1.302,2.594 1.958,2.917 0.656,0.323 10 false 8 mm (0.315 in.) 0.208,2.031 1.667,2.229 1.458,0.198 10 false 11 mm (0.433 in.) 3,2.375 3.177,2.552 0.177,0.177 10 false *a

*a	Protrusion Height

Using a plastic hammer, tap in 2 new stiffening crankcase ring pins until they are seated.

Standard Ring Pin:

Item	Protrusion Height	Height	Width
Stiffening crankcase ring pin	3.0 mm (0.118 in.)	8 mm (0.315 in.)	11 mm (0.433 in.)

HINT:

Standard protrusion may vary, but 3 mm (0.118 in.) is typical.

1.542,2.729 1.76,2.333 1.76,2.333 1.573,2.333 false 1.542,3.052 1.938,2.344 1.938,2.344 2.177,2.344 false 2.198,2.25 3.365,2.51 1.167,0.26 10 false 9.0 mm (0.354 in.) 0.427,2.24 1.594,2.5 1.167,0.26 10 false 9.0 mm (0.354 in.) 2.167,2.833 3.292,3.042 1.125,0.208 10 false 19 mm (0.748 in.)

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

Torque:

5.0 N*m (51 kgf*cm, 44 in.*lbf)

2.031,0.26 1.927,0.26 1.927,0.26 1.771,0.75 false 0.615,2.635 0.76,2.813 0.146,0.177 10 false A 2.115,0.167 2.427,0.365 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 Diameter:

Area	Specified Condition
Continuous Line	2.0 to 3.0 mm (0.0787 to 0.118 in.)
(A)	4.5 to 5.5 mm (0.177 to 0.217 in.)

Application Length (A):

56 mm (2.20 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 start the engine for at least 2 hours after installation.

0.823,2.375 0.969,2.563 0.146,0.188 10 8 3.135,0.688 3.292,0.875 0.156,0.188 10 A 0.813,0.188 1.167,0.323 0.354,0.135 10 B 0.625,2.229 0.792,2.448 0.167,0.219 10 C 1.396,4.406 1.552,4.635 0.156,0.229 10 1 1.729,2.396 1.927,2.635 0.198,0.24 10 2 2.167,0.333 2.333,0.552 0.167,0.219 10 C 3.125,1.635 3.281,1.823 0.156,0.188 10 A 2.344,2.188 2.51,2.406 0.167,0.219 10 C 1.813,2.198 1.979,2.417 0.167,0.219 10 C 1.375,2.219 1.542,2.438 0.167,0.219 10 C 0.99,2.229 1.156,2.448 0.167,0.219 10 C 1.698,0.229 2.052,0.604 0.354,0.375 10 B 1.333,0.188 1.688,0.563 0.354,0.375 10 B 1.833,4.385 1.979,4.583 0.146,0.198 10 3 1.365,2.385 1.531,2.573 0.167,0.188 10 4 1.021,4.406 1.167,4.594 0.146,0.188 10 5 2.198,2.51 2.333,2.688 0.135,0.177 10 6 2.365,4.375 2.51,4.573 0.146,0.198 10 7 3.146,2.917 3.344,3.156 0.198,0.24 10 9 0.604,4.417 0.854,4.604 0.25,0.188 10 10 3.125,3.844 3.385,4.052 0.26,0.208 10 11

Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

Bolt Length:

Item	Length
Bolt (A)	138 mm (5.43 in.)
Bolt (B)	35 mm (1.38 in.)
Bolt (C)	70 mm (2.76 in.)

3.156,2.042 3.156,1.896 3.156,1.896 2.917,1.688 false 0.24,1.385 0.469,1.604 0.229,0.219 10 false A 0.25,0.99 0.479,1.208 0.229,0.219 10 false B 0.865,0.99 1.094,1.208 0.229,0.219 10 false B 0.865,1.385 1.094,1.604 0.229,0.219 10 false A 0.833,3.125 1.198,3.333 0.365,0.208 10 false A - A 2.052,3.125 2.406,3.313 0.354,0.188 10 false B - B 3.083,2.083 3.302,2.26 0.219,0.177 10 false *a 0.948,2.385 1.583,2.615 0.635,0.229 10 false 6.0 mm 1.917,2.365 3,2.563 1.083,0.198 10 false 3.0 to 4.5 mm

*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

Application Specification:

Area	Seal Packing Diameter	Distance from Center of Bolt Hole to Center of Seal Packing
(A) - (A)	3.0 to 4.5 mm (0.118 to 0.177 in.)	6.0 mm (0.236 in.)
(B) - (B)		-

NOTICE:

·

Remove any oil from the contact surfaces.

