ENGINE UNIT REASSEMBLY

Tech Tips

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.


  1. INSTALL TIMING CHAIN COVER STRAIGHT PIN

    A01GWHZE01

    1. Install the timing chain cover straight pin.


      1. Using a plastic-faced hammer, tap in new straight pins to the timing chain cover.

        Standard protrusion
        5.5 to 6.5 mm (0.217 to 0.256 in.)

  2. INSTALL TIMING CHAIN COVER STUD BOLT

    A01GY45E01

    1. Install the timing chain cover stud bolt.


      1. Using an E8 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

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

  3. INSTALL OIL PAN STUD BOLT

    A01GYXPE01

    1. Install the oil pan stud bolt.


      1. 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 }

  4. INSTALL REAR CRANKSHAFT OIL SEAL

    A01GWWDE01

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

      SST
      09223-15030
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

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

  5. INSTALL NO. 1 VENTILATION CONNECTOR


    1. A01GYE4E01

      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 (0.00787 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.

  6. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY


    1. A01GXL5

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

    2. Install the 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 }

  7. INSTALL ENGINE REAR OIL SEAL RETAINER


    1. A01H0Z4E03

      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 seal retainer within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01GY5M

      Install the oil seal retainer with the 6 bolts.

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

      Note


      • 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.

  8. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01GW7P

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

    2. Install the 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.

  9. INSTALL ENGINE OIL LEVEL SENSOR


    1. A01GYVR

      Install a new gasket to the engine oil level sensor.

    2. Insert the engine oil level sensor into the oil pan and rotate it 180°.

    3. A01GW4D

      Install the engine oil level sensor with the 4 bolts.

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

    4. Connect the engine oil level sensor connector.

  10. INSTALL NO. 2 OIL PAN BAFFLE PLATE


    1. A01H0GV

      Install the baffle plate with the 4 bolts.

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

  11. INSTALL NO. 1 OIL PAN BAFFLE PLATE

    A01GY58

    Install the baffle plate with the 4 bolts.

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

  12. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY


    1. A01H0P3E01

      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 within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01GZKCE02

      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
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      for nut
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

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

  13. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01GZOVE01

      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. A01GXH9E01

      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.

  14. INSTALL VENTILATION PIPE GASKET


    1. A01GZL0E01

      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 )

      Note


      • Do not tap the gasket at an angle.

      • Do not tap the gasket excessively.

  15. INSTALL NO. 1 HEAT EXCHANGER COVER


    1. A01GX4VE03

      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. A01GWTUE02

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

      Torque:
      for bolt A and B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt length
      Item Length Thread diameter
      Bolt A 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt B 20 mm (0.787 in.) 8 mm (0.315 in.)

      Note

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

  16. INSTALL NO. 2 OIL RETURN PIPE

    A01GWZ2E01

    1. Apply adhesive to a new return pipe.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using SST and a hammer, tap in the return pipe.

      SST
      09950-60010   ( 09951-00300 )
      09950-70010   ( 09951-07100 )

  17. INSTALL OIL RETURN PIPE SUB-ASSEMBLY

    A01H1Z5E01

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

    2. Install the O-ring to the return pipe.

    3. Insert the oil return pipe into the No. 2 oil return pipe, and then temporarily install bolt B.

    4. Install and tighten a new bolt A until the bolt head breaks off.

    5. Tighten bolt B.

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

  18. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01GZCKE01

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

      Tech Tips


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

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

  19. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH


    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. A01H0J0E02

      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.

      • Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.

    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. A01H0DSE02

      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. A01GZ5IE02

      Step 2:


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

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

    7. Step 3:


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

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

    8. A01H20TE02

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

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

  20. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


    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. A01H0HFE02

      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.

      • Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.

    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. A01GZ9ZE02

      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. A01GZ5IE02

      Step 2:


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

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

    7. Step 3:


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

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

    8. A01GYF7E02

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

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

  21. 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.

  22. 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 to the same place it was removed from.

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


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

    2. A01GZ1TE04
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Install the 32 valve rocker arms as shown in the illustration.

  24. INSTALL CAMSHAFT BEARING CAP LH


    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 camshafts to the camshaft housing.

