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ENGINE UNIT REASSEMBLY

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  1. Click here

    INSTALL STUD BOLT

    Note:

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


    1. Install the timing chain cover stud bolt.


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

        20 N*m 204 kgf*cm 15 ft.*lbf
    2. A01588ZE01

      Install the oil pan stud bolt.


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

        for stud bolt A
        5.0 N*m 51 kgf*cm 44 in.*lbf
        for stud bolt B
        9.0 N*m 92 kgf*cm 80 in.*lbf
  2. Click here

    INSTALL RING PIN

    Note:

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


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

      Standard Protrusion
      Item Ring Pin Diameter Specified Condition
      Ring pin A 13 mm (0.512 in.) 7.5 to 8.5 mm (0.295 to 0.335 in.)
      Ring pin B 11 mm (0.433 in.) 3.6 to 4.6 mm (0.142 to 0.181 in.)
      Table 1. Text in Illustration
      *a 7.5 to 8.5 mm
      *b 3.6 to 4.6 mm
  3. Click here

    INSTALL REAR CRANKSHAFT OIL SEAL


    1. A015B6OE02

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

      09223-15030
      09950-70010 09951-07100
      Standard depth
      0 to 1.0 mm (0 to 0.0394 in.)
      Note:

      • Keep the lip free from foreign matter.

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

  4. Click here

    INSTALL OIL DRAIN PIPE SUB-ASSEMBLY


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

    2. Install the O-ring to the drain pipe.

    3. Install the oil drain pipe with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
  5. Click here

    INSTALL ENGINE REAR OIL SEAL RETAINER


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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Application position from inside edge of retainer
      3.5 mm (0.138 in.)
      Table 2. Text in Illustration
      *a 2.0 to 3.0 mm
      Note:

      • Remove any oil from the contact surface.

      • Install the oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    2. Install the oil seal retainer with the 6 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
      Note:

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

      • When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.

      • When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.

  6. Click here

    INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. Install the O-ring to the oil strainer.

    3. Install the oil strainer with the 2 bolts.

      12 N*m 122 kgf*cm 9 ft.*lbf
      Note:

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

  7. Click here

    INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. Install the baffle plate with the 7 bolts.

      12 N*m 122 kgf*cm 9 ft.*lbf
  8. Click here

    INSTALL NO. 1 OIL PAN SUB-ASSEMBLY


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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)
      Table 3. Text in Illustration
      *a 3.0 to 4.0 mm
      Note:

      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01566BE01

      Install the oil pan with the 14 bolts and 2 nuts.

      for bolt A
      10 N*m 102 kgf*cm 7 ft.*lbf
      for bolt B
      35 N*m 357 kgf*cm 26 ft.*lbf
      for nut
      35 N*m 357 kgf*cm 26 ft.*lbf
      Table 4. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
      Note:

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

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

    INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)
      Table 5. Text in Illustration
      *a 3.0 to 4.0 mm
      Note:

      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A0156QF

      Install the oil pan with the 14 bolts and 2 nuts.

      10 N*m 102 kgf*cm 7 ft.*lbf
      Table 6. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
      Note:

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

  10. Click here

    INSTALL NO. 1 HEAT EXCHANGER COVER


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

      Seal packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)
      Table 7. Text in Illustration
      *a 3.0 to 4.0 mm
      Note:

      • Remove any oil from the contact surface.

      • Install the heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A0159ZSE01

      Install the heat exchanger cover with the 12 bolts and 2 nuts.

      21 N*m 214 kgf*cm 15 ft.*lbf
      Table 8. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
      Note:

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

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

    INSTALL VENTILATION PIPE GASKET


    1. Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.

      09950-60010 09951-00360
      09950-70010 09951-07100
      Note:

      • Do not tap the gasket at an angle.

      • Do not tap the gasket excessively.

  12. Click here

    INSTALL CYLINDER BLOCK WATER JACKET SPACER


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

      Table 9. Text in Illustration
      *a UP Mark
      Tip:

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

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

  13. Click here

    INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


    1. Clean the cylinder block with solvent.

    2. Set the piston of the No. 1 cylinder to slightly ATDC.

    3. A015B1CE05

      Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

      Table 10. Text in Illustration
      *1 Lot No.
      *a Front
      Note:

      • Be careful of the installation direction.

      • Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.

    4. Place the cylinder head on the cylinder block.

      Note:

      • Ensure that no oil is on the mounting surface of the cylinder head.

      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

      Tip:

      The cylinder head bolts are tightened in 3 progressive steps.

