Toyota Corolla Cross: Reassembly

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.

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CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)

Procedure		Part Name Code
1	STRAIGHT PIN	-		-	-
2	RING PIN	-		-	-
3	STUD BOLT	-		-	-

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

●

Non-reusable part

Procedure		Part Name Code
4	STRAIGHT SCREW PLUG	-		-	-
5	OIL PUMP ASSEMBLY	15100	-	-	-
6	ENGINE BALANCER ASSEMBLY	-	-	-	-
7	STIFFENING CRANKCASE ASSEMBLY	11420		-	-
8	ENGINE OIL LEVEL SENSOR	89491		-	-
9	OIL STRAINER SUB-ASSEMBLY	15104		-	-
10	OIL PAN SUB-ASSEMBLY	12101		-	-
11	OIL PAN DRAIN PLUG	12101A	-	-	-
12	OIL FILTER UNION	15600A		-	-
13	OIL FILTER SUB-ASSEMBLY	15601	-	-	-
14	REAR ENGINE OIL SEAL	11401L		-	-
15	CYLINDER BLOCK WATER JACKET SPACER	11445	-	-	-

	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
	MP grease	●	Non-reusable part

Procedure		Part Name Code
16	CYLINDER HEAD GASKET	11115		-	-
17	CYLINDER HEAD SUB-ASSEMBLY	11101		-	-
18	NO. 1 WATER BY-PASS PIPE	16268		-	-
19	VALVE STEM CAP	13716		-	-
20	VALVE LASH ADJUSTER ASSEMBLY	13750		-	-
21	NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY	13801		-	-
22	CAMSHAFT BEARING CAP SETTING RING PIN	11155B		-	-
23	EXHAUST CAMSHAFT SUB-ASSEMBLY	13502B		-	-
24	INTAKE CAMSHAFT SUB-ASSEMBLY	13501A		-	-
25	CAMSHAFT BEARING CAP	-		-	-
26	CAMSHAFT HOUSING SUB-ASSEMBLY	11103		-	-
27	FUEL PUMP LIFTER GUIDE	23477		-	-

	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
●	Non-reusable part	-	-
*T1	1st: 50 (510, 37) 2nd: Turn 90° 3rd: Turn 90°	-	-

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

*1	CRANKSHAFT TIMING SPROCKET	*2	OIL PUMP DRIVE SPROCKET
*3	OIL PUMP DRIVE SHAFT SPROCKET	*4	CHAIN TENSIONER PLATE
*5	CHAIN DAMPER SPRING	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque		Do not apply lubrications to the threaded parts

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

*1	ENGINE MOUNTING BRACKET RH	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
●	Non-reusable part	★	Precoated part

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

	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
●	Non-reusable part	★	Precoated part

PROCEDURE

1. INSTALL STRAIGHT PIN

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

*a

Protrusion Height

-

-

(1) 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.)

2. INSTALL RING PIN

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

*a

Protrusion Height

-

-

(1) Using a plastic hammer, tap in 6 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)

4.3 to 5.3 mm (0.169 to 0.209 in.)

3. INSTALL STUD BOLT

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

*a	9 mm (0.354 in.)	*b	19 mm (0.748 in.)
*c	21 mm (0.827 in.)	*d	34 mm (1.34 in.)
*e	14 mm (0.551 in.)	*f	13 mm (0.512 in.)
*g	29 mm (1.14 in.)	-	-

(1) 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}

(2) 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}

(3) Using an E8 "TORX" socket wrench, install the stud bolt to the cylinder head sub-assembly.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

(4) Using an E8 "TORX" socket wrench, install the 2 stud bolts to the cylinder block sub-assembly.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

4. INSTALL STRAIGHT SCREW PLUG

(1) 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}

5. INSTALL OIL PUMP ASSEMBLY

Click here

6. INSTALL ENGINE BALANCER ASSEMBLY

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

7. INSTALL STIFFENING CRANKCASE ASSEMBLY

*a	270°	*b	Crankshaft Timing Gear Key Groove
*c	Seal Packing	*d	Cutout
*e	Bolt Type	*f	Tightening Order

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

(2) 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.).

(3) Check that the rear cutouts are as shown in the illustration.

(4) Clean the bolts and bolt holes.

(5) 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.)

(6) 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}

8. INSTALL ENGINE OIL LEVEL SENSOR

Click here

9. INSTALL OIL STRAINER SUB-ASSEMBLY

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

(2) 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}

10. INSTALL OIL PAN SUB-ASSEMBLY

*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

(1) 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.).

(2) 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}

11. INSTALL OIL PAN DRAIN PLUG

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

12. INSTALL OIL FILTER UNION

(1) 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}

13. INSTALL OIL FILTER SUB-ASSEMBLY

Click here

14. INSTALL REAR ENGINE OIL SEAL

Click here

15. INSTALL CYLINDER BLOCK WATER JACKET SPACER

16. INSTALL CYLINDER HEAD GASKET

Click here

17. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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

*a	Paint Mark	-	-
	Front of Engine	-	-

(1) 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.

(2) 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.)

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

(4) 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.

(5) 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.

