ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Note

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 RING PIN

    Note

    It is not necessary to remove a ring pin unless it is being replaced.


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

      Standard protrusion height
      3.2 to 3.8 mm (0.125 to 0.149 in.)
      B006B9BC02
      *A for Bank 2 *B for Bank 1
      *a Protrusion Height - -

  2. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. B0069IZC02
      B006AHR Front Side

      Install the 2 cylinder block water jacket spacers as shown in the illustration.

  3. INSTALL NO. 1 OIL PIPE


    1. Install the No. 1 oil pipe and PCV pipe with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  4. INSTALL NO. 1 PCV CASE


    1. Install a new gasket to the No. 1 PCV case.

      Note

      Check that the gasket is securely fitted into the installation groove.

    2. B006E1EC01
      *a Protrusion
      *b Paint mark

      Connect the PCV pipe to the No. 1 PCV case.

      Tech Tips

      Align the protrusion of the No. 1 PCV case with the paint mark of the PCV hose.

    3. B006ADSE01

      Install the No. 1 PCV case with the 9 bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  5. INSTALL KNOCK CONTROL SENSOR

    Click here

  6. INSTALL SENSOR WIRE


    1. Install the sensor wire with the 2 connectors and 2 clamps.

  7. INSTALL CYLINDER HEAD GASKET LH

    Click here

  8. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

    Click here

  9. INSTALL CYLINDER HEAD GASKET RH

    Click here

  10. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

    Click here

  11. INSTALL VALVE STEM CAP

    Click here

  12. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

  13. INSTALL VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

    Click here

  15. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY LH

    Click here

  16. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY LH

    Click here

  17. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. Install the No. 3 chain tensioner assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  18. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

    Click here

  19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here

  20. INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY RH

    Click here

  21. INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY RH

    Click here

  22. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. Install the No. 2 chain tensioner assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  23. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  24. INSTALL REAR ENGINE OIL SEAL


    1. Place the rear engine oil seal retainer on wooden blocks.

    2. B006E76C02
      *1 Rear Engine Oil Seal Retainer
      *a 0 to 0.5 mm (-0 to 0.0197 in.)

      Using SST, tap in a new rear engine oil seal until its surface is flush with the rear engine oil seal retainer edge.

      SST
      09223-56010
      Oil Seal Protrusion Height
      0 to 0.5 mm (-0 to 0.0197 in.)

      Note


      • Keep the lip free of foreign matter.

      • Do not tap on the rear engine oil seal at an angle.

  25. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. B006GHF

      Install a new gasket as shown in the illustration.

      Note

      The claws of the gasket must face the rear engine oil seal retainer.

    2. Apply MP grease to the lip of the rear engine oil seal.

    3. B006CXHC02
      B006ECJ 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
      Seal diameter
      2.0 to 8.0 mm (0.0787 to 0.315 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the rear engine oil seal retainer within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

    4. B006BL7C02
      B006AHR Bolt A (Do not reuse)
      B006EC9 Bolt B

      Install the rear engine oil seal retainer with the new 6 bolts and 4 bolts.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  26. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. B006GN4

      Temporarily install the No. 1 oil pan baffle plate with the 4 bolts.

      Tech Tips

      After temporarily installing the 4 bolts, install the oil strainer sub-assembly.

  27. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket with the oil strainer sub-assembly.

      Note

      Check that the gasket is securely fitted into the installation groove.

    2. Temporarily install the oil strainer sub-assembly to the crankshaft bearing cap sub-assembly with the 3 bolts.

    3. Tighten the 7 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      B006EXQC01
      *A for 2WD *B for AWD

    4. Connect the PCV pipe clamp to the No. 1 oil pan baffle plate.

  28. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY


    1. Remove any remaining seal packing material and be careful not to drop any oil on the contact surfaces of the No. 1 oil pan sub-assembly and crankshaft bearing cap sub-assembly.

    2. B006AP6C02
      *a

      Standard Seal Packing Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)
      *b

      Wide Seal Packing Diameter

      5.5 to 6.5 mm (0.216 to 0.255 in.)
      *c Thick Coating Cross-section
      *d Seal Packing Width 38 mm (1.49 in.)
      *e Seal Packing Width 60 mm (2.36 in.)
      *f 3.0 mm (0.118 in.) or more
      *g 8.0 to 12 mm (0.315 to 0.472 in.)

      for 2WD:

      Apply seal packing in a continuous line as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the No. 1 oil pan sub-assembly within 3 minutes after applying seal packing.

