M20D-FKS ENGINE MECHANICAL  ENGINE UNIT  REASSEMBLY  

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

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

*a

Protrusion Height

-

-

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.)

2.667,2.5 2.979,2.698 0.313,0.198 10 false *a 1.708,0.302 1.865,0.5 0.156,0.198 10 true A 2.208,0.188 2.365,0.385 0.156,0.198 10 false A 2.604,1.458 2.76,1.656 0.156,0.198 10 false A 2.896,1.01 3.052,1.208 0.156,0.198 10 false A 0.958,0.552 1.115,0.75 0.156,0.198 10 false B 1.813,1.625 1.969,1.823 0.156,0.198 10 false B

*a	Protrusion Height

Using a plastic-faced hammer, tap in 6 new ring pins to the stiffening crankcase assembly.

Standard Protrusion Height:

3.5 to 4.5 mm (0.138 to 0.177 in.)

1.615,2.563 1.927,2.719 0.313,0.156 10 false *a 2.333,2.771 2.646,2.927 0.313,0.156 10 false *b 1.604,2.896 1.917,3.052 0.313,0.156 10 false *a

*a	9 mm (0.354 in.)
*b	19 mm (0.748 in.)

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)

1.458,2.531 1.771,2.688 0.313,0.156 10 false *a 1.49,3.031 1.802,3.188 0.313,0.156 10 false *b 2.438,2.781 2.75,2.938 0.313,0.156 10 false *c

*a	21 mm (0.827 in.)
*b	9 mm (0.354 in.)
*c	34 mm (1.34 in.)

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)

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

Torque:

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

Install the engine balancer assembly to the stiffening crankcase assembly with the 2 bolts.

Torque:

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

1.979,1.063 2.146,1.594 2.146,1.594 2.375,1.594 true 2.438,1.5 2.75,1.698 0.313,0.198 10 true *1 1.406,0.635 1.615,0.865 0.208,0.229 10 true *a

*1	Crankshaft Timing Gear Key
*a	270°

Rotate the crankshaft clockwise so that the crankshaft timing gear key is at the position 270° from the bottom as shown in the illustration.

1.885,2.052 1.75,2.052 1.75,2.052 1.573,1.677 false 1.948,1.958 2.26,2.156 0.313,0.198 10 false *a

*a	Seal Packing

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.).

1.563,1.031 1.323,0.438 1.323,0.438 2.146,1.052 false 1.135,0.281 1.448,0.479 0.313,0.198 10 false *a

*a

Cutout

Check that the rear cutouts are as shown in the illustration.

0.094,0.115 0.406,0.313 0.313,0.198 10 false *a 1.104,0.115 1.26,0.313 0.156,0.198 10 false A 2.833,1.833 2.99,2.031 0.156,0.198 10 false A 2.771,0.188 2.927,0.385 0.156,0.198 10 false B 2.083,0.073 2.24,0.271 0.156,0.198 10 false B 1.177,1.969 1.333,2.167 0.156,0.198 10 false B 0.531,1.719 0.688,1.917 0.156,0.198 10 false C 1.74,1.958 1.896,2.156 0.156,0.198 10 false C 2.167,1.938 2.323,2.135 0.156,0.198 10 false C 1.594,0.094 1.75,0.292 0.156,0.198 10 false C 2.063,1.01 2.219,1.208 0.156,0.198 10 true C 0.521,0.323 0.677,0.521 0.156,0.198 10 false C

*a

Bolt Type

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.)

0.146,0.146 0.458,0.344 0.313,0.198 10 false *a 1.99,1.052 2.146,1.25 0.156,0.198 10 true 1 1.729,1.979 1.885,2.177 0.156,0.198 10 true 2 2.146,1.948 2.302,2.146 0.156,0.198 10 true 3 1.604,0.063 1.76,0.26 0.156,0.198 10 true 4 2.125,0.042 2.281,0.25 0.156,0.208 10 true 5 1.156,1.969 1.313,2.177 0.156,0.208 10 true 6 1.104,0.115 1.26,0.323 0.156,0.208 10 true 7 0.469,1.771 0.625,1.979 0.156,0.208 10 true 8 0.448,0.375 0.604,0.583 0.156,0.208 10 true 9 2.854,1.802 3.083,2.01 0.229,0.208 10 true 10 2.792,0.25 3.021,0.458 0.229,0.208 10 true 11

*a	Tightening Order

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)

Install the crankcase cap assembly to the stiffening crankcase assembly with the a new clip.