    3. A01GZVJ

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

    4. A01GYTFE01

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

  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01H1LCE03
      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. A01GX4RE04

      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 4.5 mm (0.138 to 0.177 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

    3. A01GYV1E01

      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


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

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

    4. A01GXGEE02

      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.

  26. INSTALL CAMSHAFT BEARING CAP RH


    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 camshafts to the camshaft housing.

    3. A01GZI5

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

    4. A01H11CE01

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

  27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01H1LCE03
      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. A01GYG1E05

      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 4.5 mm (0.138 to 0.177 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

    3. A01H12FE01

      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


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

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

    4. A01H0O6E02

      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.

  28. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A01H1DT

      Install the timing gear key.

      Tech Tips

      The other timing gear key will be installed at a later step.

  29. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    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.

      A01GWJXE01

  30. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01GYZME03

      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 of 1.0 mm (0.0394 in.) into the hole to fix it in place.

  31. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A01GW20E02

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

    2. A01GZSJE02

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

    3. A01GY0QE02

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

      Tech Tips

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

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

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

    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.

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

    8. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, temporarily install a new bolt, with a 12 mm socket hexagon wrench.

    9. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, temporarily install the bolt.

  32. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH


    1. A01GXME

      Install the vibration damper with the 2 bolts.

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

  33. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

    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.

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A01GY7ZE01

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

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

    3. A01H090

      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.

  35. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01GYL6E03

      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 (0.0394 in.) into the hole to fix it in place.

  36. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A01GXGIE03

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

    2. A01GXDZE02

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

    3. A01GWHSE02

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

      Tech Tips

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

    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.

    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.

      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.

    8. Using a wrench to hold the hexagonal portion of the No. 3 camshaft, temporarily install a new bolt, with a 12 mm socket hexagon wrench.

    9. Using a wrench to hold the hexagonal portion of the No. 4 camshaft, temporarily install the bolt.

  37. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

    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.

  38. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A01GY7ZE01

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

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

    3. A01GYAO

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

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

  39. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH


    1. A01GWQP

      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.

  40. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY


    1. for Bank 1:


      1. A01H1RGE02

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

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

        Torque:
        79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      3. A01GYCHE01

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

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

    2. for Bank 2:


      1. A01GZJKE02

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

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

        Torque:
        79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      3. A01GXPTE01

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

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

  41. 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.

      A01GZIXE01

  42. INSTALL WATER INLET PIPE


    1. A01GY03

      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.

  43. INSTALL WATER PUMP


    1. A01GX0QE01

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

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

  44. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01GW7S

      Install a new oil pump gasket.

    2. A01GZLH

      Install a new O-ring.

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

      A01GY9KE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A01H1XPE03
        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 (0.118 to 0.157 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 3.0 to 4.0 mm (0.118 to 0.157 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. A01GW1X

      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. A01H1IOE02

      Temporarily install the timing chain cover 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 (2.17 in.) 8 mm (0.315 in.)
      Bolt C 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt D 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt E 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt F 80 mm (3.15 in.) 10 mm (0.394 in.)

      Note

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

    6. A01GYCF

      Tighten the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    7. A01GYJT

      Install the belt tensioner with the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    8. A01GXF1E01

      Tighten the 10 bolts in several steps, in the sequence shown in the illustration.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    9. A01GZTJE01

      Tighten the 19 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.

      A01H1RZE01
    10. A01H0LK

      Install 2 new gaskets and the 2 plugs.

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

  45. INSTALL FRONT CRANKSHAFT OIL SEAL

    A01GYB3E02

    1. Apply MP grease to the lip of a new oil seal.

    2. Using SST and a hammer, tap in the oil seal to a depth between 0 to 1.0 mm (0 to 0.0394 in.) from the timing chain cover edge.

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  46. INSTALL CRANKSHAFT TIMING GEAR KEY

    A01GWH0E01

    1. Install the crankshaft timing gear key to the crankshaft.

  47. INSTALL OIL CONTROL VALVE FILTER


    1. for LH:


      1. A01GY9SE02

        Install the valve filter to 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 RH:


      1. A01GZXRE02

        Install the valve filter to 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 }

  48. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01GZM6

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

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

      Note

      Remove any oil from the contact surface.

    3. A01H0L9E01

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      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.

