ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL WATER INLET PIPE


    1. B004007

      Install the water inlet pipe with the 2 bolts.

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

  2. INSTALL NO. 2 CYLINDER HEAD GASKET

    Click here

  3. INSTALL CYLINDER HEAD LH


    1. Place the cylinder head LH onto the cylinder block sub-assembly.

      Note


      • Do not allow oil to adhere to the bottom of the cylinder head LH.

      • Gently lower the cylinder head LH in order not to damage the No. 2 cylinder head gasket with the bottom of the cylinder head LH.

      Tech Tips

      The cylinder head set 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 set bolts.

    3. Step 1:


      1. B00409IN02

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

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    4. Step 2:


      1. B003Z6ZC01
        *a Turn 90°
        *b Paint Mark
        B003ZIE Front of Engine

        Mark each cylinder head set bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head set bolts 90° in the order shown in step 1.

    5. Step 3:


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

      2. Check that the paint marks are now facing rearward.

    6. B003ZEVN02

      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

  4. INSTALL CYLINDER HEAD GASKET

    Click here

  5. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. Place the cylinder head sub-assembly onto the cylinder block sub-assembly.

      Note


      • Do not allow oil to adhere to the bottom of the cylinder head sub-assembly.

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

      Tech Tips

      The cylinder head set 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 set bolts.

    3. Step 1:


      1. B003ZNVN02

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

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    4. Step 2:


      1. B003Z6ZC01
        *a Turn 90°
        *b Paint Mark
        B003ZIE Front of Engine

        Mark each cylinder head set bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head set bolts 90° in the order shown in step 1.

    5. Step 3:


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

      2. Check that the paint marks are now facing rearward.

        Tech Tips

        Perform Inspection After Repair after replacing the cylinder head sub-assembly.

        Click here

  6. INSTALL REAR ENGINE OIL SEAL


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

    2. Apply MP grease to the lip of a new rear engine oil seal.

    3. B003ZSFC01
      *1 Rear Engine Oil Seal Retainer
      *a Oil Seal Protrusion Height

      Using SST and a hammer, tap in the rear engine oil seal.

      SST
      09223-15030
      09950-70010   ( 09951-07100 )
      Oil Seal Protrusion Height
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note


      • Keep the lip free from foreign matter.

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

  7. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. B003ZZ3C01
      *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 Packing Diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      Note


      • Remove any oil from the contact surfaces.

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

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

    2. B003ZREN02

      Install the rear engine oil seal retainer to the cylinder block sub-assembly with the 6 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 to the bolts (A) before installing them.

      • Wipe off any seal packing that seeped out from the crankshaft position sensor insert part (B).

  8. INSTALL SENSOR WIRE


    1. B003ZVC

      Install the sensor wire to the cylinder head LH and cylinder block sub-assembly with the 3 bolts.

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

  9. INSTALL VALVE STEM CAP


    1. B003ZHP

      Install the 24 valve stem caps to the cylinder head sub-assembly and cylinder head LH.

      Note


      • Install each part to its original position.

      • Do not drop the valve stem caps into the cylinder head sub-assembly.

  10. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assembly.

      Click here

    2. B003Z6R

      Install the 24 valve lash adjuster assemblies to the cylinder head sub-assembly and cylinder head LH.

      Note

      Install each part to its original position.

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


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

    2. B003YYPC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

      Install the 24 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note

      Install each part to its original position.

  12. INSTALL STRAIGHT PIN (for Bank 2)

    Tech Tips

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


    1. B003YXDC01
      *a Protrusion Height

      Using a plastic hammer, tap in a new straight pin to the camshaft housing sub-assembly LH.

      Standard Protrusion Height
      7.7 to 8.3 mm (0.303 to 0.327 in.)

  13. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN (for Bank 2)

    Tech Tips

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.


    1. B00409MC01
      *a Protrusion Height

      Using a plastic hammer, tap 10 new camshaft bearing cap setting ring pins into the camshaft housing sub-assembly LH.

