ENGINE UNIT REASSEMBLY


  1. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY


    1. A0162ZT

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

    2. Install the new O-ring to the oil drain pipe sub-assembly.

    3. Install the oil drain pipe sub-assembly with the bolt.

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

  2. INSTALL ENGINE REAR OIL SEAL RETAINER


    1. A01632JE01

      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 (0.0787 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 the oil seal retainer.

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

      • When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is folded correctly.

    2. A0160LU

      Install the engine rear oil seal retainer with the 6 bolts.

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

  3. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A015ZUA

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

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

    3. Install the oil strainer sub-assembly with the 2 bolts.

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

      Note

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

  4. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A015YS5

      Install the No. 1 oil pan baffle plate with the 8 bolts.

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

  5. INSTALL OIL PAN SUB-ASSEMBLY


    1. A016064E01

      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.)
      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 sub-assembly 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 the oil pan sub-assembly.

    2. A0160X1E03

      Install the oil pan sub-assembly with the 14 bolts and 2 nuts.

      Torque:
      Bolt A
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      Bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Nut
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  6. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0161ETE01

      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 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 the oil pan sub-assembly.

    2. A0162P0E01

      Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts.

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

  7. INSTALL VENTILATION PIPE GASKET


    1. A015YS4E01

      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 ventilation pipe gasket at an angle.

      • Do not tap the ventilation pipe gasket excessively.

  8. INSTALL HEAT EXCHANGER ASSEMBLY


    1. A0160XOE03

      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.

    2. A0163COE02

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

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

      Note


      • Install the No. 1 heat exchanger cover 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 the cover.

    3. A0160EA

      Install the bolt.

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

  9. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A015ZIOE01

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

      Tech Tips


      • Face the cutouts away from the center of the engine.

      • Face each "Up" mark as shown in the illustration.

  10. INSTALL NO. 2 CYLINDER HEAD GASKET (for Bank 1)


    1. A015ZIQE01

      Place a new No. 2 cylinder head gasket the cylinder block surface with the Lot No. stamp facing upward.

      Note


      • Be sure to place the gasket in the correct direction.

      • Gently place the cylinder head on the cylinder block in order to prevent damaging the gasket.

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


    1. Place the cylinder head sub-assembly on the cylinder block.

      Note


      • Clean and degrease all contact surface.

      • Inspect and clean each cylinder head set bolt and installation hole.

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

      Tech Tips

      Tighten the cylinder head set bolts in 3 progressive steps.

    3. A0162SME02

      Step 1:


      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head set 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 }
    4. A0162POE01

      Step 2:


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

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

    5. Step 3:


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

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

    6. A015ZR9E02

      Install the 2 bolts in the sequence shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    7. A01610WE02

      Place the camshaft housing on the cylinder head sub-assembly.

    8. Temporarily tighten the camshaft housing with the 3 bolts in the sequence shown in the illustration.

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

    9. Fully tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  12. INSTALL CYLINDER HEAD GASKET (for Bank 2)


    1. A015YOHE01

      Place a new cylinder head gasket onto the cylinder block surface with the Lot No. stamp facing upward.

      Note


      • Be sure to place the gasket in the correct direction.

      • Gently place the cylinder head onto the cylinder block in order to prevent damaging the gasket.

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


    1. Place the cylinder head sub-assembly on the cylinder block.

      Note


      • Clean and degrease all contact surface.

      • Inspect and clean each cylinder head set bolt and installation hole.

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

      Tech Tips

      Tighten the cylinder head set bolts in 3 progressive steps.

    3. A015ZSLE02

      Step 1:


      1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head set 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 }
    4. A0162POE01

      Step 2:


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

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

    5. Step 3:


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

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

    6. A0161ZUE02

      Install the 2 cylinder head set bolts in the sequence shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    7. A015ZTKE02

      Place the camshaft housing on the cylinder head sub-assembly.

