ENGINE UNIT REASSEMBLY


  1. INSTALL OIL PAN STUD BOLT

    Note

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


    1. A01GKWFE01

      for 2WD:

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. A01GLH2E01

      for AWD:

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  2. INSTALL NO. 1 VENTILATION CONNECTOR


    1. A01GKYOE01

      Install the No. 1 ventilation connector as shown in the illustration.

      Acceptable angle (A)
      -5 to 5°
      Tap-in depth (B)
      0.2 to 3.2 mm (0.008 to 0.126 in.)

      Note

      After the installation of the ventilation connector, do not rotate it.

      Tech Tips

      Connect the No. 1 ventilation connector so that its flat surface faces the rear part of the engine.

  3. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY


    1. A01GLNX

      Apply a light coat of engine oil to a new O-ring.

    2. Install the new O-ring to the drain pipe.

    3. Install the oil drain pipe with the bolt.

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

  4. INSTALL ENGINE REAR OIL SEAL RETAINER


    1. A01GJVOE01

      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 3.0 mm (0.079 to 0.118 in.)
      Application position from inside edge of retainer
      3.5 mm (0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

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

      • When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.

      • When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.

    2. A01GJWG

      Install the oil seal retainer with the 6 bolts.

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

  5. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01GJT0E01

      Apply a light coat of engine oil to a new O-ring.

    2. Install the new O-ring to the oil strainer.

    3. Install the oil strainer with the 2 bolts.

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

      Note

      Make sure the O-ring is not twisted or damaged.

  6. INSTALL NO. 2 OIL PAN BAFFLE PLATE (for AWD)


    1. A01GL3F

      Install the baffle plate with the 4 bolts.

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

  7. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01GLLF

      for 2WD:

      Install the baffle plate with the 8 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01GHXR

      for AWD:

      Install the baffle plate with the 4 bolts.

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

  8. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01GNVBE01

      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 0.156 in.)
      Application position from inside edge of oil pan
      6.0 mm (0.236 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01GMDVE01

      Install the oil pan with the 14 bolts and 2 nuts.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B and nut
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

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

  9. INSTALL OIL PAN PROTECTOR (for 2WD)

    A01GIM0E01

    1. Install the protector with the 2 nuts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Tech Tips

      Install the oil pan protector with its protrusion facing the bottom of the engine.

  10. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01GJ6IE01

      for 2WD:


      1. 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 0.156 in.)

        Note


        • Remove any oil from the contact surface.

        • Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

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

      2. A01GNAGE01

        Install the oil pan with the 15 bolts and 2 nuts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01GJN4E01

      for AWD:


      1. 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 oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      2. A01GIZZE01

        Install the oil pan with the 13 bolts and 2 nuts.

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

        Note

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

  11. INSTALL VENTILATION PIPE GASKET


    1. A01GJNNE01

      Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.

      SST
      09950-60010   ( 09951-00360 )
      09950-70010   ( 09951-07100 )

      Tech Tips


      • Do not tap the gasket at an angle.

      • Do not tap the gasket excessively.

  12. INSTALL NO. 1 HEAT EXCHANGER COVER


    1. A01GLBSE03

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

      Seal packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B 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 heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01GNWDE01

      Install the heat exchanger cover with the 11 bolts and 2 nuts.

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

      Note

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

    3. A01GM4ZE01

      Install the bolt.

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

  13. INSTALL OIL RETURN PIPE GASKET


    1. A01GHRD

      Install a new oil return pipe gasket.

  14. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01GK1RE01

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

      Tech Tips


      • Face the cutouts (indicated by arrows in illustration) away from the engine.

      • Face the "up mark" as shown in the illustration.

  15. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)


    1. Check the piston protrusions for each cylinder.


      1. Clean the cylinder block with solvent.

      2. Set the piston of the cylinder to be measured to slightly ATDC.

    2. A01GKSPE01

      Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

      Note


      • 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.

    3. Place the cylinder head on the cylinder block.

      Note

      Ensure that no oil is on the mounting surface of the cylinder head.

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

    4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    5. A01GHT8E02

      Step 1:


      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps, in the sequence shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    6. A01GHYSE01

      Step 2:


      1. Mark the cylinder head bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

    7. Step 3:


      1. Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.

      2. Check that the painted marks are now facing rearward.

    8. A01GK0AE02

      Uniformly install the 2 bolts in the sequence shown in the illustration.

