.552 true 4.188,3.865 4.688,3.802 true 4.344,1.156 4.656,1.313 0.313,0.156 10 false *1 3.104,1.74 3.417,1.896 0.313,0.156 10 false *2 2.385,0.417 2.698,0.573 0.313,0.156 10 false *3 5.229,2.427 5.542,2.583 0.313,0.156 10 false *4 0.396,4.073 0.708,4.229 0.313,0.156 10 false *5 1.875,4.031 2.083,4.219 0.208,0.188 10 true *6 4.583,0.302 4.896,0.458 0.313,0.156 10 false *a 4.51,0.823 4.823,0.979 0.313,0.156 10 false *b 3.188,2.604 3.5,2.76 0.313,0.156 10 false *c 4.688,4.385 5,4.542 0.313,0.156 10 false *d 3.146,2.063 3.458,2.219 0.313,0.156 10 false *b 5.844,4.542 6.292,4.698 0.448,0.156 10 false SST 3.875,3.823 4.323,3.979 0.448,0.156 10 false SST 0.479,0.125 1.531,0.417 1.052,0.292 18 false i, ii, iii, iv 3.906,2.938 4.958,3.229 1.052,0.292 18 true vi, vii, viii 0.281,3.146 0.51,3.417 0.229,0.271 18 false v
*1 Oil Pump Drive Sprocket *2 Oil Pump Drive Shaft Sprocket
*3 Crankshaft Timing Gear Key *4 Oil Pump Sub-assembly
*5 Chain Tensioner Plate *6 Chain Damper Spring
*a Mark Plate (Yellow) *b Timing Mark
*c Mark Plate (Orange) *d Bolt


i.

Set the crankshaft timing gear key as shown in the illustration.


ii.

Turn the oil pump drive shaft so that the flat face is facing upward.


iii.

Align the mark plates with the timing marks of the oil pump drive sprocket and oil pump drive shaft sprocket as shown in the illustration.

HINT:

Make sure the mark plates of the oil pump drive chain sub-assembly are facing away from the engine assembly.



iv.

With the oil pump drive chain sub-assembly placed around the oil pump drive sprocket and oil pump drive shaft sprocket, install the oil pump drive sprocket to the crankshaft and temporarily install the oil pump drive shaft sprocket to the oil pump drive shaft.


v.

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


vi.

Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.


vii.

Using SST, hold the crankshaft pulley assembly and tighten the bolt.

SST
09213-54015  
09330-00021  

Torque:
50 N*m (510 kgf*cm, 37 ft.*lbf)


viii.

Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.



Hide 37.SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Z101186

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Hide 11320B 38.INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

a.
A426794C04
0.979,0.198 1.292,0.354 0.313,0.156 10 false *a 3.927,0.198 4.24,0.354 0.313,0.156 10 false *b 0.208,0.052 0.49,0.406 0.281,0.354 18 false i
*a No. 2 Timing Chain Cover Assembly Side *b Timing Chain Cover Assembly Side


i.

Clean the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.



b.
A528778C01
4.51,0.365 4.667,0.563 0.156,0.198 10 false 6 4.563,0.677 4.719,0.875 0.156,0.198 10 false 7 4.635,0.969 4.792,1.167 0.156,0.198 10 false 8 4.854,1.229 5.01,1.427 0.156,0.198 10 true 9 4.708,1.427 4.906,1.625 0.198,0.198 10 true 10 4.688,1.74 4.885,1.938 0.198,0.198 10 true 11 5.51,0.677 5.635,0.875 0.125,0.198 10 true 1 4.667,2.115 4.896,2.323 0.229,0.208 10 false 12 4.615,2.396 4.844,2.604 0.229,0.208 10 false 13 5.219,2.802 5.448,3.01 0.229,0.208 10 false 14 5.688,2.604 5.885,2.802 0.198,0.198 10 true 15 5.979,2.313 6.177,2.51 0.198,0.198 10 true 16 5.469,1.823 5.583,2.01 0.115,0.188 10 true 5 5.271,1.344 5.385,1.531 0.115,0.188 10 true 3 5.646,1.323 5.76,1.51 0.115,0.188 10 true 2 6.344,0.313 6.573,0.521 0.229,0.208 10 false 20 6.271,0.927 6.5,1.135 0.229,0.208 10 false 19 6.135,1.365 6.354,1.552 0.219,0.188 10 true 18 6.115,1.688 6.333,1.875 0.219,0.188 10 true 17 5.969,1.885 6.083,2.073 0.115,0.188 10 true 4 5.083,3.74 5.229,3.948 0.146,0.208 10 true 1 6,3.031 6.146,3.24 0.146,0.208 10 true 2 5.906,4.563 6.052,4.771 0.146,0.208 10 true 3 0.427,0.25 0.708,0.604 0.281,0.354 18 false i 4.021,0.073 4.573,0.354 0.552,0.281 18 false ii, iii 4.031,2.938 4.313,3.292 0.281,0.354 18 false iv
V100155

Seal Packing - -


i.

