Partial Engine: Overhaul

1. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.

1. Remove the pulley bolt, cover plate and idler pulley.

1. Remove the 2 bolts and timing belt cover.

1. Remove the both, 2 nuts and belt tensioner.

1. Remove the 2 bolts, 2 nuts and idler pulley.

1. Using SST, remove the damper bolt.

   SST 09213-70010, 09330-00021

   Fig 1: Removing Damper Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the crankshaft damper.

   SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05020)

Fig 2: Removing Crankshaft Damper

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1. Remove the 4 bolts and timing belt cover.

1. If re-using the timing belt, check the installation marks on the timing belt.
   1. Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.
      Fig 3: Aligning Timing Belt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the installation marks have disappeared, place a new installation mark on the timing belt before removing each part.

2. Set the No. 1 cylinder to approx. 50° BTDC/compression.
   1. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
      Fig 4: Aligning Crankshaft Timing Pulley With Oil Pump Body Timing Mark

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Check that the timing marks of the camshaft timing pulleys and timing belt plates aligned.

      If not, turn the crankshaft 1 revolution (360°).

      Fig 5: Aligning Camshaft Timing Pulleys With Timing Belt Plate Mark

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 50°.
   NOTE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley (steps 19 and 20) and camshaft (steps 21 and 22), causing damage. So always set the crankshaft pulley at the correct angle.
3. Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot.
   Fig 6: Turning Crankshaft Counterclockwise

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4. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley counterclockwise.

   SST 09960-10010 (09962-01000, 09963-00350)

5. Disconnect the timing belt from the timing belt idler No. 1, and remove the timing belt.

Fig 7: Loosening Tension Between Camshaft (RH Bank) And Crankshaft Timing Pulley

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If there are any defects, check these points:

1. Premature parting
   • Check for proper installation.
   • Check the timing cover gasket for damage and proper installation.
2. If the belt teeth are cracked or damaged, check to see if either camshaft is locked.
3. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump.
4. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
5. If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth.

If necessary, replace the timing belt.

1. Visually check the seal portion of the tensioner for oil leakage.

   HINT:

   If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right.

   If leakage is found, replace the tensioner.

   Fig 9: Inspecting Tensioner For Oil Leak

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move.

   If the push rod moves, replace the tensioner.

   NOTE: Never hold the tensioner push rod facing downward.
   Fig 10: Checking Push Rod Movement

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3. Measure the protrusion of the push rod from the housing end.

   Protrusion: 9.5 - 10.5 mm (0.374 - 0.413 in.) 

If the protrusion is not as specified, replace the tensioner.

Fig 11: Measuring Push Rod Protrusion From Housing End

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1. Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.

1. Remove the bolt and idler.

1. Visually check the seal portion of the idler pulley for oil leakage.

   If leakage is found, replace the idler pulley.

2. Check that the idler pulley turns smoothly.

If necessary, replace the idler.

Fig 12: Checking Idler Pulley Seal For Oil Leakage

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1. Using SST, remove the timing pulley.

   SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)

Fig 13: Removing Crankshaft Timing Pulley

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1. Remove the 4 bolts and timing pulley.

Fig 14: Removing Camshaft Timing Pulley

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1. Remove the 4 bolts and timing pulley.

Fig 15: Removing Camshaft Timing Pulley Sub-Assembly (LH)

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1. Remove the camshafts of the RH bank.
   1. Boring the service bolt hole of the sub gear upward by turning the hexagon wrench head portion of the No. 2 camshaft with a wrench.
   2. Secure the sub gear to the main gear with a service bolt.

      Recommended service bolt:

      SERVICE BOLT SPECIFICATIONS
      
      

      Thread diameter	6 mm
      Thread pitch	1.0 mm
      Bolt length	16 - 20 mm (0.63 - 0.79 in.)

