ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove a camshaft bearing cap setting ring pin unless it is being replaced.


    1. Using a plastic-faced hammer, tap in 20 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)
      B003WI7C03
      *a for Bank 2 *b for Bank 1
      *c Protrusion Height - -

  2. INSTALL STRAIGHT PIN

    Note

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


    1. Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing sub-assembly.

      Standard protrusion height
      7.7 to 8.3 mm (0.303 to 0.327 in.)
      B003T00C03
      *a for Bank 2 *b for Bank 1
      *c Protrusion Height - -

  3. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. B003WRHC03
      B003WAF Front Side

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

  4. INSTALL REAR ENGINE OIL SEAL


    1. Place the rear engine oil seal retainer on wooden blocks.

    2. B003W9OE10

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

      SST
      09223-15030
      09950-70010   ( 09951-07100 )
      Standard depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note


      • Keep the lip free of foreign matter.

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

  5. INSTALL REAR ENGINE OIL SEAL RETAINER


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

    2. B003U3EC03
      *a 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
      2.0 to 3.0 mm (0.0787 to 0.1181 in.)

      Note


      • Remove any oil from the contact surface.

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

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

    3. B003TCWE01

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


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

      • Install the bolt within 3 minutes after applying adhesive.

  6. INSTALL NO. 1 WATER OUTLET PIPE


    1. B003T47

      Install the No. 1 water outlet pipe with the 2 bolts.

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

  7. INSTALL KNOCK CONTROL SENSOR

    Click here

  8. INSTALL NO. 5 ENGINE WIRE


    1. B003WGX

      Install the No. 5 engine wire with the 2 clamps.

    2. Connect the 2 connectors.

  9. INSTALL CYLINDER HEAD GASKET

    Click here

  10. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  11. INSTALL NO. 2 CYLINDER HEAD GASKET

    Click here

  12. INSTALL CYLINDER HEAD LH

    Click here

  13. INSTALL VALVE STEM CAP

    Click here

  14. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

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

    Click here

  16. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET LH


    1. B003UHX

      Install the camshaft bearing cap oil hole gasket LH to the No. 6 camshaft bearing cap.

  17. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET RH


    1. B003U3Q

      Install the camshaft bearing cap oil hole gasket RH to the No. 7 camshaft bearing cap.

  18. INSTALL OIL CONTROL VALVE FILTER (for Bank 1)


    1. B003TYHC03
      *a Camshaft Installation Surface

      Install the 2 oil control valve filters to the No. 1 and No. 2 camshaft bearing caps.

      Note

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

  19. INSTALL OIL CONTROL VALVE FILTER (for Bank 2)

    Tech Tips

    Use the same procedure described for the Bank 1.

  20. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

    Click here

  21. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY

    Click here

  22. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

    Click here

  23. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

    Click here

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

    Click here

  25. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)

    Click here

  26. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)

    Click here

  27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

    Click here

  28. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 2)

    Click here

  29. INSTALL CAMSHAFT

    Click here

  30. INSTALL NO. 2 CAMSHAFT

    Click here

  31. INSTALL FUEL PUMP LIFTER HOUSING

    Click here

  32. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  33. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

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

    Click here

  35. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)

    Click here

  36. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)

    Click here

  37. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here

  38. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 1)

    Click here

  39. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. B003WMB

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

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

  40. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. B003VRE

      Install the 2 No. 2 chain vibration dampers.

  41. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. B003WP5

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

  42. INSTALL IDLE SPROCKET ASSEMBLY


    1. B003WNMC01
      *1 No. 1 Idle Gear Shaft
      *2 Idle Sprocket Assembly
      *3 No. 2 Idle Gear Shaft
      *a Knock Pin
      B003WAF 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 assembly 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 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.

  43. INSTALL CHAIN SUB-ASSEMBLY


    1. Check that the camshaft timing gear position on the bank 2 and the timing marks on the bank 1 and crankshaft are positioned as shown in the illustration.

      B003UDKC02
      *a Timing Mark *b Center Line
      *c Timing Gear Set Key *d Flat Surface

      Tech Tips

      The flat surface on the camshaft timing exhaust gear assembly must be positioned as shown in the illustration.

    2. B003VT0C03
      *a Mark Plate (Yellow)
      *b Timing Mark

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

      Tech Tips

      The camshaft mark plates are yellow.

    3. B003TJM

      Rest the chain sub-assembly on top of the crankshaft.