NOTICE:

Make sure to position the crankcase cap assembly as shown in the illustration.

Install the oil strainer sub-assembly and oil strainer gasket with the bolt.

Torque:

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

0.625,2.26 0.74,2.26 0.74,2.26 0.958,1.875 true 0.448,2.177 0.74,2.396 0.292,0.219 10 false *a 0.698,3.188 0.938,3.427 0.24,0.24 10 false *b 0.708,3.479 0.927,3.719 0.219,0.24 10 false *c 2.052,3.219 2.25,3.417 0.198,0.198 10 false *b 2.052,3.51 2.271,3.719 0.219,0.208 10 false *c 0.615,2.865 1.01,3.094 0.396,0.229 10 false A - A 2.406,2.865 2.833,3.115 0.427,0.25 10 false B - B 0.417,0.271 0.594,0.458 0.177,0.188 10 false A 0.417,0.677 0.563,0.865 0.146,0.188 10 true A 1.083,0.271 1.271,0.531 0.188,0.26 10 false B 1.083,0.677 1.229,0.854 0.146,0.177 10 true B

*a	Seal Packing
*b	4.5 mm (0.177 in.)
*c	2.5 to 3.5 mm (0.0984 to 0.138 in.)

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 No. 2 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.).

1.438,1.719 1.688,1.177 1.688,1.177 2.24,1.198 true 1.521,0.969 1.708,1.135 0.188,0.167 10 true *a 1.063,0.156 1.198,0.333 0.135,0.177 10 true 3 1.573,0.021 1.708,0.198 0.135,0.177 10 true 4 1.844,0.021 1.979,0.177 0.135,0.156 10 true 5 2.135,0.021 2.271,0.177 0.135,0.156 10 true 6 2.438,0.021 2.573,0.177 0.135,0.156 10 true 7 3.021,0.479 3.219,0.708 0.198,0.229 10 true 8 2.563,1.5 2.917,1.677 0.354,0.177 10 true 1, 10 1.844,1.99 2.094,2.177 0.25,0.188 10 false 12 1.427,2 1.615,2.177 0.188,0.177 10 false 13 1.073,1.885 1.292,2.063 0.219,0.177 10 false 14 0.375,1.427 0.573,1.583 0.198,0.156 10 true 15 0.25,0.417 0.646,0.583 0.396,0.167 10 true 2, 16 2.365,1.896 2.74,2.156 0.375,0.26 10 false 11 2.865,1.292 3.063,1.521 0.198,0.229 10 true 9

*a

Nut

Install the No. 2 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)

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)

Install the cylinder block water jacket spacer to the exhaust side of the cylinder block sub-assembly.

0.51,0.292 0.667,0.49 0.156,0.198 10 true A 0.49,1.979 0.646,2.177 0.156,0.198 10 true A 2.875,1.948 3.031,2.146 0.156,0.198 10 true A 2.865,0.281 3.021,0.479 0.156,0.198 10 true A 1.094,1.948 1.292,2.146 0.198,0.198 10 true B 1.667,1.938 1.833,2.125 0.167,0.188 10 true B 2.271,1.938 2.438,2.135 0.167,0.198 10 true B 1.104,0.302 1.302,0.469 0.198,0.167 10 true B 1.677,0.302 1.844,0.49 0.167,0.188 10 true B 2.302,0.313 2.469,0.479 0.167,0.167 10 true B

Front of Engine

Install the 10 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.)

Step 1:

i.

0.417,0.26 0.854,0.479 0.438,0.219 10 true 7, 17 0.99,0.24 1.375,0.458 0.385,0.219 10 true 5, 15 1.573,0.25 1.958,0.469 0.385,0.219 10 true 2, 12 2.167,0.25 2.552,0.469 0.385,0.219 10 true 4, 14 2.74,0.26 3.167,0.479 0.427,0.219 10 true 10, 20 2.813,1.958 3.24,2.177 0.427,0.219 10 true 8, 18 2.208,1.948 2.635,2.167 0.427,0.219 10 true 6, 16 1.604,1.948 2.031,2.167 0.427,0.219 10 true 1, 11 1,1.958 1.427,2.177 0.427,0.219 10 true 3, 13 0.427,1.938 0.854,2.156 0.427,0.219 10 true 9, 19

Front of Engine

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.

