Part 2
ENGINE UNITCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6) (RH Side):
COMPONENTS (Part 7) (LH Side):
COMPONENTS (Part 8):
COMPONENTS (Part 9):
COMPONENTS (Part 10):
REASSEMBLY Continued
20. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the valve stem caps to the cylinder head.
21. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 2.0 to 3.0 mm (0.079 to 0.118 in.)
NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installation.
(b) Install the oil seal retainer with the 6 bolts.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)
NOTICE:
Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
22. INSTALL WATER INLET PIPE
(a) Install the water inlet pipe with the 2 bolts.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)
(b) Install the water by-pass hose No. 1.
23. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
NOTICE:
^ Be careful of the installation direction.
^ Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
(b) Place the cylinder head on the cylinder block.
NOTICE: Ensure that no oil is on the mounting surface of the cylinder head.
HINT: The cylinder head bolts are tightened in 3 progressive steps.
(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(d) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
Torque: 36 N*m (367 kgf/cm, 27 ft. lbs.)
(e) Step 2
(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Tighten the cylinder head bolts another 90°.
(f) Step 3
(1) Tighten the cylinder head bolts by an additional 90°.
(2) Check that the painted mark is now facing rearward.
(g) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
24. INSTALL CYLINDER HEAD LH
(a) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
NOTICE:
^ Be careful of the installation direction.
^ Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
(b) Place the cylinder head on the cylinder block.
NOTICE: Ensure that no oil is on the mounting surface of the cylinder head.
HINT: The cylinder head bolts are tightened in 3 progressive steps.
(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(d) Step 1
(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
Torque: 36 N*m (367 kgf/cm, 27 ft. lbs.)
(e) Step 2
(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Tighten the cylinder head bolts another 90°.
(f) Step 3
(1) Tighten the cylinder head bolts by an additional 90°.
(2) Check that the painted mark is now facing rearward.
(g) Tighten the 2 bolts in the order shown in the illustration.
Torque: 30 N*m (306 kgf/cm, 22 ft. lbs.)
NOTICE: Only use the specifications stated above when tightening the bolts 1 and 2 shown in the illustration.
(h) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
25. INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
^ Keep the lash adjuster free from dirt and foreign objects.
^ Only use clean engine oil.
(a) Place the lash adjuster into a container full of engine oil.
(b) Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.
SST 09276-75010
(c) Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed the air.
OK: Plunger moves up and down.
NOTICE: When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.
(e) After bleeding the air, remove SST. Then quickly and firmly press the plunger with a finger.
OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
(f) Install the lash adjusters.
NOTICE: Install the lash adjuster at the same place it was removed from.
26. INSTALL NO. 1 VALVE ROCKER ARM SUBASSEMBLY
(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.
(b) Make sure that the valve rocker arms are installed as shown in the illustration.
27. INSTALL CAMSHAFT BEARING CAP RH
(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the camshaft and camshaft No. 2 to the camshaft housing RH.
(c) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
(d) Temporarily tighten the 8 bolts in the order shown in the illustration.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)
28. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
(a) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.)
NOTICE:
^ Remove any oil from the contact surface.
^ Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.
(b) Install the camshaft housing RH, and tighten the 12 bolts in the order shown in the illustration.
Torque: 28 N*m (286 kgf/cm, 21 ft. lbs.)
NOTICE: Make sure that the knock pins of the camshafts are positioned as shown in the illustration before installing the camshaft housing RH.
(c) Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 N*m (163 kgf/cm, 12 ft. lbs.)
NOTICE: Thoroughly wipe clean any seal packing.
(d) Install 3 new gaskets.
29. INSTALL CAMSHAFT BEARING CAP
(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing LH.
(c) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
(d) Temporarily tighten the 8 bolts in the order shown in the illustration.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)
30. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
(a) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.)
NOTICE:
^ Remove any oil from the contact surface.
^ Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.
(b) Install the camshaft housing LH, and tighten the 13 bolts in the order shown in the illustration.
Torque: 28 N*m (286 kgf/cm, 21 ft. lbs.)
NOTICE: Make sure that the knock pins of the camshafts are positioned as shown in the illustration before installing the camshaft housing LH.
(c) Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 N*m (163 kgf/cm, 12 ft. lbs.)
NOTICE: Thoroughly wipe clean any seal packing.
(d) Install 3 new gaskets.
31. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner No. 2 with the bolt.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
(b) While pushing in the tensioner, insert a pin of diameter 1.0 mm (0.039 in.) into the hole to fix it.
32. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for RH BANK)
(a) Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.
(b) Apply a small amount of engine oil to the bolt threads and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed.
(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 N*m (1,020 kgf/cm, 74 ft. lbs.)
(e) Remove the pin from the chain tensioner No. 2.
33. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner No. 3 with the bolt.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
(b) While pushing in the tensioner, insert a pin of diameter 1.0 mm (0.039 in.) into the hole to fix it.
34. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for LH BANK)
(a) Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration.
(b) Apply a small amount of engine oil to the bolt threads and bolt-seating surface.
(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed.
(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 N*m (1,020 kgf/cm, 74 ft. lbs.)
(e) Remove the pin from the chain tensioner No. 2.
35. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper No. 1 with the 2 bolts.
Torque: 23 N*m (230 kgf/cm, 17 ft. lbs.)
36. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the 2 chain vibration damper.
37. INSTALL CRANKSHAFT TIMING GEAR
(a) Install the timing gear set keys and timing gear as shown in the illustration.
38. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to the rotating surface of the idle gear shaft No. 1.
(b) Temporarily install the idle gear shaft No. 1 and idle sprocket 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 N*m (612 kgf/cm, 44 ft. lbs.)
39. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the mark plate and timing marks as shown in the illustration and install the chain.
HINT: The camshaft mark plate is orange.
(b) Do not pass the chain over the crankshaft, just put it on it.
(c) Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.
NOTICE: When the idle sprocket is reused, align the chain plates with the marks on the sprocket in order to tighten the chain between the banks.
(d) Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.
HINT: The crankshaft mark plate is yellow.
(e) Temporarily tighten the pulley set bolt.
(f) Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).