ENGINE UNIT REASSEMBLY


  1. INSTALL RING PIN

    Note

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


    1. Using a plastic-faced hammer, tap in new ring pins to the camshaft housing.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)
      A01FGHEE01
      Text in Illustration
      *1 Protrusion Height - -
      *a LH *b RH

  2. INSTALL NO. 1 STRAIGHT PIN

    Note

    It is not necessary to remove a No. 1 straight pin unless it is being replaced.


    1. Using a plastic-faced hammer, tap in new No. 1 straight pins to the camshaft housing.

      Standard Protrusion Height
      Item Specified Condition
      Straight pin A 7.7 to 8.3 mm (0.303 to 0.327 in.)
      Straight pin B 5.7 to 6.3 mm (0.224 to 0.248 in.)
      A01FDWTE01
      Text in Illustration
      *1 Protrusion Height - -
      *a LH *b RH

  3. INSTALL REAR CRANKSHAFT OIL SEAL


    1. Place the oil seal retainer on wooden blocks.

    2. A01FF1PE01

      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 )

      Note


      • Keep the lip free of foreign matter.

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

  4. INSTALL ENGINE REAR OIL SEAL RETAINER


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

    2. A01FEPXE01
      Text in Illustration
      *1 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
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil seal retainer within 3 minutes after applying seal packing.

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

    3. A01FIRKE01

      Install the 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 in the places indicated by A before installing them.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

  5. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY


    1. Install the water outlet pipe with the 2 bolts.

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

  6. INSTALL CYLINDER BLOCK WATER JACKET SPACER RH


    1. A01FEWTE02
      Text in Illustration
      *1 Slope

      Install the water jacket spacer as shown in the illustration.

      Tech Tips

      Be sure to face the slope to the front of the engine.

  7. INSTALL CYLINDER BLOCK WATER JACKET SPACER LH


    1. Install the water jacket spacer as shown in the illustration.

      Tech Tips

      Be sure to face the slope to the front of the engine.

  8. INSTALL KNOCK CONTROL SENSOR


    1. A01FG4LE01
      Text in Illustration
      *A for Bank 1
      *B for bank 2
      *a View A
      *b View B
      *c Top
      *d Engine Front
      *e Engine Rear
      A01FGIV Front
      A01FJ4N View A
      A01FI67 View B

      Install the 2 knock sensors so that they are horizontal as shown in the illustration. Then install the 2 bolts.

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

      Tech Tips

      It is acceptable for the sensor to be tilted +10° to -5°.

    2. Connect the 2 knock sensor connectors.

  9. INSTALL NO. 5 ENGINE WIRE


    1. Install the No. 5 engine wire with the clamp.

  10. INSTALL CYLINDER HEAD GASKET


    1. A01FEKUE01
      Text in Illustration
      *1 Seal Packing
      *2 Gasket

      Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      2.5 to 3.0 mm (0.0984 to 0.118 in.)
      Seal Packing Application Range
      A 10 to 15 mm (0.394 to 0.591 in.)
      B 1.25 to 1.50 mm (0.0492 to 0.0591 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head gasket within 3 minutes after applying the seal packing.

      • Do not apply engine oil within 2 hours of installation.

    2. A01FGESE04
      Text in Illustration
      *1 Lot No.
      *a Engine Front

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

      Note


      • Be careful of the installation direction.

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

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. Place the cylinder head on the cylinder block.

      Note

      Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      Tech Tips

      The cylinder head 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 bolts.

    3. Step 1:


      1. A01FIGME01

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head 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. Step 2:


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

      2. Tighten the cylinder head bolts another 90°.

    5. 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.

    6. A01FGEAE09
      Text in Illustration
      *1 Cylinder Head
      *2 Cylinder Head Gasket
      *3 Cylinder Block
      *a Wipe Clean

      Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

  12. INSTALL NO. 2 CYLINDER HEAD GASKET


    1. A01FIPEE10
      Text in Illustration
      *1 Seal Packing
      *2 Gasket

      Apply a continuous line of seal packing to a new No. 2 cylinder head gasket as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      2.5 to 3.0 mm (0.0984 to 0.118 in.)
      Seal Packing Application Range
      A 10 to 15 mm (0.394 to 0.591 in.)
      B 1.25 to 1.50 mm (0.0492 to 0.0591 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head gasket within 3 minutes after applying the seal packing.

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

    2. A01FDP0E03
      Text in Illustration
      *1 Lot No.
      *a Engine Front

      Place the No. 2 cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

      Note


      • Be careful of the installation direction.