·

Install the No. 2 oil pan sub-assembly within 3 minutes of applying seal packing.

·

Tighten the bolts and nuts within 15 minutes of applying seal packing.

·

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

0.229,1.885 0.542,2.083 0.313,0.198 10 false *a 2.948,1.74 3.135,1.906 0.188,0.167 10 true *a

*a

Nut

Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.

Torque:

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

Install a new gasket and the oil pan drain plug.

Torque:

37 N*m (377 kgf*cm, 27 ft.*lbf)

2.156,0.833 2.667,1.146 2.667,1.146 2.667,1.625 false 1.688,0.458 1.521,0.219 1.521,0.219 1.396,0.219 false 1.115,1.083 0.74,1.083 false 2.063,0.865 1.417,1.781 1.417,1.781 1.156,1.781 false 1.24,0.135 1.552,0.333 0.313,0.198 10 false *1 0.583,1 0.896,1.198 0.313,0.198 10 false *2 1,1.698 1.313,1.896 0.313,0.198 10 false *a 2.615,1.656 2.927,1.854 0.313,0.198 10 false *3

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

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

NOTICE:

Install each No. 1 valve rocker arm sub-assembly to the same place it was removed from.

Install the oil control valve filter to the camshaft bearing cap.

NOTICE:

Do not touch the mesh when installing the oil control valve filter.

0.938,4.313 0.938,3.99 false 1.031,3.385 1.188,3.583 0.156,0.198 10 false A 0.875,4.333 1.188,4.531 0.313,0.198 10 false *a

*a	Vernier Caliper

Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

Dimension (A):

1.05 to 1.75 mm (0.0413 to 0.0689 in.)

NOTICE:

Position the No. 2 camshaft bearings to the center of the camshaft housing sub-assembly by measuring dimension (A).

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

HINT:

Perform "Inspection After Repair" after replacing the No. 2 camshaft.

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

Install the camshaft to the camshaft housing sub-assembly.

HINT:

Perform "Inspection After Repair" after replacing the camshaft.

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

1.271,2.115 1.781,2.458 1.781,2.458 2.49,2.156 false 1.052,2.427 1.052,2.802 false 2.583,2.458 2.583,2.802 false 2.51,2.844 2.698,3.031 0.188,0.188 10 false *1 0.969,2.854 1.177,3.01 0.208,0.156 10 false *2 1.698,2.531 1.906,2.688 0.208,0.156 10 false *a 2.781,1.99 3.083,2.198 0.302,0.208 10 false 50°

*1	Camshaft
*2	No. 2 Camshaft
*a	Straight Pin

Make sure of the marks and numbers on the 5 camshaft bearing caps and place them in each proper position and direction.

HINT:

Make sure that the straight pin of each camshaft is positioned as shown in the illustration.

0.763,0.321 0.96,0.484 0.197,0.162 10 10 0.742,1.579 0.883,1.741 0.142,0.162 10 9 1.375,1.579 1.516,1.741 0.142,0.162 10 5 1.404,0.335 1.546,0.498 0.142,0.162 10 6 1.944,1.579 2.086,1.741 0.142,0.162 10 1 1.944,0.335 2.086,0.498 0.142,0.162 10 2 2.449,1.579 2.591,1.741 0.142,0.162 10 3 2.449,0.335 2.591,0.498 0.142,0.162 10 4 2.953,1.579 3.095,1.741 0.142,0.162 10 7 2.953,0.335 3.095,0.498 0.142,0.162 10 8

Tighten the 10 bolts in the order shown in the illustration.

Torque:

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

2.156,0.833 2.667,1.146 2.667,1.146 2.667,1.625 false 1.688,0.458 1.521,0.219 1.521,0.219 1.396,0.219 false 1.115,1.083 0.74,1.083 false 2.063,0.865 1.417,1.781 1.417,1.781 1.156,1.781 false 1.24,0.135 1.552,0.333 0.313,0.198 10 false *1 0.583,1 0.896,1.198 0.313,0.198 10 false *2 1,1.698 1.313,1.896 0.313,0.198 10 false *a 2.615,1.656 2.927,1.854 0.313,0.198 10 false *3

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

Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

1.771,2.354 1.885,2.917 1.885,2.917 2.063,2.917 false 0.417,2.896 0.688,3.125 0.271,0.229 10 false B 0.396,0.302 0.552,0.479 0.156,0.177 10 false A 2.104,2.833 3.042,3.031 0.938,0.198 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 Diameter:

Area	Specified Condition
Continuous line	2.0 to 3.0 mm (0.0787 to 0.118 in.)
(A)	8.0 mm (0.315 in.)
(B)	7.0 mm (0.276 in.)