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

  16. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2)


    1. Check the piston protrusions for each cylinder.


      1. Clean the cylinder block with solvent.

      2. Set the piston of the cylinder to be measured to slightly ATDC.

    2. A01GJYQE01

      Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

      Note


      • 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.

    3. Place the cylinder head on the cylinder block.

      Note

      Ensure that no oil is on the mounting surface of the cylinder head.

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

    4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    5. A01GJN2E02

      Step 1:


      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps, in the sequence shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    6. A01GHYSE01

      Step 2:


      1. Mark the cylinder head bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

    7. Step 3:


      1. Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.

      2. Check that the painting marks are now facing rearward.

    8. A01GL5KE02

      Uniformly install the 2 bolts in the sequence shown in the illustration.

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

  17. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem caps.

    2. Install the 32 valve stem caps to the cylinder head.

  18. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Be sure to inspect the valve lash adjuster before installing it Click here.

    2. Install the 32 valve lash adjusters to the cylinder head.

      Note

      Install the lash adjuster at the same place it was removed from.

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


    1. A01GNOHE04
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Apply engine oil to the lash adjuster tips and valve stem cap ends.

    2. Make sure that the 32 valve rocker arms are installed as shown in the illustration.

  20. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. Install the No. 1 and No. 2 camshaft to the camshaft housing.

    3. A01GJDJ

      Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper positions and directions.

    4. A01GLILE01

      Temporarily install the 8 bolts in the order shown in the illustration.

  21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2)


    1. A01GK7NE03
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a INCORRECT
      *b CORRECT

      Make sure that the valve rocker arms are installed as shown in the illustration.

    2. A01GJ37E01

      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
      3.5 to 4.0 mm (0.138 to 0.158 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing 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 the installation.

    3. A01GNQJE01

      Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      except bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

    4. A01GMRQE03

      Tighten the 8 bolts in the order shown in the illustration.

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

      Note

      Thoroughly wipe clean any seal packing.

  22. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. Install the No. 3 and No. 4 camshaft to the camshaft housing.

    3. A01GIGI

      Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper positions and directions.

    4. A01GHROE01

      Temporarily install the 8 bolts in the order shown in the illustration.

  23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1)


    1. A01GK7NE03
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a INCORRECT
      *b CORRECT

      Make sure that the valve rocker arms are installed as shown in the illustration.

    2. A01GLUHE01

      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
      3.5 to 4.0 mm (0.138 to 0.158 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing 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 the installation.

    3. A01GJXWE01

      Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      except bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

    4. A01GMMXE02

      Tighten the 8 bolts in the order shown in the illustration.

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

      Note

      Thoroughly wipe clean any seal packing.

  24. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A01GL39

      Install the 2 timing gear keys.

  25. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01GIWWE01

    2. Rotate the crankshaft so that the timing gear key is as shown in the illustration. Then, using a wrench, rotate each camshaft so that the timing marks are as shown in the illustration.

      Note

      When the crankshaft or a camshaft is rotated excessively, the valves and pistons may interfere with each other.

    3. Remove the crankshaft pulley bolt.

  26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01GLEWE01

      Install the chain tensioner with the 2 bolts.

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

    2. While raising up the No. 2 chain tensioner, insert a pin with a diameter 1.0 mm (0.039 in.) into the hole to fix it in place.

  27. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)


    1. A01GJXQE01

      Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark and install the chain to the gear as shown in the illustration.

    2. A01GKJPE01

      Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark and install the chain to the gear as shown in the illustration.

    3. A01GKO4E01

      Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly and install the No. 2 chain to the gears as shown in the illustration.

      Tech Tips

      The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears.

    4. Install the crankshaft timing gear to the crankshaft.

    5. A01GNBWE02

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly.

      Tech Tips

      Make sure that the arrow is facing upward with respect to the ground.

    6. Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

    7. Remove the pin from the No. 2 chain tensioner.

  28. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)


    1. A01GLQT

      Install the vibration damper with the 2 bolts.

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

  29. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)

    Tech Tips

    If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.

  30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)


    1. A01GHN8E01

      Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

    3. A01GL6T

      Install the chain tensioner with the 2 bolts.

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

    4. Remove the hexagon wrench from the chain tensioner.

  31. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01GLNRE01

      Install the chain tensioner with the 2 bolts.

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

    2. While pushing down the No. 3 chain tensioner, insert a pin with a diameter of 1.0 mm (0.039 in.) into the hole to fix it in place.

  32. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A01GNILE01

      Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark and install the chain to the gear as shown in the illustration.