      Fig 16: Securing Sub Gear To Main Gear With Service Bolt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When removing the camshafts, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.
   3. Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagon wrench head portion of the No. 2 camshaft with a wrench.
      Fig 17: Setting Camshaft Main Gear Timing Mark

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Uniformly loosen the 22 bearing cap bolts in several passes, in the sequence shown.
   5. Remove the 22 bearing cap bolts, 4 seal washer oil feed pipe, 9 bearing caps, camshaft , plug, oil control valve filter and 2 camshafts.

Fig 18: Loosening Bearing Cap Bolts In Sequence

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1. Remove the camshafts of the LH bank.
   1. Boring the service bolt hole of the sub gear upward by turning the hexagon wrench head portion of the No. 4 camshaft with a wrench.
   2. Secure the sub gear to the main gear with a service bolt.
      Fig 19: Securing Sub Gear To Main Gear With Service Bolt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Recommended service bolt:

      SERVICE BOLT SPECIFICATIONS
      
      

      Thread diameter	6 mm
      Thread pitch	1.0 mm
      Bolt length	16 - 20 mm (0.63 - 0.79 in.)

      NOTE: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.
   3. Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the No. 4 camshaft with a wrench.
      Fig 20: Aligning Camshaft Drive Gear Timing Mark

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Uniformly loosen the 22 bearing cap bolts in several passes, in the sequence shown.
      Fig 21: Loosening Bearing Cap Bolts In Sequence

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.

1. Remove the 2 bolts and timing belt plate.

1. Remove the bolt, stud bolt and timing belt plate.

1. Remove the 2 bolts and timing belt plate.

1. Remove the bolt and timing belt plate.

1. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown.
   Fig 22: Loosening Cylinder Head Bolts In Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Cylinder head warpage or cracking could result from removing bolts in incorrect order.
   • Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
     Fig 23: Identifying Portion A Of Cylinder Head

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver.

Fig 24: Prying Cylinder Head Loose From Block

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1. Uniformly loosen the 10 cylinder head bolts of each cylinder head in several passes, in the sequence shown.
   Fig 25: Loosening Cylinder Head Bolts (LH) In Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Cylinder head warpage or cracking could result from removing bolts in incorrect order.
   • Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
   Fig 26: Identifying Portion A Of Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

Fig 27: Prying Cylinder Head Loose From Block

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1. Remove the 5 bolts, 2 stud bolts and nut, water pump and gasket.

1. Remove the 3 bolts, 2 nuts and baffle plate.

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

1. Remove the 7 bolts.
2. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
   Fig 28: Removing Engine Rear Oil Seal Retainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring.

1. Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more.
2. Using a screwdriver, pry out the gasket.
   Fig 29: Removing Spark Plug Tube Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.

   SST 09950-60010 (09551-00240, 09951-00440, 09952-06010), 09950-70010 (09951-07100)

   NOTE: Be careful of the installation direction.
2. Apply a light coat of MP grease to the gasket lip.
3. Return the 4 ventilation case claws to its original position.

Fig 30: Installing Spark Plug Tube Gasket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Mount the hexagon wrench head portion of the camshaft in a vise.
   Fig 31: Mounting Camshaft Hexagon Wrench Head Portion In Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Be careful not to damage the camshaft.
   • The 4 bolts shown in the illustration determine the backlash of the gear in the timing tube, so do not remove them. If any of the 4 bolts are removed, install a new timing tube assembly.
2. Remove the screw plug and seal washer.
3. Using a 10 mm hexagon wrench, and remove the bolt.
4. Pull out the timing tube and drive gear assembly from the camshaft.
   Fig 32: Removing Camshaft Timing Tube Assembly Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST and a 5 mm hexagon wrench, and remove the 4 bolts, drive gear and oil seal.

   SST 09960-10010 (09962-01000, 09963-00500)

Fig 33: Removing Drive Gear And Oil Seal

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1. Place a new oil seal to the timing tube.

Fig 34: Installing Camshaft Setting Oil Seal

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1. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
2. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.

   SST 09960-10010 (09962-01000, 09963-00500)

   Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

   NOTE: Be careful not to damage the timing tube.
   Fig 35: Tightening Drive Gear Mounting Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mount the hexagon wrench head portion of the camshaft in a vise.
   NOTE: Be careful not to damage the camshaft.
   Fig 36: Mounting Camshaft Hexagon Wrench Head Portion In Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until you feel it touch the bottom.
5. Using a 10 mm hexagon wrench, install the bolt.