    8. Temporarily tighten the camshaft housing with the 3 bolts in the sequence shown in the illustration.

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

    9. Fully tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  14. INSTALL VALVE ROCKER ARM PIVOT


    1. Install the 32 valve rocker arm pivots to the cylinder head assembly.

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

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


    1. Apply engine oil to the valve rocker arm pivot and valve adjusting shim.

    2. Install the 32 No. 1 valve rocker arm sub-assembly on the cylinder heads.

    3. A0162R9E01

      Make sure that the 32 No. 1 valve rocker arm subassembly are installed as shown in the illustration.

  16. INSTALL NO. 3 CAMSHAFT


    1. Apply a light coat of engine oil to the camshaft journals.

    2. Install the No. 3 camshaft to the cylinder head sub-assembly.

  17. INSTALL NO. 4 CAMSHAFT


    1. Apply a light coat of engine oil to the camshaft journals.

    2. Install the No. 4 camshaft to the cylinder head sub-assembly.

  18. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

    Note

    When rotating the camshafts without the timing chains installed, be careful to ensure that the valves do not contact the pistons. If contact occurs between the valves and pistons, damage may result.


    1. A0162QDE01

      Make sure that each knock pin of the camshafts is positioned as shown in the illustration.

    2. Apply a light coat of engine oil to the camshaft housing and bearing caps.

    3. A01603I

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

    4. A0160P5E02

      Temporarily install the 20 bolts in the sequence shown in the illustration.

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

    5. Tighten the 20 bolts in the sequence shown in the illustration.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  19. INSTALL CAMSHAFT


    1. Apply a light coat of engine oil to the camshaft journals.

    2. Install the camshaft to the cylinder head sub-assembly.

  20. INSTALL NO. 2 CAMSHAFT


    1. Apply a light coat of engine oil to the camshaft journals.

    2. Install the No. 2 camshaft to the cylinder head sub-assembly.

  21. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

    Note

    When rotating the camshafts without the timing chains installed, be careful to ensure that the valves do not contact the pistons. If contact occurs between the valves and pistons, damage may result.


    1. A0160AHE01

      Make sure that each knock pin of the camshafts is positioned as shown in the illustration.

    2. Apply a light coat of engine oil to the camshaft housing and bearing caps.

    3. A0163A8

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

    4. A0162T9E02

      Temporarily install the 20 bolts in the sequence shown in the illustration.

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

    5. Tighten the 20 bolts in the sequence shown in the illustration.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  22. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A0160LW

      Install the crankshaft timing gear key.

    2. A0161E4E01

      Temporarily install the crankshaft pulley set bolt, and set the crankshaft timing gear key in the position as shown in the illustration.

    3. Remove the crankshaft pulley set bolt.

  23. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 2)


    1. A015Z1ME01

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

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

    2. While raising the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) pin into the hole to fix it in place.

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

    Tech Tips

    The crankshaft timing gear, camshaft timing gear assembly and camshaft timing exhaust gear assembly will be installed with the chain sub-assembly and No. 2 chain sub-assembly connected to the gears.


    1. A0161CHE01

      Align the chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain sub-assembly to the gear as shown in the illustration.

    2. A015Z2IE01

      Align the chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain sub-assembly to the gear as shown in the illustration.

    3. A015ZV6E01

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

    4. Install the crankshaft timing gear to the crankshaft.

    5. Align and attach the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    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.

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


    1. A015ZZV

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

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

  26. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)


    1. A015YU9

      Install the chain tensioner slipper.

      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.

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


    1. A0163GFE01

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

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

    3. A0162ED

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

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

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.

  28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01634QE01

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

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

    2. While raising the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) pin into the hole to fix it in place.

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

    Tech Tips

    The crankshaft timing sprocket LH, camshaft timing gear assembly and camshaft timing exhaust gear assembly will be installed with the chain sub-assembly and No. 2 chain sub-assembly connected to the gears.


    1. A01619BE01

      Align the chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain sub-assembly to the gear as shown in the illustration.

    2. A015Z44E01

      Align the chain's orange mark plate with the crankshaft timing sprocket's timing mark, and attach the chain sub-assembly to the gear as shown in the illustration.