    2. A01GIYWE01

      Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark and install the chain to the gear as shown in the illustration.

    3. A01GMTJE01

      Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly and install the No. 2 chain to the gears as shown in the illustration.

      Tech Tips

      The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears.

    4. Install the crankshaft timing gear to the crankshaft.

    5. A01GI71E02

      Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly.

      Tech Tips

      Make sure that the arrow is facing upward with respect to the ground.

    6. Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

      Note

      Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

    7. Remove the pin from the No. 2 chain tensioner.

  33. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)

    Tech Tips

    If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner.

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)


    1. A01GHN8E01

      Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

    3. A01GI31

      Install the chain tensioner and a new gasket with the 2 bolts.

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

  35. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)


    1. A01GJ1V

      Install the vibration damper with the 2 bolts.

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

    2. Remove the hexagon wrench from the No. 1 chain tensioner.

  36. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY


    1. for Bank 1:


      1. A01GKVDE01

        Using a wrench, hold the hexagonal portion of the No. 3 camshaft.

      2. Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.

        Torque:
        79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      3. A01GHWPE01

        Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    2. for Bank 2:


      1. A01GLPRE01

        Using a wrench, hold the hexagonal portion of the No. 1 camshaft.

      2. Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.

        Torque:
        79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      3. A01GJVXE01

        Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

  37. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft clockwise and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

      A01GMUJE01

  38. INSTALL WATER INLET PIPE


    1. A01GIAM

      Apply soapy water to 2 new O-rings and install them to the inlet pipe.

    2. Install the inlet pipe to the No. 1 heat exchanger cover.

  39. INSTALL WATER PUMP ASSEMBLY


    1. A01GL1XE01

      Install the engine water pump and gasket with the 9 bolts as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf, for bolt A }
      23 N*m  { 235 kgf*cm, 17 ft.*lbf, for bolt B }
      47 N*m  { 479 kgf*cm, 35 ft.*lbf, for bolt C }

  40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01GII0

      Install a new oil pump gasket.

    2. A01GNMX

      Install a new O-ring.

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

      A01GNVTE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A01GIUKE01
        Apply Seal Packing as Follows
        Area Seal packing diameter Application position from inside edge of cover
        Continuous Line Area 3.0 to 4.0 mm (0.1181 to 0.1575 in.) 2.5 mm (0.098 in.)
        Dashed Line Area 6.4 mm (0.2520 in.) or more, or within OK area shown in illustration 0.5 mm (0.020 in.)
        Diagonal Line Area 3.0 to 4.0 mm (0.1181 to 0.1575 in.) 5.5 mm (0.217 in.)

      Note


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

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

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

    4. A01GJ9P

      Align the drive rotor spline of the oil pump and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

    5. A01GNNEE01

      Temporarily install the 30 bolts and nut.

      Bolt Length
      Item Length Thread diameter
      Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.165 in.) 8 mm (0.315 in.)
      Bolt C 70 mm (2.756 in.) 8 mm (0.315 in.)
      Bolt D 35 mm (1.378 in.) 10 mm (0.394 in.)
      Bolt E 55 mm (2.165 in.) 10 mm (0.394 in.)
      Bolt F 80 mm (3.150 in.) 10 mm (0.394 in.)

      Note

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

    6. A01GM5KE01

      Tighten the 11 bolts in several steps, in the sequence shown in the illustration.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    7. A01GJ5R

      Temporarily tighten the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

    8. A01GNG8E01

      Tighten the 21 bolts and nut in several steps, in the sequence shown in the illustration.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Note

      After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

      A01GK79E01
    9. A01GL8Q

      Install the 2 new gaskets and the 2 plugs.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  41. INSTALL OIL CONTROL VALVE FILTER


    1. for Bank 1:


      1. A01GNJ7E01

        Install the valve filter in the cylinder head.

      2. Install a new gasket and the cylinder head cover spacer with the 2 bolts.

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

    2. for Bank 2:


      1. A01GNAFE01

        Install the valve filter in the cylinder head.

      2. Install a new gasket and the cylinder head cover spacer with the 2 bolts.

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

  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01GILM

      Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3, No. 7).

    2. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    3. A01GILTE01

      Apply seal packing as shown the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover 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 the installation.

    4. A01GKDQE01

      Install the cylinder head cover with 2 new seal washers and the 15 bolts.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    5. Install the fuel pump spacer gasket.

  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01GM0S

      Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps. (No. 1, No. 3, No. 6).

    2. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    3. A01GIYKE01

      Apply seal packing as shown the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover 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 the installation.