   Torque: 78 N.m (790 kgf.cm, 58 ft.lbf) 

6. Install the seal washer and screw plug.

   Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 

Fig 37: Installing Camshaft Timing Tube Assembly Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Mount the hexagon wrench head portion of the camshaft in a vise.
   NOTE: Be careful not to damage the camshaft.
   Fig 38: Mounting Camshaft Hexagon Wrench Head Portion In Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, turn the sub gear clockwise, and remove the service bolt.

   SST 09960-10010 (09962-01000, 09963-00500)

   Fig 39: Removing Service Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using snap ring pliers, remove the snap ring.
   Fig 40: Removing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the wave washer, sub gear and gear bolt washer.

1. Using vernier calipers, measure the free distance between the washer ends.

   Free distance: 18.2 - 18.8 mm (0.712 - 0.740 in.) 

If the free distance is not as specified, replace the washer.

Fig 41: Inspecting Camshaft Timing Gear Bolt Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the gear bolt washer (1), sub gear (2) and wave washer (3).
   NOTE: Attach the pins on the gears to the gear bolt washer ends.
   Fig 42: Installing Gear Bolt Washer, Sub Gear And Wave Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using snap ring pliers, install the snap ring.
   Fig 43: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mount the hexagon wrench head portion of the camshaft in a vise.
   NOTE: Be careful not to damage the camshaft.
   Fig 44: Mounting Camshaft Hexagon Wrench Head Portion In Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt.

   SST 09960-10010 (09962-01000, 09963-00500)

   Fig 45: Installing Service Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.

1. Using a screwdriver, pry out the oil seal.
   Fig 46: Removing Oil Pump Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09316-60011 (09316-00011)

   Fig 47: Installing Oil Pump Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease to the oil seal lip.

1. Using a screwdriver and hammer, tap out the oil seal.

Fig 48: Removing Engine Rear Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09223-56010

2. Apply MP grease to the oil seal lip.

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
   1. Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
   2. Thoroughly clean all components to remove all the loose material.
   3. Using a non-residue solvent, clean both sealing surfaces.
   Fig 49: Installing Engine Rear Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to the oil seal retainer as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

   1. Install a nozzle that has been cut to a 3 - 4 mm (0. - 0.16 in.) opening.
   2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
   3. Immediately remove nozzle from the tube and reinstall cap.
   Fig 50: Applying Seal Packing To Oil Seal Retainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new O-ring to the cylinder block.
4. Install the oil seal retainer with the 7 bolts.

   Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

Fig 51: Installing O-Ring To Cylinder Block

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.

   Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

Fig 53: Installing Water Pump Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place a new cylinder head gasket on the cylinder block.
   NOTE: On the rear side of the cylinder head gasket are marks to distinguish the RH and LH banks, a "3R" mark for the RH bank
   NOTE: Be careful of the installation direction.
2. Place the cylinder head on the cylinder head gasket.
   Fig 54: Identifying Correct Cylinder Head Gasket Installation Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cylinder head bolts.
   • The cylinder head bolts are tightened in 2 progressive steps (steps (3) and (5)).
   • If any cylinder head bolt is broken or deformed, replace it.
     1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
     2. Install the plate washer to the cylinder head bolt.
     3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.
        Fig 55: Identifying Cylinder Head Bolt Torque Sequence

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 59 N.m (600 kgf.cm, 44 ft.lbf) 

        If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

        NOTE: Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
        Fig 56: Identifying Portion "A" Of Cylinder Head

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     4. Mark the front of the cylinder head bolt head with paint.
     5. Retighten the cylinder head bolts by 90° in the numerical order shown.
     6. Check that the painted mark is now at a 90° angle to front.
        Fig 57: Identifying Cylinder Head Bolt Painted Mark Position