Apply seal packing in a continuous line to the No. 2 timing chain cover assembly as shown in the illustration.

Seal Packing:

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


Standard Seal Packing Diameter:

2.5 to 3.5 mm (0.0984 to 0.138 in.)


NOTICE:
·

Clean the surfaces with non-residue solvent before applying seal packing.

·

Install the No. 2 timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

·

Do not add engine oil for at least 2 hours after installation.

·

Do not start the engine for at least 2 hours after installation.

·

Make sure that the diameter at the start and end of each line of seal packing is 5 +/- 2 mm (0.197 +/- 0.0787 in.).




ii.

Temporarily install the No. 2 timing chain cover assembly to the timing chain cover assembly with the 20 bolts.

NOTICE:

Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.



iii.

Tighten the 20 bolts in the order shown in the illustration.

Torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)


iv.

Install the engine mounting bracket RH with the 3 bolts in the order shown in the illustration.

Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf)

NOTICE:

After applying seal packing to the No. 2 timing chain cover assembly, install the engine mounting bracket RH within 10 minutes.




Hide 39.INSTALL STRAIGHT SCREW PLUG

a.
A470545N02
0.438,0.094 0.719,0.448 0.281,0.354 18 false i 4.208,0.115 4.49,0.469 0.281,0.354 18 false ii

i.

Apply adhesive to the straight screw plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent



ii.

Using a 10 mm hexagon wrench, install the straight screw plug to the No. 2 timing chain cover assembly.

Torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)

NOTICE:
·

Install the straight screw plug within 3 minutes of applying adhesive.

·

Do not add engine oil for at least 1 hour after installation.





Hide 11301C 40.INSTALL TIMING CHAIN COVER OIL SEAL

Z101186

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Hide 11193 41.INSTALL SPARK PLUG TUBE GASKET

Hide 11201 42.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

a.
A528780C02
3.365,3.646 3.729,3.823 3.729,3.823 3.323,3.49 true 2,4.594 1.708,4.208 1.708,4.208 1.99,3.927 true 1.698,3.677 1.281,3.865 1.281,3.865 1.698,3.49 true 3.083,4.583 3.438,4.292 3.438,4.292 3.083,3.76 true 1.938,4.635 2.49,5.063 2.49,5.063 1.99,4.615 true 3.146,4.625 2.458,5.052 2.458,5.052 3.042,4.573 true 5.75,1.74 5.906,1.938 0.156,0.198 10 false A 4.74,1.76 4.896,1.958 0.156,0.198 10 false A 5.24,1.76 5.396,1.958 0.156,0.198 10 false A 6.208,1.781 6.365,1.979 0.156,0.198 10 false A 6.688,1.792 6.844,1.99 0.156,0.198 10 false A 6.948,2.521 7.104,2.719 0.156,0.198 10 false A 6.906,3.219 7.063,3.417 0.156,0.198 10 false A 6.833,2.865 6.99,3.063 0.156,0.198 10 true B 5.875,2.385 6.031,2.583 0.156,0.198 10 true B 6.229,3.031 6.385,3.229 0.156,0.198 10 true C 5.813,3.063 5.969,3.26 0.156,0.198 10 true C 5.385,3.042 5.542,3.24 0.156,0.198 10 true C 4.406,2.948 4.563,3.146 0.156,0.198 10 false A 4.635,3.469 4.792,3.667 0.156,0.198 10 false A 5.052,3.438 5.208,3.635 0.156,0.198 10 false A 5.479,3.417 5.635,3.615 0.156,0.198 10 false A 5.979,3.365 6.135,3.563 0.156,0.198 10 false A 6.677,3.708 6.896,3.896 0.219,0.188 10 false 16 6.229,3.719 6.448,3.906 0.219,0.188 10 false 15 5.635,3.708 6.042,3.896 0.406,0.188 10 false 7, 14 5.115,3.813 5.333,4 0.219,0.188 10 false 13 4.521,3.823 4.74,4.01 0.219,0.188 10 false 12 4.385,4.854 4.604,5.042 0.219,0.188 10 false 11 4.792,5.479 5.01,5.667 0.219,0.188 10 false 10 5.219,5.5 5.438,5.688 0.219,0.188 10 false 9 5.552,5.479 5.958,5.667 0.406,0.188 10 false 8, 20 6.104,5.469 6.323,5.656 0.219,0.188 10 false 19 6.854,5.177 7.073,5.365 0.219,0.188 10 false 18 6.906,4.417 7.125,4.604 0.219,0.188 10 false 17 6.865,4.771 7.083,4.958 0.219,0.188 10 false 2 1.083,3.781 1.396,3.979 0.313,0.198 10 false *a 3.771,3.729 4.104,3.938 0.333,0.208 10 false *a 1.521,4.135 1.833,4.333 0.313,0.198 10 false *a 3.479,4.198 3.792,4.396 0.313,0.198 10 false *a 2.344,5.125 2.563,5.344 0.219,0.219 10 true *b 0.417,0.063 0.698,0.417 0.281,0.354 18 false i 4.073,0.125 4.354,0.479 0.281,0.354 18 false ii 0.49,2.49 0.771,2.844 0.281,0.354 18 false iii 4.042,1.896 4.323,2.25 0.281,0.354 18 false iv
*a Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.) *b Mark
V100143