Application Length (A) and (B):

15 mm (0.591 in.)

NOTICE:

·

Remove any oil from the contact surfaces.

·

Install the camshaft housing 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.

1.854,3.156 2.01,3.354 0.156,0.198 10 false 3 2.302,3.167 2.458,3.365 0.156,0.198 10 false 6 2.76,3.167 3.052,3.385 0.292,0.219 10 false 12 2.927,2.583 3.208,2.781 0.281,0.198 10 false 10 3.094,2 3.354,2.229 0.26,0.229 10 false 16 2.875,1.448 3.167,1.698 0.292,0.25 10 false 11 2.427,1.427 2.583,1.625 0.156,0.198 10 false 5 1.958,1.427 2.115,1.625 0.156,0.198 10 false 2 1.49,1.427 1.646,1.625 0.156,0.198 10 false 8 1.146,1.406 1.448,1.635 0.302,0.229 10 false 17 0.177,1.635 0.438,1.844 0.26,0.208 10 false 14 0.167,2.271 0.417,2.479 0.25,0.208 10 false 13 0.167,2.906 0.406,3.104 0.24,0.198 10 false 15 1.927,1.917 2.083,2.115 0.156,0.198 10 false 1 2.396,1.938 2.552,2.135 0.156,0.198 10 false 4 1.469,1.906 1.625,2.104 0.156,0.198 10 false 7 1.469,3.167 1.625,3.365 0.156,0.198 10 false 9

Set the camshaft and No. 2 camshaft as shown in the illustration.

1.448,1.021 1.031,0.219 false 1.156,1 0.521,1.646 false 0.917,0.021 1.104,0.177 0.188,0.156 10 *a 0.375,1.677 0.563,1.833 0.188,0.156 10 *b

*a	Straight Pin
*b	Pin Hole

Fit the camshaft timing exhaust gear assembly and No. 2 camshaft together by aligning the pin hole and straight pin.

2.771,0.75 2.604,0.75 2.604,0.75 1.406,1.01 false 1.49,0.177 1.292,0.177 1.292,0.177 1.031,0.906 false 1.552,0.083 1.865,0.24 0.313,0.156 10 *1 2.854,0.688 3.167,0.844 0.313,0.156 10 *c 1.427,0.552 1.74,0.708 0.313,0.156 10 *a 1.427,1.969 1.74,2.125 0.313,0.156 10 *b

*1	Camshaft Timing Exhaust Gear Assembly
*a	Gap
*b	No Gap
*c	No. 2 Camshaft Flange

Check that there is no gap between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

Tighten the bolt while holding the hexagonal portion of the No. 2 camshaft.

Torque:

54 N*m (551 kgf*cm, 40 ft.*lbf)

1.292,1.052 0.531,1.615 0.531,1.615 0.531,1.771 false 2.406,0.25 2.271,0.25 2.271,0.25 1.948,1.083 false 2.438,0.146 3.208,0.323 0.771,0.177 10 *a 0.448,1.771 0.625,1.948 0.177,0.177 10 *b

*a	Straight Pin
*b	Key Groove

Fit the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned as shown in the illustration.

NOTICE:

Do not forcibly push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.

0.833,1.344 1.458,1.802 false 0.813,0.594 1.125,0.208 false 2.594,0.74 2.938,1.125 0.344,0.385 10 false A 1.177,0.073 1.365,0.229 0.188,0.156 10 false *a 1.5,1.74 1.771,1.896 0.271,0.156 10 false *b 0.208,0.271 0.625,0.75 0.417,0.479 10 false *c

*a	Straight Pin
*b	Key Groove
*c	View (A)

Turn the camshaft timing gear assembly as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the straight pin fits into the key groove.

NOTICE:

Do not turn the camshaft timing gear assembly in the retard direction (clockwise).

2.771,0.75 2.604,0.75 2.604,0.75 1.406,1.01 false 1.49,0.177 1.292,0.177 1.292,0.177 1.031,0.906 false 1.552,0.083 1.865,0.24 0.313,0.156 10 *1 2.854,0.688 3.167,0.844 0.313,0.156 10 *c 1.427,0.552 1.74,0.708 0.313,0.156 10 *a 1.427,1.969 1.74,2.125 0.313,0.156 10 *b

*1	Camshaft Timing Gear Assembly
*a	Gap
*b	No Gap
*c	Camshaft Flange

Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

Tighten the bolt while holding the hexagonal portion of the camshaft.