      Standard Protrusion Height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  14. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


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

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

      Tech Tips

      Perform Inspection After Repair after replacing the No. 3 camshaft sub-assembly.

      Click here

  15. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY


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

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

      Tech Tips

      Perform Inspection After Repair after replacing the No. 4 camshaft sub-assembly.

      Click here

  16. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. B003ZNS

      Install the 2 oil control valve filters to the 2 camshaft bearing caps.

    2. Apply engine oil to the 5 camshaft bearing caps.

    3. B003ZZ5

      Install the 5 camshaft bearing caps to the camshaft housing sub-assembly LH.

    4. B004011N01

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

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

  17. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B003Z25C01
      *a Pin
      *b Plunger
      *c Push

      Install the No. 3 chain tensioner assembly to the camshaft housing sub-assembly LH with the bolt.

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

    2. While pushing down the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure it.

  18. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)


    1. B003YYZC01
      *a Timing Mark
      *b Mark Plate

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

    2. Align the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly with the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

      Note

      Be careful not to damage the contact surface of the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly.

      Tech Tips

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

      Click here

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

    Click here

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

    Click here

  21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B003YYPC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. B003Z0EC01
      *a Continuous Line Area
      *b Dashed Line Area
      *c 3.0 to 4.0 mm
      *d Separated by 4.0 to 6.0 mm (0.157 to 0.236 in.)

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Packing Application Specification
      Area Seal Packing Diameter
      Continuous Line Area 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Dashed Line Area 4.0 to 4.5 mm (0.157 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 within 15 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    3. Install the camshaft housing sub-assembly LH and tighten the 15 bolts in the order shown in the illustration.

      B00403JC01
      *a Straight Pin *b Intake Side
      *c Exhaust Side - -
      B003ZIE Bolt (A) B003Z8F Bolt (B)
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


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

      • Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed.

      • If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.

      • If it is necessary to remove the camshaft housing sub-assembly LH during installation, make sure that the previously applied seal packing does not enter any oil passages.

      Bolt Length
      Item Length
      Bolt (A) 68 mm (2.68 in.)
      Bolt (B) 48 mm (1.89 in.)
    4. B003ZS8N01

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

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

    5. Remove any protruding seal packing black.

      Note

      Be careful not to drop seal packing black into the cylinder head LH.

  22. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)


    1. B003ZGHC01
      *a Hold
      B003ZIE Turn

      Using a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.

  23. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)


    1. B003ZGBC01
      *a Hold
      B003ZIE Turn

      Using a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.

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

  24. INSTALL STRAIGHT PIN (for Bank 1)

    Tech Tips

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


    1. B004033C01
      *a Protrusion Height

      Using a plastic hammer, tap in a new straight pin to the camshaft housing sub-assembly.

      Standard Protrusion Height
      7.7 to 8.3 mm (0.303 to 0.327 in.)

  25. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN (for Bank 1)

    Tech Tips

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.


    1. B003YZIC01
      *a Protrusion Height

      Using a plastic hammer, tap 10 new camshaft bearing cap setting ring pins into the camshaft housing sub-assembly.

      Standard Protrusion Height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  26. INSTALL CAMSHAFT


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

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

      Tech Tips

      Perform Inspection After Repair after replacing the camshaft.

      Click here

  27. INSTALL NO. 2 CAMSHAFT


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

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

      Tech Tips

      Perform Inspection After Repair after replacing the No. 2 camshaft.

      Click here

  28. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. B003Z6N

      Install the 2 oil control valve filters to the 2 camshaft bearing caps.

    2. Apply engine oil to the 5 camshaft bearing caps.

    3. B003ZFT

      Install the 5 camshaft bearing caps to the camshaft housing sub-assembly.

    4. B003ZHJ

      Install the fuel pump lifter housing to the camshaft housing sub-assembly.

