ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL RING PIN

    Note

    It is not necessary to remove a ring pin unless it is being replaced.


    1. Using a plastic-faced hammer, tap in new ring pins to the camshaft housing.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)
      A000QZIE01
      Text in Illustration
      *1 Protrusion Height - -
      *a LH *b RH

  2. INSTALL NO. 1 STRAIGHT PIN

    Note

    It is not necessary to remove a No. 1 straight pin unless it is being replaced.


    1. Using a plastic-faced hammer, tap in new No. 1 straight pins to the camshaft housing.

      Standard Protrusion Height
      Item Specified Condition
      Straight pin A 7.7 to 8.3 mm (0.303 to 0.327 in.)
      Straight pin B 5.7 to 6.3 mm (0.224 to 0.248 in.)
      A000NNNE01
      Text in Illustration
      *1 Protrusion Height - -
      *a LH *b RH

  3. INSTALL REAR CRANKSHAFT OIL SEAL


    1. Place the oil seal retainer on wooden blocks.

    2. A000PG5E01

      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 of foreign matter.

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

  4. INSTALL ENGINE REAR OIL SEAL RETAINER


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

    2. A000Q1ME01
      Text in Illustration
      *1 Seal Packing

      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 seal retainer within 3 minutes after applying seal packing.

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

    3. A000P67E02

      Install the 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

  5. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY


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

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

  6. INSTALL KNOCK SENSOR

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  7. INSTALL NO. 5 ENGINE WIRE


    1. Install the No. 5 engine wire with the clamp.

  8. INSTALL CYLINDER HEAD GASKET

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  9. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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  10. INSTALL NO. 2 CYLINDER HEAD GASKET

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  11. INSTALL CYLINDER HEAD LH

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  12. INSTALL VALVE STEM CAP

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  13. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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  15. INSTALL OIL CHECK VALVE


    1. Install the oil check valve to the camshaft bearing cap.

  16. INSTALL OIL CONTROL VALVE FILTER LH


    1. A000SW7E01
      Text in Illustration
      *a Camshaft Installation Surface

      Install the oil control valve filter LH to the camshaft bearing cap.

      Note

      Make sure the oil control valve filter does not protrude past the camshaft installation surface shown in the illustration.

  17. INSTALL OIL CONTROL VALVE FILTER RH

    Tech Tips

    Use the same procedure described for the LH side.

  18. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

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  19. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY

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  20. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

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  21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

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  22. INSTALL CAMSHAFT

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  23. INSTALL NO. 2 CAMSHAFT

    Click here

  24. INSTALL FUEL PUMP LIFTER HOUSING

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  25. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  26. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here

  27. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

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

    Click here

  29. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

    Click here

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

    Click here

  31. INSTALL NO. 1 CHAIN VIBRATION DAMPER


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

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

  32. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

  33. INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the 2 timing gear set keys and timing sprocket to the crankshaft.

  34. INSTALL IDLE SPROCKET ASSEMBLY


    1. A000MV0E01
      Text in Illustration
      *1 No. 1 Idle Gear Shaft
      *2 Idle Sprocket
      *3 No. 2 Idle Gear Shaft
      *4 Knock Pin
      B002B6O Apply Engine Oil

      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 with the knock pin groove of the cylinder block.

      Note

      Make sure that the idle gear is facing the correct direction.

      Tech Tips

      Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.

    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.

  35. INSTALL CHAIN SUB-ASSEMBLY


    1. Check that the camshaft timing gear position on the RH bank and the timing marks on the LH bank and crankshaft are positioned as shown in the illustration.

      A000MXXE02
      Text in Illustration
      *1 Timing Mark *2 Center Line
      *a Approximately 10° - -
    2. A000OAME02
      Text in Illustration
      *1 Mark Plate (Pink)
      *2 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 pink.

    3. A000N3I

      Rest the chain on top of the crankshaft.

    4. A000MZDE02
      Text in Illustration
      *1 Chain Plate
      *a When idle sprocket is reused
      *b Mark
      *c Align
      B002B6O Turn

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

      Note

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

    5. A000ND9E02
      Text in Illustration
      *1 Mark Plate (Yellow)
      *2 Timing Mark

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

      Tech Tips

      The crankshaft mark plate is yellow.

    6. Temporarily install the pulley set bolt.

    7. A000RT5E01
      Text in Illustration
      *1 Timing Mark
      *a Center Line
      B002B6O Turn

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

  36. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A000QWLE04
      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 pin of 1.27 mm (0.0500 in.) diameter into the hole of the stopper plate.

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

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

    4. Remove the lock pin of the chain tensioner.

  38. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


      • Check each timing mark from a viewpoint directly inline 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.

      A000RQ7E02
      Text in Illustration
      *1 Timing Mark - -
      *a 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.