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

  13. INSTALL CYLINDER HEAD LH


    1. Place the cylinder head on the cylinder block.

      Note

      Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      Tech Tips

      The cylinder head 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 bolts.

    3. Step 1:


      1. A01FG7QE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 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 }

    4. Step 2:


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

      2. Tighten the cylinder head bolts another 90°.

    5. 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.

    6. A01FECAE01

      Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. A01FGEAE09
      Text in Illustration
      *1 Cylinder Head
      *2 Cylinder Head Gasket
      *3 Cylinder Block
      *a Wipe Clean

      Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

  14. INSTALL VALVE STEM CAP


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

    2. Install the 24 valve stem caps to the cylinder head.

      Note

      Install the valve stem cap at the same place it was removed from.

  15. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster Click here.

    2. Install the 24 valve lash adjusters to the cylinder head.

      Note

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

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


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

    2. A01FHUUE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Install the 24 No. 1 valve rocker arms as shown in the illustration.

      Note

      Install the No. 1 valve rocker arm at the same place it was removed from.

  17. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


    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 sub-assembly to the camshaft housing sub-assembly LH.

  18. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY


    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 sub-assembly to the camshaft housing sub-assembly LH.

  19. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01FEDH

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

    3. A01FICGE04

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

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

  20. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01FHUUE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
      *a CORRECT
      *b INCORRECT

      Make sure that the No. 1 valve rocker arm is installed as shown in the illustration.

    2. A01FGU8E09
      Text in Illustration
      *1 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
      3.5 to 4.0 mm (0.138 to 0.158 in.)

      Note


      • Remove any oil from the contact surface.

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

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

    3. A01FDKNE09
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

      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 with a piston at TDC, valve contact 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. A01FIFWE02

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

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

  21. 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.

  22. 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.

  23. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01FFYZ

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

    3. A01FIDOE02

      Temporarily tighten the 9 bearing cap bolts in the order shown in the illustration.

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

  24. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01FHUUE06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
      *a CORRECT
      *b INCORRECT

      Make sure that the No. 1 valve rocker arm is installed as shown in the illustration.

    2. A01FGABE03
      Text in Illustration
      *1 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
      3.5 to 4.0 mm (0.138 to 0.158 in.)

      Note


      • Remove any oil from the contact surface.

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

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

    3. A01FEW1E01
      Text in Illustration
      *1 Knock Pin
      *a EX
      *b IN

      Install the camshaft housing sub-assembly RH and tighten the 14 bolts in the order shown in the illustration.

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

      Note


      • When installing the camshaft housing 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 with a piston at TDC, valve contact 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. A01FHWRE07

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

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

  25. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01FFPTE11
      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.

  26. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)


    1. A01FI4IE01
      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 assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

    4. A01FIZ1E04
      Text in Illustration
      *a Turn
      *b Hold

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

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

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

  27. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01FIZWE10
      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.

  28. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)


    1. A01FIXCE01
      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 assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.

    4. A01FGE8E07
      Text in Illustration
      *a Turn
      *b Hold

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

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

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

  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. Install the chain vibration damper with the 2 bolts.

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

  30. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. Install the 2 chain vibration dampers.

  31. INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the 2 timing gear set keys and timing sprocket to the crankshaft.

  32. INSTALL IDLE SPROCKET ASSEMBLY


    1. A01FEDDE10
      Text in Illustration
      *1 No. 1 Idle Gear Shaft
      *2 Idle Sprocket
      *3 No. 2 Idle Gear Shaft
      *4 Knock Pin
      A01FGIV Apply Engine Oil

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

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

      Note

      Make sure that the idle gear is facing the correct direction.

      Tech Tips

      Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.

    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 turns smoothly.

  33. INSTALL CHAIN SUB-ASSEMBLY


    1. A01FE4KE06
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark

      Align the mark plates and timing marks as shown in the illustration and install the chain.

      Tech Tips

      The camshaft mark plates are orange.

    2. A01FHTJE01

      Rest the chain on top of the crankshaft.

    3. A01FHW8E03
      Text in Illustration
      *1 Chain Plate
      *a When idle sprocket is reused
      *b Mark
      *c Align
      A01FGIV Turn

      Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.

      Note

      When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

    4. A01FEMJE07
      Text in Illustration
      *1 Mark Plate (Yellow)
      *2 Timing Mark

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

      Tech Tips

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the pulley set bolt.

