ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STUD BOLT

    A01WT3GE04
    *1 24.5 mm (0.965 in.)
    *2 14 mm (0.551 in.)
    *3 40 mm (1.58 in.)

    1. Install the timing chain cover stud bolt.


      1. Using an E10 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01WS3WE05

      Install the oil pan stud bolt.


      1. Using an E6 and E7 "TORX" socket wrench, install the 3 stud bolts as shown in the illustration.

        Torque:
        for stud bolt A
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
        for stud bolt B
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  2. INSTALL RING PIN

    A01WUF9E06
    *1 3.6 to 4.6 mm
    *2 7.5 to 8.5 mm

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

      Standard Protrusion
      Item Ring Pin Diameter Specified Condition
      Ring pin A 13 mm (0.512 in.) 7.5 to 8.5 mm (0.295 to 0.335 in.)
      Ring pin B 11 mm (0.433 in.) 3.6 to 4.6 mm (0.142 to 0.181 in.)

  3. INSTALL REAR CRANKSHAFT OIL SEAL


    1. A01WUJYE04

      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 )
      Standard depth
      0 to 1.0 mm (0 to 0.0394 in.)

      Note


      • Keep the lip free from foreign matter.

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

  4. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY

    A01WSBW

    1. 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 }

  5. INSTALL ENGINE REAR OIL SEAL RETAINER

    A01WU0TE18
    *1 2.0 to 3.0 mm
    *2 3.5 mm

    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
      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 within 15 minutes after applying seal packing.

    2. A01WSXS

      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.

  6. INSTALL OIL STRAINER SUB-ASSEMBLY

    A01WST2

    1. 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:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

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

  7. INSTALL NO. 1 OIL PAN BAFFLE PLATE

    A01WRY7

    1. Install the baffle plate with the 7 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  8. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

    A01WW7CE08
    *1 3.0 to 4.0 mm

    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 15 minutes after applying seal packing.

    2. A01WWBLE15
      *1 Nut

      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.

      Standard Bolt
      Item Length Thread Diameter
      Bolt A 92 mm (3.62 in.) 6 mm (0.236 in.)
      Bolt B 30 mm (1.18 in.) 10 mm (0.394 in.)

  9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    A01WPMYE01
    *1 Seal diameter: 3.0 to 4.0 mm

    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 15 minutes after applying seal packing.

    2. A01WWK3E08
      *1 Nut

      Install the oil pan with the 14 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.

    3. Install the engine oil level sensor Click here.

  10. INSTALL NO. 1 HEAT EXCHANGER COVER

    A01WVCOE01
    *1 Seal diameter: 3.0 to 4.0 mm

    1. 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. A01WUOSE13
      *1 Nut

      Install the heat exchanger cover with the 12 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.

      Standard Bolt
      Item Length Thread Diameter
      Bolt A 20 mm (0.787 in.) 8 mm (0.315 in.)
      Bolt B 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt C 16 mm (0.630 in.) 6 mm (0.236 in.)

  11. INSTALL VENTILATION PIPE GASKET

    A01WTPFE07

    1. 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.

  12. INSTALL CYLINDER BLOCK WATER JACKET SPACER

    A01WT63E08
    *1 UP Mark

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

      Tech Tips


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

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

  13. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

    Click here

  14. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

    Click here

  15. 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 heads.

  16. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster before installing it Click here.

    2. Install the 32 valve lash adjusters to the cylinder heads.

      Note

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

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


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

    2. A01WV4RE01
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster

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

  18. INSTALL CAMSHAFT BEARING CAP RH

    Click here

  19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here

  20. INSTALL CAMSHAFT BEARING CAP LH

    Click here

  21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

    Click here

  22. INSTALL CRANKSHAFT TIMING GEAR KEY

    A01WPSZ

    1. Install the timing gear key.

      Tech Tips

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

  23. 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.

      A01WU2AE05
      *1 Toward Ceiling
      *2 Knock Pin
      *3 Key

  24. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

    A01WR1VE01
    *1 Push
    *2 Plunger
    *3 Pin

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

  25. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH

    A01WTVAE09
    *1 Mark Plate
    *2 Timing Mark

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

    2. A01WRW9E15
      *1 Timing Mark
      *2 Mark Plate

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

    3. A01WTF5E14
      *1 Timing Mark
      *2 Mark Plate

      Align the No. 2 chain 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.

      Note

      The camshaft timing exhaust gear has 2 grooves. Align the mark plates of the No. 2 chain with the first groove.

      Tech Tips

      The crankshaft timing sprocket RH and camshaft timing 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 the bolt.

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

  26. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH

    A01WTHB

    1. Install the vibration damper with the 2 bolts.

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

  27. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

    A01WWQ9

    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.

  28. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH

    A01WWACE11
    *1 Stopper Plate
    *2 Plunger

    1. 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. A01WPYZ

      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.

