0.208,0.896 0.208,0.688 0.208,0.688 0.531,0.458 false 0.854,0.646 1.031,0.813 0.177,0.167 10 false *1 1.073,0.021 3,0.198 1.927,0.177 10 false 2 to 4 mm (0.0787 to 0.157 in.) 0.021,0.896 0.896,1.083 0.875,0.188 10 false 4.0 mm 0.302,1.146 1.5,1.49 1.198,0.344 10 false 10 to 15 mm (0.394 to 0.591 in.) 0.281,2.458 1.479,2.802 1.198,0.344 10 false 10 to 15 mm (0.394 to 0.591 in.)

*1	Cylinder Block Sub-assembly
	Engine Front

Apply seal packing (diameter 4.0 mm (0.157 in.)) to the cylinder block sub-assembly as shown in the illustration.

Seal Packing:

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

NOTICE:

Remove any oil from the cylinder block sub-assembly.

1.97,0.157 2.121,0.309 0.151,0.151 10 *a 1.464,0.494 1.649,0.248 1.649,0.248 1.954,0.248 false

*a	Lot No.
	Engine Front

Place a new cylinder head gasket on the cylinder block sub-assembly with the Lot No. stamp facing upward.

NOTICE:

Install the cylinder head gasket within 3 minutes of applying seal packing.

0.438,0.833 0.438,0.74 0.438,0.74 0.729,0.458 false 1.688,0.417 1.563,0.417 1.563,0.417 1.365,0.625 false 1.646,2.573 1.448,2.375 1.448,2.375 1.302,2.375 false 1.656,1.063 0.917,1.177 0.917,1.177 0.906,1.302 false 1.771,0.333 2.042,0.5 0.271,0.167 10 false *1 1.271,0 2.948,0.177 1.677,0.177 10 false 0 to 2 mm (0 to 0.0787 in.) 0.281,0.865 0.938,1.125 0.656,0.26 10 false 4.0 mm 0.302,1.333 1.5,1.677 1.198,0.344 10 false 10 to 15 mm (0.394 to 0.591 in.) 0.083,2.281 1.281,2.625 1.198,0.344 10 false 10 to 15 mm (0.394 to 0.591 in.)

*1	Cylinder Head Gasket
	Engine Front

Apply seal packing (diameter 4.0 mm (0.157 in.)) to the cylinder head gasket as shown in the illustration.

Seal Packing:

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

NOTICE:

·

Remove any oil from the cylinder head gasket and cylinder head sub-assembly.

·

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

0.583,0.099 0.691,0.25 0.108,0.152 10 8 1.122,0.099 1.229,0.25 0.108,0.152 10 4 1.668,0.113 1.775,0.264 0.108,0.152 10 2 2.2,0.113 2.308,0.264 0.108,0.152 10 5 2.768,0.092 2.875,0.244 0.108,0.152 10 9 1.647,1.78 1.761,1.935 0.114,0.155 10 1 1.095,1.782 1.202,1.933 0.108,0.152 10 6 0.506,1.782 0.697,1.933 0.191,0.152 10 10 2.225,1.782 2.333,1.933 0.108,0.152 10 3 2.775,1.782 2.883,1.933 0.108,0.152 10 7

Step 1:

1.635,1.688 1.948,1.094 false 1.521,1.75 1.833,1.948 0.313,0.198 10 *a 1.469,0.333 1.781,0.531 0.313,0.198 10 90° 2.583,0.094 3.042,0.292 0.458,0.198 10 45°

*a	Paint Mark
	Engine Front

Step 2:

0.893,2.009 1.056,2.193 0.163,0.184 10 *a 2.508,2.009 2.691,2.177 0.183,0.168 10 *b

*a	Before Wiping Off
*b	After Wiping Off

After tightening the cylinder head set bolts, wipe off any seal packing material that seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly.

HINT:

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

Click hereEngine / Hybrid System>2ZR-FE ENGINE CONTROL>SFI SYSTEM>INITIALIZATION

Install the No. 2 camshaft to the camshaft housing sub-assembly.

