ENGINE UNIT REASSEMBLY


  1. INSTALL STUD BOLT

    A01ENFXE02

    1. Install the timing chain cover stud bolt.


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

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01ENEVE01

      Install the oil pan stud bolt.


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

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

  2. INSTALL RING PIN

    A01EOH0E01

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

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

  3. INSTALL REAR CRANKSHAFT OIL SEAL


    1. A01ESMEE02

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

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

      Note


      • Keep the lip free from foreign matter.

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

  4. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY

    A01EMZC

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

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

    3. Install the oil drain pipe with the bolt.

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

  5. INSTALL ENGINE REAR OIL SEAL RETAINER

    A01EN7HE05

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Application position from inside edge of retainer
      3.5 mm (0.138 in.)

      Note


      • Remove any oil from the contact surface.

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

    2. A01EPP9

      Install the oil seal retainer with the 6 bolts.

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

      Note


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

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

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

  6. INSTALL OIL STRAINER SUB-ASSEMBLY

    A01ENDA

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

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

    3. Install the oil strainer with the 2 bolts.

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

      Note

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

  7. INSTALL NO. 1 OIL PAN BAFFLE PLATE

    A01EOGM

    1. Install the baffle plate with the 7 bolts.

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

  8. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

    A01ENESE02

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

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

      Note


      • Remove any oil from the contact surface.

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

    2. A01EN6XE01

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

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      for nut
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

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

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

  9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    A01ERSTE01

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.156 in.)

      Note


      • Remove any oil from the contact surface.

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

    2. A01EPI7E01

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

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

      Note

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

    3. Install the engine oil level sensor Click here.

  10. INSTALL NO. 1 HEAT EXCHANGER COVER

    A01ENCTE01

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

      Seal packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

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

    2. A01ERAME03

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

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

      Note

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

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

  11. INSTALL VENTILATION PIPE GASKET

    A01ER6SE02

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

      SST
      09950-60010   ( 09951-00360 )
      09950-70010   ( 09951-07100 )

      Note


      • Do not tap the gasket at an angle.

      • Do not tap the gasket excessively.

  12. INSTALL CYLINDER BLOCK WATER JACKET SPACER

    A01ENIWE03

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

      Tech Tips


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

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

  13. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


    1. Clean the cylinder block with solvent.

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

    3. A01EO5AE04

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

      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.

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

      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.

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

    6. A01EQYGE04

      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.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    7. A01EN81E03

      Step 2:


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

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

    8. Step 3:


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

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

    9. A01EQ0ME05

      Uniformly install the 2 bolts in the sequence shown in the illustration.

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

  14. 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. A01EQKLE04

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

      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.

      Tech Tips

      The cylinder head bolts are tightened in 3 progressive steps.

      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.

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

    6. A01ER4XE06

      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.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    7. A01EN81E03

      Step 2:


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

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

    8. Step 3:


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

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

    9. A01EP6EE06

      Uniformly install the 2 bolts in the sequence shown in the illustration.

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

  15. INSTALL VALVE STEM CAP


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

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

  16. INSTALL VALVE LASH ADJUSTER ASSEMBLY


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

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

      Note

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

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


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

    2. A01EP4DE01

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

  18. INSTALL CAMSHAFT BEARING CAP RH


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

    2. A01ES1NE01

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

      Tech Tips

      Check the identification mark stamped on the camshaft.

      Item Mark
      for Intake Side NO. 1
      for Exhaust Side NO. 2

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

    4. A01ENKSE02

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

  19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01EOPTE01

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

    2. A01ENFJE04

      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.)

      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. A01EP84E03

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

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      except bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      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. A01EQ1SE04

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

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

      Note

      Thoroughly wipe clean any seal packing.

  20. INSTALL CAMSHAFT BEARING CAP LH


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

    2. A01EP3PE01

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

      Tech Tips

      Check the identification mark stamped on the camshaft.

      Item Mark
      for Intake Side NO. 3
      for Exhaust Side NO. 4

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

    4. A01ESJTE01

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

  21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01EOPTE01

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

    2. A01EPKNE01

      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.)

      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. A01EPSSE03

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

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      except bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      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. A01EPQME04

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

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

      Note

      Thoroughly wipe clean any seal packing.

  22. INSTALL CRANKSHAFT TIMING GEAR KEY

    A01EN9W

    1. Install the timing gear key.

      Tech Tips

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

  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

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

      Note

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

    3. Remove the crankshaft pulley bolt.

      A01EOY1E01

  24. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

    A01ES4KE04

    1. Install the chain tensioner with the 2 bolts.

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

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

  25. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH

    A01ERHYE01

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

    2. A01EO2QE03

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

    3. A01ERJHE02

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

      Note

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

      Tech Tips

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

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

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

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

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

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

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

  26. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH

    A01ESIK

    1. Install the vibration damper with the 2 bolts.

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

  27. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

    A01ERPK

    Tech Tips

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

  28. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH

    A01EP5SE02

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

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

    3. A01EN7X

      Install the chain tensioner with the 2 bolts.