    3. A01605SE01

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

    4. Install the crankshaft timing sprocket LH to the crankshaft.

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

    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 chain sub-assembly, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner assembly is installed.

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

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


    1. A0160SV

      Install the No. 1 chain 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 assembly.

  31. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)


    1. A015Z64

      Install the chain tensioner slipper.

      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 install the chain tensioner slipper.

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


    1. A0163GFE01

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

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

    3. A0160XY

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

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

  33. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY


    1. for Bank 1:


      1. A01626OE01

        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. A015Z0VE01

        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. A01605NE01

        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. A0162NRE01

        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 }

  34. INSPECT NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set 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 set bolt.

      A0162ITE03

  35. INSPECT VALVE CLEARANCE


    1. Using a feeler gauge, measure the clearance between the indicated valve rocker arms and camshafts.

      A0162BXE01
      Standard Valve Clearance (Cold)
      Item Specified Condition
      Intake 0.12 to 0.18 mm (0.00472 to 0.00709 in.)
      Exhaust 0.22 to 0.28 mm (0.00866 to 0.0110 in.)

      Tech Tips


      • On this engine, valve clearance is measured between the valve rocker arms and the camshaft lobes. The shims used to adjust the valve clearance are located on the top of the valve stems.

      • The valve clearance shown in the Standard Valve Clearance table is the clearance as measured between the cam lobe and valve rocker arm.

      • Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve adjusting shim.

    2. Turn the crankshaft 1 revolution (360°) to set the No. 6 cylinder to TDC compression.

    3. Using a feeler gauge, measure the clearance between the indicated valve rocker arms and camshafts.

      A0160UGE01
      Standard Valve Clearance (Cold)
      Item Specified Condition
      Intake 0.12 to 0.18 mm (0.00472 to 0.00709 in.)
      Exhaust 0.22 to 0.28 mm (0.00866 to 0.0110 in.)

      Tech Tips


      • On this engine, valve clearance is measured between the valve rocker arms and the camshaft lobes. The shims used to adjust the valve clearance are located on the top of the valve stems.

      • The valve clearance shown in the Standard Valve Clearance table is the clearance as measured between the cam lobe and valve rocker arm.

      • Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve adjusting shim.

  36. ADJUST VALVE CLEARANCE


    1. Remove the timing chain cover sub-assembly Click here.

    2. Remove the camshaft Click here.

    3. A015ZU2E01

      Raise the valve rocker arm above the shim being replaced, and remove the valve adjusting shim.

      Note


      • Be careful not to drop the adjusting shim into the cylinder head.

      • To prevent damage, do not attempt to adjust valve clearance by tightening or loosening the valve rocker arm pivots.

      Tech Tips

      Arrange the removed parts in the correct order.

    4. A0161YWE01

      Using a dial gauge, measure the thickness of the existing valve adjusting shim after removing it.

      Tech Tips

      Be careful not to measure at the valve adjusting shim center groove.

    5. Determine the replacement valve adjusting shim thickness according to the formula or charts below.


      1. Calculate the thickness of the replacement valve adjusting shim so that the valve clearance comes within the specified value.

        T2 Thickness of replacement shim
        T1 Thickness of existing shim
        A Measured valve clearance
        Valve clearance
        Intake
        T2 = T1 + (A - 0.15 mm (0.0059 in.)) x 1.8
        Exhaust
        T2 = T1 + (A - 0.25 mm (0.0098 in.)) x 1.6

        This example is provided only as a calculation example, based on the clearance adjustment of an intake valve. If non-metric units are being used, substitute those measurements for the values shown below.

        Step 1 - Determining the amount of excess clearance


        • The specified clearance (0.15) is subtracted from the measured value (0.40), and the result is then multiplied by the rocker ratio compensation value (1.8).


        • (Measured value - specification) x compensation value = amount of excess clearance


        • (0.40 - 0.15) x 1.8 = 0.450

        Step 2 - Using the existing valve adjusting shim to determine the required thickness of the replacement valve adjusting shim


        • The amount of excess clearance (0.450) is added to the thickness of the existing valve adjusting shim (2.300). The resulting value is the ideal thickness of a replacement valve adjusting shim.