    5. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    6. A0158VTE04

      Step 1:


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

        36 N*m 367 kgf*cm 27 ft.*lbf

    7. Step 2:


      1. Mark the front side of each cylinder head bolt head with paint.

      2. Tighten the cylinder head bolts another 90°.

    8. Step 3:


      1. Tighten the cylinder head bolts an additional 90°.

      2. Check that the paint marks are now at a 180° angle to the front.

    9. A01571FE05

      Install and uniformly tighten the 2 bolts in the sequence shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf
  14. Click here

    INSTALL CYLINDER HEAD SUB-ASSEMBLY LH


    1. Clean the cylinder block with solvent.

    2. Set the piston of the No. 1 cylinder to slightly ATDC.

    3. A015BUIE06

      Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

      Table 11. Text in Illustration
      *1 Lot No.
      *a Front
      Note:

      • Be careful of the installation direction.

      • Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.

    4. Place the cylinder head on the cylinder block.

      Note:

      • Ensure that no oil is on the mounting surface of the cylinder head.

      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

      Tip:

      The cylinder head bolts are tightened in 3 progressive steps.

    5. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    6. A0159FJE06

      Step 1:

      Tip:

      The cylinder head bolts are tightened in 3 progressive steps.


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

        36 N*m 367 kgf*cm 27 ft.*lbf

    7. Step 2:


      1. Mark the front side of each cylinder head bolt head with paint.

      2. Tighten the cylinder head bolts another 90°.

    8. Step 3:


      1. Tighten the cylinder head bolts an additional 90°.

      2. Check that the paint marks are now at a 180° angle to the front.

    9. A01554AE06

      Install and uniformly tighten the 2 bolts in the sequence shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf
  15. Click here

    INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem caps.

    2. Install the 32 valve stem caps to the cylinder heads.

  16. Click here

    INSTALL VALVE LASH ADJUSTER ASSEMBLY


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

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

      Note:

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

  17. Click here

    INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


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

    2. A0159JME04

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

      Table 12. Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster
  18. Click here

    INSTALL CAMSHAFT BEARING CAP RH


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. Install the No. 1 and No. 2 camshafts to the camshaft housing.

    3. A015C4ME02

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    4. A015BM7E02

      Temporarily install the 10 bolts in the order shown in the illustration.

  19. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A015BGHE04

      Make sure that the valve rocker arms are installed as shown in the illustration.

      Table 13. Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster
      *a INCORRECT
      *b CORRECT
    2. A01581UE07

      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 4.0 mm (0.138 to 0.157 in.)
      Table 14. Text in Illustration
      *a 3.5 to 4.0 mm
      Note:

      • Remove any oil from the contact surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A015BTQE05

      Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

      for bolt A
      10 N*m 102 kgf*cm 7 ft.*lbf
      except bolt A
      30 N*m 306 kgf*cm 22 ft.*lbf
      Table 15. Text in Illustration
      *1 EX
      *2 IN
      *3 Knock Pin
      Note:

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

      • Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

    4. A015CH9E04

      Tighten the 10 bolts in the order shown in the illustration.

      16 N*m 163 kgf*cm 12 ft.*lbf
      Note:

      Thoroughly wipe clean any seal packing.

  20. Click here

    INSTALL CAMSHAFT BEARING CAP LH


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. Install the No. 3 and No. 4 camshafts to the camshaft housing.

    3. A0157DIE01

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    4. A015AA6E01

      Temporarily install the 10 bolts in the order shown in the illustration.

  21. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A015BGHE04

      Make sure that the valve rocker arms are installed as shown in the illustration.

      Table 16. Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster
      *a INCORRECT
      *b CORRECT
    2. A015B0EE02

      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 4.0 mm (0.138 to 0.157 in.)
      Table 17. Text in Illustration
      *a 3.5 to 4.0 mm
      Note:

      • Remove any oil from the contact surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A015E6QE05

      Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

      for bolt A
      10 N*m 102 kgf*cm 7 ft.*lbf
      except bolt A
      30 N*m 306 kgf*cm 22 ft.*lbf
      Table 18. Text in Illustration
      *1 IN
      *2 EX
      *3 Knock Pin
      Note:

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

      • Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

    4. A015BV1E04

      Tighten the 10 bolts in the order shown in the illustration.

      16 N*m 163 kgf*cm 12 ft.*lbf
      Note:

      Thoroughly wipe clean any seal packing.

  22. Click here

    INSTALL CRANKSHAFT TIMING GEAR KEY


    1. Install the timing gear key.

      Tip:

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

  23. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft so that the timing gear key is as shown in the illustration. Then using a wrench, rotate each camshaft so that the timing marks are as shown in the illustration.