(6) 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 here

18. INSTALL NO. 1 WATER BY-PASS PIPE

(1) Using an 8 mm socket wrench, install the No. 1 water by-pass pipe and a new water by-pass pipe gasket to the cylinder head sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

19. INSTALL VALVE STEM CAP

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

(2) 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.

20. INSTALL VALVE LASH ADJUSTER ASSEMBLY

(1) Inspect the 16 valve lash adjuster assemblies before installing them.

Click here

(2) 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.

21. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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

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

(2) 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.

22. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

NOTICE: It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.

*a

Protrusion Height

-

-

(1) Using a plastic 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.)

23. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the exhaust camshaft sub-assembly. Click here

(1) Clean the camshaft journals and camshaft housing sub-assembly.

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

(3) Install the exhaust camshaft sub-assembly to the camshaft housing sub-assembly.

24. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the intake camshaft sub-assembly. Click here

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

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

(3) Install the intake camshaft sub-assembly to the camshaft housing sub-assembly.

25. INSTALL CAMSHAFT BEARING CAP

(1) 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.

(2) Uniformly tighten the 9 bolts in the order shown in the illustration.

(3) Check the torque of each bolt again.

26. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

*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

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

(2) 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.).

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

(4) 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.)

(5) 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.

27. INSTALL FUEL PUMP LIFTER GUIDE

(1) 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}

28. INSTALL CRANKSHAFT TIMING GEAR KEY

(1) 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.

29. INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY

30. INSTALL TIMING CHAIN COVER ASSEMBLY

*a

Timing Chain Cover Assembly Side

*b

Engine Assembly Side

(1) 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.

*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	-	-

(1) 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.).

(1) 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.

(2) Tighten the 20 bolts in the order shown in the illustration.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

31. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly. Click here

*a

Knock Pin Hole

*b

Knock Pin

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

(2) 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.

(3) 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.

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

32. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

*1	Crankshaft Timing Gear Key	-	-
*a	44.2°	*b	Timing Mark

(1) Temporarily install the crankshaft pulley bolt.

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

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

33. INSTALL NO. 1 CHAIN VIBRATION DAMPER

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

34. INSTALL CHAIN TENSIONER SLIPPER

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

35. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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

(1) 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.

(2) Using an 8 mm socket wrench, install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(3) Install the nut.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

36. INSTALL CHAIN SUB-ASSEMBLY

*1	Crankshaft Timing Gear Key	-	-
*a	Paint Mark (Yellow)	*b	Timing Mark
*c	Paint Mark (Orange)	-	-
	Turn	-	-

(1) Set the crankshaft timing gear key as shown in the illustration.

(2) Remove the crankshaft pulley bolt.

(3) Install the crankshaft timing sprocket and chain sub-assembly.

(4) 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.

(5) 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.

37. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

HINT: Perform "Inspection After Repair" after replacing the camshaft timing gear assembly. Click here

*a	Loosen	*b	Paint Mark (Orange)
*c	Timing Mark	*d	Knock Pin Hole
*e	Knock Pin	*f	Hold
	Turn	-	-

(1) 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.

(2) 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.

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

(4) 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.

(5) 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}

38. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

*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

(1) Set the crankshaft timing gear key as shown in the illustration.

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

(3) 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.

(4) 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.

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

(6) Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.

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

SST: 09213-54015

SST: 09330-00021

Torque:

50 N·m {510 kgf·cm, 37 ft·lbf}

(8) Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.

39. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

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40. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

*a

No. 2 Timing Chain Cover Assembly Side

*b

Timing Chain Cover Assembly Side

(1) 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.

(1) 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.).

(2) 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.

(3) Tighten the 20 bolts in the order shown in the illustration.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(4) 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.

41. INSTALL STRAIGHT SCREW PLUG

(1) Apply adhesive to the straight screw plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(2) 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.

42. INSTALL TIMING CHAIN COVER OIL SEAL

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43. INSTALL SPARK PLUG TUBE GASKET

44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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

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

NOTICE:

Remove any oil from the contact surfaces.

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

NOTICE:

Remove any oil from the contact surfaces.

(3) 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.

(4) 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.

45. INSTALL WATER BY-PASS OUTLET

(1) 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}

46. INSTALL WATER OUTLET SUB-ASSEMBLY

47. INSTALL OUTLET HEATER WATER HOSE

48. INSTALL INLET HEATER WATER HOSE

49. INSTALL CRANKSHAFT PULLEY ASSEMBLY

*a

Hold

*b

Turn

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

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

SST: 09213-54015

SST: 09330-00021

Torque:

260 N·m {2651 kgf·cm, 192 ft·lbf}

50. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

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51. INSTALL CRANKSHAFT POSITION SENSOR

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52. INSTALL OIL FILLER CAP GASKET

53. INSTALL OIL FILLER CAP ASSEMBLY

54. INSTALL CAM TIMING CONTROL MOTOR O-RING

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55. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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56. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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57. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

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58. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

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59. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

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60. INSTALL OIL PRESSURE AND TEMPERATURE SENSOR

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61. INSTALL KNOCK CONTROL SENSOR

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62. INSTALL SPARK PLUG

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