    3. B006BIIC02
      *a

      Standard Seal Packing Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)
      *b

      Wide Seal Packing Diameter

      5.5 to 6.5 mm (0.216 to 0.255 in.)
      *c Thick Coating Cross-section
      *d Seal Packing Width 38 mm (1.49 in.)
      *e Seal Packing Width 60 mm (2.36 in.)
      *f 3.0 mm (0.118 in.) or more
      *g 8.0 to 12 mm (0.315 to 0.472 in.)

      for AWD:

      Apply seal packing in a continuous line as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the No. 1 oil pan sub-assembly within 3 minutes after applying seal packing.

    4. B006CF7C02
      B006AHR Bolt A
      B006EC9 Bolt B

      for 2WD:

      Install the No. 1 oil pan sub-assembly with the 12 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 30 mm (1.18 in.)
      Bolt B 92 mm (3.62 in.)
    5. B006FT5C02
      B006AHR Bolt A
      B006EC9 Bolt B
      B006FCW Bolt C

      for AWD:

      Install the No. 1 oil pan sub-assembly with the 12 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A and C
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 30 mm (1.18 in.)
      Bolt B 92 mm (3.62 in.)
      Bolt C 90 mm (3.54 in.)

  29. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  30. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. B006D8ZC02
      *a 3.0 to 4.0 mm (0.118 to 0.157 in.)
      B006ECJ Seal Packing

      for 2WD:

      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
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

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

    2. B006BLMC02
      *a 3.0 to 4.0 mm (0.118 to 0.157 in.)
      B006ECJ Seal Packing

      for AWD:

      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
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

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

    3. B006DB5C04
      B006AHR Bolt
      B006EC9 Nut

      for 2WD:

      Install the No. 2 oil pan sub-assembly with the 12 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


      • Tighten the nuts first. After tightening the bolts, check that the nuts and bolts are tightened to the specified torque.

      • Do not start the engine for at least 2 hours after the installation.

    4. B006BXYC04
      B006AHR Bolt
      B006EC9 Nut

      for AWD:

      Install the No. 2 oil pan sub-assembly with the 9 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


      • Tighten the nuts first. After tightening the bolts, check that the nuts and bolts are tightened to the specified torque.

      • Do not start the engine for at least 2 hours after the installation.

  31. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and the oil pan drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  32. INSTALL NO. 6 ENGINE COVER


    1. Install the No. 6 engine cover to the cylinder block sub-assembly.

  33. INSTALL TIMING CHAIN COVER ASSEMBLY


    1. Remove any remaining seal packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover assembly and cylinder block sub-assembly and cylinder head sub-assembly.

    2. B006DLX

      CylinderBlock Sub-assembly Side:

      Install 3 new oil pump gaskets to the cylinder block sub-assembly.

    3. B006C5X

      Timing Chain Cover Assembly Side:

      Install 2 new oil pump gaskets and 2 new water pump gaskets to the timing chain cover assembly.

    4. B006BVMC02
      *a 3.0 to 3.5 mm (0.118 to 0.137 in.)
      B006ECJ Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      3.0 to 3.5 mm (0.118 to 0.137 in.)

      Note


      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

    5. B006BW9

      Temporarily install the timing chain cover assembly with the 28 bolts.

      Note

      Make sure that there is no oil on the bolt threads.

    6. B006FGRE02

      Tighten the bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note


      • Do not start the engine for at least 2 hours after installation.

      • Wipe off any seal packing that seeped out around the surfaces of the No. 1 oil pan sub-assembly and cylinder head cover sub-assembly and make sure that there is no seal packing seeping out around the edges.

  34. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. Install the 2 timing gear set keys and camshaft timing gear or sprocket to the crankshaft.

  35. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. Install the 2 No. 2 chain vibration dampers with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  36. INSTALL NO. 1 CHAIN VIBRATION DAMPER


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

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  37. INSTALL IDLE SPROCKET ASSEMBLY


    1. B006GHBC02
      *1 No. 1 Idle Gear Shaft
      *2 Idle Sprocket
      *3 No. 2 Idle Gear Shaft
      *a Knock Pin
      B006AHR Apply Engine Oil

      Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

    2. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block sub-assembly.

      Note

      Make sure that the idle gear is facing the correct direction.

      Tech Tips

      Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.

    3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      Tech Tips

      After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.

  38. INSTALL NO. 1 CHAIN SUB-ASSEMBLY


    1. B006GQXC01
      *1 Crankshaft Pulley Set Key
      *a 60°

      Turn the crankshaft 60° counterclockwise and set it as shown in the illustration.

    2. B006AC9C03
      *A for Bank 1
      *a Timing Mark

      Check that the camshaft timing gear position on the bank 1 as shown in the illustration.