    4. A01GHZKE01

      Install the cylinder head cover with 2 new seal washers and the 15 bolts.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    5. Install the fuel pump spacer gasket.

  44. INSTALL SPARK PLUG TUBE GASKET


    1. A01GKK9E01

      Perform a visual inspection on the spark plug tube gasket.

      Standard
      Area Specified Condition
      Upper surface No scratches or deformation
      Outer lip No scratches or deformation
      Inner lip No scratches
    2. A01GJDN

      Install the 8 plug tube gaskets to the cylinder head cover.

  45. INSTALL TIMING CHAIN CASE OIL SEAL


    1. A01GIUWE01

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

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap timing chain case oil seal at an angle.

  46. INSTALL CRANKSHAFT PULLEY


    1. A01GNCEE02

      Align the pulley set key with the key groove of the pulley, and slide on the pulley.

    2. Using SST, install the pulley bolt.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  47. INSTALL FRONT WATER BY-PASS JOINT


    1. A01GHO4

      Install the 2 new gaskets and water by-pass joint with the 4 nuts.

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

  48. INSTALL OIL FILTER BRACKET (for 2WD)


    1. A01GLHS

      Install 2 new gaskets and the filter bracket with the 3 bolts.

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

  49. INSTALL OIL FILTER BRACKET (for AWD)


    1. A01GL3X

      Install 2 new gaskets and the filter bracket with the 3 bolts.

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

  50. INSTALL OIL FILTER ELEMENT (for 2WD)


    1. Clean the inside of the oil filter cap, the threads and O-ring groove.

    2. A01GMZAE01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

      Apply a small amount of engine oil to a new O-ring for the cap, and then install the O-ring to the groove of the oil filter cap.

      Note


      • Be sure to install the O-ring in the proper location, otherwise oil may leak.

      • Do not twist the O-ring.

    3. Set a new oil filter element to the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and install the oil filter cap.

      Note

      Do not pinch the O-ring for the cap.

    6. A01GJKHE01
      Text in Illustration
      *1 Oil Filter Bracket Clip
      *2 Oil Filter Cap
      *3 O-Ring
      *4 Oil Filter Bracket
      *a No Clearance

      Using SST, tighten the oil filter cap.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note


      • Do not remove the oil filter bracket clip.

      • Make sure that the oil filter is installed securely as shown in the illustration.

      • Be careful that the O-ring does not get caught between the parts.

    7. A01GJGRE02
      Text in Illustration
      *1 O-Ring

      Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

      Note

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

    8. Install the oil filter drain plug.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Be careful that the O-ring does not get caught between the parts.

  51. INSTALL OIL FILTER ELEMENT (for AWD)


    1. Clean the inside of the oil filter cap, the threads and O-ring groove.

    2. A01GMZAE01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

      Apply a small amount of engine oil to a new O-ring for the cap, and then install O-ring to the groove of the oil filter cap.

    3. Set a new oil filter element to the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and install the oil filter cap.

    6. A01GNWGE01
      Text in Illustration
      *1 Oil Filter Bracket Clip
      *2 Oil Filter Cap
      *3 O-Ring
      *4 Oil Filter Bracket
      *a No Clearance

      Using SST, tighten the oil filter cap.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note


      • Do not remove the oil filter bracket clip.

      • Make sure that the oil filter is installed securely as shown in the illustration.

      • Be careful that the O-ring does not get caught between the parts.

    7. A01GN3ZE02
      Text in Illustration
      *1 O-Ring

      Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

      Note

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

    8. Install the oil filter drain plug.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Be careful that the O-ring does not get caught between the parts.

  52. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01GLUSE01

      Apply adhesive to 2 or 3 threads of the drain cock.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the water drain cocks as shown in the illustration.

      A01GJDIE01
      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note


      • Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

      • Do not loosen the drain cocks to adjust them. If an adjustment is necessary, remove the drain cocks and reinstall them.

    3. Install the water drain cock plugs to the water drain cocks.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  53. INSTALL CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY LH


    1. A01GNVYE01

      Turn the camshaft timing gear's eccentric shaft keyway part counterclockwise by hand and set it to the maximum retard angle.

      Tech Tips


      • When the cam of the camshaft lifts the valve, the eccentric shaft becomes difficult to turn.

      • The position where the eccentric shaft stops is the maximum retard angle.

      Note

      When turning the eccentric shaft keyway part, do not use any tools as the keyway part may be damaged.