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place a new cylinder head gasket on the cylinder block.
   NOTE: On the rear side of the cylinder head gasket are marks to distinguish the RH and LH banks, a "3L" mark for the LH bank
   NOTE: Be careful of the installation direction.
2. Place the cylinder head on the cylinder head gasket.
   Fig 58: Identifying Correct Cylinder Head Gasket Installation Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cylinder head bolts.
   • The cylinder head bolts are tightened in 2 progressive steps (steps (3) and (5)).
   • If any cylinder head bolt is broken or deformed, replace it.
     1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
     2. Install the plate washer to the cylinder head bolt.
     3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown

        Torque: 59 N.m (600 kgf.cm, 44 ft.lbf) 

        Fig 59: Identifying Cylinder Head Bolt Torque Sequence

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

        NOTE: Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
        Fig 60: Identifying Portion "A" Of Cylinder Head

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     4. Mark the front of the cylinder head bolt head with paint.
     5. Retighten the cylinder head bolts by 90° in the numerical order shown.
     6. Check that the painted mark is now at a 90° angle to front.

Fig 61: Identifying Cylinder Head Bolt Painted Mark Position

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1. Set the crankshaft position.
   1. Using the crankshaft damper bolt, turn the crankshaft, and set the set key of the crankshaft at the position of 90° counterclockwise from the timing mark (dot) of the oil pump body.
   NOTE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.
   Fig 62: Setting Crankshaft Key

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshafts of the RH bank.
   1. Apply MP grease to the thrust portion of the camshafts.
   2. Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts.
   3. Set the timing mark (1 dot mark) of the camshaft drive and driven main gears at approx. 10° angle.
      Fig 63: Aligning Camshaft Drive And Driven Main Gear Timing Marks

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Apply seal packing to the camshaft housing plug.
      • Remove the old packing (FIPG) material.
      • Apply seal packing to the housing plug.

      Seal packing: Part No. 08826-00080 or equivalent

      Fig 64: Applying Seal Packing To Camshaft Housing Plug

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Install the camshaft housing plug to the cylinder head as shown in the illustration.
   6. Install the oil control valve filter to the cylinder head.
      NOTE: Be careful of the installation direction.
      Fig 65: Installing Camshaft Housing Plug To Cylinder Head

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   7. Apply seal packing to the front bearing cap.
      • Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.

        Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.

        Thoroughly clean all components to remove all the loose material.

        Using a non-residue solvent, clean both sealing surfaces.

      • Apply seal packing to the bearing cap as shown in the illustration.

        Install a nozzle that has been cut to a 1.5 - 2.0 mm (0.059 - 0.79 in.) opening.

        Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

        Immediately remove nozzle from the tube and reinstall cap.

      Fig 66: Applying Seal Packing To Bearing Cap

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: Part No. 08826-00080 or equivalent

      NOTE: Do not apply seal packing to the front bearing cap grooves.
   8. Install the front bearing cap.
      NOTE: Installing the front bearing cap will determine the thrust portion of the camshaft.
   9. Install the other bearing caps in the sequence shown with the arrow mark facing forward.
      Fig 67: Identifying Correct Bearing Cap Installation Position

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   10. Push in the camshaft setting oil seal.
       Fig 68: Inserting Camshaft Setting Oil Seal

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   11. Install a new seal washer to the bearing cap bolt (A and B).
   12. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (D and E).
       NOTE: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C).
       NOTE: Each bolt length is indicated in the illustration.
       Fig 69: Identifying Correct Bearing Cap Bolt Lengths

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Bolt length:

       94 mm (3.70 in.) for A with seal washer

       72 mm (2.83 in.) for B with seal washer

       25 mm (0.98 in.) for C

       52 mm (2.05 in.) for D

       38 mm (1.50 in.) for E

   13. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
   14. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown.

       Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt C 

       16 N.m (160 kgf.cm, 12 ft.lbf) for others 

       Fig 70: Tightening Bearing Cap Bolts In Sequence

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   15. Remove the service bolt.
       Fig 71: Removing Service Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the set key of the crankshaft is at the position of 90° counterclockwise from the timing mark (dot) of the oil pump body.
   NOTE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.
   Fig 72: Setting Crankshaft Key

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshafts of the LH bank.
   1. Apply MP grease to the thrust portion of the camshafts.
   2. Align the timing marks (2 dot marks) of the camshaft drive and driven main gears, and place the 2 camshafts.
      Fig 73: Aligning Camshaft Drive And Driven Main Gear Timing Marks

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Apply seal packing to the camshaft housing plug.
      • Remove the old packing (FIPG) material.
      • Apply seal packing to the housing plug.

      Seal packing: Part No. 08826-00080 or equivalent

      Fig 74: Applying Seal Packing To Camshaft Housing Plug

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Install the camshaft housing plug to the cylinder head as shown in the illustration.
   5. Install the oil control valve filter to the cylinder head.
      NOTE: Be careful of the installation direction.
      Fig 75: Installing Camshaft Housing Plug To Cylinder Head

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   6. Apply seal packing to the front bearing cap.
      • Remove any old packing (FIPG) material and be care not to drop any oil on the contact surfaces of the bearing cap and cylinder head. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material fro the gasket surfaces and groove.

        Thoroughly clean all components to remove all the loose material.

        Fig 76: Applying Seal Packing To Front Bearing Cap

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Using a non-residue solvent, clean both sealing surfaces.

      • Apply seal packing to the bearing cap as shown in the illustration.

        Install a nozzle that has been cut to a 1.5 - 2.0 mm (0.059 - 0.79 in.) opening.

        Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

        Immediately remove nozzle from the tube and reinstall cap.

      Seal packing: Part No. 08826-00080 or equivalent

      NOTE: Do not apply seal packing to the front bearing cap grooves.
   7. Install the front bearing cap.
      NOTE: Installing the front bearing cap will determine the thrust portion of the camshaft.
   8. Install the other bearing cap in the sequence shown with the arrow mark facing forward.
      Fig 77: Identifying Bearing Cap Installation Position

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   9. Push in the camshaft setting oil seal.
      Fig 78: Inserting Camshaft Setting Oil Seal

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   10. Install a new seal washer to the bearing cap bolt (A and B).
   11. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts (D and E).
       NOTE: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C).
       NOTE: 4 Each bolt length is indicated in the illustration.
       Fig 79: Identifying Correct Bearing Cap Bolt Length

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Bolt length:

       94 mm (3.70 in.) for A with seal washer

       72 mm (2.83 in.) for B with seal washer

       25 mm (0.98 in.) for C

       52 mm (2.05 in.) for D

       38 mm (1.50 in.) for E

   12. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
   13. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown.

       Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt C 

       16 N.m (160 kgf.cm, 12 ft.lbf) for others 

       Fig 80: Tightening Bearing Cap Bolts In Sequence

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   14. Remove the service bolt.
       Fig 81: Removing Service Bolt

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1. Install the timing belt plate with the bolt and stud bolt.

   Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

1. Install the timing belt plate with the 2 bolts.

   Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

1. Install the timing belt plate with the bolt.

   Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

1. Install the timing belt plate with the 2 bolts.

   Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Attach the timing pulley to the camshaft timing tube, facing the "R" mark forward.
3. Hold the hexagon wrench head portion of the camshaft, install the 4 pulley bolts.

   Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

Fig 82: Installing Camshaft Timing Pulley

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
2. Attach the timing pulley to the camshaft timing tube, facing the "L" mark forward.
3. Hold the hexagon wrench head portion of the camshaft, install the 4 pulley bolts.

   Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

Fig 83: Installing Camshaft Timing Pulley Sub-Assembly (LH)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the timing pulley set key with the key groove of the pulley.
2. Using SST and a hammer, tap in the timing pulley, facing the flange side inward.

   SST 09223-46011

Fig 84: Installing Crankshaft Timing Pulley

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the idler with the bolt.

   Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) 

2. Check that the idler moves smoothly.

1. Apply adhesive 2 or 3 threads of the pivot bolt.

   Adhesive: - Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

2. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.
   Fig 85: Installing Plate Washer And Idler With Pivot Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) 

3. Check that the idler bracket moves smoothly.

1. Set the No. 1 cylinder to TDC/compression.
   1. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates aligned.
      Fig 86: Aligning Camshaft Pulleys

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Setting positions of the camshaft timing pulleys by turning them slightly clockwise makes it easy to install the timing belt:

      Camshaft timing pulley of LH bank: 1/2 teeth

      Camshaft timing pulley of RH bank: 1 tooth

      Fig 87: Setting Camshaft Timing Pulley Position

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
   Fig 88: Aligning Crankshaft Timing Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the timing belt.
   1. Remove any oil or water on the each pulley, and keep them clean.
      NOTE: Only wipe the pulleys; do not use any cleansing agent.
   2. Face the front mark (arrow) on the timing belt forward.
   3. Connect the timing belt to the crankshaft timing pulley.
      • Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
      Fig 89: Installing Timing Belt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Connect the timing belt to the idler No. 2.
   5. Connect the timing belt to the camshaft timing pulley LH.
      • Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
   6. Connect the timing belt to the water pump pulley.
   7. Connect the timing belt to the camshaft timing pulley (RH bank).
      • Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
   8. Connect the timing belt to the idler No. 1.
3. Set the belt tensioner.
   1. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of pressure.
   2. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
   3. Release the press.
   4. Install the dust boot to the belt tensioner.
   Fig 90: Securing Push Rod Setting Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the belt tensioner.
   1. Temporarily install the belt tensioner with the 2 bolts.
   2. Alternately tighten the 2 bolts.

      Torque: 26 N.m (270 kgf.cm, 19 ft.lbf) 

   3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
   Fig 91: Installing Belt Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the valve timing.
   1. Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
      NOTE: Always turn the crankshaft pulley clockwise.
      Fig 92: Turning Crankshaft Pulley

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Check that each pulley aligns with the timing marks as shown in the illustration.

   If the timing marks do not align, remove the timing belt and reinstall it.

   Fig 93: Confirming Proper Camshaft Timing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the sensor plate, facing the cup side outward.

1. Install the gasket to the cover spacer.
2. Install the cover spacer.

1. Install the timing belt cover with the 4 bolts.

1. Using SST and a hammer, tap in the crankshaft damper.

   SST 09223-46011

   Fig 94: Installing Crankshaft Damper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the damper bolt.

   SST 09213-70010, 09330-00021

   Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf) 

3. Align the pulley set key with the key groove of the crankshaft damper.

Fig 95: Installing Damper Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the idler pulley with the 2 bolts and 2 nuts.

   Torque: 

   16 N.m (160 kgf.cm, 12 ft.lbf) for 12 mm head 

   32 N.m (330 kgf.cm, 24 ft.lbf) for 14 mm head 

HINT:

Each bolt length is indicated in the illustration.

Bolt Length:

106 mm (4.17 in.) for 12 mm head (A)

114 mm (4.49 in.) for 14 mm head (B)

Fig 96: Installing Idler Pulley Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the belt tensioner with the bolt and 2 nuts.

   Torque: 15.5 N.m (160 kgf.cm, 11 ft.lbf) 

1. Fit the timing belt cover, matching the claws and pin with each part.
2. Install the timing belt cover with the 2 bolts.

   Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

Fig 97: Installing Timing Belt Cover Sub-Assembly No. 2

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the idler pulley and cover plate with the bolt.

   Torque: 39 N.m (398 kgf.cm, 29 ft.lbf) 

1. Remove any old packing (FIPG) material.
2. Apply seal packing to the semicircular plug grooves.

   Seal packing: Part No. 08826-00080 or equivalent 

   Fig 98: Applying Seal Packing To Semicircular Plug Grooves

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 semicircular plugs to the cylinder heads a shown in the illustration.
   Fig 99: Installing Semicircular Plugs To Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing (FIPG) material.
2. Apply seal packing to the cylinder heads as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

3. Install the gasket to the cylinder head cover.
4. Install the seal washer to the bolt.
5. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.

   Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf) 

Fig 100: Installing Cylinder Head Cover Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002