      Note:

      When the crankshaft or a camshaft is rotated excessively, the valves and pistons may interfere with each other.

    3. A015DKRE02

      Remove the crankshaft pulley bolt.

      Table 19. Text in Illustration
      *1 IN *2 EX
      *3 Knock Pin *4 Key
      *a Toward Ceiling - -
  24. Click here

    INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. Install the chain tensioner with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
      Table 20. Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

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

  25. Click here

    INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A015CSME02

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

      Table 21. Text in Illustration
      *1 Mark Plate
      *2 Timing Mark
    2. A015AIKE06

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

      Table 22. Text in Illustration
      *1 Mark Plate
      *2 Timing Mark
    3. A015AFYE05

      Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

      Table 23. Text in Illustration
      *1 Mark Plate
      *2 Timing Mark
      Tip:

      The crankshaft timing sprocket RH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.

    4. Install the crankshaft timing sprocket RH to the crankshaft.

    5. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    6. Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.

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

    8. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, temporarily install the bolt.

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

  26. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER RH


    1. Install the vibration damper with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
  27. Click here

    INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

    Tip:

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

  28. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

      Table 24. Text in Illustration
      *1 Stopper Plate
      *2 Plunger

    2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

    3. Install the chain tensioner with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    4. Remove the hexagon wrench from the chain tensioner.

  29. Click here

    INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. Install the chain tensioner with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
      Table 25. Text in Illustration
      *1 Plunger
      *2 Pin
      *a Push

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

  30. Click here

    INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A015BQNE02

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

      Table 26. Text in Illustration
      *1 Mark Plate
      *2 Timing Mark
    2. A015BBGE06

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

      Table 27. Text in Illustration
      *1 Mark Plate
      *2 Timing Mark
    3. A0158NIE05

      Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

      Table 28. Text in Illustration
      *1 Mark Plate
      *2 Timing Mark
      Tip:

      The crankshaft timing sprocket LH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.

    4. Install the crankshaft timing sprocket LH to the crankshaft.

    5. Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear.

    6. Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear.

      Note:

      Because the timing mark positions of the gears may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

    7. Remove the pin from the No. 3 chain tensioner.

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

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

  31. Click here

    INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

    Tip:

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

  32. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

      Table 29. Text in Illustration
      *1 Stopper Plate
      *2 Plunger

    2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

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

      10 N*m 102 kgf*cm 7 ft.*lbf
  33. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER LH


    1. Install the vibration damper with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    2. Remove the hexagon wrench from the No. 1 chain tensioner.

  34. Click here

    TIGHTEN CAMSHAFT TIMING GEAR


    1. A015AAJE02

      for Bank 1:


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

        Table 30. Text in Illustration
        *a Hold
        A015DIT Turn

      2. Tighten the bolt of the camshaft timing gear.

        100 N*m 1020 kgf*cm 74 ft.*lbf
      3. A0159C0E02

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

        100 N*m 1020 kgf*cm 74 ft.*lbf
        Table 31. Text in Illustration
        *a Hold
        A015DIT Turn
    2. A0158D6E02

      for Bank 2:


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

        Table 32. Text in Illustration
        *a Hold
        A015DIT Turn

      2. Tighten the bolt of the camshaft timing gear.

        100 N*m 1020 kgf*cm 74 ft.*lbf
      3. A0156CEE02

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

        100 N*m 1020 kgf*cm 74 ft.*lbf
        Table 33. Text in Illustration
        *a Hold
        A015DIT Turn
  35. Click here

    CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

    3. A0156GJE02

      Remove the crankshaft pulley bolt.

      Table 34. Text in Illustration
      *1 Timing Mark *2 Timing Mark Position
      *3 Knock Pin Position *4 Key
      *a Toward Ceiling *b Approximately 2°
      *c Approximately 45° *d Approximately 16°
      *e Approximately 18° *f Approximately 32°
  36. Click here

    INSTALL WATER INLET PIPE


    1. Apply soapy water to 2 new O-rings and install them to the inlet pipe.

    2. Install the inlet pipe to the No. 1 heat exchanger cover.

  37. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

    2. Install the oil pump gasket.

    3. Apply a light coat of engine oil to a new O-ring.

    4. Install the O-ring.

    5. A015CH6E03

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

      Table 35. Text in Illustration
      *1 Continuous line area *2 Dashed line area
      *3 Diagonal line area - -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A015CATE08
        Apply Seal Packing as Follows
        Area Seal Packing Diameter Application Position from Inside Edge of Cover
        Continuous Line Area 3.0 to 4.0 mm (0.118 to 0.157 in.) 2.5 mm (0.0984 in.)
        Dashed Line Area 6.4 mm (0.252 in.) or more, or within OK area shown in illustration 7.0 mm (0.276 in.)
        Diagonal Line Area 3.0 to 4.0 mm (0.118 to 0.157 in.) 5.5 mm (0.217 in.)
        Table 36. Text in Illustration
        *1 Seal Packing Thickness mm (in.)
        *2 Seal Packing Width mm (in.)
        *3 Seal Packing Thickness
        *4 Seal Packing Width
        *5 OK Area
      Note:

      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

    6. A0156CW

      Align the oil pump drive rotor spline and crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

    7. A0155BDE04

      Temporarily install the timing chain cover with the 28 bolts and nut.

      Standard Bolt
      Item Length Thread Diameter
      Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.17 in.) 8 mm (0.315 in.)
      Bolt C 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt D 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt E 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt F 80 mm (3.15 in.) 10 mm (0.394 in.)
      Table 37. Text in Illustration
      *1 Nut
      Note:

      Make sure that there is no oil on the bolt threads.

    8. A015DI7E01

      Tighten the 3 bolts in several steps in the sequence shown in the illustration.

      47 N*m 479 kgf*cm 35 ft.*lbf
    9. A015B96E01

      Temporarily install the fluid coupling bracket with the 4 bolts.

      Standard Bolt
      Item Length Thread Diameter
      Bolt A 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt B 80 mm (3.15 in.) 10 mm (0.394 in.)
    10. A01560I

      Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

    11. A0155ZRE01

      Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.

      47 N*m 479 kgf*cm 35 ft.*lbf
    12. A015COZE01

      Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.

      23 N*m 235 kgf*cm 17 ft.*lbf
      Note:

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

      • A015564E01

        After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

  38. Click here

    INSTALL WATER PUMP ASSEMBLY


    1. A015E4WE01

      Install a new gasket and the water pump with the 8 bolts shown in the illustration.

      for bolt A
      47 N*m 479 kgf*cm 35 ft.*lbf
      for bolt B
      23 N*m 235 kgf*cm 17 ft.*lbf
      for bolt C
      20 N*m 204 kgf*cm 15 ft.*lbf
      Standard Bolt
      Item Length Thread Diameter
      Bolt A 80 mm (3.15 in.) 10 mm (0.394 in.)
      Bolt B 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt C 25 mm (0.984 in.) 8 mm (0.315 in.)
  39. Click here

    INSTALL FRONT CRANKSHAFT OIL SEAL


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

    2. A015BP7E01

      Using SST and a hammer, tap in the oil seal to a depth between 0 and 1.0 mm (0 and 0.0394 in.) from the timing chain cover edge.

      09223-22010
      09506-35010
      Note:

      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  40. Click here

    INSTALL CRANKSHAFT TIMING GEAR KEY


    1. Install the crankshaft timing gear key.

  41. Click here

    INSTALL CRANKSHAFT PULLEY


    1. A015B87E06

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

    2. Using SST, install the pulley set bolt.

      09213-70011
      09330-00021
      300 N*m 3059 kgf*cm 221 ft.*lbf
      Table 38. Text in Illustration
      *a Hold
      A015DIT Turn
  42. Click here

    INSTALL SPARK PLUG TUBE GASKET


    1. A0158WCE07

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

      Table 39. Text in Illustration
      A015DSP Area to cut off
    2. A015BHTE02

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

      Table 40. Text in Illustration
      *1 Removed Gasket
      *2 New Gasket
      Tip:

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

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

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

  43. Click here

    INSTALL OIL CONTROL VALVE FILTER


    1. A015D8ME03

      LH:


      1. Install the filter in the cylinder head.

        Table 41. Text in Illustration
        *1 Cylinder Head Cover Spacer
        *2 Gasket
        *3 Filter

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

        10 N*m 102 kgf*cm 7 ft.*lbf
    2. A0158UTE03

      RH:


      1. Install the filter in the cylinder head.

        Table 42. Text in Illustration
        *1 Cylinder Head Cover Spacer
        *2 Gasket
        *3 Filter

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

        10 N*m 102 kgf*cm 7 ft.*lbf
  44. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).

    2. Install a new gasket to the cylinder head cover.

      Note:

      Remove any oil from the contact surface.