    5. B003ZOLC01
      B003ZIE Bolt (A)
      B003Z8F Bolt (B)

      Temporarily install and tighten the 9 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt Length
      Item Length
      Bolt (A) 40 mm (1.57 in.)
      Bolt (B) 58 mm (2.28 in.)

  29. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003ZKRC01
      *a Pin
      *b Plunger
      *c Push

      Install the No. 2 chain tensioner assembly to the camshaft housing sub-assembly with the bolt.

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

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

  30. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)


    1. B00409FC01
      *a Timing Mark
      *b Mark Plate

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

    2. Align the straight pins of the camshaft and No. 2 camshaft with the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

      Note

      Be careful not to damage the contact surface of the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the straight pins of the camshaft and No. 2 camshaft.

      Tech Tips

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

      Click here

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

    Click here

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

    Click here

  33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B003YYPC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. B003ZMEC01
      *a Seal Packing
      *b 3.0 to 4.0 mm
      *c Separated by 4.0 to 6.0 mm (0.157 to 0.236 in.)

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Packing Diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    3. Install the camshaft housing sub-assembly and tighten the 15 bolts in the order shown in the illustration.

      B00404RC01
      *a Straight Pin *b Intake Side
      *c Exhaust Side *d 45°
      B003ZIE Bolt (A) B003Z8F Bolt (B)
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


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

      • Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed.

      • If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly, clean the installation surfaces, and reapply seal packing.

      • If it is necessary to remove the camshaft housing sub-assembly during installation, make sure that the previously applied seal packing does not enter any oil passages.

      Bolt Length
      Item Length
      Bolt (A) 68 mm (2.68 in.)
      Bolt (B) 48 mm (1.89 in.)
    4. B003ZRIN01

      Tighten the 9 bolts in the order shown in the illustration.

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

    5. Remove any protruding seal packing black.

      Note

      Be careful not to drop seal packing black into the cylinder head sub-assembly.

  34. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)


    1. B003ZY0C01
      *a Hold
      B003ZIE Turn

      Using a wrench to hold the hexagonal portion of camshaft, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.

  35. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)


    1. B003ZNPC01
      *a Hold
      B003ZIE Turn

      Using a wrench to hold the hexagonal portion of No. 2 camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.

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

  36. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. B003ZZW

      Install the 2 crankshaft timing gear keys to the crankshaft.

  37. INSTALL CRANKSHAFT TIMING SPROCKET


    1. B003ZPC

      Install the crankshaft timing sprocket to the crankshaft.

  38. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. B00405X

      Install the 2 No. 2 chain vibration dampers to the cylinder head LH and cylinder head sub-assembly.

  39. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. B003Z9M

      Install the No. 1 chain vibration damper to the cylinder head LH and cylinder block sub-assembly with the 2 bolts.

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

  40. INSTALL IDLE SPROCKET ASSEMBLY


    1. B00409WC01
      *a Knock Pin
      B003ZIE Light coat of 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 shaft with the pin hole of the cylinder block sub-assembly.

      Note

      Make sure to install the No. 1 idle gear shaft installation in the correct direction.

      Tech Tips

      Check that there is no foreign matter on the No. 1 idle gear shaft or No. 2 idle gear shaft.

    3. Using a 10 mm hexagon socket 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 assembly turns smoothly.

  41. INSTALL CHAIN SUB-ASSEMBLY


    1. B003Z2IC01
      *a Mark Plate
      *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.

    2. B003YXY

      Temporarily place the chain sub-assembly on the crankshaft as shown in the illustration.

    3. B003ZFEC01
      *a Chain Plate
      *b When the idle sprocket assembly is reused
      *c Mark
      *d Align
      B003ZIE Turn

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

      Note

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

    4. B00400WC01
      *a Mark Plate
      *b Timing Mark

      Align the mark plate and timing marks as shown in the illustration and install the chain sub-assembly around the crankshaft timing sprocket.

