Part 3

OVERHAUL (CONTINUED)





64. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)
a. Align the yellow mark links with the timing marks (1 dot mark) of camshaft timing gears as shown in the illustration.





b. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain onto the RH camshafts.
c. Temporarily install the 2 camshaft timing gear bolts.

NOTICE: Do not push the camshaft timing gear assembly onto the camshaft forcibly when installing it.





d. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
e. Remove the pin from the chain tensioner No.2.





65. INSTALL CHAIN TENSIONER ASSEMBLY NO.3
a. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 inch) into the hole to hold it.





b. Install the chain tensioner No.3 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)





66. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (LH BANK)
a. Align the yellow mark links with the timing marks (1 dot mark and 2 dot marks) on camshaft timing gears as shown in the illustration.





b. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain onto the LH camshafts.
c. Temporarily install the 2 camshaft timing gear bolts.

NOTICE: Do not push camshaft timing gear assembly onto the camshaft forcibly when installing it.





d. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
e. Remove the pin from the chain tensioner No.3.





67. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the chain vibration damper No.1 with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)





68. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
a. Align the timing gear set key with the key groove of the timing gear.
b. Install the timing gear onto the crankshaft with the gear side facing inward.
69. INSTALL CHAIN TENSIONER SLIPPER





70. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
a. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
b. While turning the stopper plate of the tensioner counterclockwise, insert a bar of 3.5 mm (0.138 inch) into the holes in the stopper plate and tensioner to fix the stopper plate.
c. Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.)





71. INSTALL CHAIN SUB-ASSEMBLY
a. Set the No.1 cylinder to TDC/compression.
(1) Align the timing marks of the camshaft timing gears and bearing caps.





(2) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.





b. Align the yellow mark link with the timing mark of the crankshaft timing gear.





c. Align the orange mark links with the timing marks of the camshaft timing gears, and install the chain.





72. INSTALL CHAIN VIBRATION DAMPER NO.2
a. Instal the 2 chain vibration dampers No.2.
73. INSTALL IDLE SPROCKET ASSEMBLY
a. Apply a light coat of engine oil to rotating surface of the idle gear shaft No.1.





b. Temporarily install the idle gear shaft No.1 together with the idle gear shaft No.2 while aligning the knock pin of the idle gear shaft No.1 with the knock pin groove of the cylinder block.

NOTICE: Be careful of the idle gear direction.

c. Using a 10 mm hexagon wrench, tighten the idle gear shaft No.2.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
d. Remove the bar from the chain tensioner.





74. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09226-10010





b. Apply MP grease to the oil seal lip.
75. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
b. Install a new O-ring onto the LH cylinder head as shown in the illustration.





c. Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to 4 locations as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent





d. Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to the timing chain cover as shown in the illustration.
Seal packing:
Water pump part: Part No.08826-00100 or equivalent
Other part: Part No.08826-00080 or equivalent

NOTICE:
- Install the timing chain cover within 3 minutes of applying the seal packing. After installation, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be re moved and reapplied.
- Do not apply seal packing to A as shown in the illustration.





e. Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.





f. Install the timing chain cover with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)

NOTICE:
- Take care not to wrap the chain and slipper beyond the timing chain cover seal line.
- After installing the timing chain cover, install the water pump within 15 minutes.





HINT: Each bolt length is as above





76. INSTALL WATER PUMP ASSEMBLY
a. Install a new gasket and the water pump with the 17 bolts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
23 Nm (235 kgf-cm, 17 ft. lbs.) for 12 mm (0.47 inch) head
77. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.





b. Install the 4 stud bolts (for 2WD).
Torque: 4.0 Nm (41 kgf-cm, 35 inch lbs.)





c. Install the 4 stud bolts (for Pre Runner and 4WD).
Torque: 4.0 Nm (41 kgf-cm, 35 inch lbs.)





d. Install a new O-ring onto the oil pump.





e. Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 1.16 inch)) to the oil pan as shown in the illustration (for 2WD).
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the oil pan within 3 minutes of applying the seal packing. After installation, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.