        • Excess clearance + thickness of existing shim = thickness of ideal replacement shim


        • 0.450 + 2.300 = 2.750

        Step 3 - Select the valve adjusting shim closest to the thickness of the ideal replacement shim


        • Compare the thickness of the available replacement valve adjusting shims to the ideal replacement shim and choose the shim that is the closest match.


        • Closest replacement valve adjusting shim = 2.750 (Select a new No. 74 shim.)

        Tech Tips


        • Select a replacement shim with a thickness as close to the calculated value as possible.

        • Shims are available in 41 sizes in increments of 0.020 mm (0.0008 in.), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102 in.).

        • To select a replacement valve adjusting shim, refer to the following Valve Adjusting Shim Selection Chart and New Shim Thickness tables.

        A0162DGE01
        Intake valve clearance (Cold)
        0.12 to 0.18 mm (0.00472 to 0.00709 in.)

        EXAMPLE:

        If the existing shim (installed shim) is 2.300 mm (0.0906 in.), and the measured clearance is 0.39 mm (0.0154 in.), then a new 2.740 mm (0.1079 in.) No. 74 shim should be used as a replacement for the existing shim.

        New Shim Thickness mm (in.)
        Shim No. Thickness Shim No. Thickness Shim No. Thickness
        00 2.000 (0.0787) 28 2.280 (0.0898) 56 2.560 (0.1008)
        02 2.020 (0.0795) 30 2.300 (0.0906) 58 2.580 (0.1016)
        04 2.040 (0.0803) 32 2.320 (0.0913) 60 2.600 (0.1024)
        06 2.060 (0.0811) 34 2.340 (0.0921) 62 2.620 (0.1031)
        08 2.080 (0.0819) 36 2.360 (0.0929) 64 2.640 (0.1039)
        10 2.100 (0.0827) 38 2.380 (0.0937) 66 2.660 (0.1047)
        12 2.120 (0.0835) 40 2.400 (0.0945) 68 2.680 (0.1055)
        14 2.140 (0.0843) 42 2.420 (0.0953) 70 2.700 (0.1063)
        16 2.160 (0.0850) 44 2.440 (0.0961) 72 2.720 (0.1071)
        18 2.180 (0.0858) 46 2.460 (0.0969) 74 2.740 (0.1079)
        20 2.200 (0.0866) 48 2.480 (0.0976) 76 2.760 (0.1087)
        22 2.220 (0.0874) 50 2.500 (0.0984) 78 2.780 (0.1094)
        24 2.240 (0.0882) 52 2.520 (0.0992) 80 2.800 (0.1102)
        26 2.260 (0.0890) 54 2.540 (0.1000)
        A01610ME01
        Exhaust valve clearance (Cold)
        0.22 to 0.28 mm (0.00866 to 0.0110 in.)

        EXAMPLE:

        If the existing shim (installed shim) is 2.300 mm (0.0906 in.), and the measured clearance is 0.39 mm (0.0154 in.), then a new 2.520 mm (0.0992 in.) No. 52 shim should be used as a replacement for the existing shim.

        New Shim Thickness mm (in.)
        Shim No. Thickness Shim No. Thickness Shim No. Thickness
        00 2.000 (0.0787) 28 2.280 (0.0898) 56 2.560 (0.1008)
        02 2.020 (0.0795) 30 2.300 (0.0906) 58 2.580 (0.1016)
        04 2.040 (0.0803) 32 2.320 (0.0913) 60 2.600 (0.1024)
        06 2.060 (0.0811) 34 2.340 (0.0921) 62 2.620 (0.1031)
        08 2.080 (0.0819) 36 2.360 (0.0929) 64 2.640 (0.1039)
        10 2.100 (0.0827) 38 2.380 (0.0937) 66 2.660 (0.1047)
        12 2.120 (0.0835) 40 2.400 (0.0945) 68 2.680 (0.1055)
        14 2.140 (0.0843) 42 2.420 (0.0953) 70 2.700 (0.1063)
        16 2.160 (0.0850) 44 2.440 (0.0961) 72 2.720 (0.1071)
        18 2.180 (0.0858) 46 2.460 (0.0969) 74 2.740 (0.1079)
        20 2.200 (0.0866) 48 2.480 (0.0976) 76 2.760 (0.1087)
        22 2.220 (0.0874) 50 2.500 (0.0984) 78 2.780 (0.1094)
        24 2.240 (0.0882) 52 2.520 (0.0992) 80 2.800 (0.1102)
        26 2.260 (0.0890) 54 2.540 (0.1000)