Step 2:

i.

1.24,1.563 1.5,1.156 false 1.094,1.563 1.271,1.75 0.177,0.188 10 false *a 0.896,0.375 1.198,0.531 0.302,0.156 10 false 90° 2.583,0.375 2.885,0.531 0.302,0.156 10 false 90°

*a	Paint Mark
	Front of Engine

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

Install the No. 1 water by-pass pipe and a new gasket to the cylinder head sub-assembly with the 2 bolts.

Torque:

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

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.

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.

2.531,0.906 2.896,0.906 false 1.885,0.406 2.052,0.24 2.052,0.24 2.208,0.24 false 0.677,0.76 1.042,0.76 false 2.26,0.146 2.573,0.344 0.313,0.198 10 false *1 2.958,0.823 3.271,1.021 0.313,0.198 10 false *2 0.479,0.667 0.792,0.865 0.313,0.198 10 false *3

*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Lash Adjuster Assembly
*3	Valve Stem Cap

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

2.354,2.646 2.667,2.802 0.313,0.156 10 false *a

*a	Protrusion Height

Using a plastic-faced hammer, tap in 10 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

Standard Protrusion Height:

3.2 to 4.3 mm (0.126 to 0.169 in.)

1.198,1.969 1.354,2.135 0.156,0.167 10 false 2 1.677,1.969 1.833,2.135 0.156,0.167 10 false 3 2.188,1.969 2.344,2.135 0.156,0.167 10 false 4

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.

0.073,1.104 0.188,1.25 0.115,0.146 10 false 9 0.688,1.469 0.802,1.667 0.115,0.198 10 true 5 1.198,1.448 1.313,1.635 0.115,0.188 10 true 1 1.708,1.427 1.823,1.615 0.115,0.188 10 true 3 2.188,1.781 2.302,1.969 0.115,0.188 10 true 8 3.01,1.448 3.177,1.646 0.167,0.198 10 false 7 2.5,0.5 2.615,0.667 0.115,0.167 10 true 4 1.99,0.49 2.104,0.656 0.115,0.167 10 true 2 1.427,0.563 1.542,0.729 0.115,0.167 10 true 6

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

Torque:

16 N*m (163 kgf*cm, 12 ft.*lbf)

1,0.427 1.427,0.427 false 2.01,0.198 2.385,0.115 2.385,0.115 2.604,0.115 false 2.292,0.802 2.719,0.802 false 2.344,2.521 2.771,2.521 false 1.979,1.969 2.208,1.802 2.208,1.802 2.365,1.802 false 1.042,2.146 1.469,2.146 false 0.146,0.125 0.458,0.323 0.313,0.198 10 false *a 0.188,1.781 0.5,1.979 0.313,0.198 10 false *b 2.688,0.052 3,0.25 0.313,0.198 10 false *1 2.448,1.688 2.76,1.885 0.313,0.198 10 false *1 0.813,0.333 1.125,0.531 0.313,0.198 10 false *2 0.865,2.052 1.177,2.25 0.313,0.198 10 false *2 2.781,0.698 3.094,0.896 0.313,0.198 10 false *3 2.844,2.438 3.156,2.635 0.313,0.198 10 false *3

*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Stem Cap
*3	Valve Lash Adjuster Assembly
*a	Incorrect
*b	Correct

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

1.313,0.635 1.615,0.208 true 1.667,0.115 1.979,0.271 0.313,0.156 10 false *a

*a	Seal Packing

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.).

