A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY; 2019 - 2020 MY RAV4 HV [02/2019

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001HGV1
Model Year Start: 2019	Model: RAV4 HV	Prod Date Range: [02/2019 - 06/2020]
Title: A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY; 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]

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.

Click here

PROCEDURE

1. INSTALL STRAIGHT PIN

NOTICE:

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

(a) No. 2 timing chain cover assembly side:

(1) Using a plastic-faced hammer, tap in 4 new straight pins to the No. 2 timing chain cover assembly.

Protrusion Height

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.)

(b) Timing chain cover assembly side:

(1) Using a plastic-faced hammer, tap in a new straight pin to the timing chain cover assembly.

Standard Protrusion Height:

18.9 to 19.5 mm (0.744 to 0.768 in.)

*a	Protrusion Height

2. INSTALL RING PIN

NOTICE:

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

(a) Camshaft housing sub-assembly side:

(1) Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing sub-assembly.

Standard Protrusion Height:

3.7 to 4.3 mm (0.146 to 0.169 in.)

*a	Protrusion Height

(b) Stiffening crankcase assembly side:

(1) Using a plastic-faced 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.)

*a	Protrusion Height

(1) Using a plastic-faced hammer, tap in a new ring pin to the timing chain cover assembly.

Standard Protrusion Height:

3.0 to 5.0 mm (0.118 to 0.197 in.)

*a	Protrusion Height

3. INSTALL STUD BOLT

NOTICE:

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

(a) Stiffening crankcase assembly side:

(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}

*a	9.0 mm (0.354 in.)
*b	19 mm (0.748 in.)

(b) Timing chain cover assembly side:

(1) 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}

*a	21 mm (0.827 in.)
*b	9 mm (0.354 in.)
*c	34 mm (1.34 in.)

4. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Stiffening crankcase assembly side:

(1) Install the wire harness clamp bracket to the stiffening crankcase assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Cylinder block sub-assembly side:

(1) Install the wire harness clamp bracket to the cylinder block sub-assembly with the bolt.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(1) Install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon socket wrench, install the 3 straight screw plugs and 3 new gaskets to the stiffening crankcase assembly.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

6. INSTALL ENGINE BALANCER ASSEMBLY

(a) Install the engine balancer assembly to the stiffening crankcase assembly with the 2 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

7. INSTALL STIFFENING CRANKCASE ASSEMBLY

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

*1	Crankshaft Timing Gear Key
*a	270°

(b) 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.).
Do not start the engine for at least 2 hours after installation.
After installation, if the seal packing has seeped out, wipe it off.

*a	Seal Packing

Cutout

(d) Clean the bolts and bolt holes.

(e) 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.)

Bolt Type

(f) 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}

*a	Tightening Order

8. INSTALL OIL PUMP ASSEMBLY

Click here

9. INSTALL OIL PUMP BRACKET

(a) Install the oil pump bracket with the 2 bolts as shown in the illustration.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

*a	Front Mark

10. INSTALL ENGINE OIL LEVEL SENSOR

Click here

11. INSTALL OIL STRAINER SUB-ASSEMBLY

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

(b) Using an 8 mm socket wrench, install the oil strainer sub-assembly and oil strainer gasket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

12. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) 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 No. 2 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.).
Do not add engine oil for at least 2 hours after the installation.

*a	Seal Packing
*b	4.5 mm (0.177 in.)
*c	2.5 to 3.5 mm (0.0984 to 0.138 in.)

(b) Install the No. 2 oil pan sub-assembly with the 11 bolts and 2 nuts in several steps in the order shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

Nut

13. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and the oil pan drain plug to the No. 2 oil pan sub-assembly.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

14. INSTALL OIL FILTER UNION

(a) 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}

15. INSTALL OIL FILTER SUB-ASSEMBLY

Click here

16. INSTALL REAR ENGINE OIL SEAL

Click here

17. INSTALL CYLINDER BLOCK WATER JACKET SPACER

(a) Install the cylinder block water jacket spacer to the exhaust side of the cylinder block sub-assembly.

18. INSTALL CYLINDER HEAD GASKET

Click here

19. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT:

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

(a) 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.

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

Bolt Length:

Item	Length
Bolt (A)	139.1 to 140.9 mm (5.48 to 5.55 in.)
Bolt (B)	149.1 to 150.9 mm (5.87 to 5.94 in.)

Front of Engine

(d) 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.