    6. Install the camshaft Click here.

    7. Install the chain sub-assembly Click here.


      1. Install the chain sub-assembly (for Bank 2).

      2. Install the No. 1 chain vibration damper (for Bank 2).

      3. Install the chain tensioner slipper (for Bank 2).

      4. Install the No. 1 chain tensioner assembly (for Bank 2).

      5. Install the chain sub-assembly (for Bank 1).

      6. Install the No. 1 chain vibration damper (for Bank 1).

      7. Install the chain tensioner slipper (for Bank 1).

      8. Install the No. 1 chain tensioner assembly (for Bank 1).

      9. Tighten the camshaft timing gear assembly.

    8. Inspect the valve clearance again.

      Note

      Be sure to inspect the valve clearance with the chain cub-assembly installed. When rotating the camshaft without the chain sub-assembly installed, contact between the valves and pistons may occur.

      Tech Tips

      If the valve clearance is not as specified, readjust the valve clearance.

  37. INSTALL OIL REFLECTOR PLATE LH (for Bank 1)


    1. A0161NQ

      Install the oil reflector plate LH with the 2 bolts.

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

  38. INSTALL OIL REFLECTOR PLATE RH (for Bank 2)


    1. A0162QZ

      Install the oil reflector plate RH with the 2 bolts.

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

  39. INSTALL INLET WATER PIPE


    1. A015ZWJ

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

    2. Install the inlet water pipe to the heat exchanger assembly.

  40. INSTALL SCAVENGING PUMP ASSEMBLY


    1. Temporarily install the scavenging pump assembly and a new gasket with the 6 bolts.

    2. A016144E01

      Using several steps, uniformly install and tighten the 6 bolts in the sequence shown in the illustration.

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

  41. INSTALL NO. 3 OIL PIPE


    1. Install a new O-ring to the No. 3 oil pipe.

    2. Connect the No. 3 oil pipe to the scavenging pump assembly and align the bolt holes.

      Note


      • Be careful not to damage the O-ring.

      • Do not rotate the oil pipe when connecting it to the scavenging pump.

    3. A0161C4

      Install the No. 3 oil pipe with the 2 bolts.

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

  42. INSTALL NO. 2 OIL PIPE


    1. Install a new O-ring and oil pipe seal to the No. 2 oil pipe.

    2. Connect the No. 2 oil pipe to the scavenging pump assembly and align the bolt holes.

      Note


      • Be careful not to damage the O-ring.

      • Do not rotate the oil pipe when connecting it to the scavenging pump.

    3. A015YVU

      Install the No. 2 oil pipe with the 2 bolts.

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

  43. INSTALL NO. 1 OIL PIPE


    1. Install a new O-ring and oil pipe seal to the No. 1 oil pipe.

    2. Connect the No. 1 oil pipe to the scavenging pump assembly and align the bolt holes.

      Note


      • Be careful not to damage the O-ring.

      • Do not rotate the oil pipe when connecting it to the scavenging pump.

    3. A0160ZR

      Install the No. 1 oil pipe with the 2 bolts.

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

  44. INSTALL WATER PUMP ASSEMBLY


    1. A0163JD

      Install the water pump assembly and new water pump gasket with the 5 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  45. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any old packing material remaining on the sealing surfaces before applying seal packing.

    2. Clean and degrease the contact surfaces of the timing chain cover sub-assembly, cylinder head, and cylinder block and confirm that no oil, moisture, or other foreign matter remains on the surfaces.