    4. B003WOBC03
      *a When idle sprocket is reused
      *b Mark
      *c Align
      *d Chain Plate
      B003WAF Turn

      Turn the camshaft timing gear assembly on the bank 2 counterclockwise to tighten the chain sub-assembly 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 sub-assembly between the banks.

    5. B003WY5C03
      *a Mark Plate (Pink)
      *b Timing Mark

      Align the mark plate and timing mark as shown in the illustration and install the chain sub-assembly onto the crankshaft timing gear or sprocket.

      Tech Tips

      The crankshaft mark plate is pink.

    6. Temporarily install the crankshaft pulley set bolt.

    7. B003SZBC02
      *a Timing Gear Set Key
      *b Center Line
      *c 10°

      Turn the crankshaft clockwise 10° to set it to the bank 2 block bore center line (TDC/compression).

  44. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  45. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B003VGKC07
      *a Stopper Plate
      *b Plunger

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

    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 assembly with the 2 bolts.

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

    4. Remove the lock pin of the No. 1 chain tensioner assembly.

  46. 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.

      B003USTC03
      *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.

      B003WIQE01

    3. If the valve timing is misaligned, reinstall the chain sub-assembly.

    4. Remove the crankshaft pulley set bolt.

  47. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. Install the new water pump gasket.

    2. B003VR0N01

      Install the engine water pump assembly with the 7 bolts.

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

      Note


      • Be sure to apply adhesive to the 2 bolts labeled A before reusing them, or replace them with new ones if necessary.

      • Install the bolt within 3 minutes after applying adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  48. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  49. INSTALL TIMING CHAIN COVER PLATE

    Click here

  50. INSTALL TIMING CHAIN CASE OIL SEAL

    Click here

  51. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. B003UMFE01

      Install the No. 1 oil pan 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.

  52. INSTALL OIL STRAINER SUB-ASSEMBLY

    Click here

  53. INSTALL OIL PAN SUB-ASSEMBLY

    Click here

  54. INSTALL OIL LEVEL SENSOR BRACKET

    Click here

  55. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  56. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  57. 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 }

  58. INSTALL SPARK PLUG TUBE GASKET


    1. B003VTO

      Install 6 new spark plug tube gaskets to the cylinder head cover sub-assembly.

  59. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  60. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  61. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  62. INSTALL REAR WATER BY-PASS JOINT


    1. B003V4M

      Install a new O-ring to the No. 1 water outlet pipe.

      Tech Tips

      Apply water to the O-ring.

    2. B003VFD

      Install 2 new water by-pass joint gaskets to the rear water by-pass joint.

    3. B003UJ0C01
      B003WAF Bolt
      B003U82 Nut

      Install the rear water by-pass joint with the 4 bolts and 2 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.

  63. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

    Click here

  64. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

    Click here

  65. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

    Click here

  66. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

    Click here

  67. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. B003TFUC01
      B003WAF Bolt
      B003U82 Nut

      Install a new water inlet housing gasket and the water inlet with thermostat sub-assembly with the 2 bolts and nut.

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

  68. INSTALL WATER OUTLET SUB-ASSEMBLY


    1. B003VJ2

      Install a new O-ring to the No. 1 water outlet pipe.

    2. B003U5U

      Install the water outlet sub-assembly with the 2 bolts.

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

      Note

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

  69. INSTALL CRANKSHAFT PULLEY

    Click here

  70. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)

    Click here

  71. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

    Click here

  72. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  73. INSTALL CYLINDER BLOCK WATER DRAIN COCK PLUG


    1. Apply adhesive around the cylinder block water drain cock plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. B003TKX

      Install the cylinder block water drain cock plug.

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

      Note

      Install the cylinder block water drain cock plug within 3 minutes after applying adhesive.

  74. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. B003UKSC01
      *a 80°

      Install the cylinder block water drain cock sub-assembly as shown in the illustration.

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

      Note


      • Install the cylinder block water drain cock sub-assembly within 3 minutes after applying adhesive.

      • Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening the drain cock to the specified torque.

      • Do not loosen the cylinder block water drain cock sub-assembly after setting it correctly.

      • Do not add engine coolant for at least 1 hours after installing the cylinder block water drain cock sub-assembly.

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

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

  75. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  76. INSTALL VENTILATION VALVE SUB-ASSEMBLY

    Click here

  77. INSTALL VENTILATION HOSE ASSEMBLY


    1. B003V52

      Install the ventilation hose assembly to the cylinder head cover sub-assembly LH with the hose clamp.

  78. INSTALL NO. 1 FUEL TUBE SUB-ASSEMBLY

    Click here

  79. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  80. INSTALL SPARK PLUG

    Click here