ENGINE UNIT REASSEMBLY


  1. INSTALL ENGINE REAR OIL SEAL


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

    2. A01G5EXE07

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

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

      Note


      • Keep the lip free of foreign matter.

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

    3. Apply MP grease to the engine rear oil seal lip.

  2. INSTALL ENGINE REAR OIL SEAL RETAINER


    1. A01G6I4E01
      Text in Illustration
      *a

      Seal Packing Diameter

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

      Apply seal packing in a continuous line as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      Note


      • Remove any oil from the contact surfaces.

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

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

    2. A01G84DE01

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

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

      Note

      Be sure to apply adhesive 1324 to the bolts (A) before installing them.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

  3. INSTALL WATER INLET PIPE


    1. A01G4TYE07
      *A w/o Oil Cooler
      *B w/ Oil Cooler

      Install the water inlet pipe with the 2 bolts.

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

    2. Connect the No. 1 water by-pass hose to the water inlet pipe and slide the clip to secure it.

  4. INSTALL CYLINDER HEAD GASKET RH


    1. A01G9PGE02
      Text in Illustration
      *a Lot No.
      A01G8AH Engine Front

      Place a new cylinder head gasket RH on the cylinder block sub-assembly surface with the lot No. stamp facing upward.

      Note

      Be careful of the installation direction.

  5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


    1. Place the cylinder head sub-assembly RH on the cylinder block sub-assembly.

      Note


      • Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly RH.

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

      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. A01G45IE02

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

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    4. A01G4GEE05
      Text in Illustration
      *a Turn 90°
      *b Painted Mark
      A01G8AH Engine Front

      Step 2


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

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

    5. Step 3


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

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

        Tech Tips

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

  6. INSTALL CYLINDER HEAD GASKET LH


    1. A01G9DPE02
      Text in Illustration
      *a Lot No.
      A01G8AH Engine Front

      Place a new cylinder head gasket LH on the cylinder block sub-assembly surface with the lot No. stamp facing upward.

      Note

      Be careful of the installation direction.

  7. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH


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

      Note


      • Be careful not to allow oil to adhere to the bottom part of the cylinder head sub-assembly LH.

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

      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. A01G9FBE02

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

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    4. A01G4GEE05
      Text in Illustration
      *a Turn 90°
      *b Painted Mark
      A01G8AH Engine Front

      Step 2


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

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

    5. Step 3


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

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

    6. A01G6L7E02

      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 sub-assembly LH Click here.

  8. INSTALL VALVE STEM CAP


    1. Install the 24 valve stem caps.

  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


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

    • Only use clean engine oil.


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

    2. A01G7QRE17
      Text in Illustration
      *1 Tapered Part
      *2 Plunger
      *3 Check Ball
      *a Correct
      *b Incorrect
      *c Low Pressure Chamber
      *d High Pressure Chamber

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

      SST
      09276-75010

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

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

      OK
      Plunger moves up and down.

      Note

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

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

      OK
      Plunger is very difficult to move.

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

    6. Install the valve lash adjuster assemblies.

      Note

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

  10. 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. A01G4JOE06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

  11. INSTALL NO. 3 CAMSHAFT


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

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

      Tech Tips

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

  12. INSTALL NO. 4 CAMSHAFT


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

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

      Tech Tips

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

  13. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01G9BW

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

    3. A01G6DVE01

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

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

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01G4JOE06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    2. A01G9KCE01
      Text in Illustration
      *a

      Seal packing diameter

      (3.5 to 4.5 mm)

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.5 to 4.5 mm (0.138 to 0.177 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts.

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

    3. A01G5KSE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

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

      Note


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

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

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

    4. A01G9RTE02

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

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

  15. INSTALL CAMSHAFT


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

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

      Tech Tips

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

  16. INSTALL NO. 2 CAMSHAFT


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

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

      Tech Tips

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

  17. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01G63O

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

    3. A01G799E01

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

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

  18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01G4JOE06
      Text in Illustration
      *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-assembly is installed as shown in the illustration.