2.052,1.146 1.646,1.781 1.646,1.781 1.323,1.115 true 1.438,0.344 1.75,0.542 0.313,0.198 10 false *a 1.906,0.563 2.125,0.729 0.219,0.167 10 true *b 1.583,1.833 1.896,2.031 0.313,0.198 10 false *c

*a	17° to 47°
*b	42° to 72°
*c	No. 1 Cylinder Cam Nose

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

0.052,0.083 0.208,0.281 0.156,0.198 10 false B 0.802,0.042 0.958,0.24 0.156,0.198 10 false B 1.656,0.031 1.813,0.229 0.156,0.198 10 false B 2.302,0.021 2.458,0.219 0.156,0.198 10 false B 2.844,0.021 3,0.219 0.156,0.198 10 false B 3.271,0.125 3.427,0.323 0.156,0.198 10 false B 2.448,0.5 2.604,0.698 0.156,0.198 10 true B 1.906,0.542 2.063,0.74 0.156,0.198 10 true A 1.26,0.552 1.417,0.75 0.156,0.198 10 true A 0.5,0.646 0.656,0.844 0.156,0.198 10 true A 0.063,1.208 0.229,1.406 0.167,0.198 10 false B 0.073,1.875 0.24,2.073 0.167,0.198 10 false B 0.854,1.979 1.01,2.177 0.156,0.198 10 false B 1.469,1.979 1.625,2.177 0.156,0.198 10 false B 2.302,1.979 2.469,2.177 0.167,0.198 10 false B 3.104,1.906 3.271,2.104 0.167,0.198 10 false B 3.25,1.271 3.417,1.469 0.167,0.198 10 false B

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.)

3.219,1.281 3.406,1.5 0.188,0.219 10 false 16 3.229,0.104 3.427,0.323 0.198,0.219 10 false 17 2.844,0.031 3.063,0.26 0.219,0.229 10 true 15 3.104,1.896 3.323,2.104 0.219,0.208 10 false 14 2.344,0.552 2.552,0.74 0.208,0.188 10 true 13 0.031,0.052 0.219,0.26 0.188,0.208 10 false 12 0.042,1.854 0.281,2.073 0.24,0.219 10 false 11 0.052,1.24 0.292,1.469 0.24,0.229 10 true 10 2.375,0.083 2.5,0.25 0.125,0.167 10 true 9 2.333,1.979 2.552,2.146 0.219,0.167 10 false 8 1.875,0.552 2.052,0.729 0.177,0.177 10 true 7 0.813,0.042 1.031,0.208 0.219,0.167 10 false 6 0.854,1.979 1.073,2.146 0.219,0.167 10 true 5 0.573,0.604 0.719,0.771 0.146,0.167 10 true 4 1.698,0.031 2.135,0.198 0.438,0.167 10 true 3, 20 1.448,1.979 1.906,2.177 0.458,0.198 10 true 2, 19 1.271,0.563 1.677,0.75 0.406,0.188 10 true 1, 18

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.

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)

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

HINT:

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

Install the oil nozzle valve sub-assembly to the cylinder block sub-assembly.

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.

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

*a

Timing Chain Cover Assembly Side

*b

Engine Assembly Side

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

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 (★)

*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.)	-	-
	Seal Packing	-	-

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.).

0.76,1.604 0.917,1.802 0.156,0.198 10 false A 0.708,1.979 0.865,2.177 0.156,0.198 10 false A 0.698,2.406 0.854,2.604 0.156,0.198 10 false A 1.167,3.219 1.323,3.417 0.156,0.198 10 false A 1.458,3.219 1.615,3.417 0.156,0.198 10 false A 1.948,2.875 2.104,3.073 0.156,0.198 10 true A 2.469,2.344 2.625,2.542 0.156,0.198 10 true A 2.521,1.99 2.677,2.188 0.156,0.198 10 true A 2.385,1.583 2.542,1.781 0.156,0.198 10 true A 1.448,2.156 1.604,2.354 0.156,0.198 10 true A 1.021,1.323 1.177,1.521 0.156,0.198 10 true A 0.75,0.125 0.906,0.323 0.156,0.198 10 false B 0.625,0.542 0.781,0.74 0.156,0.198 10 false B 0.719,1 0.875,1.198 0.156,0.198 10 false B 2.531,1.083 2.688,1.281 0.156,0.198 10 false B 2.646,0.552 2.802,0.75 0.156,0.198 10 false B 2.563,0.188 2.719,0.385 0.156,0.198 10 false B 1.729,0.385 1.875,0.552 0.146,0.167 10 true B 0.729,0.75 0.885,0.948 0.156,0.198 10 false B 1.438,0.531 1.583,0.698 0.146,0.167 10 true B

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.