    3. B0069SVC02
      *A for Bank 2
      *a Timing Mark

      Check that the camshaft timing gear position on the bank 2 as shown in the illustration.

    4. B006CLEC02
      *a Mark Plate (Pink)
      *b Timing Mark

      Align the mark plates and timing marks as shown in the illustration and install the No. 1 chain sub-assembly.

      Tech Tips

      The camshaft mark plates are pink.

    5. B006FBE

      Rest the No. 1 chain sub-assembly on top of the crankshaft.

    6. B006APPC02
      *a When idle sprocket is reused
      *b Mark
      *c Align
      *d Chain Plate
      *e Chain sub-assembly between the banks
      B006AHR Turn

      Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain sub-assembly between the banks.

      Note

      When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain sub-assembly between the banks.

    7. B006ACFC02
      *a Mark Plate (Orange)
      *b Timing Mark

      Align the mark plate and timing mark as shown in the illustration and install the No. 1 chain sub-assembly onto the crankshaft timing sprocket.

      Tech Tips

      The crankshaft mark plate is orange.

    8. Temporarily install the crankshaft pulley set bolt.

    9. B006G1EC01
      *1 Crankshaft Pulley Set Key
      *a Center Line

      Turn the crankshaft clockwise to set it to the block bore center line RH (TDC/compression).

  39. INSTALL CHAIN TENSIONER SLIPPER


    1. B006G6W

      Install the chain tensioner slipper with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  40. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B006AWAC03
      *a Stopper Plate
      *b Plunger
      *c Pin

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

    2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.0500 in.) diameter into the hole of the stopper plate.

    3. Install the new gasket to the No. 1 chain tensioner assembly.

    4. Install the No. 1 chain tensioner assembly with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    5. Remove the lock pin of the No. 1 chain tensioner assembly.

  41. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


      • Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

    2. for Bank 1 side:

      Check that each camshaft timing mark is positioned as shown in the illustration.

      B006CZGC03
      *a Timing Mark (Camshaft Timing Intake Gear Assembly Side) *b Timing Mark (Camshaft Timing Exhaust Gear Assembly Side)

    3. for Bank 2 side:

      Check that each camshaft timing mark is positioned as shown in the illustration.

      B006FKUC03
      *a Timing Mark (Camshaft Timing Intake Gear Assembly Side) *b Timing Mark (Camshaft Timing Exhaust Gear Assembly Side)

    4. If the valve timing is misaligned, reinstall the timing chain.

    5. Remove the crankshaft pulley set bolt.

  42. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

    Click here

  43. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  44. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

    Click here

  45. INSTALL TIMING CHAIN CASE OIL SEAL

    Click here

  46. INSTALL CRANKSHAFT PULLEY

    Click here

  47. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  48. INSTALL CRANKSHAFT PULLEY COVER

    Click here

  49. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

    Click here

  50. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  51. INSTALL GENERATOR BRACKET SUB-ASSEMBLY


    1. Install the generator bracket sub-assembly with the 4 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  52. DISCONNECT NO. 1 WATER BY-PASS PIPE

    Click here

  53. INSTALL WATER INLET ASSEMBLY


    1. B006A2N

      Install a new water inlet pipe gasket to the water inlet assembly.

    2. Install the water inlet assembly with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  54. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  55. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  56. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  57. INSTALL SPARK PLUG TUBE GASKET


    1. Install 6 new spark plug tube gaskets to the cylinder head cover sub-assembly.

  58. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

    Click here

  59. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  60. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY LH

    Click here

  61. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY RH

    Click here

  62. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY LH

    Click here

  63. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY RH

    Click here

  64. INSTALL NO. 2 ENGINE COVER RH


    1. Install the No. 2 engine cover RH to the cylinder head cover sub-assembly RH.

  65. INSTALL NO. 2 ENGINE COVER LH


    1. Install the No. 2 engine cover LH to the cylinder head cover sub-assembly LH.

  66. INSTALL SPARK PLUG

    Click here

  67. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY LH

    Click here

  68. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY RH

    Click here

  69. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

    Click here

  70. INSTALL LOWER INTAKE MANIFOLD SUB-ASSEMBLY

    Click here

  71. INSTALL FUEL VAPOR FEED PIPE SUB-ASSEMBLY

    Click here

  72. INSTALL NO. 2 MANIFOLD STAY

    Click here

  73. INSTALL NO. 1 FUEL DELIVERY PIPE SUB-ASSEMBLY LH

    Click here

  74. INSTALL NO. 1 FUEL DELIVERY PIPE SUB-ASSEMBLY RH

    Click here