      A015Z9UE01
    3. A01615S

      Install a new oil pump gasket.

    4. A015ZXR

      Install a new O-ring.

    5. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the illustration.

      A01637WE02
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A0163GDE01
        Apply seal packing as follows
        Area Seal Packing Diameter Application Position from Inside Edge of Cover
        Continuous Line Area 2.5 to 3.5 mm (0.0984 to 0.1378 in.) 2.5 mm (0.0984 in.)
        Dashed Line Area 6.4 mm (0.252 in.) or more, or within OK area shown in illustration 0.5 mm (0.0197 in.)
        Diagonal Line Area 2.5 to 3.5 mm (0.0984 to 0.1378 in.) 5.5 mm (0.217 in.)

      Note


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

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

      • Do not add engine oil for at least 2 hours after installing the timing chain cover sub-assembly.

      • Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.

    6. A0161B4

      Align the oil pump drive rotor spline and the crankshaft as shown in the illustration. Install the spline and timing chain cover sub-assembly to the crankshaft.

    7. A015ZAHE02

      Temporarily install the timing chain cover sub-assembly with 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 80 mm (3.150 in.) 10 mm (0.394 in.)
      Bolt F 80 mm (3.150 in.) 10 mm (0.394 in.)
      Bolt G 80 mm (3.150 in.) 8 mm (0.315 in.)

      Note

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

    8. A0161YUE01

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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    9. A0162C7E01

      Temporarily install the v-ribbed belt tensioner assembly with the standard bolt and hexagon bolt.

    10. A0160NRE01

      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 }

      Tech Tips

      Use a 6 mm socket hexagon wrench to tighten the bolt numbered 22 in the illustration.

    11. A015Z0PE01

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

  46. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. A0160DVE01

      Using SST, tap in a new 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 on the oil seal at an angle.

      • Do not install the oil seal excessively.

  47. INSTALL OIL CONTROL VALVE FILTER


    1. for Bank 1:


      1. A0160ZC

        Install the oil control valve filter to the cylinder head cover spacer LH.

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

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

    2. for Bank 2:


      1. A0160SW

        Install the oil control valve filter to the cylinder head cover spacer.

      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 }

  48. INSTALL SPARK PLUG TUBE GASKET


    1. A015ZC7E01

      Install the 8 new spark plug tube gaskets to each cylinder head sub-assembly.

      Note


      • Install the gaskets in the correct direction.

      • Push in each gasket until its bottom surface contacts the cylinder head.

  49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 1)


    1. A0161DZ

      Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.

    2. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

      Note

      Remove any oil from the contact surface.

    3. A0160RHE01

      Apply seal packing 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 cylinder head cover 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 the cylinder head cover sub-assembly LH.

    4. A0163HNE02

      Install the cylinder head cover sub-assembly LH with 3 new seal washers and the 16 bolts.

      Torque:
      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 a new fuel pump spacer gasket.

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


    1. A015Z76

      Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.

    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

      Note

      Remove any oil from the contact surface.

    3. A0161LGE01

      Apply seal packing 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 cylinder head cover sub-assembly 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 the cylinder head cover sub-assembly.

    4. A01604XE02

      Install the cylinder head cover sub-assembly with 3 new seal washers and the 16 bolts.

      Torque:
      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 a new fuel pump spacer gasket.

  51. INSTALL NO. 1 V-BANK COVER BRACKET


    1. A01613K

      Install the No. 1 V-bank cover bracket to the cylinder head cover sub-assembly LH.

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

  52. INSTALL NO. 1 V-BANK COVER BRACKET


    1. A015ZEC

      Install the No. 1 V-bank cover bracket to the cylinder head cover sub-assembly RH.

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

  53. INSTALL CRANKSHAFT PULLEY


    1. A016158E01

      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
      09213-38010
      09330-00021
      Torque:
      330 N*m  { 3365 kgf*cm, 243 ft.*lbf }

  54. INSTALL OIL FILTER BRACKET


    1. A016253

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

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A015ZVB

      Install the oil filter bracket stay with the 2 bolts.