    4. A01H0U2E06

      Install the cylinder head cover and 2 new seal washers with the 15 bolts in the order shown in the illustration.

      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 }

      Note

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

    5. Install a new fuel pump spacer gasket.

      Note

      After pressing in the fuel pump spacer gasket, make sure the gasket protrudes 1 mm (0.0394 in) or less from the cylinder head cover.

    6. Install the fuel pump spacer.

  49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01H1IN

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

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

      Note

      Remove any oil from the contact surface.

    3. A01GWURE01

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      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.

    4. A01GYY9E05

      Install the cylinder head cover and 2 new seal washers with the 15 bolts in the order shown in the illustration.

      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 }

      Note

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

    5. Install a new fuel pump spacer gasket.

      Note

      After pressing in the fuel pump spacer gasket, make sure the gasket protrudes 1 mm (0.0394 in) or less from the cylinder head cover.

    6. Install the fuel pump spacer.

  50. INSTALL SPARK PLUG TUBE GASKET


    1. A01H0G8E02

      Visual check the spark plug tube gasket.

      OK
      Inspection Area Specified Condition
      Upper surface No scratches or deformation
      Outer lip No scratches or deformation
      Inner lip No scratches

      If the result is not as specified, replace the spark plug tube gasket.

    2. A01H0YQ

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

      Note

      After pressing in the spark plug tube gasket, make sure the gasket protrudes 1 mm (0.0394 in) or less from the cylinder head cover.

  51. INSTALL CRANKSHAFT PULLEY


    1. A01GX5JE01

      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 }

  52. INSTALL FRONT WATER BY-PASS JOINT


    1. A01H0BH

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

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

  53. INSTALL WATER PUMP PULLEY


    1. A01GXZLE01

      Temporarily install the pulley with the 4 bolts.

    2. Using SST, hold the pulley and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  54. INSTALL OIL FILTER BRACKET


    1. A01GYZS

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

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

  55. INSTALL OIL FILTER ELEMENT


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

    2. A01GYR8E01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

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

    6. A01H13BE01
      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 any surrounding parts.

    7. A01H1MRE02
      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 any surrounding parts.

  56. INSTALL WIRE HARNESS CLAMP BRACKET

    A01GXLQ

    1. Install the wire harness clamp bracket with the bolt.

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

  57. INSTALL CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY RH


    1. A01H1MBE02

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

      Tech Tips


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

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

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

    3. A01GW8R

      Align the joint of the cam timing control with EDU motor assembly RH and the keyway of the camshaft timing gear assembly, and install the cam 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 cam timing control with EDU motor assembly RH (connecting surface with timing chain cover).

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

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

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

      Tech Tips


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

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

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

    4. A01H15TE01

      Install the engine wire bracket with the bolt.

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

    5. Connect the 2 cam timing control with EDU motor assembly RH connectors.

  58. INSTALL CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY LH


    1. A01H0K3E02

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

      Tech Tips


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

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

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

    3. A01GYDH

      Align the joint of the cam timing control with EDU motor assembly LH and the keyway of the camshaft timing gear, and install the cam 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 cam timing control with EDU motor assembly LH (connecting surface with timing chain cover).

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

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

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

      Tech Tips


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

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

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

    4. A01GZRR

      Connect the 2 cam timing control with EDU motor assembly LH connectors and wire harness clamp.

  59. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01GXJLE05

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01H0PEE01

      Install the water drain cocks as shown in the illustration.

      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 to 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 }

  60. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. for Bank 1:


      1. A01GWFU

        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. A01GX96

        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 }

  61. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01GWV4

      Install the crankshaft position sensor with the bolt.

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

  62. INSTALL CAMSHAFT POSITION SENSOR


    1. A01H1NV

      Install the camshaft position sensor with the bolt.

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

  63. INSTALL VVT SENSOR


    1. A01H234

      for Bank 1:

      Install the 2 VVT sensors with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01GWHF

      for Bank 2:

      Install the 2 VVT sensors with the 2 bolts.

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

  64. 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 }

  65. INSTALL OIL FILLER CAP HOUSING


    1. A01GXAT

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

    2. A01GX2E

      Install the cap housing with the 2 bolts.

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

  66. INSTALL OIL FILLER CAP SUB-ASSEMBLY