Torque:

54 N*m (551 kgf*cm, 40 ft.*lbf)

2.448,1.563 2.635,1.729 0.188,0.167 10 *a

*a

Lock

Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and locks in the most retarded position.

HINT:

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

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

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.

Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.

Temporarily install the crankshaft pulley set bolt.

1.375,1.906 1.958,1.688 1.958,1.688 2.156,1.688 false 1.313,2.052 2.021,2.125 2.021,2.125 2.198,2.125 false 1.458,2.667 2.135,3.156 2.135,3.156 2.333,3.156 false 1.729,3.76 2.188,3.5 2.188,3.5 2.385,3.5 false 1.646,4.385 2.302,4.156 2.302,4.156 2.531,4.156 false 1.75,4.552 2.042,4.573 2.042,4.573 2.198,4.573 false 2.198,1.625 2.51,1.781 0.313,0.156 10 false *a 2.229,2.052 2.542,2.208 0.313,0.156 10 false *b 2.375,3.083 2.688,3.24 0.313,0.156 10 false *1 2.427,3.438 2.74,3.594 0.313,0.156 10 false *2 2.573,4.104 2.885,4.26 0.313,0.156 10 false *b 2.26,4.51 2.573,4.667 0.313,0.156 10 false *a

*1	Oil Pump Drive Gear
*2	Oil Pump Drive Shaft Gear
*a	Yellow Mark Plate
*b	Timing Mark
	Engine Front

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

1.125,0.635 0.656,0.229 false 1.406,0.542 0.656,0.229 false 0.333,0.146 0.656,0.323 0.323,0.177 10 false SST

Using SST, hold the crankshaft pulley. Then tighten the oil pump drive shaft gear nut.

SST

09213-54015  09330-00021  

Torque:

28 N*m (286 kgf*cm, 21 ft.*lbf)

HINT:

Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

1.156,0.719 1.156,0.708 false

Engine Front

Install the crankshaft timing sprocket to the crankshaft as shown in the illustration.

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

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

Install the chain tensioner slipper to the cylinder block sub-assembly.

Install the No. 2 chain vibration damper to the camshaft bearing cap with the 2 bolts.

Torque:

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

Install the No. 1 generator bracket to the cylinder block sub-assembly with the 4 bolts.

Torque:

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

Install a new gasket and water inlet housing to the timing chain cover sub-assembly with the 3 bolts.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

1.563,2.521 1.875,2.677 0.313,0.156 10 *a 1.583,3.021 1.896,3.177 0.313,0.156 10 *b 2.531,2.729 2.844,2.885 0.313,0.156 10 *c

*a	21 mm (0.827 in.)
*b	9.0 mm (0.354 in.)
*c	34 mm (1.34 in.)

Using an E5 "TORX" socket wrench, install the 2 water inlet housing stud bolts as shown in the illustration.

Torque:

5.0 N*m (51 kgf*cm, 44 in.*lbf)

0.055,0.529 0.375,0.69 0.319,0.161 10 SST 0.429,0.609 0.499,0.609 0.499,0.609 0.713,0.855 false

Using SST, tap in a new timing chain cover oil seal until its surface is flush with the timing chain cover sub-assembly edge.

SST

09223-22010  

Install a new water pump gasket to the timing chain cover sub-assembly.

NOTICE:

Remove any oil from the contact surfaces.

Install the engine water pump assembly to the timing chain cover sub-assembly with the 3 bolts.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

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

1.688,0.333 2,0.531 0.313,0.198 10 *a 5.198,0.427 5.51,0.625 0.313,0.198 10 *b

*a	Engine Assembly Side	*b	Timing Chain Cover Sub-assembly Side
	Clean and degrease	-	-

Install 2 new O-rings to the cylinder head sub-assembly.

Apply seal packing to the engine unit as shown in the illustration.

4.927,2.292 5.844,2.49 0.917,0.198 10 5.0 mm 0.302,1.51 0.458,1.708 0.156,0.198 10 A 2.594,1.521 2.75,1.719 0.156,0.198 10 A 4.365,1.219 4.521,1.417 0.156,0.198 10 A

Seal Packing:

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

Standard Seal Diameter:

5.0 mm (0.197 in.)