      Tech Tips

      The crankshaft mark plate is pink.

    5. Temporarily tighten the crankshaft pulley set bolt to the crankshaft.

    6. B004051C01
      *a Center Line
      *b Key Groove

      Turn the crankshaft clockwise to set it to the center line of the block bore (for Bank 1) (TDC /compression).

  42. INSTALL CHAIN TENSIONER SLIPPER


    1. B003Z9J

      Install the chain tensioner slipper to the cylinder block sub-assembly.

  43. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B003Z3AC01
      *a Stopper Plate
      *b Plunger

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

    2. Turn the stopper plate counterclockwise to set the lock, and insert a 1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate.

    3. B00405T

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

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

    4. Remove the 1.0 mm (0.0394 in.) diameter pin from the No. 1 chain tensioner assembly.

  44. 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 assembly and each camshaft timing exhaust gear assembly.

      • 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.

      B003Z1ZC01
      *a Timing Mark *b Viewpoint

      Tech Tips

      For the camshaft or No. 3 camshaft sub-assembly:

      B003ZIVN01

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

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

    4. Remove the crankshaft pulley set bolt from the crankshaft.

  45. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. B00403M

      Install a new water pump gasket and the engine water pump assembly with the 7 bolts.

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

  46. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  47. INSTALL TIMING CHAIN CASE OIL SEAL

    Click here

  48. INSTALL TIMING CHAIN COVER PLATE


    1. B003YZP

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

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

  49. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. B00404CN01

      Install the No. 1 oil pan baffle plate to the crankshaft bearing cap set bolt.

    2. Temporarily tighten the 2 bolts (A).

    3. Fully tighten the 8 bolts order shown in the illustration.

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

  50. INSTALL OIL FILTER BRACKET CLIP


    1. B003ZBE

      Install the oil filter bracket clip to the oil pan sub-assembly.

  51. INSTALL OIL PAN SUB-ASSEMBLY

    Note

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


    1. Using an E8 and E6 "TORX" socket wrench, install the 6 stud bolts to the oil pan sub-assembly and cylinder block sub-assembly.

      B003YX4C02
      *a 20 mm (0.787 in.) *b 13 mm (0.512 in.)
      *c 35 mm (1.38 in.) *d 16 mm (0.630 in.)
      *e 9 mm (0.354 in.) *f 27 mm (1.06 in.)
      Torque:
      Stud bolt (A)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Stud bolt (B)
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install the oil pan sub-assembly.

      Click here

  52. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  53. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to a new oil strainer gasket.

    2. B003ZFUC01
      *a Protrusion
      *b Cutout

      Align the protrusion of the oil strainer gasket with the cutout of the oil strainer sub-assembly, and install the oil strainer gasket to the oil strainer sub-assembly.

    3. B003ZQY

      Install the oil strainer sub-assembly to the timing chain cover assembly with the 2 nuts.

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

  54. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Note

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


    1. B00401WC01
      *a 9 mm (0.354 in.)
      *b 19 mm (0.748 in.)

      Using an E6 "TORX" socket wrench, install the 2 stud bolts to the oil pan sub-assembly as shown in the illustration.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. B003Z2TC01
      *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 Packing Diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

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

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

    3. B003YYLC01
      *a Nut

      Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts as shown in the illustration.

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

  55. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  56. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  57. INSTALL OIL PAN DRAIN PLUG


    1. B003ZMQ

      Install a new oil pan drain plug gasket and the oil pan drain plug to the No. 2 oil pan sub-assembly.

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

  58. INSTALL SPARK PLUG TUBE GASKET


    1. B003Z77

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

  59. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B003ZF6

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

      Note

      Make sure that there is no oil or foreign matter inside the groove of the camshaft housing sub-assembly LH or on the contact surfaces of the cylinder head cover sub-assembly LH and timing chain cover assembly. Clean if necessary.

