ENGINE UNIT REASSEMBLY


  1. INSTALL ENGINE REAR OIL SEAL


    1. Place the oil seal retainer on wooden blocks.

    2. A01HZC0E03
      Text in Illustration
      *a Depth

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

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

      Note


      • Keep the lip free of foreign matter.

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

  2. INSTALL ENGINE REAR OIL SEAL RETAINER


    1. A01I1J9E01
      Text in Illustration
      *a

      Seal Packing Diameter

      (2.0 to 3.0 mm (0.0787 to 0.118 in.))

      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.)

      Note


      • Remove any oil from the contact surfaces.

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

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

    2. A01HZJIE01

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

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

      Note

      Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

  3. INSTALL WATER INLET PIPE

    A01HYV1

    1. Install the water inlet pipe with the 2 bolts.

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

    2. Install the No. 1 water by-pass hose.

  4. INSTALL CYLINDER HEAD GASKET RH


    1. A01I0X1E02
      Text in Illustration
      *a Lot No.
      A01I0B8 Engine Front

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

      Note

      Be careful of the installation direction.

  5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


    1. Place the cylinder head on the cylinder block.

      Note


      • Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      • Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

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

    3. Step 1


      1. A01HY7QE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    4. A01I0IFE05
      Text in Illustration
      *a Turn 90°
      *b Painted Mark
      A01I0B8 Engine Front

      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.

    5. Step 3


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

      2. Check that the painted mark is now facing rearward.

        Tech Tips

        Perform "Inspection After Repair" after replacing the cylinder head RH Click here.

  6. INSTALL CYLINDER HEAD GASKET LH


    1. A01HZLRE02
      Text in Illustration
      *a Lot No.
      A01I0B8 Engine Front

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

      Note

      Be careful of the installation direction.

  7. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH


    1. Place the cylinder head on the cylinder block.

      Note


      • Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      • Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

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

    3. Step 1


      1. A01I02JE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 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 }
    4. A01I0IFE05
      Text in Illustration
      *a Turn 90°
      *b Painted Mark
      A01I0B8 Engine Front

      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.

    5. Step 3


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

      2. Check that the painted mark is now facing rearward.

    6. A01I12PE02

      Tighten the 2 bolts in the order shown in the illustration.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the cylinder head LH Click here.

  8. INSTALL VALVE STEM CAP


    1. Install the 24 valve stem caps.

  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the lash adjuster free of dirt and foreign matter.

    • Only use clean engine oil.


    1. Place the lash adjuster into a container filled with engine oil.

    2. A01HZ7CE17
      Text in Illustration
      *1 Tapered Part
      *2 Plunger
      *3 Check Ball
      *a CORRECT
      *b INCORRECT
      *c Low Pressure Chamber
      *d High Pressure Chamber

      Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed the air.

      OK
      Plunger moves up and down.

      Note

      When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

    5. After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly by hand.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster.

    6. Install the valve lash adjusters.

      Note

      Install each valve lash adjuster to the same place it was removed from.

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


    1. Apply engine oil to the lash adjuster tip and valve stem cap end.

    2. A01HZ5VE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Install the valve rocker arms as shown in the illustration.

  11. INSTALL NO. 3 CAMSHAFT


    1. Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH.

    2. Install the No. 3 camshaft to the camshaft housing sub-assembly LH.

      Tech Tips

      Perform "Inspection After Repair" after replacing the No. 3 camshaft Click here.

  12. INSTALL NO. 4 CAMSHAFT


    1. Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.

    2. Install the No. 4 camshaft to the camshaft housing sub-assembly LH.

      Tech Tips

      Perform "Inspection After Repair" after replacing the No. 4 camshaft Click here.

  13. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01I0OM

      Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

    3. A01HXVME01

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

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

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01HZ5VE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Make sure that the valve rocker arm is installed as shown in the illustration.

    2. A01HZ76E01
      Text in Illustration
      *a

      Seal packing diameter

      (3.5 to 4.5 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
      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 sub-assembly LH within 3 minutes and tighten the bolts.

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

    3. A01I1NNE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

      Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated, valve contact with a piston at TDC will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

    4. A01HY6EE02

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

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

  15. INSTALL CAMSHAFT


    1. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH.

