PROCEDURE
INSTALL STUD BOLT
Note
If a stud bolt is deformed or its threads are damaged, replace it.
Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.
| *a | Timing Chain Cover Sub-assembly | *b | Cylinder Block Sub-assembly |
| *c | 9.0 mm (0.354 in.) | *d | 19 mm (0.748 in.) |
| *e | 16 mm (0.630 in.) | *f | 27 mm (1.06 in.) |
| *a | 9.0 mm (0.354 in.) |
| *b | 19 mm (0.748 in.) |
Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.
| *1 |
Cylinder Head Cover Sub-assembly |
| *a | 19 mm (0.748 in.) |
| *b | 16 mm (0.630 in.) |
| *c | 44 mm (1.73 in.) |
Using an E8 "TORX" socket wrench, install the stud bolts as shown in the illustration.
INSTALL RING PIN
Note
It is not necessary to remove the ring pins unless they are being replaced.
Using a plastic hammer, tap in new ring pins to the camshaft housing sub-assemblies.
| Standard Protrusion Height |
|---|
| 2.7 to 3.3 mm (0.106 to 0.130 in.) |
| *a | for Bank 2 | *b | for Bank 1 |
| *c | Protrusion Height | - | - |
INSTALL NO. 1 STRAIGHT PIN
Note
It is not necessary to remove the No. 1 straight pins unless they are being replaced.
Using a plastic hammer, tap in new No. 1 straight pins to the camshaft housing sub-assemblies.
| Standard Protrusion Height | ||||||
|---|---|---|---|---|---|---|
|
| *a | for Bank 2 | *b | for Bank 1 |
| *c | Protrusion Height | - | - |
INSTALL REAR ENGINE OIL SEAL
Place the rear engine oil seal retainer on wooden blocks.
| *a | Standard Depth |
Using SST, tap in a new engine rear oil seal until its surface is flush with the rear engine oil seal retainer edge.
| Standard Depth |
|---|
| -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
Note
Keep the lip free from foreign matter.
Do not tap in the rear engine oil seal at an angle.
Do not tap in the rear engine oil seal more than necessary.
Do not deform the rear engine oil seal.
INSTALL REAR ENGINE OIL SEAL RETAINER
Apply MP grease to the lip of the rear engine oil seal.
| *a | Seal Packing |
Apply seal packing in a continuous line as shown in the illustration.
| Seal Packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Seal Diameter |
|---|
| 2.2 to 3.2 mm (0.0866 to 0.126 in.) |
Note
Remove any oil from the contact surfaces.
Install the rear engine oil seal retainer within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
Apply adhesive to the 2 bolts (A).
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Note
Tighten the bolts within 3 minutes of applying adhesive.
Install the rear engine oil seal retainer with the 6 bolts.
Note
Thoroughly wipe clean any seal packing.
Do not add engine oil for at least 2 hours after installation.
Do not start the engine for at least 2 hours after installation.
INSTALL WATER OUTLET PIPE SUB-ASSEMBLY
Install the water outlet pipe sub-assembly with the 2 bolts.
INSTALL KNOCK CONTROL SENSOR
INSTALL NO. 5 ENGINE WIRE
Install the No. 5 engine wire with the clamp.
INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
INSTALL NO. 2 CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
INSTALL VALVE STEM CAP
INSTALL VALVE LASH ADJUSTER ASSEMBLY
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
INSTALL CAMSHAFT BEARING CAP (for Bank 2)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
INSTALL CAMSHAFT
INSTALL NO. 2 CAMSHAFT
INSTALL CAMSHAFT BEARING CAP (for Bank 1)
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)
INSTALL NO. 1 CHAIN VIBRATION DAMPER
Install the No. 1 chain vibration damper with the 2 bolts.
INSTALL NO. 2 CHAIN VIBRATION DAMPER
Install the 2 No. 2 chain vibration dampers.
INSTALL CRANKSHAFT TIMING GEAR KEY
Install the 2 crankshaft timing gear keys to the crankshaft.
INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
Install the crankshaft timing gear or sprocket to the crankshaft.
INSTALL IDLE SPROCKET ASSEMBLY
| *1 | No. 1 Idle Gear Shaft |
| *2 | No. 2 Idle Gear Shaft |
| *3 | Idle Sprocket Assembly |
| *a | Knock Pin |
|
Apply engine oil |
Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
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
Make sure that the idle sprocket assembly is facing the correct direction.
Tech Tips
Check that no foreign matter is on the No. 1 idle gear shaft and No. 2 idle gear shaft.
Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
Tech Tips
After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
INSTALL CHAIN SUB-ASSEMBLY
Check that the camshaft timing gear on bank 1 and each timing mark on bank 2 and crankshaft are positioned as shown in the illustration.
| *a | Approximately 10° | *b | Timing Mark |
| *c | Bank 1 Cylinder Block Center Line | - | - |
| *a | Mark Plate (Orange) |
| *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.
Place the chain sub-assembly on the crankshaft.
| *a | Chain Sub-assembly between Banks |
| *b | When Reusing Idle Sprocket Assembly |
| *c | Mark |
| *d | Inner Chain Plate |
| *e | Outer Chain Plate |
Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain sub-assembly between the banks.