    2. B003ZVJ

      Install a new camshaft bearing cap oil hole gasket LH to the camshaft bearing cap.

    3. Apply seal packing as shown in the illustration.

      B003Z1AC01
      *1 Timing Chain Cover Assembly *2 Camshaft Housing Sub-assembly LH
      *a Seal Packing (Diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.)) *b Seal Packing (Diameter 5.0 to 7.0 mm (0.197 to 0.276 in.))
      *c Mark *d 5.0 to 10 mm (0.197 to 0.394 in.)
      *e Thickness: 1.0 to 3.0 mm (0.0394 to 0.118 in.) - -
      B003ZIE Seal Packing - -
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Packing Application Specification
      Area Seal Packing Diameter
      (A)

      Thickness: 5 to 10 mm (0.197 to 0.394 in.)

      Width: 2 to 3 mm (0.0787 to 0.118 in.)
      (B)

      Thickness: 1 to 3 mm (0.0394 to 0.118 in.)

      Width: 5 to 7 mm (0.197 to 0.276 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

    4. Apply a light coat of engine oil to the 2 new O-rings of the 2 VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2).

      Note

      If reusing the 2 VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2), be sure to inspect them before installation.

    5. Clean the 2 bolts and 2 bolt holes of the VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2).

    6. B003ZXJC77
      *a Adhesive

      Apply adhesive to 2 or 3 threads at the end of the 2 bolts of the VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    7. B003ZM9C01
      *a Bolt with VVT Sensor

      Install the cylinder head cover sub-assembly LH with the 16 bolts and 2 VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2) in the order shown in the illustration.

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

      Note


      • If a VVT sensor (for Exhaust Side of Bank 2 and for Intake Side of Bank 2) has been struck or dropped, replace it.

      • Make sure that the 2 O-rings are not cracked or moved out of place when installing the 2 VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2).

      Tech Tips

      After tightening all bolts, check the tightening torque of the bolts (1) and (18). Retighten them if necessary.

    8. B003ZV9

      Install the 2 No. 1 V-bank cover brackets to the cylinder head cover sub-assembly LH.

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

  60. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B003ZGO

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

      Note

      Make sure that there is no oil or foreign matter inside the groove of the camshaft housing sub-assembly or on the contact surfaces of the cylinder head cover sub-assembly and timing chain cover assembly. Clean if necessary.

    2. B00404Q

      Install a new camshaft bearing cap oil hole gasket to the camshaft bearing cap.

    3. Apply seal packing as shown in the illustration.

      B003ZPJC01
      *1 Timing Chain Cover Assembly *2 Camshaft Housing Sub-assembly
      *a Seal Packing (Diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.)) *b Seal Packing (Diameter 5.0 to 7.0 mm (0.197 to 0.276 in.))
      *c Mark *d 5.0 to 10 mm (0.197 to 0.394 in.)
      *e Thickness: 1.0 to 3.0 mm (0.0394 to 0.118 in.) - -
      B003ZIE 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 within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

    4. Apply a light coat of engine oil to the 2 new O-rings of the 2 VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1).

      Note

      If reusing the 2 VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1), be sure to inspect them before installation.

    5. Clean the 2 bolts and 2 bolt holes of the VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1).

    6. B003ZXJC77
      *a Adhesive

      Apply adhesive to 2 or 3 threads at the end of the 2 bolts of the VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    7. B003ZW0C01
      *a Bolt with VVT Sensor

      Install the cylinder head cover sub-assembly with the 15 bolts and 2 VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1) in the order shown in the illustration.

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

      Note


      • If a VVT sensor (for Exhaust Side of Bank 1 and for Intake Side of Bank 1) has been struck or dropped, replace it.

      • Make sure that the 2 O-rings are not cracked or moved out of place when installing the 2 VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1).

      Tech Tips

      After tightening all bolts, check the tightening torque of the bolts (1) and (17). Retighten them if necessary.