    2. A01G9UWE01
      Text in Illustration
      *a

      Seal packing diameter

      (3.5 to 4.5 mm)

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.5 to 4.5 mm (0.138 to 0.177 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts.

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

    3. A01G6CEE04
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

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

      Note


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

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

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

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

    4. A01G57SE02

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

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

  19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01G4M2E08
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

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

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

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

  20. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)


    1. A01G9ONE12
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

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

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

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

    4. A01G5BWE06
      Text in Illustration
      *a Turn
      *b Hold

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

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

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

      Tech Tips

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

  21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01G5IPE08
      Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

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

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

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

  22. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A01G8ZLE15
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

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

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

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

    4. A01G4KJE06
      Text in Illustration
      *a Turn
      *b Hold

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

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

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

      Tech Tips

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

  23. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01G8QV

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

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  24. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

  25. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01G492

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

  26. INSTALL IDLE SPROCKET ASSEMBLY


    1. A01G5ZVE06
      Text in Illustration
      *a Knock Pin

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

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

      Note

      Be careful of the idle gear shaft installation position.

      Tech Tips

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

    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 assembly turns smoothly.

  27. INSTALL CHAIN SUB-ASSEMBLY


    1. A01G93KE07
      Text in Illustration
      *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 orange.

    2. A01G77C

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

    3. A01G4QOE20
      Text in Illustration
      *a Mark Plate
      *b Turn
      *c When the idle sprocket is reused
      *d Mark
      *e Align

      Turn the camshaft timing gear assembly on bank 1 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.

    4. A01G8A0E08
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

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

      Tech Tips

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the crankshaft pulley set bolt.

    6. A01G8YAE09
      Text in Illustration
      *a Center Line
      *b Timing Mark
      *c Sensor Plate

      Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

  28. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01G99WE08
      Text in Illustration
      *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 hexagon wrench into the hole of the stopper plate.

    3. A01G5OG

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

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

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.

  30. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


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

      A01G8X2E06
      Text in Illustration
      *a Timing Mark *b Viewpoint

      Tech Tips

      For the camshaft or No. 3 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.

      A01G8APE03

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

    4. Remove the crankshaft pulley set bolt.

  31. INSTALL TIMING CHAIN CASE OIL SEAL


    1. A01G83UE04

      Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing chain cover sub-assembly edge.

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

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

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

      Tech Tips

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

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

  32. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. A01G9FEE01

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

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

      Note

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

  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

      A01G889E19
      Text in Illustration
      *a Seal Diameter: 3.0 mm or more A01G8AH Seal Packing
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Diameter
      3.0 mm (0.118 in.)

      Note


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

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

      • Install the timing chain cover sub-assembly within 3 minutes of applying seal packing.

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

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

      A01G6B2E01
      Text in Illustration
      *a

      Dashed line area

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

      		 *b

      Continuous line area

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

      Alternate long and short dashed line area

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

      		 *d

      Diagonal line area

      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      A01G8AH Be sure to apply seal packing - -
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


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

      • Install the timing chain 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 installing.

      Seal Packing Application Chart
      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm or more (0.177 in.) 1.0 to 2.0 mm (0.0394 to 0.0787 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.)
    3. A01G8BM

      Install a new gasket.

    4. A01G626E07
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft

      Align the drive rotor spline of the oil pump and the crankshaft as shown in the illustration. Install the drive rotor spline and timing chain cover sub-assembly to the crankshaft.

    5. A01G5DDE01
      Text in Illustration
      *1 Nut

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

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

      Note

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

    6. A01G4VME01
      Text in Illustration
      *a Area 1
      *b Area 2
      *c Area 3
      *d Area 4

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

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

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

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

      Tech Tips

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

    8. Fully tighten the bolts in Area 4.

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

      Tech Tips

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

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

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

  34. INSTALL WATER INLET HOUSING


    1. A01G4OHE01

      Install 2 new O-rings.