  29. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

    A01WTRNE01
    *1 Push
    *2 Pin
    *3 Plunger

    1. Install the chain tensioner with the 2 bolts.

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

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

  30. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH

    A01WVV7E09
    *1 Mark Plate
    *2 Timing Mark

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

    2. A01WTZSE17
      *1 Timing Mark
      *2 Mark Plate

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

    3. A01WUQ5E13
      *1 Timing Mark
      *2 Mark Plate

      Align the No. 2 chain 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.

      Note

      The camshaft timing exhaust gear has 2 grooves. Align the mark plates of the No. 2 chain with the first groove.

      Tech Tips

      The crankshaft timing sprocket LH and camshaft timing 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 timing mark positions of the gears 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. 3 chain tensioner.

    8. Using a wrench to hold the hexagonal portion of the No. 3 camshaft, temporarily install the bolt.

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

  31. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

    A01WQHI

    Tech Tips

    If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and install the chain tensioner slipper.

  32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH

    A01WWACE12
    *1 Stopper Plate
    *2 Plunger

    1. 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. A01WPU7

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

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

  33. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH

    A01WUPC

    1. 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.

  34. TIGHTEN CAMSHAFT TIMING GEAR


    1. A01WS02E08
      *1 Turn
      *2 Hold

      for Bank 1:


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

      2. Tighten the bolt of the camshaft timing gear.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
      3. A01WW0ME07
        *1 Turn
        *2 Hold

        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. A01WVPAE07
      *1 Hold
      *2 Turn

      for Bank 2:


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

      2. Tighten the bolt of the camshaft timing gear.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
      3. A01WTL6E07
        *1 Hold
        *2 Turn

        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 }

  35. 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 sprocket and camshaft timing gears are as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

      A01WTYXE11

  36. INSTALL WATER INLET PIPE

    Click here

  37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  38. INSTALL WATER PUMP ASSEMBLY

    Click here

  39. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A01WTJRE13

      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 and 1.0 mm (0 and 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.

  40. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. B0018E2

      Install the crankshaft timing gear key to the crankshaft.

  41. INSTALL CRANKSHAFT PULLEY

    Click here

  42. INSTALL SPARK PLUG TUBE GASKET

    A01WS3SE01
    *1 Area to cut off

    1. Using a cutter knife, cut off the seal part of the removed gasket.

    2. A01WT53E07
      *1 Removed Gasket
      *2 New Gasket

      Using the removed gasket and a hammer, tap in a new gasket until it stops.

      Tech Tips

      If the removed gasket does not fit on the new one, correct the removed one with pliers.

    3. Apply a light coat of MP grease to the lip of the gasket.

    4. Return the 4 ventilation baffle plate claws to the original positions.

  43. INSTALL OIL CONTROL VALVE FILTER

    A01WRW8E19
    *1 Cylinder Head Cover Spacer
    *2 Gasket
    *3 Filter

    1. LH:


      1. Install the filter in the cylinder head.

      2. Install a new gasket and the cylinder head cover spacer with the 3 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01WQG5E16
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Filter

      RH:


      1. Install the filter in the cylinder head.

      2. Install a new gasket and the cylinder head cover spacer with the 3 bolts.

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

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

    Click here

  45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  46. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  47. INSTALL WATER PUMP PULLEY

    Click here

  48. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY


    1. A01WWE6

      for Bank 1:


      1. Apply a light coat of engine oil to 2 new O-rings.

      2. Install the 2 O-rings to the 2 oil control valves.

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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01WWKP

      for Bank 2:


      1. Apply a light coat of engine oil to 2 new O-rings.

      2. Install the 2 O-rings to the 2 oil control valves.

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

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

  49. INSTALL CRANKSHAFT POSITION SENSOR

    A01WPLR

    1. Install the crankshaft position sensor with the bolt.

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

  50. INSTALL CRANK POSITION SENSOR PROTECTOR

    A01WTB6

    1. Install the sensor protector with the 2 bolts.

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

  51. INSTALL CAMSHAFT POSITION SENSOR

    A01WSCA

    1. Install the camshaft position sensor with the bolt.

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

  52. INSTALL VVT SENSOR


    1. A01WQR3

      for Bank 1:

      Install the 2 VVT sensors with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01WVVG

      for Bank 2:

      Install the 2 VVT sensors with the 2 bolts.

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

  53. 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 }

  54. INSTALL OIL FILLER CAP HOUSING


    1. A01WQYU

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

    2. A01WQAD

      Install the cap housing with the 2 bolts.

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

  55. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  56. INSTALL OIL FILTER BRACKET (w/o Oil Cooler)

    Click here

  57. INSTALL OIL FILTER BRACKET (w/ Oil Cooler)

    Click here

  58. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)

    Click here

  59. INSTALL OIL FILTER ELEMENT

    Click here

  60. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here