f. Apply a continuous bead of the seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to the oil pan as shown in the illustration (for Pre Runner and 4WD).
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the oil pan within 3 minutes of applying the seal packing. After installation, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.





g. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps (for 2WD).
Torque:
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for 10 mm (0.39 inch) head
21 Nm (214 kgf-cm, 16 ft. lbs.) for 12 mm (0.47 inch) head





HINT: Each bolt length is as above





h. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps (for Pre Runner and 4WD).
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for 10 mm (0.39 inch) head
21 Nm (214 kgf-cm, 16 ft. lbs.) for 12 mm (0.47 inch) head





HINT: Each bolt length is as above





78. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket, then install the oil strainer with the 2 nuts (for 2WD).
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





b. Install a new gasket, then install the oil strainer with the 2 nuts (for Pre Runner and 4WD).
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

79. INSTALL OIL PAN SUB-ASSEMBLY NO.2
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No.2.





b. Apply a continuous bead of the seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration (for 2WD).
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the oil pan No.2 within 3 minutes of applying the seal packing. After installation, oil pan No.2 bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.





c. Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration (for Pre Runner and 4WD).
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the oil pan No.2 within 3 minutes of applying the seal packing. After installation, the oil pan No.2 bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.





d. Install the oil pan No.2 with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps (for 2WD).
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolts
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for nut





e. Install the oil pan No.2 with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps (for Pre Runner and 4WD).
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolts
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for nut
80. INSTALL OIL PAN DRAIN PLUG
a. Install the drain plug with a new gasket.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)





81. INSTALL CRANKSHAFT PULLEY
a. Using SST, fix the pulley and tighten the bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 185 ft. lbs.)
82. SET NO.1 CYLINDER TO TDC/COMPRESSION
83. INSPECT VALVE CLEARANCE
84. ADJUST VALVE CLEARANCE
85. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
b. Install the gasket onto the cylinder head cover.





c. Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 inch)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the cylinder head cover within 3 minutes of applying the seal packing. After installation, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

d. Install the seal washers onto the bolts.





e. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for bolts A
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolts B
9.0 Nm (92 kgf-cm, 80 inch lbs.) for nuts





HINT: Each bolt length is as above.

86. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
b. Apply adhesive to the threads of the ventilation valve.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
c. Install the ventilation valve onto the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
d. Install the gasket onto the cylinder head cover.





e. Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 inch)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the cylinder head cover of 3 minutes of applying the seal packing. After installation, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

f. Install the seal washers onto the bolts.





g. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for bolts A
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolts B
9.0 Nm (92 kgf-cm, 80 inch lbs.) for nuts





HINT: Each bolt length is as above.





87. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign objects on the mesh part of the 2 filters.
b. Install 2 new gaskets onto each new plug.
c. Insert the filters into the plugs.
d. Apply adhesive to 2 or 3 threads of the plugs.
Adhesive: Part No.08833-00080, THREE BOND 1344 LOCTITE 242 or equivalent
e. Install the plugs onto each cylinder head.
Torque: 62 Nm (632 kgf-cm, 46 ft. lbs.)





88. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque:10 Nm (102 kgf-cm, 7.4 ft. lbs.)





89. INSTALL WT SENSOR
a. Apply a light coat of engine oil to the O-ring of each WT sensor.
b. Install the 2 WT sensors with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





90. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the drain cocks end.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent





b. Tighten the drain cocks to the specified torque, and rotate them clockwise as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

NOTICE:
- Do not rotate the drain cocks more than 1 complete revolution (360°) after tightening the drain cocks to the specified torque.
- Do not loosen the drain cocks after setting it correctly.





91. INSTALL OIL LEVEL GAGE GUIDE
a. Install a new O-ring onto the oil level gauge guide.
b. Apply a light coat of engine oil to the O-ring.
c. Push the oil level gauge guide end into the guide hole of the oil pan.
d. Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





92. INSTALL ENGINE HANGERS
a. Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
b. Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)