    6. A01FGIGE03
      Text in Illustration
      *1 Timing Mark
      *a Center Line
      A01FGIV Turn

      Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

  34. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  35. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01FDIGE04
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

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

    2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.0500 in.) diameter into the hole of the stopper plate.

    3. Install the chain tensioner with the 2 bolts.

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

    4. Remove the lock pin of the chain tensioner.

  36. INSPECT VALVE TIMING


    1. 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.

      • 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.

      A01FEVAE07
      Text in Illustration
      *1 Timing Mark - -
      *a Viewpoint - -

      Tech Tips

      For the intake 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.

      A01FI2RE01

    3. If the valve timing is misaligned, reinstall the timing chain.

    4. Remove the pulley set bolt.

  37. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. A01FGK0E01

      Install a new water pump gasket and the engine water pump assembly with the 16 bolts.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B, C
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Text in Illustration
      A01FGIV Bolt A
      A01FJ4N Bolt B
      A01FI67 Bolt C

      Note


      • Be sure to apply adhesive to the 2 bolts labeled C before reusing them, or replace them with new ones if necessary.

        Adhesive
        Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

      Standard length
      Item Length
      Bolt A 55 mm (2.17 in.)
      Bolt B, C 22 mm (0.87 in.)

  38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any old packing material remaining on the sealing surfaces before applying seal packing.

    2. Clean and degrease the contact surfaces of the timing chain cover, cylinder head and cylinder block, and confirm that no oil, moisture or other foreign matter remains on the surfaces.

      A01FFJYE01
      Text in Illustration
      *1 Cylinder Head and Cylinder Block *2 Timing Chain Cover
      A01FHQY Area to be cleaned and degreased - -

      Note

      Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by A in the illustration.

    3. Install a new gasket.

    4. A01FGYWE03
      Text in Illustration
      *a 3.0 mm (0.118 in.) or more

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      3.0 mm (0.118 in.) or more

      Note


      • If 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 15 minutes after applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the chain cover.

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

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

      A01FEYWE01
      Text in Illustration
      *a 3.0 to 4.0 mm (0.118 to 0.157 in.) *b 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *c 6.0 mm (0.236 in.) or more *d 4.5 mm (0.177 in.) or more
      *e 20 mm (0.787 in.) *f

      Dashed line area

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

      Alternate long and short dashed line area

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

      		 *h

      Continuous line area

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

      Diagonal line area

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

      		 - -
      Seal Packing Application Chart
      Area Seal Packing Diameter Application Position from Inside Seal Line
      Diagonal Line Area 6.0 mm (0.236 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Dashed Line Area 3.5 mm (0.138 in.) or more

      • a - a: 3.0 to 4.0 mm (0.118 to 0.158 in.)

      • b - b: 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Alternate Long and Dashed Line Area 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • If 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 15 minutes after applying seal packing.

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

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

    6. A01FDYXE05
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft

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

    7. A01FDNC

      Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

      Text in Illustration
      A01FGIV Bolt A
      A01FJ4N Bolt B
      A01FI67 Nut
      A01FIHD Bolt C
      Bolt Length
      Item Specified Condition
      Bolt A 50 mm (1.97 in.)
      Bolt B 25 mm (0.984 in.)
      Bolt C 55 mm (2.17 in.)

      Note

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

    8. A01FHWXE03

      Fully tighten the 3 bolts shown in the illustration.

      Torque:
      for bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    9. A01FGQZ

      Fully tighten the 3 bolts shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    10. A01FDDTE02
      Text in Illustration
      *1 Nut

      Fully tighten the 7 bolts and 2 nuts shown in the illustration.

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

      Tech Tips

      Tighten the bolts and nuts in order from upper to lower as shown in the illustration.

    11. A01FIJZ

      Fully tighten the 12 bolts shown in the illustration.

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

      Tech Tips

      Tighten the bolts in order from lower to upper as shown in the illustration.

    12. Install the wiring harness clamp bracket with the bolt.

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

  39. INSTALL TIMING CHAIN CASE OIL SEAL


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

      Note

      Keep the lip free of foreign matter.

    2. A01FI9VE01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain case edge.

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free of foreign matter.

      • Do not tap the oil seal at an angle.

  40. INSTALL OIL STRAINER SUB-ASSEMBLY


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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      A01FEBXE10
      Text in Illustration
      *a Timing Chain Cover *b Cylinder Block Lower
    2. A01FGKWE01

      Install the baffle plate with the 8 bolts.