Note
When reusing the idle sprocket, align the chain plate with the mark where the plate had been when tightening the chain sub-assembly between the banks.
| *a | Mark Plate (Yellow) |
| *b | Timing Mark |
Align the mark plate and timing marks as shown in the illustration and install the chain sub-assembly to the crankshaft timing gear or sprocket.
Tech Tips
The crankshaft mark plate is yellow.
Temporarily install the crankshaft pulley set bolt.
| *a | Timing Mark |
| *b | Bank 1 Cylinder Bore Center Line (TDC/compression) |
|
Turn |
Turn the crankshaft clockwise to set the timing mark to the bank 1 cylinder bore center line (TDC/compression).
INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
| *1 | Pin |
| *2 | Stopper Plate |
| *3 | Plunger |
| *a | Move stopper plate upward |
| *b | Move stopper plate downward |
Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
Turn the stopper plate counterclockwise to set the lock, and insert a pin of 1.27 mm (0.0500 in.) diameter into the hole of the stopper plate.
Install the No. 1 chain tensioner assembly with the 2 bolts.
Remove the lock pin from the No. 1 chain tensioner assembly.
INSPECT VALVE TIMING
Check the camshaft timing marks.
Note
Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear assembly.
If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
Check that each camshaft timing mark is positioned as shown in the illustration.
| *a | Timing Mark | *b | Viewpoint |
Tech Tips
For the intake camshaft:
Be sure to check the mark (A) at the point where marks (B), (C), and (D) are positioned in line.
If the marks are checked from any other viewpoint, they cannot be checked correctly.
If the timing marks are not positioned correctly, reinstall the chain sub-assembly.
Remove the crankshaft pulley set bolt.
INSTALL ENGINE WATER PUMP ASSEMBLY
Install a new water pump gasket and the engine water pump assembly with the 7 bolts.
Note
Be sure to replace the 2 bolts (A) with new ones or reuse them after applying adhesive.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
INSTALL TIMING CHAIN COVER PLATE
INSTALL NO. 1 OIL PAN BAFFLE PLATE
Temporarily install the No. 1 oil pan baffle plate with the 8 bolts.
Tighten the 2 bolts (A) shown in the illustration.
Tighten the other 6 bolts.
INSTALL OIL STRAINER SUB-ASSEMBLY
Install a new oil strainer gasket and the oil strainer sub-assembly with the 3 nuts.
INSTALL OIL PAN SUB-ASSEMBLY
Install 2 new O-rings.
| *a | Seal Packing |
Apply seal packing in a continuous line as shown in the illustration.
| Seal Packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Seal Diameter |
|---|
| 3.0 to 4.0 mm (0.118 to 0.157 in.) |
Note
Check and clean the bolts and bolt holes.
Remove any oil from the contact surfaces.
Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
Do not add engine oil for at least 2 hours after installation.
Do not start the engine for at least 2 hours after installation.
|
Bolt |
|
Nut |
Install the oil pan sub-assembly and temporarily tighten the 16 bolts and 2 nuts in several steps.
Tech Tips
| Item | Length |
|---|---|
| Bolt (A) | 25 mm (0.984 in.) |
| Bolt (B) | 45 mm (1.77 in.) |
| Bolt (C) | 16 mm (0.630 in.) |
|
Bolt |
|
Nut |
Tighten the 16 bolts and 2 nuts in the order shown in the illustration.
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
| *a | Seal Packing |
Apply seal packing in a continuous line as shown in the illustration.
| Seal Packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Seal Diameter |
|---|
| 3.0 to 4.0 mm (0.118 to 0.157 in.) |
Note
Check and clean the bolts and bolt holes.
Remove any oil from the contact surfaces.
Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installation.
Do not add engine oil for at least 2 hours after installation.
|
Bolt |
|
Nut |
Install the No. 2 oil pan sub-assembly and tighten the 15 bolts and 2 nuts in several steps in the order shown in the illustration.
INSTALL OIL PAN DRAIN PLUG
Install a new gasket and the oil pan drain plug.
INSTALL SPARK PLUG TUBE GASKET
| *a | Before cutting off |
| *b | After cutting off |
|
Area to be cut off |
Using a cutter, cut off the sealing part of the removed spark plug tube gasket.
| *a | Spark Plug Tube Gasket without Sealing Part |
| *b | New Spark Plug Tube Gasket |
| *c | Claw |
Using a spark plug tube gasket which has had the sealing part cut off, uniformly press in a new spark plug tube gasket all the way.
Note
Keep the lip free from foreign matter.
Do not tap in the spark plug tube gasket at an angle.
Tech Tips
If a spark plug tube gasket that will be used to install the spark plug tube gasket is deformed, and cannot be positioned on a new spark plug tube gasket, correct the deformation using pliers.
Return the claws of the ventilation baffle plate to their original positions.