      Tech Tips

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

    2. A01G97IE02

      Install the 2 stud bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A01G9QHE03
      Text in Illustration
      *1 Nut
      *2 Bolt

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

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

      Note

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

    4. Connect the No. 1 water by-pass hose to the water inlet housing and slide the clip to secure it.

    5. Apply adhesive around the drain cock assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    8. Install a new gasket to the thermostat.

    9. A01G6JTE01

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

      Tech Tips

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

    10. A01G540

      Install the water inlet with the 2 nuts.

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

  35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01G69ZE04
      Text in Illustration
      *1 Stud Bolt

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

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

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

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

      Note


      • Install the water inlet and No. 1 front engine mounting bracket LH within 15 minutes of installing the timing chain cover sub-assembly.

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

  36. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01G73GE01

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

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

      Tech Tips

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

  37. INSTALL OIL PAN SUB-ASSEMBLY


    1. w/ Oil Cooler:


      1. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

        A01G7KQE04
        Text in Illustration
        *A w/ Oil Cooler - -
        *a Lower Cylinder Block Sub-assembly Side *b Timing Chain Cover Sub-assembly Side
        *c Oil Pan Sub-assembly LH Side - -
        Torque:
        Bolt A
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
        Bolt B
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. w/o Oil Cooler:


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

        Torque:
        Bolt A
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A01G76L

      Install 2 new O-rings.

    4. A01G59RE01
      Text in Illustration
      *a Seal Diameter

      Apply seal packing in a continuous line as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan sub-assembly within 3 minutes of applying seal packing.

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

    5. A01G7AIE15
      Text in Illustration
      *A w/o Oil Cooler
      *B w/ Oil Cooler
      *1 Nut

      Install the oil pan sub-assembly with the 16 bolts and 2 nuts.

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

  38. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01G5U8E07
      Text in Illustration
      *a Timing Chain Cover

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01G751E02
      Text in Illustration
      *1 Nut

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

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

  39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01G68HE02

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01G8R6E01
      Text in Illustration
      *a Seal Diameter

      Apply seal packing in a continuous line as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

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

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

    3. A01G5WAE02
      Text in Illustration
      *1 Nut

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

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

  40. INSTALL OIL PAN DRAIN PLUG


    1. A01G516

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

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

  41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01G93C

      Apply seal packing as shown in the illustration.

      Text in Illustration
      A01G8AH Seal Packing
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

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

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

    2. A01G6GM

      Install 3 new gaskets as shown in the illustration.

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

    4. A01G5LGE04
      Text in Illustration
      *1 Seal Washer

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

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

      Tech Tips

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

  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01G7R7

      Apply seal packing as shown in the illustration.

      Text in Illustration
      A01G8AH Seal Packing
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

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

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

    2. A01G4HP

      Install 3 new gaskets as shown in the illustration.

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

    4. A01G5VNE08
      Text in Illustration
      *1 Seal Washer

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

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

      Tech Tips

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

  43. INSTALL WATER OUTLET


    1. A01G5DK

      Install 2 new gaskets and a new O-ring.

      Tech Tips

      Apply soapy water to the O-ring.

    2. A01G6G6E02
      Text in Illustration
      *A w/ Oil Cooler
      *B w/o Oil Cooler
      *1 Nut
      *2 Bolt

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

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

      Note

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

  44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01G587

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

    2. w/ Oil Cooler:


      1. A01G90F

        Install the engine oil level dipstick guide.

    3. w/o Oil Cooler


      1. A01G7NO

        Install the engine oil level dipstick guide with the bolt.

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

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


    1. A01G5QYE03

      Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01G7YUE01
      Text in Illustration
      *1 Nut
      *2 Bolt

      Install a new gasket to the No. 1 oil cooler bracket.

    3. Install the oil cooler pipe with the bolt and 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01G7GAE01
      Text in Illustration
      *1 Stud Bolt

      Using an E7 "TORX" socket wrench, install the stud bolt as shown in the illustration.