    2. Install the camshaft to the camshaft housing sub-assembly RH.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft Click here.

  16. INSTALL NO. 2 CAMSHAFT


    1. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH.

    2. Install the No. 2 camshaft to the camshaft housing sub-assembly RH.

      Tech Tips

      Perform "Inspection After Repair" after replacing the No. 2 camshaft Click here.

  17. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01HZG2

      Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

    3. A01I242E01

      Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.

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

  18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01HZ5VE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

    2. A01I1IGE01
      Text in Illustration
      *a

      Seal packing diameter

      (3.5 to 4.5 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
      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 sub-assembly RH within 3 minutes and tighten the bolts.

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

    3. A01HZ9LE04
      Text in Illustration
      *1 Knock Pin
      *a Front View

      Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


      • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration.

        Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated, valve contact with a piston at TDC will occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

    4. A01I1DIE02

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

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

  19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01I0CQE08
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

      Install the No. 3 chain tensioner assembly with the bolt.

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

    2. While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

  20. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)


    1. A01HZ46E08
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

    4. A01HXE2E06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Remove the pin from the No. 3 chain tensioner assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly Click here.

  21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01I1S2E08
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

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

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

    2. While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

  22. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)


    1. A01I02PE11
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

    3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

    4. A01HY78E06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      SST
      09922-10010
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly Click here.

  23. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01HXNI

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

      Torque:
      23 N*m  { 230 kgf*cm, 17 ft.*lbf }

  24. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. Install the 2 No. 2 chain vibration dampers.

  25. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01HXTN

      Install the 2 keys and crankshaft timing sprocket as shown in the illustration.

  26. INSTALL IDLE SPROCKET ASSEMBLY


    1. A01HYH4E03
      Text in Illustration
      *1 Knock Pin

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

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

      Note

      Be careful of the idle gear installation position.

      Tech Tips

      Check that no foreign matter is on the No. 1 and No. 2 idle gear shafts.

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

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Tech Tips

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

  27. INSTALL CHAIN SUB-ASSEMBLY


    1. A01HZ80E04
      Text in Illustration
      *1 Mark Plate
      *a Timing Mark

      Align the mark plates and timing marks as shown in the illustration and install the chain.

      Tech Tips

      The camshaft mark plates are orange.

    2. A01HYCF

      Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.

    3. A01I1YZE15
      Text in Illustration
      *1 Mark Plate
      *a Turn
      *b When the idle sprocket is reused
      *c Mark
      *d Align

      Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks.

      Note

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

    4. A01HXHME05
      Text in Illustration
      *1 Mark Plate
      *a Timing Mark

      Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.

      Tech Tips

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the pulley set bolt.

    6. A01I1UXE03
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

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

  28. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01HYG0E04
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

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

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

    3. A01HYJQ

      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.

  30. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


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

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

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

      A01HZDFE06
      Text in Illustration
      *a Timing Mark *b Viewpoint

      Tech Tips

      For the intake camshaft:

      Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      A01I26DE01

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

    4. Remove the pulley set bolt.

  31. INSTALL TIMING CHAIN CASE OIL SEAL


    1. A01I14ZE04

      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.

      • Make sure that the oil seal edge does not stick out of the timing chain case.

      Tech Tips

      Tap in the oil seal so that it is positioned within 1.0 mm from the edge of the timing chain case.

    2. Apply a light coat of MP grease to the timing chain cover oil seal lip.

  32. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. A01I040E01

      Install a new water pump gasket and the engine water pump assembly with the 8 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note

      Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

      A01HZNRE12
      Text in Illustration
      *a Seal Diameter: 3.0 mm or more A01I0B8 Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      3.0 mm (0.118 in.)

      Note


      • Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.

      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover within 3 minutes.

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

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

      A01HZV3E01
      Text in Illustration
      *a

      Dashed line area

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

      		 *b

      Continuous line area

      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *c

      Alternate long and short dashed line area

      (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)

      		 *d

      Diagonal line area

      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      A01I0B8 Be sure to apply seal packing - -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain 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 installing.