POUR ENGINE OIL
Tech Tips
Before installing the cylinder head cover sub-assemblies, pour engine oil into the oil holes shown in the illustration until the oil holes are filled with engine oil.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Remove any old seal packing and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain or belt cover sub-assembly or cylinder head cover sub-assembly.
| *1 | Timing Chain Cover Sub-assembly |
| *2 | Camshaft Housing Sub-assembly RH |
| *a | 2.0 to 3.0 mm (0.0787 to 0.118 in.) |
| *b | 5.0 to 10.0 mm (0.197 to 0.394 in.) |
|
Seal Packing |
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 surfaces.
Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
Do not add engine oil for at least 2 hours after installation.
Do not start the engine for at least 2 hours after installation.
Install 3 new gaskets to the camshaft bearing caps.
Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
| *a | Bolt with cylinder head cover seal washer |
|
Apply adhesive 1324 to these bolts |
Apply adhesive 1324 to the threads of the 11 bolts indicated by the black arrows in the illustration.
Note
Tighten the bolts within 3 minutes after applying adhesive.
Install the cylinder head cover sub-assembly with new 2 cylinder head cover seal washers and 14 bolts.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
Remove any old seal packing and be careful not to drop any oil on the contact surfaces of the cylinder head LH, timing chain or belt cover sub-assembly or cylinder head cover sub-assembly LH.
| *1 | Timing Chain Cover Sub-assembly |
| *2 | Camshaft Housing Sub-assembly RH |
| *a | 2.0 to 3.0 mm(0.0787 to 0.118 in.) |
| *b | 5.0 to 10.0 mm(0.197 to 0.394 in.) |
|
Seal Packing |
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 surfaces.
Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
Do not add engine oil for at least 2 hours after installation.
Do not start the engine for at least 2 hours after installation.
Install 3 new gaskets to the camshaft bearing caps.
Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.
| *a | Bolt with cylinder head cover seal washer |
|
Apply adhesive 1324 to these bolts |
Apply adhesive 1324 to the threads of the 10 bolts indicated by the black arrows in the illustration.
Note
Tighten the bolts within 3 minute after applying adhesive.
Install the cylinder head cover sub-assembly LH with the cylinder head cover seal washer and 12 bolts.
INSTALL REAR WATER BY-PASS JOINT
Install 2 new water outlet gaskets and a new water outlet pipe O-ring.
Tech Tips
Apply water to the water outlet pipe O-ring.
Install the rear water by-pass joint with the 2 bolts and 4 nuts.
Note
Make sure that the water outlet pipe O-ring does not get caught between the parts.
INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
INSTALL WATER INLET
INSTALL CRANKSHAFT PULLEY
INSTALL OIL FILTER CAP ASSEMBLY
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
| *a | Adhesive |
Apply adhesive to 2 or 3 threads at the end of the cylinder block water drain cock sub-assembly.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
Note
Install the cylinder block water drain cock sub-assembly within 3 minutes of applying adhesive.
| *a | for Bank 1 |
| *b | for Bank 2 |
Install the cylinder block water drain cock sub-assembly as shown in the illustration.
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.
Do not loosen the cylinder block water drain cock sub-assembly after setting it to the correct position.
Install the water drain cock plug to each cylinder block water drain cock sub-assembly.
INSTALL TAPER SCREW PLUG
Tech Tips
Perform this operation only when a taper screw plug is installed.
Apply adhesive to the taper screw plug.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
Install the taper screw plug to the cylinder block sub-assembly.
INSTALL NO. 1 OIL PIPE
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.
| *a | Oil Pipe Union |
| *b | Oil Check Valve Bolt |
Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe to the cylinder head cover sub-assembly LH.
Install a new gasket and temporarily install the No. 1 oil pipe to the cylinder head sub-assembly LH with the oil check valve bolt.
Tighten the oil pipe union on the cylinder head cover sub-assembly LH side.
Tighten the oil check valve bolt on the cylinder head sub-assembly LH side.
Note
If the link that connects the gaskets is broken, remove the connecting link by using nippers or equivalent.
INSTALL NO. 2 OIL PIPE
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.
| *a | Oil Pipe Union |
| *b | Oil Check Valve Bolt |
Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe to the cylinder head cover sub-assembly.
Install a new gasket and temporarily install the oil pipe to the cylinder head sub-assembly RH with the oil check valve bolt.
Tighten the oil pipe union on the cylinder head cover sub-assembly side.
Tighten the oil check valve bolt on the cylinder head sub-assembly RH side.
Note
If the link that connects the gaskets is broken, remove the connecting link by using nippers or equivalent.
INSTALL CRANKSHAFT POSITION SENSOR
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
INSTALL ENGINE OIL LEVEL SENSOR
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)
INSTALL VVT SENSOR (for Exhaust Side of Bank 2)
INSTALL VVT SENSOR (for Intake Side of Bank 2)
INSTALL VVT SENSOR (for Exhaust Side of Bank 1)
INSTALL VVT SENSOR (for Intake Side of Bank 1)
INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)
INSTALL SPARK PLUG
INSTALL RADIATOR CAP SUB-ASSEMBLY
Install the radiator cap sub-assembly.
INSTALL OIL FILLER CAP SUB-ASSEMBLY
Install a new gasket.
Install the oil filler cap sub-assembly.
INSTALL FUEL INJECTOR SEAL