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

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

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

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

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


    1. Clean the oil cooler assembly contact surface on the cooler mounting.

    2. Install a new O-ring to the oil cooler assembly.

    3. Install the oil cooler assembly with the oil cooler union bolt.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

    4. Install the No. 4 water by-pass hose and No. 5 water by-pass hose with the bolt, 2 clamps and 4 clips.

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

  47. INSTALL CRANKSHAFT PULLEY


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

    2. A01G6SXE03
      Text in Illustration
      *a Hold
      A01G8AH Turn

      Using SST, install the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      250 N*m  { 2549 kgf*cm, 184 ft.*lbf }

  48. INSTALL OIL FILTER CAP ASSEMBLY


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

    2. A01G6EFE01
      Text in Illustration
      *1 O-ring
      *a CORRECT
      *b INCORRECT

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

      Note


      • Be sure to install the O-ring in the proper location, otherwise oil may leak.

      • Do not twist the O-ring.

    3. Install a new oil filter element to the oil filter cap assembly.

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

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

      Note

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

    6. A01G8WXE01
      Text in Illustration
      *1 Oil Filter Cap Assembly
      *2 O-ring
      *3 Oil Filter Bracket
      *a No Gap

      Using SST, install the oil filter cap assembly.

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

      Note

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

    7. A01G4D1E03
      Text in Illustration
      *1 O-ring

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

      Note

      Remove all dirt and foreign matter from the installation surface.

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

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

      Note

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

  49. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. for Bank 1:


      1. A01G9P5E21
        Text in Illustration
        *a Adhesive

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

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      2. A01G4PWE04
        Text in Illustration
        *A for Bank 1

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

    2. for Bank 2:

      Tech Tips

      Perform this operation only when a cylinder block water drain cock sub-assembly is installed.


      1. A01G9P5E21
        Text in Illustration
        *a Adhesive

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

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      2. A01G7BUE05
        Text in Illustration
        *A for Bank 2

        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

        Do not rotate the cylinder block water drain cock sub-assembly 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 }

  50. INSTALL TAPER SCREW PLUG

    Tech Tips

    Perform this operation only when a taper screw plug is installed.


    1. Apply adhesive to the taper screw plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

  51. INSTALL NO. 1 OIL PIPE


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

      Note

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

    2. A01G5QEE04
      Text in Illustration
      *1 Oil Pipe Union

      Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe (on the cylinder head cover sub-assembly side) with the oil pipe union.

    3. Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head sub-assembly side) with the oil pipe union.

    4. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

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

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

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

      Note

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

  52. INSTALL OIL PIPE


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

      Note

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

    2. A01G79BE07
      Text in Illustration
      *1 Oil Pipe Union
      *2 Bolt

      Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the cylinder head cover sub-assembly side) with the oil pipe union.

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

    4. Install the bolt to the cylinder head sub-assembly.

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

    5. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

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

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

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

      Note

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

  53. INSTALL CRANK POSITION SENSOR


    1. Clean and degrease the threads of the bolt for the crank position sensor.

    2. A01G8AJE02
      Text in Illustration
      *1 O-ring

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

    3. Install the crank position sensor with the bolt.

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

      Note

      Make sure that the O-ring is not cracked or does not move out of place during installation.

    4. Connect the crank position sensor connector.

  54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01G8MOE06
      Text in Illustration
      *1 New O-ring

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

    2. Install the 4 camshaft timing oil control valve assemblies with the 4 bolts.

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

      Note


      • Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (connecting surface with the cylinder head cover).

      • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft timing oil control valve assembly.

    3. Connect the 4 camshaft timing oil control valve assembly connectors.

  55. INSTALL VVT SENSOR


    1. Clean and degrease the threads of the bolt for the camshaft position sensor.

    2. Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

      Note

      Make sure that the O-ring is not cracked or does not move out of place during installation.

    3. Install the 4 VVT sensors with the 4 bolts.

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

    4. Connect the 4 VVT sensor connectors.

  56. INSTALL VENTILATION VALVE SUB-ASSEMBLY


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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01G7NW

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

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

  57. INSTALL SPARK PLUG


    1. A01G6AJ

      Install the 6 spark plugs.

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

      Tech Tips

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

  58. INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

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