ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL OIL PAN STUD BOLT

    Note

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


    1. A001EKNE01
      *1 9 mm (0.354 in.)
      *2 19 mm (0.748 in.)

      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. A001FK3E01
      *1 9 mm (0.354 in.)
      *2 19 mm (0.748 in.)

      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. A001B6LE04
      *1 Front

      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. A001EG3

      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. A001CYSE19
      *1 2.0 to 3.0 mm
      *2 3.5 mm

      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. A001BNO

      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. A0019KQE01
      *1 for 2WD:
      *2 for AWD:

      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. A001B74

      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. A001EXV

      for 2WD:

      Install the baffle plate with the 8 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A001BS7

      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. A001FMFE05
      *1 for 2WD:
      *2 3.0 to 4.0 mm
      *3 6.0 mm
      *4 for AWD:

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.156 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. A001D29E03
      *1 for 2WD:
      *2 Nut
      *3 for AWD:

      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)

    A001EW2E01
    *1 Protrusion

    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. A001CO3E01
      *1 3.0 to 4.0 mm

      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. A001DN9E04
        *1 Nut

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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A0019ENE01
      *1 3.0 to 4.0 mm

      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. A001FDAE04
        *1 Nut

        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. A001EZ7E03

      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. A001C0ME03
      *1 3.0 to 4.0 mm

      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. A001E52E03
      *1 Nut

      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. A001BLJ

      Install the bolt.

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

  13. INSTALL OIL RETURN PIPE GASKET


    1. A001FR0

      Install a new oil return pipe gasket.

  14. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A001DRSE05
      *1 "UP"Mark

      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)

    Click here

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

    Click here

  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. A0019WFE02
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly

      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)

    Click here

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

    Click here

  22. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

    Click here

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

    Click here

  24. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A001BP0

      Install the 2 timing gear keys.

  25. SET NO. 1 CYLINDER TO TDC / COMPRESSION

    Click here

  26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

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

    Click here

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

    Click here

  29. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)

    Click here

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

    Click here

  31. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

    Click here

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

    Click here

  33. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)

    Click here

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

    Click here

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

    Click here

  36. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  37. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION

    Click here

  38. INSTALL WATER INLET PIPE

    Click here

  39. INSTALL WATER PUMP ASSEMBLY

    Click here

  40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  41. INSTALL OIL CONTROL VALVE FILTER


    1. for Bank 1:


      1. A0019SBE04
        *1 Filter
        *2 Gasket
        *3 Cylinder Head Cover Spacer

        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. A001F8UE04
        *1 Filter
        *2 Gasket
        *3 Cylinder Head Cover Spacer

        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. A0018YZ

      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. A001FC0E01
      *1 Seal Packing

      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. A001BHZE06
      *1 Fuel Pump Spacer Gasket

      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. A001ACI

      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. A001B7IE01
      *1 Seal Packing

      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. A001EGQE07
      *1 Fuel Pump Spacer Gasket

      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. A001BZ7E07
      *1 Upper Surface
      *2 Outer Lip
      *3 Inner Lip

      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. A001CEX

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

  45. INSTALL TIMING CHAIN CASE OIL SEAL

    Click here

  46. INSTALL CRANKSHAFT PULLEY

    Click here

  47. INSTALL FRONT WATER BY-PASS JOINT


    1. A001EW5

      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)

    Click here

  49. INSTALL OIL FILTER BRACKET (for AWD)

    Click here

  50. INSTALL OIL FILTER ELEMENT (for 2WD)

    Click here

  51. INSTALL OIL FILTER ELEMENT (for AWD)

    Click here

  52. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A001BNDE29
      *1 Adhesive

      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.

      A001AS2E01
      *1 for 2WD:
      *2 for AWD:
      *3 RH Side:
      *4 LH Side:
      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

    Click here

  54. INSTALL CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY RH

    Click here

  55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. for Bank 1:


      1. A001DHN

        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. A001DW1

        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. A001E97

      Install the crankshaft position sensor with the bolt.

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

  57. INSTALL CAMSHAFT POSITION SENSOR


    1. A001DK8

      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. A001E8V

        Install the 2 VVT sensors with the 2 bolts.

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

    2. for Bank 2:


      1. A001ESP

        Install the 2 VVT sensors with the 2 bolts.

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

  59. INSTALL SPARK PLUG

    Click here

  60. INSTALL OIL FILLER CAP HOUSING


    1. A001D81

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

    2. A001DYH

      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