    8. B003ZPK

      Install the No. 1 engine cover sub-assembly to the cylinder head cover sub-assembly with the 2 clips.

  61. INSTALL WATER OUTLET


    1. B003Z6S

      Install 2 new No. 2 water inlet housing gaskets to the water outlet.

    2. B003Z2KC01
      B003ZIE Bolt
      B003Z8F Nut

      Install the water outlet to the cylinder head sub-assembly and cylinder head LH with the 4 bolts and 2 nuts.

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

  62. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  63. INSTALL OIL COOLER PIPE

    Note

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


    1. B003ZVQ

      Install the No. 2 cylinder block insulator and No. 3 cylinder block insulator to the cylinder block sub-assembly and oil pan sub-assembly.

    2. B003Z5IC01
      *a 20 mm (0.787 in.)
      *b 13 mm (0.512 in.)
      *c 35 mm (1.38 in.)
      *d 14 mm (0.551 in.)
      *e 29 mm (1.14 in.)

      Using an E8 "TORX" socket wrench, install the 4 stud bolts to the No. 1 oil cooler bracket as shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B00408C

      Install the oil cooler pipe and oil cooler gasket to the No. 1 oil cooler bracket with the bolt and 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. B00400VC02
      *a Stud Bolt
      *b Nut
      *c 22 mm (0.866 in.)
      *d 12 mm (0.472 in.)
      *e 39 mm (1.54 in.)

      Using an E7 "TORX" socket wrench, install the stud bolt to the cylinder block sub-assembly as shown in the illustration.

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

    5. Install a new oil hole cover gasket to the oil pan sub-assembly.

    6. Install the oil cooler pipe with No. 1 oil cooler bracket with the 4 bolts and 3 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Length
      Bolt (A) 30 mm (1.18 in.)
      Bolt (B) 20 mm (0.787 in.)

  64. INSTALL NO. 5 WATER BY-PASS HOSE


    1. B003ZTV

      Install the No. 5 water by-pass hose to the water outlet and slide the clip to secure it.

  65. INSTALL NO. 4 WATER BY-PASS HOSE


    1. B003ZYC

      Install the No. 4 water by-pass hose to the water inlet pipe and slide the clip to secure it.

  66. INSTALL OIL COOLER ASSEMBLY

    Click here

  67. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  68. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  73. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

    Click here

  74. INSTALL WATER BY-PASS HOSE


    1. B003ZAJ

      Install the water by-pass hose to the water inlet pipe and water inlet with thermostat sub-assembly and slide the 2 clips to secure it.

  75. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

    Note

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


    1. B003Z5GC01
      *a 14 mm (0.551 in.)
      *b 13 mm (0.512 in.)
      *c 29 mm (1.14 in.)

      Using an E8 "TORX" socket wrench, install the 2 stud bolts to the front No. 1 engine mounting bracket LH.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B003ZS5N01

      Install the front No. 1 engine mounting bracket LH to the timing chain cover assembly with the 7 bolts in the order shown in the illustration.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

      Note

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

      Bolt Length
      Item Length
      Bolt (A) 115 mm (4.53 in.)
      Bolt (B) 85 mm (3.35 in.)
      Bolt (C) 40 mm (1.57 in.)

  76. INSTALL CRANKSHAFT PULLEY

    Click here

  77. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. B004080C01
      *a Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    2. B003ZLBC01
      *a 20°
      *b 12°

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

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

      Note


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

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

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

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

  78. INSTALL TAPER SCREW PLUG


    1. B00403KC01
      *a Adhesive

      Apply adhesive to the taper screw plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the taper screw plug within 3 minutes of applying adhesive.

    2. B003ZJQ

      Install the taper screw plug to the cylinder block sub-assembly.

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

  79. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  80. INSTALL SPARK PLUG

    Click here

  81. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. B004026

      Install a new oil filler cap gasket to the oil filler cap sub-assembly.

    2. B00407U

      Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly LH.