Front of Engine

Torque:

90 N·m {918 kgf·cm, 66 ft·lbf}

NOTICE:

Be careful not to drop the plate washers into the cylinder head sub-assembly.

(e) Step 2:

(1) Mark each cylinder head set bolt head with paint as shown in the illustration.

*a	Paint Mark
*b	90°
*c	90°
	Front of Engine

(2) Tighten the cylinder head set bolts 90° in the order shown in step 1.

(f) 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.

w/ Canister Pump Module:
Click here
w/o Canister Pump Module:
Click here

20. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Using an 8 mm socket wrench, install the water by-pass pipe sub-assembly and a new gasket to the cylinder head sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

21. INSTALL NO. 2 CAMSHAFT

HINT:

Perform inspection after repair after replacing the No. 2 camshaft.

w/ Canister Pump Module:
Click here
w/o Canister Pump Module:
Click here

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

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

22. INSTALL CAMSHAFT

HINT:

Perform inspection after repair after replacing the camshaft.

w/ Canister Pump Module:
Click here
w/o Canister Pump Module:
Click here

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

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

23. INSTALL CAMSHAFT BEARING CAP

(a) 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.

(b) Uniformly tighten the 8 bolts in the order shown in the illustration.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

24. INSTALL VALVE STEM CAP

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

(b) 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.

25. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

Click here

(b) 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.

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

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

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

(b) 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.

27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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

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

(b) 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.).

*a	Seal Packing

*a	28° to 58°
*b	43° to 73°
*c	No. 1 Cylinder Cam Nose

(d) Temporarily install the camshaft housing sub-assembly with the 18 bolts.

Bolt Length:

Item	Length
Bolt (A)	40 mm (1.57 in.)
Bolt (B)	65 mm (2.56 in.)

(e) Install the camshaft housing sub-assembly, and then tighten the 18 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.

28. INSTALL FUEL PUMP LIFTER GUIDE

(a) 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}

29. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Using a plastic-faced 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.

30. INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY

(a) Install the oil nozzle valve sub-assembly to the cylinder block sub-assembly.

31. INSTALL TIMING CHAIN COVER ASSEMBLY

(a) 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.

Timing Chain Cover Assembly Side

Engine Assembly Side

(b) Apply seal packing in a continuous line to the timing chain cover assembly as shown in the illustration.

*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	4.0 to 6.0 mm (0.157 to 0.236 in.)	*f	3.0 to 4.0 mm (0.118 to 0.157 in.)
*g	8.0 to 10 mm (0.315 to 0.394 in.)	*h	30 mm (1.18 in.)
	Seal Packing	-	-

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.).

Bolt Length:

Bolt	Length	Thread Diameter
(A)	30 mm (1.18 in.)	12 mm (0.472 in.)
(B)	45 mm (1.77 in.)	12 mm (0.472 in.)

NOTICE:

Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

(d) Tighten the 19 bolts in the order shown in the illustration.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

32. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

HINT:

Perform inspection after repair after replacing the camshaft timing exhaust gear assembly.

w/ Canister Pump Module:
Click here
w/o Canister Pump Module:
Click here

(a) Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.

*a	Knock Pin Hole
*b	Knock Pin

(b) Using a wrench, hold the hexagonal portion of the No. 2 camshaft.

NOTICE:

Be careful not to damage the camshaft housing sub-assembly and spark plug tube with the wrench.
Do not disassemble the camshaft timing exhaust gear assembly.

(c) Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly with the 3 bolts and install the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly).

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

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

(a) Temporarily install the crankshaft pulley bolt.

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

*1	Crankshaft Timing Gear Key
*a	44.2°

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

*a	Timing Mark

34. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

35. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper with the bolt.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

36. 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) While slightly pushing in the plunger of the No. 1 chain tensioner assembly, install the chain tensioner slipper.

HINT:

Make sure that the end of the plunger is correctly seated in the groove of the chain tensioner slipper.
Make sure that the oil hole of the plunger is facing up.

*a	End of the Plunger
*b	Groove
*c	Oil Hole
*d	Chain Tensioner Slipper
*e	Plunger

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

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

37. INSTALL CHAIN SUB-ASSEMBLY

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

*1	Crankshaft Timing Gear Key

(b) Remove the crankshaft pulley bolt.

(d) 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.