Install the camshaft to the camshaft housing sub-assembly.

Check that the No. 1 cylinder is at TDC/compression.

ii.

1.642,0.666 1.812,0.818 0.171,0.153 10 *1 1.703,1.585 1.219,0.759 1.219,0.759 1.608,0.759 false

*1	Crankshaft Timing Gear Key

Turn the crankshaft counterclockwise to position the crankshaft timing gear key to the top.

iv.

0.448,0.854 0.958,1.406 0.958,1.406 1.521,0.906 true 0.885,1.469 1.063,1.667 0.177,0.198 10 *a

*a	Timing Mark

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

0.656,0.396 1.26,0.188 1.26,0.188 1.531,0.188 true 0.656,0.479 1.365,0.573 1.365,0.573 1.615,0.573 true 2.604,2.5 2.302,2.99 2.302,2.99 2.302,3.385 true 1.24,4.021 0.677,4.021 true 1.573,0.104 1.802,0.323 0.229,0.219 10 *c 1.667,0.469 1.896,0.646 0.229,0.177 10 *d 2.24,3.427 2.49,3.594 0.25,0.167 10 *a 1.292,3.948 1.51,4.115 0.219,0.167 10 *b

*a	Place the Chain Sub-assembly on the Sprocket
*b	Pass the Chain Sub-assembly through the Damper
*c	Mark Plate (Orange)
*d	Timing Mark

Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain sub-assembly.

HINT:

·

Be sure to position the mark plate at the front of the engine assembly.

·

The mark plate on the camshaft side is colored orange.

·

Do not pass the chain sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.

·

Pass the chain sub-assembly through the No. 1 chain vibration damper.

Place the chain sub-assembly on the crankshaft without passing it around the shaft.

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plates (orange) and timing mark.

4.25,1.448 4.792,0.854 4.792,0.854 4.406,1.385 true 4.083,2.094 4.167,2.094 4.167,2.094 4.344,1.542 false 5.188,2.208 5.292,2.208 5.292,2.208 5.646,1.344 true 4.802,0.719 5.115,0.875 0.313,0.156 10 *c 3.927,2.01 4.24,2.167 0.313,0.156 10 *d 1.99,0.396 2.302,0.552 0.313,0.156 10 *a 5.021,2.125 5.333,2.281 0.313,0.156 10 *b

*a	Turn	*b	Tension the Chain Sub-assembly
*c	Mark Plate (Orange)	*d	Timing Mark

HINT:

·

Be sure to position the mark plates at the front of the engine assembly.

·

The mark plates on the camshaft side are colored orange.

1.969,1.802 1.99,0.313 1.99,0.313 1.75,0.313 true 2.115,1.948 2.146,2.979 true 2.083,3 2.271,3.156 0.188,0.156 10 false *b 1.552,0.229 1.74,0.385 0.188,0.156 10 false *a

*a	Timing Mark
*b	Mark Plate (Pink)

Align the mark plate (pink) and timing mark and install the chain sub-assembly to the crankshaft timing gear assembly.

HINT:

The mark plate on the crankshaft side is colored pink.

Recheck each timing mark at TDC/compression.

0.625,1.083 1.438,2.125 1.438,2.125 2.198,1.156 false 6.031,2.198 6.031,1.677 false 0.615,1 0.615,0.438 0.615,0.438 2.438,0.438 false 2.167,1.063 2.167,0.438 false 2.271,1.094 2.271,0.438 false 6.583,2.188 6.583,1.979 6.583,1.979 6.115,1.667 false 1.365,2.156 1.677,2.354 0.313,0.198 10 false *a 5.969,2.229 6.281,2.427 0.313,0.198 10 false *a 2.479,0.365 2.792,0.563 0.313,0.198 10 false *b 6.521,2.198 6.833,2.396 0.313,0.198 10 false *c

*a	Timing Mark	*b	Mark Plate (Orange)
*c	Mark Plate (Pink)	-	-