NOTICE:

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

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

2.115,1.979 2.281,1.979 2.281,1.979 2.51,1.771 false 1.479,3 1.646,3 1.646,3 2.51,2.708 true 4.344,1.802 4.448,2.167 4.448,2.167 4.646,2.167 false 4.208,2.677 4.698,2.677 4.698,2.677 3.219,1.25 true 1.344,5.271 1.531,5.469 1.531,5.469 1.667,5.469 false 3.365,5.229 3.552,5.427 3.552,5.427 3.688,5.427 false 5.344,5.271 5.531,5.469 5.531,5.469 5.667,5.469 false 2.781,0.74 2.938,0.938 0.156,0.198 10 false A 2.146,1.031 2.302,1.229 0.156,0.198 10 false A 1.51,1.177 1.667,1.375 0.156,0.198 10 false F 1.208,1.948 1.365,2.146 0.156,0.198 10 false G 0.833,2.052 0.99,2.25 0.156,0.198 10 false H 0.563,3.958 0.719,4.156 0.156,0.198 10 false I 1.948,1.896 2.104,2.094 0.156,0.198 10 false D 2.198,2.219 2.354,2.417 0.156,0.198 10 false O 1.281,2.906 1.438,3.104 0.156,0.198 10 false *a 4.813,1.135 4.969,1.333 0.156,0.198 10 false J 5.24,1.927 5.396,2.125 0.156,0.198 10 false K 5.74,2.073 5.896,2.271 0.156,0.198 10 false L 6.26,2.115 6.417,2.313 0.156,0.198 10 false M 6.594,3.979 6.75,4.177 0.156,0.198 10 false N 4.729,2.083 4.885,2.281 0.156,0.198 10 false E 4.75,2.604 4.906,2.802 0.156,0.198 10 false *b 0.677,4.927 1.135,5.125 0.458,0.198 10 false A - A 2.49,4.906 2.948,5.104 0.458,0.198 10 false B - B 4.469,4.896 4.927,5.094 0.458,0.198 10 false C - C 0.969,6.417 1.125,6.615 0.156,0.198 10 false D 4.375,6.417 4.531,6.615 0.156,0.198 10 false E 1.667,5.01 2.583,5.208 0.917,0.198 10 false 2.5 mm 3.667,4.927 4.583,5.125 0.917,0.198 10 false 5.0 mm 5.625,4.969 6.542,5.167 0.917,0.198 10 false 7.5 mm 1.729,5.396 2.781,5.604 1.052,0.208 10 false 2.5 to 3.5 mm 3.76,5.354 4.813,5.563 1.052,0.208 10 false 4.5 to 5.5 mm 5.74,5.396 6.792,5.604 1.052,0.208 10 false 7.0 to 8.0 mm 2.146,7.156 2.604,7.354 0.458,0.198 10 false B 1.531,7.375 1.99,7.573 0.458,0.198 10 false B 1.448,7.833 1.906,8.031 0.458,0.198 10 false C 2.177,7.844 2.635,8.042 0.458,0.198 10 false C 5.552,7.417 6.01,7.615 0.458,0.198 10 false B 4.875,7.135 5.333,7.333 0.458,0.198 10 false B 4.688,8.125 5.146,8.323 0.458,0.198 10 false B 5.313,8.49 5.771,8.688 0.458,0.198 10 false B 4.969,7.781 5.427,7.979 0.458,0.198 10 false C 5.604,7.885 6.063,8.083 0.458,0.198 10 false C

*a

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

*b

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

Seal Packing:

Item	Seal Packing
Dashed line	Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Continuous line
Alternate long and short dashed line	Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

Seal Packing Application Chart:

Area	Seal Packing Diameter	Distance from Edge of Cover to:	Seal Packing Application Length	Distance from Top of Cover to Top of Seal Packing
Dashed line	2.5 to 3.5 mm (0.0984 to 0.138 in.)	Center of seal packing 2.5 mm (0.0984 in.)	-	-
Continuous line	4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.)	-	-	-
Alternate long and short dashed line	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-
(A) - (A)	2.5 to 3.5 mm (0.0984 to 0.138 in.)	Center of seal packing 2.5 mm (0.0984 in.)	-	-
(B) - (B)	4.5 to 5.5 mm (0.177 to 0.217 in.)	Center of seal packing 5.0 mm (0.197 in.)	-	-
(C) - (C)	7.0 to 8.0 mm (0.276 to 0.315 in.)	Opposite edge of seal packing 7.5 mm (0.295 in.)	-	-
(F)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	15.5 mm (0.610 in.)	50.4 mm (1.98 in.)
(G)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	10.3 mm (0.406 in.)	143.1 mm (5.63 in.)
(H)	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	19.5 mm (0.768 in.)	153.4 mm (6.04 in.)
(I)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	16.0 mm (0.630 in.)	385.8 mm (1.27 ft.)
(J)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	18.6 mm (0.732 in.)	51.4 mm (2.02 in.)
(K)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	25.3 mm (0.996 in.)	121.9 mm (4.80 in.)
(L)	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	25.8 mm (1.02 in.)	147.2 mm (5.80 in.)
(M)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	5.1 mm (0.201 in.)	173.0 mm (6.81 in.)
(N)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	14.6 mm (0.575 in.)	385.8 mm (1.27 ft.)
(O)	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-