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

      Tech Tips

      Temporarily tighten the 8 bolts. Fully tighten 2 bolts A shown in the illustration before tightening the other bolts.

    3. Install a new gasket and the oil strainer with the 3 nuts.

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

    4. Install 2 new O-rings.

  41. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01FH4VE04

      When replacing a stud bolt, install it by using an E6 "TORX" socket wrench.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01FELSE13
      Text in Illustration
      *1 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 0.156 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes after applying seal packing.

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

    3. A01FD7O

      Install the oil pan with the 16 bolts and 2 nuts.

      Torque:
      for bolt A, B and nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt C
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 45 mm (1.77 in.)
      Bolt C 16 mm (0.630 in.)
      Text in Illustration
      A01FGIV Bolt A
      A01FJ4N Bolt B
      A01FI67 Bolt C
      A01FIHD Nut

  42. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01FFLME18
      Text in Illustration
      *1 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
      4.0 to 6.0 mm (0.156 to 0.236 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan within 3 minutes after applying seal packing.

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

    2. A01FIXU

      Install the oil pan with the 15 bolts and 2 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      A01FGIV Bolt
      A01FJ4N Nut

  43. INSTALL OIL PAN DRAIN PLUG


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

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

  44. INSTALL SPARK PLUG TUBE GASKET


    1. A01FIM1E07
      Text in Illustration
      *a Before cutting off
      *b After cutting off
      A01FE8R Area to be cut off

      Using a cutter, cut off the sealing part of the removed plug tube gasket.

    2. A01FGZJE08
      Text in Illustration
      *1 Plug tube gasket without sealing part
      *2 New plug tube gasket
      *3 Claw

      Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.

      Note


      • Keep the lip free of foreign matter.

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

      Tech Tips

      If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

    3. Return the claws of the ventilation baffle plate to their original positions.

  45. POUR ENGINE OIL

    A01FDF4

    Tech Tips

    Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.

  46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01FH32E01
      Text in Illustration
      *a 2.0 to 3.0 mm
      A01FGIV 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 surface.

      • Install the head cover within 3 minutes after applying seal packing.

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

    2. Install 3 new gaskets to the camshaft bearing caps.

    3. Install a new gasket to the head cover.

    4. A01FFYVE01

      Apply adhesive 1324 to the threads of the 11 cylinder head cover bolts indicated by the black arrows in the illustration.

      Text in Illustration
      A01FGIV Apply adhesive 1324 to these bolts

    5. Install the head cover with the 14 bolts.

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

  47. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 2)


    1. A01FFAKE02
      Text in Illustration
      *a 2.0 to 3.0 mm
      A01FGIV 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 surface.

      • Install the head cover within 3 minutes after applying seal packing.

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

    2. Install 3 new gaskets to the camshaft bearing caps.

    3. Install a new gasket to the head cover.

    4. A01FHPVE01

      Apply adhesive 1324 to the threads of the 11 cylinder head cover bolts indicated by the black arrows in the illustration.

      Text in Illustration
      A01FGIV Apply adhesive 1324 to these bolts

    5. Install the head cover with the 12 bolts.

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

  48. INSTALL REAR WATER BY-PASS JOINT


    1. Install 2 new gaskets and a new O-ring.

      Tech Tips

      Apply soapy water to the O-ring.

    2. Install the water by-pass joint 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.

  49. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. Install a new gasket and water inlet with thermostat with the 3 nuts.

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

  50. INSTALL WATER INLET SUB-ASSEMBLY


    1. Install the 3 water by-pass hoses.

    2. A01FE9OE01

      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 installing it.

    3. Install the water inlet with the 4 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. Install the 3 water by-pass hoses.

  51. INSTALL CRANKSHAFT PULLEY


    1. A01FH2PE04
      Text in Illustration
      *a Hold
      *b Turn

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

    2. Using SST, install the crankshaft pulley bolt.

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

  52. INSTALL OIL FILTER ELEMENT


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

    2. A01FHY2E01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

      Apply a light coat of engine oil to a new O-ring for the cap, and then install the O-ring to the groove of the oil filter cap.

      Note


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

      • Do not twist the O-ring.

    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 install the oil filter cap.

      Note

      Do not pinch the O-ring for the cap.

    6. A01FGASE01
      Text in Illustration
      *1 Oil Filter Cap
      *2 O-Ring
      *3 Oil Filter Bracket
      *a No Gap

      Using SST, tighten the oil filter cap.

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

      Note

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

  53. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Apply adhesive around the drain cocks.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01FI28E13
      Text in Illustration
      *a RH Side
      *b LH Side

      Install the water drain cocks as shown in the illustration.