*a	Paint Mark (Yellow)
*b	Timing Mark

(e) Using the hexagonal portion of the No. 2 camshaft, rotate the No. 2 camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing exhaust gear assembly with the paint mark (pink) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

*a	Paint Mark (Pink)
*b	Timing Mark
	Turn

38. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

HINT:

Perform inspection after repair after replacing the camshaft timing gear assembly.

w/ Canister Pump Module:
Click here
w/o Canister Pump Module:
Click here

(a) Hold the hexagonal portion of the No. 2 camshaft 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.

Loosen

(b) Align the paint mark (pink) of the chain sub-assembly and the timing mark of the camshaft timing gear assembly.

*a	Paint Mark (Pink)
*b	Timing Mark

*a	Knock Pin Hole
*b	Knock Pin

(d) Using a wrench, hold the hexagonal portion of the camshaft.

*a	Hold
	Turn

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.

(e) 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}

39. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

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

*1	Oil Pump Drive Sprocket	*2	Oil Pump Drive Shaft Sprocket
*3	Crankshaft Timing Gear Key	*4	Oil Pump Sub-assembly
*a	Mark Plate	*b	Timing Mark

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

(c) 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.

(d) 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.

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

*1	Chain Tensioner Plate
*2	Chain Damper Spring

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

(g) 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}

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

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

Click here

41. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

(a) 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.

No. 2 Timing Chain Cover Assembly Side

Timing Chain Cover Assembly Side

(b) 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 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.).

Seal Packing

NOTICE:

Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

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

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(e) Temporarily install the engine mounting insulator RH to the engine mounting bracket RH with the 3 bolts.

(f) Tighten 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.

42. INSTALL STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, install the straight screw plug.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

43. INSTALL TIMING CHAIN COVER OIL SEAL

Click here

44. INSTALL SPARK PLUG TUBE GASKET

(a) Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

NOTICE:

Keep the lip free from foreign matter.
Do not tap in the spark plug tube gaskets at an angle.

45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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

(b) Install 7 new cylinder head cover gaskets to the 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

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.

(d) Perform this procedure only when reusing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

*a	O-ring Groove
*b	Camshaft Position Sensor Tip

(1) Clean the O-ring groove of the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

NOTICE:

Make sure the O-ring groove is free of foreign matter.

(2) Install 2 new O-rings to the 2 camshaft position sensors (for Exhaust Side and for Intake Side).

NOTICE:

Set each O-ring on the tip of the 2 camshaft position sensors (for Exhaust Side and for Intake Side) and roll it into the O-ring groove with bare hands to install it.

(3) Check if each O-ring is twisted.

HINT:

Check the entire circumference of the seam of the O-ring for twisting.

*1	O-ring
*a	Correct
*b	Incorrect
*c	Seam

(e) Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

(f) Using an 8 mm socket wrench, install the 2 camshaft position sensors (for Exhaust Side and for Intake Side) with 2 new bolts (B) and the cylinder head cover sub-assembly with 4 new bolts (C) and 12 bolts (A) in the order shown in the illustration.

Bolt Length:

Bolt	Length	Thread Diameter
(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 or 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.

46. INSTALL OUTLET WATER BY-PASS SUB-ASSEMBLY

(a) Using an 8 mm socket wrench, install the outlet water by-pass sub-assembly and a new outlet water pipe gasket to the cylinder head sub-assembly with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

47. INSTALL WATER OUTLET

(a) Using an 8 mm socket wrench, install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

48. INSTALL CRANKSHAFT PULLEY ASSEMBLY

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

*a	Hold
	Turn

(b) 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}

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

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50. INSTALL CRANKSHAFT POSITION SENSOR

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51. INSTALL OIL FILLER CAP GASKET

(a) Install a new oil filler cap gasket to the oil filler cap sub-assembly.

52. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

53. INSTALL NO. 2 WATER BY-PASS HOSE

(a) Connect the No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

54. INSTALL NO. 1 WATER BY-PASS HOSE

(a) Connect the No. 1 water by-pass hose to the cylinder block sub-assembly and slide the clip to secure it.

55. INSTALL OIL COOLER ASSEMBLY

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56. INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

(a) Install the engine water pump assembly (water inlet housing) and a new gasket to the cylinder block sub-assembly with the 4 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

57. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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58. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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59. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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60. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

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61. INSTALL OIL PRESSURE AND TEMPERATURE SENSOR

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62. INSTALL STRAIGHT SCREW PLUG

(a) Install the straight screw plug and a new gasket to the cylinder block sub-assembly.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

63. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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64. INSTALL KNOCK CONTROL SENSOR

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65. INSTALL SPARK PLUG

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