      Seal Packing Application Chart
      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm or more (0.177 in.) 1.0 to 2.0 mm (0.0394 to 0.0787 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.)
    3. A01HYVO

      Install a new gasket.

    4. A01I1RYE07
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft

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

    5. A01HY8ZE01
      Text in Illustration
      *1 Nut

      Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

      Bolt Length
      Item Length
      Bolt A 40 mm (1.57 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 28 mm (1.102 in.)

      Note

      Make sure that there is no oil on the threads of bolts B and C.

    6. A01HZEBE01
      Text in Illustration
      *a Area 1
      *b Area 2
      *c Area 3
      *d Area 4

      Fully tighten the bolts in this order: Area 1 and Area 2.

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

    7. Fully tighten the bolts and nuts in Area 3.

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

      Tech Tips

      Tighten the bolts and nuts from top to bottom as shown in the illustration.

    8. Fully tighten the bolts in Area 4.

      Torque:
      Bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Torque:
      Except bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Tighten the bolts from bottom to top as shown in the illustration.

    9. Install a new timing chain cover plate gasket and the timing chain cover plate with the 4 bolts.

      Torque:
      9.1 N*m  { 93 kgf*cm, 81 in.*lbf }

  34. INSTALL WATER INLET HOUSING


    1. A01I1U4E01

      Install 2 new O-rings.

      Tech Tips

      Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.

    2. A01HZ60E02

      Install the 2 stud bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A01HXY1E03
      Text in Illustration
      *1 Nut
      *2 Bolt

      Install the water inlet housing with the 2 bolts and nut.

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

      Note

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

    4. Connect the No. 1 water by-pass hose.

    5. Apply adhesive around the drain cock.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the drain cock assembly to the water inlet housing.

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

    7. Install the drain cock plug to the drain cock assembly.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    8. Install a new gasket to the thermostat.

    9. A01HY9NE01

      Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

      Tech Tips

      The jiggle valve may be set within 10° of either side of the prescribed position.

    10. A01HZ27

      Install the water inlet with the 2 nuts.

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

  35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01I1B3E03
      Text in Illustration
      *1 Stud Bolt

      Using an E8 "TORX" socket wrench, install the 2 stud bolts.

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

    2. Install the No. 1 front engine mounting bracket LH with the 6 bolts.

      Torque:
      54 N*m  { 550 kgf*cm, 40 ft.*lbf }

      Note


      • Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.

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

  36. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01HY2RE01

      Install the No. 1 oil pan baffle plate with the 7 bolts.

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

      Tech Tips

      Temporarily tighten the 7 bolts. Fully tighten the 2 bolts (A) shown in the illustration before tightening the other bolts.

  37. INSTALL OIL PAN SUB-ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

      A01HY00E06
      Text in Illustration
      *a Timing Chain Cover *b Lower Cylinder Block
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01I1FJ

      Install 2 new O-rings.

    3. A01HZNJE01
      Text in Illustration
      *a Seal Diameter

      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
      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 after applying seal packing.

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

    4. A01HYTBE04
      Text in Illustration
      *1 Nut

      Install the oil pan with the 16 bolts and 2 nuts.

      Torque:
      Bolts A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Except bolts A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  38. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01I1WSE07
      Text in Illustration
      *a Timing Chain Cover

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01HXHKE02
      Text in Illustration
      *1 Nut

      Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

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

  39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01HZWYE02

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01HXO4E01
      Text in Illustration
      *a Seal Diameter

      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
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

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

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

    3. A01I1PVE02
      Text in Illustration
      *1 Nut

      Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

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

  40. INSTALL OIL PAN DRAIN PLUG


    1. A01HZ47

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

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

  41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01I1G7

      Apply seal packing as shown in the illustration.

      Text in Illustration
      A01I0B8 Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the head cover within 3 minutes after applying seal packing.

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

    2. A01I0B2

      Install 3 new gaskets as shown in the illustration.

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

    4. A01HXF1E01

      Install the head cover with the 12 bolts and a new seal washer.

      Torque:
      Bolts A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolts A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01I0NM

      Apply seal packing as shown in the illustration.