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

      Note

      Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.

    3. Install the water drain cock plugs to the water drain cocks.

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

  54. 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.

    2. A01FFOME06
      Text in Illustration
      *1 Oil Pipe Union
      *2 Oil Check Valve Bolt

      Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

    4. Tighten the oil pipe union (on the head cover side).

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

    5. Tighten the oil check valve bolt (on the cylinder head side).

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

  55. INSTALL NO. 2 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.

    2. A01FGGSE05
      Text in Illustration
      *1 Oil Pipe Union
      *2 Oil Check Valve Bolt

      Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

    4. Tighten the oil pipe union (on the head cover side).

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

    5. Tighten the oil check valve bolt (on the cylinder head side).

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

  56. INSTALL CRANKSHAFT POSITION SENSOR


    1. Apply a coat of engine oil to an O-ring of the crankshaft position sensor.

      Note


      • When reusing the crankshaft position sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the crankshaft position sensor.

    2. Install the crankshaft position sensor with the bolt.

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

    3. Connect the crankshaft position sensor connector.

  57. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)


    1. A01FEY0E15
      Text in Illustration
      *1 O-Ring

      Apply a light coat of engine oil to a new O-ring and install it to the oil control valve.

    2. Install the oil control valve with the bolt.

      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 (the surface that contacts the cylinder head cover).

      • Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.

    3. Connect the camshaft timing oil control valve connector.

    4. A01FDRSE01

      Install the bracket with the 2 bolts.

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

    5. Connect the 2 wiring harness clamps at the bracket.

  58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)


    1. A01FEY0E15
      Text in Illustration
      *1 O-Ring

      Apply a light coat of engine oil to a new O-ring and install it to the oil control valve.

    2. Install the oil control valve with the bolt.

      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 (the surface that contacts the cylinder head cover).

      • Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.

    3. Connect the camshaft timing oil control valve connector.

  59. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)


    1. A01FEY0E15
      Text in Illustration
      *1 O-Ring

      Apply a light coat of engine oil to a new O-ring and install it to the oil control valve.

    2. Install the oil control valve with the bolt.

      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 (the surface that contacts the cylinder head cover).

      • Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.

    3. Connect the camshaft timing oil control valve connector.

    4. Install the V-bank cover bracket with the bolt.

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

  60. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)


    1. A01FEY0E15
      Text in Illustration
      *1 O-Ring

      Apply a light coat of engine oil to a new O-ring and install it to the oil control valve.

    2. Install the oil control valve with the bolt.

      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 (the surface that contacts the cylinder head cover).

      • Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.

    3. Connect the camshaft timing oil control valve connector.

  61. INSTALL VVT SENSOR (for Exhaust Side of Bank 2)


    1. Apply a light coat of engine oil to the O-ring of the VVT sensor.

      Note


      • When reusing the VVT sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the VVT sensor.

    2. Install the VVT sensor with the bolt.

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

    3. Connect the VVT sensor connector.

  62. INSTALL VVT SENSOR (for Intake Side of Bank 2)


    1. Apply a light coat of engine oil to the O-ring of the VVT sensor.

      Note


      • When reusing the VVT sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the VVT sensor.

    2. Install the VVT sensor with the bolt.

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

    3. Connect the VVT sensor connector.

  63. INSTALL VVT SENSOR (for Exhaust Side of Bank 1)


    1. Apply a light coat of engine oil to the O-ring of the VVT sensor.

      Note


      • When reusing the VVT sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the VVT sensor.

    2. Install the VVT sensor with the bolt.

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

    3. Connect the VVT sensor connector.

  64. INSTALL VVT SENSOR (for Intake Side of Bank 1)


    1. Apply a light coat of engine oil to the O-ring of the VVT sensor.

      Note


      • When reusing the VVT sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the VVT sensor.

    2. Install the VVT sensor with the bolt.

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

    3. Connect the VVT sensor connector.

  65. INSTALL PCV VALVE SUB-ASSEMBLY


    1. Apply adhesive to 2 or 3 threads of the PCV valve.

      Adhesive
      Toyota genuine adhesive 1324, three bond 1324 or equivalent

    2. Install the PCV valve.

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

    3. Connect the PCV valve hose.

  66. INSTALL SPARK PLUG


    1. Install the 6 spark plugs.

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

  67. INSTALL RADIATOR CAP SUB-ASSEMBLY

  68. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new gasket.

    2. Install the oil filler cap.