0.708,0.104 1.021,0.302 0.313,0.198 10 false 16 0.563,0.531 0.875,0.729 0.313,0.198 10 false 15 0.667,0.76 0.979,0.958 0.313,0.198 10 false 14 0.656,1 0.969,1.198 0.313,0.198 10 false 13 1.396,0.552 1.594,0.729 0.198,0.177 10 true 12 1.698,0.385 1.896,0.563 0.198,0.177 10 true 11 2.531,1.083 2.844,1.281 0.313,0.198 10 false 17 2.646,0.542 2.958,0.74 0.313,0.198 10 false 18 2.542,0.198 2.854,0.396 0.313,0.198 10 false 19 1.135,1.198 1.292,1.365 0.156,0.167 10 true 9 0.76,1.604 0.917,1.802 0.156,0.198 10 false 8 0.719,1.979 0.875,2.177 0.156,0.198 10 false 3 0.708,2.406 0.865,2.604 0.156,0.198 10 false 2 1.177,3.229 1.333,3.427 0.156,0.198 10 false 7 1.469,3.229 1.625,3.427 0.156,0.198 10 false 6 1.417,2.208 1.615,2.385 0.198,0.177 10 true 20 1.948,2.948 2.104,3.115 0.156,0.167 10 true 5 2.479,2.354 2.635,2.521 0.156,0.167 10 true 4 2.521,1.99 2.677,2.156 0.156,0.167 10 true 1 2.375,1.604 2.573,1.781 0.198,0.177 10 true 10

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

Torque:

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

0.906,0.615 1.823,0.281 1.823,0.281 2.021,0.281 true 1.885,1.323 1.885,0.958 1.885,0.958 2.063,0.958 true 2.094,0.198 2.406,0.396 0.313,0.198 10 false *a 2.125,0.854 2.438,1.052 0.313,0.198 10 false *b

*a	Knock Pin Hole
*b	Knock Pin

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

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

Torque:

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

0.948,0.906 1.49,0.906 true 1.271,0.198 1.542,0.438 0.271,0.24 10 true *a 0.656,0.792 0.917,1 0.26,0.208 10 true *1

*1	Crankshaft Timing Gear Key
*a	44.2°

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

0.948,1.292 0.635,1.125 0.635,1.125 0.99,1.01 true 2.49,1.219 2.333,0.99 2.333,0.99 2.74,0.906 true 0.458,1.021 0.635,1.219 0.177,0.198 10 true *a 2.125,0.854 2.302,1.052 0.177,0.198 10 true *a

*a	Timing Mark

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

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

Torque:

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

Install the chain tensioner slipper with the bolt.

Torque:

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

2.031,0.604 2.219,0.313 2.219,0.313 2.51,0.313 true 2.302,0.698 2.563,0.573 2.563,0.573 2.698,0.573 false 1.281,0.792 1.427,0.302 1.427,0.302 1.563,0.302 true 1.875,0.771 1.813,1.26 1.813,1.26 1.969,1.26 true 1.438,1.281 1.438,1.042 true 2.563,0.25 2.875,0.448 0.313,0.198 10 false *b 2.781,0.51 3.094,0.708 0.313,0.198 10 false *d 1.635,0.208 1.875,0.427 0.24,0.219 10 true *c 2.031,1.198 2.344,1.396 0.313,0.198 10 true *a 1.375,1.313 1.615,1.49 0.24,0.177 10 true *e

*a	End of the Plunger
*b	Groove
*c	Oil Hole
*d	No. 1 Chain Tensioner Slipper
*e	Plunger

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

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.

Install the bolt.

Torque:

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

1.74,0.844 2.229,0.552 2.229,0.552 2.438,0.552 true 2.51,0.458 2.823,0.656 0.313,0.198 10 true *1

*1	Crankshaft Timing Gear Key

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

Install the crankshaft timing sprocket and chain sub-assembly.

1.51,1.302 1.552,1.031 1.552,1.031 1.688,1.031 true 1.135,1.74 1.26,1.74 1.26,1.74 1.313,1.469 true 0.885,1.646 1.104,1.854 0.219,0.208 10 true *a 1.729,0.917 1.948,1.125 0.219,0.208 10 true *b

*a	Paint Mark (Yellow)
*b	Timing Mark

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.