NOTICE:

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

2.156,0.26 2.031,0.26 2.031,0.26 1.75,1.292 false 2.229,0.208 2.542,0.365 0.313,0.156 10 false *a

*a

Adhesive

Apply adhesive to 5 and a half threads or more of the end of the bolt (C).

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

1.719,1.667 2.083,0.135 2.083,0.135 2.198,0.135 true 0.625,0.719 0.781,0.917 0.156,0.198 10 false A 0.75,2.26 0.906,2.458 0.156,0.198 10 false A 0.74,1.844 0.896,2.042 0.156,0.198 10 false A 0.76,1.51 0.917,1.708 0.156,0.198 10 false A 3.042,1.844 3.198,2.042 0.156,0.198 10 false A 2.375,2.74 2.531,2.938 0.156,0.198 10 false A 2.125,3.208 2.281,3.406 0.156,0.198 10 false A 2.469,2.427 2.625,2.625 0.156,0.198 10 false A 2.479,2.167 2.635,2.365 0.156,0.198 10 true A 2.406,1.906 2.563,2.104 0.156,0.198 10 true A 2.563,1.469 2.719,1.667 0.156,0.198 10 false A 2.5,1.125 2.656,1.323 0.156,0.198 10 false B 2.427,1.323 2.583,1.521 0.156,0.198 10 false B 0.646,0.969 0.802,1.167 0.156,0.198 10 false B 0.729,1.26 0.885,1.458 0.156,0.198 10 false B 0.688,0.313 0.844,0.51 0.156,0.198 10 false C 2.656,0.427 2.813,0.625 0.156,0.198 10 false C 1.625,1.75 1.781,1.948 0.156,0.198 10 true A 1.49,1.198 1.646,1.396 0.156,0.198 10 true D 2.271,0.063 2.583,0.26 0.313,0.198 10 false *1

*1	Seal Washer

Temporarily install the timing chain cover sub-assembly with the 19 bolts and a new seal washer.

Bolt Length:

Item	Length
Bolt (A), (C)	35 mm (1.38 in.)
Bolt (B)	55 mm (2.17 in.)
Bolt (D)	40 mm (1.57 in.)

NOTICE:

Make sure that there is no oil on the threads of the bolts.

Temporarily install the engine mounting bracket RH to the timing chain cover sub-assembly with the 3 bolts.

Bolt Length:

Item	Length
Bolt	80 mm (3.15 in.)

NOTICE:

Make sure that there is no oil on the threads of the bolts.

Install 2 new O-rings to the timing chain cover sub-assembly.

Temporarily install the oil filter bracket to the timing chain cover sub-assembly with the 4 bolts.

Bolt Length:

Item	Length
Bolt	35 mm (1.38 in.)

NOTICE:

Make sure that there is no oil on the threads of the bolts.

Fully tighten the 26 bolts in the order shown in the illustration.