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

    4. Remove the hexagon wrench from the chain tensioner.

  29. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

    A01EQBIE04

    1. Install the chain tensioner with the 2 bolts.

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

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

  30. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH

    A01EO99E01

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

    2. A01EPBHE03

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

    3. A01ENOSE02

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

      Note

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

      Tech Tips

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

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

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

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

      Note

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

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

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

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

  31. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

    A01EOT3

    Tech Tips

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

  32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH

    A01EP5SE01

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

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

    3. A01EPGO

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

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

  33. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH

    A01EP3K

    1. Install the vibration damper with the 2 bolts.

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

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

  34. TIGHTEN CAMSHAFT TIMING GEAR


    1. A01EPIVE01

      for Bank 1:


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

      2. Tighten the bolt of the camshaft timing gear.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
      3. A01ENPJE01

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

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
    2. A01ENBRE01

      for Bank 2:


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

      2. Tighten the bolt of the camshaft timing gear.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
      3. A01ENCWE01

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

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

  35. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

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

    3. Remove the crankshaft pulley bolt.

      A01ES9FE01

  36. INSTALL WATER INLET PIPE


    1. A01EPYT

      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. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01EQ7O

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

    2. Install the oil pump gasket.

    3. A01EP7J

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

    4. Install the O-ring.

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

      A01EPWUE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A01EPXOE02
        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.)

      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.

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

    6. A01EQYH

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

    7. A01EN80E01

      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.)

      Note

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

    8. A01ENITE01

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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    9. A01ES0CE01

      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. A01ESLZ

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

    11. A01ER1HE01

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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    12. A01ERY8E01

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

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

      Note

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

      A01ESNEE01

  38. INSTALL WATER PUMP ASSEMBLY


    1. A01EN8CE02

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

      Torque:
      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. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A01EPD1E01

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

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

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  40. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A01EQ98

      Install the crankshaft timing gear key to the crankshaft.

  41. INSTALL CRANKSHAFT PULLEY


    1. A01ERXIE02

      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.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  42. INSTALL SPARK PLUG TUBE GASKET

    A01ENJSE04

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

    2. A01ERIYE01

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

      Tech Tips

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

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

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

  43. INSTALL OIL CONTROL VALVE FILTER

    A01EN4OE01

    1. LH:


      1. Install the filter in the cylinder head.

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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01EMVBE01

      RH:


      1. Install the filter in the cylinder head.

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

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

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01ENCR

      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. A01ERL2E01

      Apply seal packing as shown in the illustration.

      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 within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

    4. A01EQUUE02

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

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    5. A01EOYL

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

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01ENO4

      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. A01ERX9E01

      Apply seal packing as shown in the illustration.

      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 within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

    4. A01ERR8E02

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

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  46. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01EPW9

      Install the idler pulley with the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  47. INSTALL WATER PUMP PULLEY


    1. A01ENNRE01

      Temporarily install the pulley with the 4 bolts.

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

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  48. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY


    1. A01ENNW

      for Bank 1:


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

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

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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01EOYZ

      for Bank 2:


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

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

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

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

  49. INSTALL CRANKSHAFT POSITION SENSOR

    A01EO1R

    1. Install the crankshaft position sensor with the bolt.

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

  50. INSTALL CRANK POSITION SENSOR PROTECTOR

    A01ER93

    1. Install the sensor protector with the 2 bolts.

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

  51. INSTALL CAMSHAFT POSITION SENSOR

    A01EPQC

    1. Install the camshaft position sensor with the bolt.

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

  52. INSTALL VVT SENSOR


    1. A01EP5P

      for Bank 1:

      Install the 2 VVT sensors with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01EO3Z

      for Bank 2:

      Install the 2 VVT sensors with the 2 bolts.

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

  53. INSTALL SPARK PLUG


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

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

  54. INSTALL OIL FILLER CAP HOUSING


    1. A01EQ3X

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

    2. A01EN2L

      Install the cap housing with the 2 bolts.

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

  55. INSTALL OIL FILLER CAP SUB-ASSEMBLY

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


    1. A01EOY3

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

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

    3. A01EREE

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

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

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


    1. A01EOY3

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

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

    3. A01EORI

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

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

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


    1. A01ESNS

      Connect the ground wire to the cylinder block.

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

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

  59. INSTALL OIL FILTER ELEMENT


    1. A01ESHVE02

      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. A01EQGPE02

      Using SST, tighten the oil filter cap.

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

      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. A01EQ01E01

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

      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.

      Torque:
      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. A01EPCF

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

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

  60. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A01ENPCE01

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      A01EN5AE01

      Do not allow adhesive to contact the oil hole.

    2. A01ERH7

      Install the oil pressure sender gauge.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note

      Do not start the engine within 1 hour after installation.

    3. A01EN3Y

      Connect the sender gauge connector.