      A000OVTE02

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

    4. Remove the pulley set bolt.

  39. INSTALL ENGINE WATER PUMP ASSEMBLY

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  40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  41. INSTALL TIMING CHAIN CASE OIL SEAL

    Click here

  42. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. When replacing a stud bolt, install it by using an E6 "TORX" socket wrench, as shown in the illustration.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      A000Q7GE12
      Text in Illustration
      *a Timing Chain Cover *b Cylinder Block Lower
    2. A000SX9E02

      Install the baffle plate with the 8 bolts.

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

      Tech Tips

      Temporarily install the 8 bolts. Tighten the 2 bolts A shown in the illustration before tightening the other bolts.

    3. Install a new gasket and the oil strainer with the 3 nuts.

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

    4. Install 2 new O-rings.

  43. INSTALL OIL PAN SUB-ASSEMBLY


    1. A000RJ0E01
      *1 9 mm (0.354 in.)
      *2 19 mm (0.748 in.)

      When replacing a stud bolt, install it by using an E6 "TORX" socket wrench.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A000OEAE15
      Text in Illustration
      *1 Seal Packing

      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 0.156 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 installation.

    3. A000N27

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

      Torque:
      for bolt A, B and nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt C
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 45 mm (1.77 in.)
      Bolt C 16 mm (0.630 in.)
      Text in Illustration
      B002B6O Bolt A
      B002BBR Bolt B
      B002BRO Bolt C
      A000R1K Nut

  44. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A000NNOE01
      Text in Illustration
      *1 Seal Packing

      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
      4.0 to 6.0 mm (0.156 to 0.236 in.)

      Note


      • Remove any oil from the contact surface.

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

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

    2. A000N2C

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

  45. INSTALL OIL PAN DRAIN PLUG


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

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

  46. INSTALL SPARK PLUG TUBE GASKET


    1. A000QL9E01
      Text in Illustration
      *a Before cutting off
      *b After cutting off
      B002BQR Area to be cut off

      Using a cutter, cut off the sealing part of the removed plug tube gasket.

    2. A000R8RE02
      Text in Illustration
      *1 Plug tube gasket without sealing part
      *2 New plug tube gasket
      *3 Claw

      Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.

      Note


      • Keep the lip free of foreign matter.

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

      Tech Tips

      If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

    3. Return the claws of the ventilation baffle plate to their original positions.

  47. POUR ENGINE OIL

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  48. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  50. INSTALL FUEL PUMP SPACER GASKET


    1. Install a new fuel pump spacer gasket to the cylinder head cover.

  51. INSTALL REAR WATER BY-PASS JOINT


    1. Install 2 new gaskets and a new O-ring.

      Tech Tips

      Apply water to the O-ring.

    2. Install the water by-pass joint 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.

  52. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. Install a new gasket and the water inlet with thermostat with the 3 nuts.

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

  53. INSTALL WATER INLET SUB-ASSEMBLY


    1. Install the 3 water by-pass hoses.

    2. A000ON3E03

      Install 2 new O-rings.

      Tech Tips

      Apply a small amount of water the O-ring (A) shown in the illustration before installing it.

    3. Install the water inlet with the 4 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. Install the 3 water by-pass hoses.

  54. INSTALL CRANKSHAFT PULLEY

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  55. INSTALL OIL FILTER ELEMENT

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  56. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Apply adhesive around the cylinder block water drain cock sub-assemblies.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A000PPHE01

      RH Side:

      Install the cylinder block water drain cock sub-assembly to the cylinder block 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 cylinder block water drain cock sub-assembly to the specified torque.

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

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

    4. LH Side:

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

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

  57. INSTALL CRANKSHAFT POSITION SENSOR

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  58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)

    Click here

  59. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)

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  60. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)

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  61. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)

    Click here

  62. INSTALL VVT SENSOR (for Exhaust Side of Bank 2)

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  63. INSTALL VVT SENSOR (for Intake Side of Bank 2)

    Click here

  64. INSTALL VVT SENSOR (for Exhaust Side of Bank 1)

    Click here

  65. INSTALL VVT SENSOR (for Intake Side of Bank 1)

    Click here

  66. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

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  67. INSTALL NO. 2 SEPARATOR CASE


    1. A000N4PE02
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of engine oil to a new O-ring and install it to the No. 2 separator case.

    2. Install the No. 2 separator case with the bolt and 2 nuts as shown in the illustration.

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

  68. INSTALL WATER BY-PASS HOSE ASSEMBLY

  69. INSTALL PCV VALVE SUB-ASSEMBLY

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  70. INSTALL SPARK PLUG

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  71. INSTALL RADIATOR CAP SUB-ASSEMBLY

  72. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the gasket.

    2. Install the oil filler cap.