0.531,1.865 0.969,1.865 0.969,1.865 1.594,1.781 true 0.438,0.052 0.771,0.333 0.333,0.281 10 false *a 4.188,0.073 4.5,0.302 0.313,0.229 10 false *b 0.615,2.521 0.771,2.688 0.156,0.167 10 false A 0.521,0.865 0.677,1.063 0.156,0.198 10 false B 1.698,1.188 1.833,1.333 0.135,0.146 10 true E 1.604,2.073 1.76,2.271 0.156,0.198 10 true D 0.448,0.458 0.615,0.625 0.167,0.167 10 false C 0.5,0.688 0.656,0.854 0.156,0.167 10 false A 0.635,1.24 0.792,1.438 0.156,0.198 10 false B 0.625,2.344 0.781,2.51 0.156,0.167 10 false A 0.625,1.979 0.781,2.146 0.156,0.167 10 false A 0.635,1.604 0.792,1.771 0.156,0.167 10 false A 0.802,2.76 0.958,2.927 0.156,0.167 10 true A 1.031,2.917 1.188,3.083 0.156,0.167 10 true A 0.802,3.094 0.958,3.26 0.156,0.167 10 true A 1.771,3.573 1.927,3.74 0.156,0.167 10 false A 2.385,2.865 2.552,3.031 0.167,0.167 10 false A 2.448,2.344 2.573,2.479 0.125,0.135 10 true A 2.333,2 2.458,2.135 0.125,0.135 10 true A 3.083,1.948 3.208,2.083 0.125,0.135 10 false A 2.448,2.51 2.573,2.646 0.125,0.135 10 false A 2.313,1.604 2.438,1.74 0.125,0.135 10 true A 2.563,1.75 2.688,1.885 0.125,0.135 10 true A 1.594,1.375 1.729,1.521 0.135,0.146 10 true E 2.396,1.219 2.552,1.417 0.156,0.198 10 false B 2.51,0.99 2.667,1.188 0.156,0.198 10 true B 2.563,0.719 2.76,0.896 0.198,0.177 10 true E 2.688,0.448 2.854,0.615 0.167,0.167 10 false C 4.125,0.458 4.375,0.625 0.25,0.167 10 false 17 4.198,0.688 4.448,0.854 0.25,0.167 10 false 16 4.302,0.854 4.552,1.021 0.25,0.167 10 false 4 4.354,1.229 4.604,1.396 0.25,0.167 12 false 2 4.313,1.594 4.563,1.76 0.25,0.167 10 false 15 4.302,1.969 4.552,2.135 0.25,0.167 11 false 14 4.271,2.323 4.521,2.49 0.25,0.167 11 false 13 4.281,2.51 4.531,2.677 0.25,0.167 11 false 22 4.448,2.76 4.698,2.927 0.25,0.167 11 true 24 4.698,2.917 4.948,3.083 0.25,0.167 11 true 25 4.417,3.083 4.667,3.25 0.25,0.167 11 true 23 5.479,3.583 5.729,3.75 0.25,0.167 11 false 12 6.115,2.844 6.365,3.01 0.25,0.167 11 false 11 6.177,2.5 6.427,2.667 0.25,0.167 11 false 10 6.177,2.323 6.427,2.49 0.25,0.167 12 true 9 6.104,1.979 6.354,2.146 0.25,0.167 12 true 8 6.813,1.917 7.063,2.083 0.25,0.167 11 false 26 6.302,1.729 6.552,1.896 0.25,0.167 12 true 7 6.031,1.583 6.281,1.75 0.25,0.167 12 true 6 5.313,2.052 5.563,2.219 0.25,0.167 11 true 18 5.396,1.167 5.646,1.333 0.25,0.167 11 true 20 5.24,1.333 5.49,1.5 0.25,0.167 11 true 21 6.135,1.208 6.385,1.375 0.25,0.167 12 false 1 6.229,0.969 6.479,1.135 0.25,0.167 12 true 3 6.313,0.698 6.563,0.865 0.25,0.167 12 true 19 6.417,0.438 6.667,0.604 0.25,0.167 12 false 5 0.333,1.771 0.646,1.969 0.313,0.198 10 false *1

*1	Seal Washer	-	-
*a	Torque	*b	Bolt Tightening Order

Torque:

Bolt (A), (C) : 25.5 N*m (260 kgf*cm, 19 ft.*lbf)

Bolt (B), (E) : 51 N*m (520 kgf*cm, 38 ft.*lbf)

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

NOTICE:

·

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.

Install the stud bolt to the engine mounting bracket RH.

Torque:

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

0.896,0.344 0.802,0.208 0.802,0.208 0.729,0.208 false 2.469,0.333 2.385,0.198 2.385,0.198 2.302,0.198 false 1.073,2.531 1.188,2.771 1.188,2.771 1.26,2.771 false 1.01,4 0.76,4.271 0.76,4.271 0.656,4.271 false 1.219,3.552 0.917,3.219 0.917,3.219 0.844,3.219 false 1.25,4.021 1.771,4.354 1.771,4.354 1.906,4.354 false 0.688,1.365 0.688,1.156 0.688,1.156 0.823,0.979 true 2.24,1.365 2.24,1.156 2.24,1.156 2.375,0.979 true 0.167,0.125 0.333,0.281 0.167,0.156 10 false *a 1.792,0.125 1.958,0.281 0.167,0.156 10 false *b 0.542,0.104 0.708,0.26 0.167,0.156 10 false *e 1.271,2.667 1.458,2.917 0.188,0.25 10 false *g 2.115,0.104 2.281,0.26 0.167,0.156 10 false *e 0.469,4.198 0.677,4.417 0.208,0.219 10 false *g 0.656,3.125 0.823,3.281 0.167,0.156 10 false *e 1.927,4.26 2.094,4.417 0.167,0.156 10 false *f 0.5,2.219 0.667,2.375 0.167,0.156 10 false *c 0.708,1.917 0.875,2.073 0.167,0.156 10 false *d 0.625,1.396 0.792,1.552 0.167,0.156 10 false *f 2.188,1.385 2.354,1.542 0.167,0.156 10 false *f