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

  55. INSTALL OIL COOLER ASSEMBLY


    1. A0162F6E01

      Temporarily install the oil cooler assembly with the bolt.

    2. Install the union bolt to the oil cooler assembly with a new gasket.

    3. Tighten the bolt and union bolt.

      Torque:
      Bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Union bolt
      59 N*m  { 602 kgf*cm, 43 ft.*lbf }

  56. INSTALL OIL FILTER ELEMENT


    1. A015Z1KE01

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

    2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

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

    4. Remove any dirt or foreign matter from the installation surface of the oil filter bracket.

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

    6. A0161FLE01

      Using SST, tighten the oil filter cap.

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

      Note


      • 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.

  57. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A015ZNPE01

      Apply adhesive to 2 or 3 threads of the cylinder block water drain cock sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A0162AAE02

      Install the cylinder block water drain cock sub-assembly as shown in the illustration.

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

      Note


      • Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening to the specified torque.

      • Do not loosen the cylinder block water drain cock sub-assembly to adjust them. If an adjustment is necessary, remove the cylinder block water drain cock sub-assembly and reinstall them.

    3. Install the cylinder block water drain cock plugs to the cylinder block water drain cock sub-assembly.

      Torque:
      13 N*m  { 132 kgf*cm, 10 ft.*lbf }

  58. INSTALL FRONT WATER BY-PASS JOINT


    1. A01633J

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

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

  59. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (for Bank 1)


    1. A0160O5E01

      Turn the camshaft timing gear assembly intermediate shaft index slot in the counterclockwise direction by hand, to set it to the maximum retard angle position.

      Tech Tips


      • When a camshaft lobe opens a valve, the intermediate shaft becomes difficult to turn.

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

    2. A016058

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

    3. A0160VO

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

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

      Note


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

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor assembly LH (the surface that contacts the timing chain cover sub-assembly).

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

      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor assembly LH.

      • Install the camshaft timing control motor assembly LH with the arrow facing upward, as shown in the illustration.

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

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

  60. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (for Bank 2)


    1. A0160G4E01

      Turn the camshaft timing gear assembly intermediate shaft index slot in the counterclockwise direction by hand, to set it to the maximum retard angle position.

      Tech Tips


      • When a camshaft lobe opens a valve, the intermediate shaft becomes difficult to turn.

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

    2. A015YZG

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

    3. A01637C

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

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

      Note


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

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor assembly RH (the surface that contacts the timing chain cover sub-assembly).

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

      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor assembly RH.

      • Install the camshaft timing control motor assembly RH with the arrow facing upward, as shown in the illustration.

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

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

  61. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH


    1. A0161DJ

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

    2. Install the O-ring to the camshaft timing oil control valve assembly LH.

    3. Install the camshaft timing oil control valve assembly LH with the bolt.

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

  62. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH


    1. A0160HV

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

    2. Install the O-ring to the camshaft timing oil control valve assembly RH.

    3. Install the camshaft timing oil control valve assembly RH with the bolt.

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

  63. INSTALL CRANKSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.

    2. A01606L

      Install the crankshaft position sensor with the bolt.

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

  64. INSTALL CAMSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring on camshaft position sensor.

    2. A015YY8

      Install the camshaft position sensor with the bolt.

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

  65. INSTALL VVT SENSOR


    1. for Bank 1:


      1. Apply a light coat of engine oil to the O-ring on each VVT sensor.

      2. A015YXS

        Install the 2 VVT sensors with the 2 bolts.

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

    2. for Bank 2:


      1. Apply a light coat of engine oil to the O-ring on the VVT sensor.

      2. A0160ZB

        Install the 2 VVT sensors with the 2 bolts.

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

  66. INSTALL SPARK PLUG


    1. A0162KA

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

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

  67. INSTALL OIL FILLER CAP HOUSING


    1. A0160Z8

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

    2. A015YK9

      Install the oil filler cap housing with the 2 bolts.

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

  68. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new oil filler cap gasket to the oil filler cap.

    2. Install the oil filler cap sub-assembly to the oil filler cap housing.