Seal Packing - -


i.

Install a new camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.

NOTICE:

Remove any oil from the contact surfaces.



ii.

Install 7 new cylinder head cover gaskets to the cylinder head cover sub-assembly.

NOTICE:

Remove any oil from the contact surfaces.



iii.

Apply seal packing as shown in the illustration.

Seal Packing:

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


Standard Seal Packing Diameter:

3.0 to 6.0 mm (0.118 to 0.236 in.)


NOTICE:
·

Remove any oil from the contact surfaces.

·

Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

·

Do not start the engine for at least 2 hours after installation.




iv.

Install the cylinder head cover sub-assembly with the 12 bolts (A) and using an 8 mm socket wrench, install 4 new bolts (C) and the 2 camshaft position sensors (for Exhaust Side and for Intake Side) with 2 new bolts (B) in the order shown in the illustration.

Bolt Length:
Bolt Length Width Across Flats
(A) 23.5 mm (0.925 in.) 10 mm (0.394 in.)
(B), (C) 30 mm (1.18 in.) 8 mm (0.315 in.)


Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

NOTICE:
·

If a camshaft position sensor (for Exhaust Side and for Intake Side) has been struck or dropped, replace it.

·

Make sure that the 2 O-rings are not cracked or moved out of place when installing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

·

Do not start the engine for at least 2 hours after installation.



HINT:

After tightening all bolts, check the tightening torque of the bolts (7) and (8). Retighten them if necessary.




Hide 16351 43.INSTALL WATER BY-PASS OUTLET

a.
A528710N02
0.417,0.063 0.698,0.417 0.281,0.354 18 false i

i.

Using an 8 mm socket wrench, install the water by-pass outlet and a new water pipe outlet gasket to the cylinder head sub-assembly with the 3 bolts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



Hide 16304 44.INSTALL WATER OUTLET SUB-ASSEMBLY

Hide 45.INSTALL OUTLET HEATER WATER HOSE

Hide 46.INSTALL INLET HEATER WATER HOSE

Hide 13470 47.INSTALL CRANKSHAFT PULLEY ASSEMBLY

a.
A528784C02
2.99,0.865 2.531,0.813 2.531,0.813 2.76,0.51 false 2.01,0.146 2.323,0.302 0.313,0.156 10 false *a 4.198,1.625 4.51,1.781 0.313,0.156 10 false *b 2.208,0.74 2.615,0.906 0.406,0.167 10 false SST 0.396,0.063 0.865,0.375 0.469,0.313 18 false i, ii
*a Hold *b Turn


i.

Align the crankshaft timing gear key with the key groove of the crankshaft pulley assembly.


ii.

Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley bolt.

SST
09213-54015  
09330-00021  

Torque:
260 N*m (2651 kgf*cm, 192 ft.*lbf)



Hide 11401G 49.INSTALL CRANKSHAFT POSITION SENSOR

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Hide 12108A 50.INSTALL OIL FILLER CAP GASKET

Hide 12180E 51.INSTALL OIL FILLER CAP ASSEMBLY

Hide 13090E 52.INSTALL CAM TIMING CONTROL MOTOR O-RING

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Hide 13090D 53.INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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Hide 15370 54.INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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Hide 11102A 55.INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

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Hide 11102A 56.INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

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Hide 15250 57.INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

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Hide 89448D 58.INSTALL OIL PRESSURE AND TEMPERATURE SENSOR

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Hide 89615 59.INSTALL KNOCK CONTROL SENSOR

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Hide 19100P 60.INSTALL SPARK PLUG

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