*a	Correct
*b	Incorrect
*c	Push
*d	Raise
*e	Cam
*f	Hook
*g	Pin

Raise the ratchet pawl, then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

NOTICE:

Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

Install a new gasket, the bracket and No. 1 chain tensioner assembly with the 2 nuts.

Torque:

12 N*m (122 kgf*cm, 9 ft.*lbf)

NOTICE:

If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, engage the hook again.

0.271,2.302 0.552,2.385 false 0.646,2.448 0.844,2.75 false 1.177,2.531 1.333,2.688 0.156,0.156 10 *a 0.573,1.917 0.729,2.073 0.156,0.156 10 *b 0.104,2.208 0.26,2.365 0.156,0.156 10 *c 0.833,2.75 0.99,2.906 0.156,0.156 10 *d

*a	Turn
*b	Released
*c	Hook
*d	Pin

Rotate the crankshaft counterclockwise slightly and check that the hook is released.

0.865,2.333 0.646,2.49 false 1.146,2.635 1.313,2.792 0.167,0.156 10 *a 0.302,2.74 0.469,2.896 0.167,0.156 10 *b 0.865,2.177 1.031,2.333 0.167,0.156 10 *c

*a	Turn
*b	Plunger Extended
*c	Plunger

Turn the crankshaft clockwise, then check that the plunger is extended.

2.448,1.656 2.229,1.656 2.229,1.656 2.083,1.135 false 1.833,0.604 1.979,0.344 1.979,0.344 2.094,0.344 false 1.479,4.344 1.604,4.344 1.604,4.344 2.188,3.927 true 2.146,0.271 2.458,0.427 0.313,0.156 10 *a 2.479,1.583 2.792,1.74 0.313,0.156 10 *b 1.313,4.271 1.625,4.427 0.313,0.156 10 *c

*a	Spark Plug Tube Gasket without Sealing Part
*b	New Spark Plug Tube Gasket
*c	Claw

Using a hammer and the spark plug tube gasket which has had the sealing part cut off, uniformly tap in 4 new spark plug tube gaskets all the way.

NOTICE:

·

Keep the lip free from foreign matter.

·

Do not tap in the spark plug tube gaskets at on angle.

HINT:

If a spark plug tube gasket that will be used to install the spark plug tube gasket is deformed, and cannot be positioned on the spark plug tube gasket, correct the deformation using pliers.

Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

NOTICE:

Remove any oil from the contact surfaces.

Install 3 new gaskets to the camshaft bearing cap.

Apply seal packing as shown in the illustration.

Seal Packing:

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

Standard Diameter:

4.0 mm (0.157 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 installing the cylinder head cover sub-assembly.

1.333,0.885 1.656,0.615 1.656,0.615 1.802,0.615 false 1.865,0.521 2.177,0.719 0.313,0.198 10 false *1 1.156,0.448 1.552,0.625 0.396,0.177 10 true 1, 14 0.042,1.271 0.219,1.5 0.177,0.229 10 true 2 0.438,0.052 0.573,0.229 0.135,0.177 10 true 3 1.156,0.063 1.333,0.229 0.177,0.167 10 false 4 1.552,0.063 1.708,0.26 0.156,0.198 10 false 5 2.281,0.063 2.438,0.26 0.156,0.198 10 false 6 3.177,0.083 3.333,0.25 0.156,0.167 10 false 7 3.271,1.24 3.417,1.417 0.146,0.177 10 false 8 3.271,1.917 3.427,2.115 0.156,0.198 10 false 9 2.385,1.917 2.698,2.115 0.313,0.198 10 false 10 1.49,1.917 1.802,2.115 0.313,0.198 10 false 11 0.896,1.979 1.208,2.177 0.313,0.198 10 false 12 0.344,1.979 0.563,2.156 0.219,0.177 10 false 13

*1	Seal Washer

Install the cylinder head cover sub-assembly to the camshaft housing sub-assembly with the 13 bolts and a new seal washer in the order shown in the illustration.

Torque:

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

Install the 2 engine cover joints to the cylinder head cover sub-assembly.

Torque:

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

Install the 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.