    3. A015AGIE06

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Table 43. Text in Illustration
      A015DIT Seal Packing
      Note:

      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    4. A015BOEE02

      Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

      for bolt A
      21 N*m 214 kgf*cm 15 ft.*lbf
      except bolt A
      12 N*m 122 kgf*cm 9 ft.*lbf
      Note:

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

    5. Install the noise filter to the cylinder head cover with the bolt.

      7.0 N*m 71 kgf*cm 62 in.*lbf
  45. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).

    2. Install a new gasket to the cylinder head cover.

      Note:

      Remove any oil from the contact surface.

    3. A01558JE06

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Table 44. Text in Illustration
      A015DIT Seal Packing
      Note:

      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    4. A0155S9E02

      Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

      for bolt A
      21 N*m 214 kgf*cm 15 ft.*lbf
      except bolt A
      12 N*m 122 kgf*cm 9 ft.*lbf
      Note:

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

  46. Click here

    INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the idler pulley with the bolt.

      43 N*m 438 kgf*cm 32 ft.*lbf
  47. Click here

    INSTALL WATER PUMP PULLEY


    1. Temporarily install the pulley with the 4 bolts.

    2. A015BB7E02

      Using SST, hold the pulley and tighten the 4 bolts.

      09960-10010 09962-01000 09963-01000
      21 N*m 214 kgf*cm 15 ft.*lbf
  48. Click here

    INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY


    1. for Bank 1:


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

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

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

        10 N*m 102 kgf*cm 7 ft.*lbf

    2. for Bank 2:


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

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

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

        10 N*m 102 kgf*cm 7 ft.*lbf
  49. Click here

    INSTALL ENGINE OIL LEVEL SENSOR


    1. Install a new gasket and the oil level sensor with the 4 bolts.

      7.0 N*m 71 kgf*cm 62 in.*lbf

    2. Connect the oil level sensor connector.

  50. Click here

    INSTALL CRANKSHAFT POSITION SENSOR


    1. Install the crankshaft position sensor with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
  51. Click here

    INSTALL CRANK POSITION SENSOR PROTECTOR


    1. Install the sensor protector with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  52. Click here

    INSTALL CAMSHAFT POSITION SENSOR


    1. Install the camshaft position sensor with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
  53. Click here

    INSTALL VVT SENSOR


    1. for Bank 1:


      1. Install the 2 VVT sensors with the 2 bolts.

        10 N*m 102 kgf*cm 7 ft.*lbf

    2. for Bank 2:


      1. Install the 2 VVT sensors with the 2 bolts.

        10 N*m 102 kgf*cm 7 ft.*lbf
  54. Click here

    INSTALL SPARK PLUG


    1. Using a 16 mm plug wrench, install the 8 spark plugs.

      21 N*m 214 kgf*cm 15 ft.*lbf
  55. Click here

    INSTALL OIL FILLER CAP HOUSING


    1. A015842

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

    2. Install the cap housing with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  56. Click here

    INSTALL OIL FILLER CAP SUB-ASSEMBLY

  57. Click here

    INSTALL OIL FILTER BRACKET


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

    2. Install the 2 O-rings to the timing chain cover.

    3. Install the oil filter bracket with the 2 nuts and 2 bolts.

      35 N*m 357 kgf*cm 26 ft.*lbf
  58. Click here

    INSTALL NO. 1 OIL COOLER BRACKET


    1. Connect the ground wire to the cylinder block.

    2. Install the oil cooler bracket with the 2 nuts.

      21 N*m 214 kgf*cm 15 ft.*lbf
  59. Click here

    INSTALL OIL FILTER ELEMENT


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

    2. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

    3. Set a new oil filter element to the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

      Note:

      Do not remove the oil filter bracket clip.

    6. A0159OCE02

      Using SST, tighten the oil filter cap.

      09228-06501
      25 N*m 255 kgf*cm 18 ft.*lbf
      Table 45. Text in Illustration
      *1 Oil Filter Bracket Clip
      Note:

      • When tightening the oil filter cap, do not remove the oil filter bracket clip.

      • Make sure that the oil filter is installed securely as shown in the illustration.

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

    7. A015BR1E01

      Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

      Table 46. Text in Illustration
      *1 O-Ring
      Note:

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

    8. Install the oil filter drain plug.

      13 N*m 127 kgf*cm 9 ft.*lbf
      Note:

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

    9. Install the No. 2 engine under cover seal with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  60. Click here

    INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      A015DZ4E02
      Note:

      Do not allow adhesive to contact the oil hole.

      Table 47. Text in Illustration
      *1 Oil Hole

    2. Install the oil pressure sender gauge.

      15 N*m 153 kgf*cm 11 ft.*lbf
      Note:

      Do not start the engine within 1 hour after installation.

    3. Connect the sender gauge connector.