0.771,3.74 0.771,3.438 0.771,3.438 0.896,3.438 true 0.646,4.302 0.771,4.302 0.771,4.302 0.771,3.979 true 0.969,3.323 1.188,3.531 0.219,0.208 10 true *a 0.406,4.177 0.625,4.385 0.219,0.208 10 true *b

*a	Paint Mark (Orange)
*b	Timing Mark
	Turn

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.

1.99,1.302 2.281,1.052 2.281,1.052 2.469,1.052 false 2.583,0.99 2.896,1.188 0.313,0.198 10 false *a

*a

Loosen

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.

1.917,0.844 2.188,0.625 2.188,0.625 2.385,0.625 true 1.365,1.448 1.563,1.448 1.563,1.448 1.854,1.219 true 1.135,1.344 1.344,1.542 0.208,0.198 10 true *a 2.438,0.521 2.646,0.719 0.208,0.198 10 true *b

*a	Paint Mark (Orange)
*b	Timing Mark

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.

1.406,0.813 2.146,0.365 2.146,0.365 2.542,0.365 true 1.958,1.177 2.021,0.958 2.021,0.958 2.229,0.958 false 2.594,0.26 2.906,0.458 0.313,0.198 10 false *a 2.292,0.854 2.604,1.052 0.313,0.198 10 false *b

*a	Knock Pin Hole
*b	Knock Pin

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

1.552,0.021 1.865,0.177 0.313,0.156 10 false *a

*a	Hold
	Turn

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 or spark plug tube with the wrench.

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

5.073,2.406 5.198,2.406 5.198,2.406 5.198,2.177 false 1.74,0.521 1.885,0.323 1.885,0.323 1.979,0.323 false 3.75,0.333 3.896,0.135 3.896,0.135 3.99,0.135 false 3.677,0.438 4.052,0.781 4.052,0.781 4.219,0.781 true 3.646,0.896 4.021,1.24 4.021,1.24 4.188,1.24 true 2.885,2.354 3.021,2.354 3.021,2.354 3.313,2.385 false 2.813,2 2.979,2 2.979,2 3.396,2.302 true 2.906,1.667 3.073,1.667 3.073,1.667 3.49,1.969 true 2.042,0.229 2.354,0.427 0.313,0.198 10 false *3 4.896,2.323 5.208,2.521 0.313,0.198 10 false *4 4.042,0.042 4.354,0.24 0.313,0.198 10 false *a 4.271,0.688 4.583,0.885 0.313,0.198 10 false *b 4.24,1.146 4.552,1.344 0.313,0.198 10 false *1 2.677,2.24 2.99,2.438 0.313,0.198 10 false *a 2.615,1.906 2.927,2.104 0.313,0.198 10 false *b 2.688,1.552 3,1.75 0.313,0.198 10 false *2

*1	Oil Pump Drive Sprocket	*2	Oil Pump Drive Shaft Sprocket
*3	Crankshaft Timing Gear Key	*4	Oil Pump Sub-assembly
*a	Mark Plate	*b	Timing Mark

1.802,1.219 1.552,1.01 true 0.594,1.438 0.417,1.24 false 0.25,1.146 0.563,1.302 0.313,0.156 10 false *1 1.833,1.135 2.021,1.313 0.188,0.177 10 true *2

*1	Chain Tensioner Plate
*2	Chain Damper Spring

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

0.656,0.677 1.031,0.833 false 1.885,1.313 2.146,1.635 true 0.344,0.583 0.677,0.76 0.333,0.177 10 false SST 2.198,1.563 2.5,1.74 0.302,0.177 10 true SST

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)

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.

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

*a

No. 2 Timing Chain Cover Assembly Side

*b

Timing Chain Cover Assembly Side

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.).