    2. Turn the eccentric shaft clockwise until the groove labeled A and mark labeled B are aligned as shown in the illustration.

      Tech Tips

      Make sure that the groove labeled A is positioned as close as possible to the center of the mark labeled B.

    3. Install a new O-ring to the timing chain cover.

    4. A01GHPG

      Align the joint of the camshaft timing control with EDU motor assembly LH and the keyway of the camshaft timing gear assembly, and install the camshaft timing control with EDU motor assembly LH with the 3 bolts.

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

      Note


      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control with EDU motor assembly LH (connecting surface with timing chain cover).

      • When installing the camshaft timing control with EDU motor assembly LH, do not use excessive force.

      • Do not drop the camshaft timing control with EDU motor assembly LH. If dropped, replace it.

      • Do not disassemble the camshaft timing control with EDU motor assembly LH. If disassembled, replace it.

      Tech Tips


      • Check that [L] is printed on the label of the camshaft timing control with EDU motor assembly LH.

      • When installing the camshaft timing control with EDU motor assembly LH, be sure to align the timing chain cover knock pin with the camshaft timing control with EDU motor assembly LH pin hole.

      • Install the camshaft timing control with EDU motor assembly LH with the arrow facing upward.

    5. A01GIVB

      Connect the 2 camshaft timing control with EDU motor assembly LH connectors and engine wire clamp.

  54. INSTALL CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY RH


    1. A01GLU4E01

      Turn the camshaft timing gear's eccentric shaft keyway part counterclockwise by hand and set it to the maximum retard angle.

      Tech Tips


      • When the cam of the camshaft lifts the valve, the eccentric shaft becomes difficult to turn.

      • The position where the eccentric shaft stops is the maximum retard angle.

      Note

      When turning the eccentric shaft keyway part, do not use any tools as the keyway part may be damaged.

    2. Turn the eccentric shaft clockwise until the groove labeled A and mark labeled B are aligned as shown in the illustration.

      Tech Tips

      Make sure that the groove labeled A is positioned as close as possible to the center of the mark labeled B.

    3. Install a new O-ring to the timing chain cover.

    4. A01GIJS

      Align the joint of the camshaft timing control with EDU motor assembly RH and the keyway of the camshaft timing gear assembly, and install the camshaft timing control with EDU motor assembly RH with the 3 bolts.

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

      Note


      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control with EDU motor assembly RH (connecting surface with timing chain cover).

      • When installing the camshaft timing control with EDU motor assembly RH, do not use excessive force.

      • Do not drop the camshaft timing control with EDU motor assembly RH. If dropped, replace it.

      • Do not disassemble the camshaft timing control with EDU motor assembly RH. If disassembled, replace it.

      Tech Tips


      • Check that [R] is printed on the label of the camshaft timing control with EDU motor assembly RH.

      • When installing the camshaft timing control with EDU motor assembly RH, be sure to align the timing chain cover knock pin with the camshaft timing control with EDU motor assembly RH pin hole.

      • Install the camshaft timing control with EDU motor assembly RH with the arrow facing upward.

    5. A01GML7

      Install the engine wire bracket with the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    6. Connect the 2 camshaft timing control with EDU motor assembly RH connectors.

  55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. for Bank 1:


      1. A01GNMQ

        Apply a light coat of engine oil to a new O-ring.

      2. Install the O-ring to the oil control valve.

      3. Install the oil control valve with the bolt.

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

    2. for Bank 2:


      1. A01GMYQ

        Apply a light coat of engine oil to a new O-ring.

      2. Install the O-ring to the oil control valve.

      3. Install the oil control valve with the bolt.

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

  56. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01GHUM

      Install the crankshaft position sensor with the bolt.

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

  57. INSTALL CAMSHAFT POSITION SENSOR


    1. A01GJ1H

      Install the camshaft position sensor with the bolt.

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

  58. INSTALL VVT SENSOR


    1. for Bank 1:


      1. A01GKUV

        Install the 2 VVT sensors with the 2 bolts.

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

    2. for Bank 2:


      1. A01GLPJ

        Install the 2 VVT sensors with the 2 bolts.

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

  59. INSTALL SPARK PLUG


    1. Using a 16 mm plug wrench, install the 8 spark plugs.

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

  60. INSTALL OIL FILLER CAP HOUSING


    1. A01GL9S

      Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing.

    2. A01GJ96

      Install the cap housing with the 2 bolts.

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

  61. INSTALL OIL FILLER CAP SUB-ASSEMBLY