      Text in Illustration
      A01I0B8 Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover sub-assembly LH within 3 minutes after applying seal packing.

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

    2. A01HXJZ

      Install 3 new gaskets as shown in the illustration.

    3. Install a new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly LH.

    4. A01HXEHE04

      Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.

      Torque:
      Bolts A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolts A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

  43. INSTALL WATER OUTLET


    1. A01I1RC

      Install 2 new gaskets and a new O-ring.

      Tech Tips

      Apply soapy water to the O-ring.

    2. A01HYA7E02
      Text in Illustration
      *1 Nut
      *2 Bolt

      Install the water outlet with the 2 bolts and 4 nuts.

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

      Note

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

  44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01I14H

      Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

    2. A01HYP5

      Install the engine oil level dipstick guide with the bolt.

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

  45. INSTALL CRANKSHAFT PULLEY


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

    2. A01HYVUE03
      Text in Illustration
      *a Hold
      A01I0B8 Turn

      Using SST, install the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      250 N*m  { 2550 kgf*cm, 184 ft.*lbf }

  46. INSTALL OIL FILTER CAP ASSEMBLY


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

    2. A01I03UE01
      Text in Illustration
      *1 O-ring
      *a CORRECT
      *b INCORRECT

      Apply a light coat 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. Install a new oil filter element to the oil filter cap.

    4. Remove all dirt and foreign matter from the installation surface and the inside of the cap on the engine side.

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

      Note

      Make sure that the O-ring does not get caught between the parts.

    6. A01I10IE01
      Text in Illustration
      *1 Oil Filter Cap Assembly
      *2 O-ring
      *3 Oil Filter Bracket
      *a No Gap

      Using SST, install the oil filter cap.

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

      Note

      After tightening the oil filter cap, make sure that there is no gap and that the O-ring is not protruding.

    7. A01I0J5E03
      Text in Illustration
      *1 O-ring

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

      Note

      Remove all dirt and foreign matter from the installation surface.

    8. Install the oil filter drain plug to the oil filter cap.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      Make sure that the O-ring does not get caught between the parts.

  47. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01HYQIE08
      Text in Illustration
      *1 Adhesive

      Apply adhesive around the drain cock sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01I0EYE07
      Text in Illustration
      *a for Bank 1
      *b for Bank 2

      Install the water drain cocks as shown in the illustration.

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

      Note

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

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

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  48. INSTALL NO. 1 OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

      Note

      Do not touch the mesh when installing the oil control valve filter.

    2. A01I1HFE02
      Text in Illustration
      *1 Oil Pipe Union

      Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union.

    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.

    4. Tighten the oil pipe union (on the head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    5. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

  49. INSTALL OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

      Note

      Do not touch the mesh when installing the oil control valve filter.

    2. A01HXF8E05
      Text in Illustration
      *1 Oil Pipe Union

      Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union.

    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.

    4. Install the bolt (A) to the cylinder head.

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

    5. Tighten the oil pipe union (on the head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    6. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

  50. INSTALL CRANK POSITION SENSOR


    1. A01I1T4E02
      Text in Illustration
      *1 O-ring

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

    2. Install the crank position sensor with the bolt.

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

    3. Connect the crank position sensor connector.

  51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01HY0DE06
      Text in Illustration
      *1 New O-ring

      Apply a light coat of engine oil to 4 new O-rings and install them to the 4 camshaft timing oil control valve assemblies.

    2. Install the 4 oil control valves with the 4 bolts.

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

      Note

      Make sure that each O-ring is not cracked or does not jump out of position during installation.

    3. Connect the 4 oil control valve connectors.

  52. INSTALL VVT SENSOR


    1. Install the 4 sensors with the 4 bolts.

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

    2. Connect the 4 sensor connectors.

  53. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. Apply adhesive around the ventilation valve sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01HYIX

      Using a deep socket wrench 19 mm, install the ventilation valve sub-assembly.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  54. INSTALL SPARK PLUG


    1. A01HY4S

      Install the 6 spark plugs.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Perform "Inspection After Repair" after replacing the spark plug Click here.

  55. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new oil filler gasket.

    2. Install the oil filler cap sub-assembly.