0.479,0.406 0.615,0.594 0.135,0.188 10 false 6 0.573,0.802 0.708,0.99 0.135,0.188 10 false 7 0.646,1.156 0.781,1.344 0.135,0.188 10 false 8 0.958,1.542 1.063,1.708 0.104,0.167 10 true 9 0.76,1.75 0.938,1.917 0.177,0.167 10 true 10 0.771,2.125 0.948,2.292 0.177,0.167 10 true 11 0.708,2.583 0.885,2.771 0.177,0.188 10 false 12 0.656,2.906 0.833,3.094 0.177,0.188 10 false 13 1.729,2.354 1.844,2.531 0.115,0.177 10 true 5 1.188,3.24 1.365,3.427 0.177,0.188 10 false 14 1.948,3.073 2.125,3.26 0.177,0.188 10 true 15 2.302,2.729 2.479,2.917 0.177,0.188 10 true 16 2.281,2.26 2.396,2.438 0.115,0.177 10 true 4 2.438,2.042 2.625,2.229 0.188,0.188 10 true 17 1.958,1.708 2.073,1.885 0.115,0.177 10 true 2 1.427,1.646 1.542,1.823 0.115,0.177 10 true 3 2.458,1.646 2.646,1.833 0.188,0.188 10 true 18 2.635,1.094 2.813,1.281 0.177,0.188 10 false 19 1.729,0.844 1.844,1.021 0.115,0.177 10 true 1 2.698,0.344 2.875,0.531 0.177,0.188 10 false 20

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.

2.115,0.063 2.281,0.24 0.167,0.177 10 true 2 0.958,0.969 1.115,1.167 0.156,0.198 10 true 1 2.01,1.927 2.167,2.125 0.156,0.198 10 true 3

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.

Using a 10 mm hexagon wrench, install the straight screw plug.

Torque:

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

Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

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

NOTICE:

Remove any oil from the contact surfaces.

0.76,1.333 0.427,1.49 0.427,1.49 0.76,1.073 true 1.135,2.427 0.635,1.885 0.635,1.885 1.083,1.615 true 2.521,2.427 1.729,3 1.729,3 1.104,2.448 true 2.375,2.344 1.729,2.99 1.729,2.99 1.177,2.427 true 2.448,2.385 2.708,1.938 2.708,1.938 2.49,1.406 true 2.771,1.073 3.083,1.5 3.083,1.5 2.781,1.271 true 0.25,1.406 0.458,1.615 0.208,0.208 10 false *a 1.656,3.01 1.865,3.188 0.208,0.177 10 true *b 0.427,1.792 0.635,2 0.208,0.208 10 false *a 2.76,1.844 2.969,2.052 0.208,0.208 10 false *a 3.135,1.417 3.344,1.625 0.208,0.208 10 false *a

*a	Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
*b	Mark
	Seal Packing

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.

1.792,1.156 1.917,0.625 1.917,0.625 2.167,0.625 false 2.708,1.365 3.01,1.365 false 2.208,0.521 2.521,0.677 0.313,0.156 10 false *a 3.031,1.271 3.375,1.51 0.344,0.24 10 false *b

*a	O-ring Groove
*b	Camshaft Position Sensor Tip

Perform this procedure only when reusing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

iii.

0.906,1.344 1.031,1.49 1.031,1.49 1.25,1.49 false 2.219,3.156 2.219,2.865 false 2.521,0.49 2.688,0.26 2.688,0.26 2.896,0.26 false 2.521,1.354 2.688,1.479 2.688,1.479 2.927,1.479 false 2.823,2.875 3.104,2.875 false 1.927,2.26 2.208,2.26 false 2.208,1.49 2.208,1.198 false 0.906,2.99 1.031,3.135 1.031,3.135 1.25,3.135 false 0.865,0.667 1.208,0.51 1.208,0.51 1.406,0.51 true 0.865,2.302 1.208,2.146 1.208,2.146 1.406,2.146 true 1.292,1.417 1.604,1.573 0.313,0.156 10 false *1 2.938,0.177 3.146,0.385 0.208,0.208 10 false *c 0.313,0.333 0.625,0.49 0.313,0.156 10 false *a 0.323,2 0.635,2.156 0.313,0.156 10 false *b 0.583,0.854 0.74,1.052 0.156,0.198 10 true A 1.031,0.854 1.188,1.052 0.156,0.198 10 true A 1.031,2.51 1.188,2.708 0.156,0.198 10 true B 0.604,2.51 0.76,2.708 0.156,0.198 10 true B 2.156,1.51 2.469,1.667 0.313,0.156 10 false *1 2.156,3.177 2.469,3.333 0.313,0.156 10 false *1 2.344,0.094 2.802,0.292 0.458,0.198 10 false A - A 2.354,1.875 2.813,2.073 0.458,0.198 10 false B - B 3.135,2.813 3.344,3.021 0.208,0.208 10 false *c 2.969,1.406 3.177,1.615 0.208,0.208 10 false *c 1.75,2.177 1.958,2.385 0.208,0.208 10 false *c 1.281,3.063 1.594,3.219 0.313,0.156 10 false *1 1.448,0.448 1.656,0.656 0.208,0.208 10 false *c 1.438,2.083 1.646,2.292 0.208,0.208 10 false *c

*1	O-ring
*a	Correct
*b	Incorrect
*c	Seam

Check if each O-ring is twisted.

HINT:

Check the entire circumference of the seam of the O-ring for twisting.

0.438,0 0.594,0.198 0.156,0.198 10 false A 1.073,0 1.229,0.198 0.156,0.198 10 false A 1.656,0 1.813,0.198 0.156,0.198 10 false A 2.24,0 2.396,0.198 0.156,0.198 10 false A 2.833,0 2.99,0.198 0.156,0.198 10 false A 3.219,0.938 3.375,1.135 0.156,0.198 10 false A 3.219,1.604 3.375,1.802 0.156,0.198 10 true A 2.115,2.135 2.271,2.333 0.156,0.198 10 true A 1.531,2.146 1.688,2.344 0.156,0.198 10 true A 0.979,2.167 1.135,2.365 0.156,0.198 10 true A 0.51,2.177 0.667,2.375 0.156,0.198 10 true A 0.792,1.271 0.948,1.469 0.156,0.198 10 true C 0.188,1.5 0.344,1.698 0.156,0.198 10 true A 1.26,1.542 1.417,1.74 0.156,0.198 10 true C 1.708,1.531 1.865,1.729 0.156,0.198 10 true C 2.177,1.531 2.333,1.729 0.156,0.198 10 true C 1.76,0.792 1.917,0.99 0.156,0.198 10 true B 0.427,2.344 0.615,2.542 0.188,0.198 10 false 12 1.063,2.344 1.25,2.542 0.188,0.198 10 false 13 1.438,4.49 1.854,4.667 0.417,0.177 10 false 8, 20 2.219,2.354 2.635,2.531 0.417,0.177 10 false 15 2.802,2.354 3.219,2.531 0.417,0.177 10 false 16 3.198,3.313 3.427,3.5 0.229,0.188 10 false 17 3,3.667 3.229,3.854 0.229,0.188 10 false 2 3.198,3.938 3.427,4.125 0.229,0.188 10 false 18 2.094,4.479 2.323,4.667 0.229,0.188 10 true 19 1,4.5 1.229,4.667 0.229,0.167 10 true 9 0.49,4.5 0.719,4.667 0.229,0.167 10 true 10 0.073,3.854 0.302,4.021 0.229,0.167 10 true 11 0.823,3.625 0.979,3.792 0.156,0.167 10 true 6 1.771,3.135 1.927,3.302 0.156,0.167 10 true 1 1.583,2.344 2,2.521 0.417,0.177 10 false 7, 14 2.167,3.833 2.323,4 0.156,0.167 10 true 5 1.302,3.854 1.458,4.021 0.156,0.167 10 true 4 2.99,1.313 3.146,1.51 0.156,0.198 10 true B 1.76,3.854 1.917,4.021 0.156,0.167 10 true 3

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

Bolt Length:

Bolt	Length	Thread Diameter
(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.

Install the outlet water by-pass sub-assembly and a new outlet water pipe gasket to the cylinder head sub-assembly with the 3 bolts.

Torque:

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

Install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 2 bolts.

Torque:

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

1.188,0.917 0.51,0.917 0.51,0.917 0.615,0.385 false 0.302,0.323 0.521,0.51 0.219,0.188 10 false *a 1.969,1.833 2.281,1.99 0.313,0.156 10 false *b 0.198,0.844 0.552,1.031 0.354,0.188 10 false SST

*a	Hold
*b	Turn

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

Install a new oil filler cap gasket to the oil filler cap sub-assembly.

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

Install the No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

Install the No. 1 water by-pass hose to the cylinder block sub-assembly and slide the clip to secure it.