CAMSHAFT INSTALLATION

INSTALL NO. 3 CAMSHAFT
1. Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH.
2. Install the No. 3 camshaft to the camshaft housing sub-assembly LH.
INSTALL NO. 4 CAMSHAFT
1. Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.
2. Install the No. 4 camshaft to the camshaft housing sub-assembly LH.
INSTALL CAMSHAFT BEARING CAP (for Bank 2)
1. Apply engine oil to the camshaft bearing caps.
2. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
3. Temporarily tighten the 8 bolts in the order shown in the illustration.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

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

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

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

Seal packing

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

Standard seal diameter

3.5 to 4.5 mm (0.138 to 0.177 in.)
Note
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly LH within 3 minutes.
- Do not start the engine for at least 2 hours after installing.
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.
Tighten the 8 bolts in the order shown in the illustration.

Torque:

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

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.
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.
INSTALL CAMSHAFT BEARING CAP (for Bank 1)
1. Apply engine oil to the camshaft bearing caps.
2. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
3. Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }

Standard seal diameter
3.5 to 4.5 mm (0.138 to 0.177 in.)

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

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

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

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

Seal packing

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

Standard seal diameter

3.5 to 4.5 mm (0.138 to 0.177 in.)
Note
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly RH within 3 minutes.
- Do not start the engine for at least 2 hours after installing.
Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
Note
- When installing the camshaft housing 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.
Tighten the 8 bolts in the order shown in the illustration.

Torque:

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

INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
1. 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.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
1. 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. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.
  
  SST
  
  09922-10010
  
  Torque:
  
  100 N*m { 1020 kgf*cm, 74 ft.*lbf }
5. Remove the pin from the No. 3 chain tensioner assembly.
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
1. 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.
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
1. 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. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.
  
  SST
  
  09922-10010
  
  Torque:
  
  100 N*m { 1020 kgf*cm, 74 ft.*lbf }
5. Remove the pin from the No. 2 chain tensioner assembly.
INSTALL IDLE SPROCKET ASSEMBLY
1. Text in Illustration
  
  *1 Knock Pin
  
  Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
2. Temporarily install the No. 1 idle gear shaft and idle sprocket 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.
  
  Note
  
  Be careful of the idle gear installation position.
  
  Tech Tips
  
  Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.
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.

Standard seal diameter
3.5 to 4.5 mm (0.138 to 0.177 in.)

Text in Illustration
*1	Timing Mark
*2	Mark Plate

Text in Illustration
*1	Timing Mark
*2	Mark Plate

Text in Illustration
*1	Knock Pin

INSTALL CHAIN SUB-ASSEMBLY

Text in Illustration

*1 Mark Plate

*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.
Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.
Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks.

Note

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

*1 Mark Plate

*2 Timing Plate

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

Tech Tips

The crankshaft mark plate is yellow.
Temporarily tighten the pulley set bolt.

Text in Illustration
*1	Mark Plate
*2	Timing Mark

Text in Illustration
*1	Mark Plate
*2	Timing Plate

Text in Illustration
*1	Center Line
*2	Timing Mark
*3	Sensor Plate

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

INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. 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 hexagon wrench into the hole of the stopper plate.
3. Install the No. 1 chain tensioner assembly with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.
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.
  
  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.
3. If the valve timing is misaligned, reinstall the timing chain.
4. Remove the pulley set bolt.
INSTALL TIMING CHAIN CASE OIL SEAL
1. Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge.
  
  SST
  
  09223-22010
  
  09506-35010
  
  Oil seal tap in depth
  
  0 to 1.0 mm (0 to 0.0393)
  Note
  
  Keep the lip free of foreign matter.
  
  Do not tap on the oil seal at an angle.
  
  Make sure that the oil seal edge does not stick out of the timing chain case.

Text in Illustration
*1	Stopper Plate
*2	Plunger

Oil seal tap in depth
0 to 1.0 mm (0 to 0.0393)

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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

Seal packing

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

Seal diameter

3.0 mm (0.118 in.)
Note
- Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
- If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain cover within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

Seal diameter
3.0 mm (0.118 in.)

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

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 start the engine for at least 2 hours after installing.

Seal Packing Application Chart
Area	Seal Packing Diameter	Application Position from Inside Seal Line
Continuous Line Area	4.5 mm or more (0.177 in.)	3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and short Dashed Line Area	3.5 mm or more (0.138 in.)	2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area	3.5 mm or more (0.138 in.)	3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area	6.0 mm or more (0.236 in.)	5.0 mm (0.197 in.)

Install a new gasket.
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 spline and chain cover to the crankshaft.

Text in Illustration
*1	Drive Rotor Spline
*2	Crankshaft

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

Bolt Length
Item	Length
Bolt A	40 mm (1.57 in.)
Bolt B	55 mm (2.17 in.)
Bolt C	25 mm (0.98 in.)

Note

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

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

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Fully tighten the bolts in Area 3.

Torque:

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

Tech Tips

First tighten the upper bolts and nuts followed by lower bolts and nuts as shown in the illustration.
Fully tighten the bolts in Area 4.

Torque:

Bolt A

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

Torque:

Except bolt A

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

Tech Tips

Tighten the bolts in the order of lower to upper as shown in the illustration.
Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.

Torque:

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

INSTALL WATER INLET HOUSING
1. Install 2 new O-rings.
  
  Tech Tips
  
  Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.
2. Install the 2 stud bolts.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
3. Text in Illustration
  
  *1 Nut
  
  *2 Bolt
  
  Install the water inlet housing with the 2 bolts and nut.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Note
  
  Be careful that the O-ring does not get caught between the parts.
4. Connect the No. 1 water by-pass hose.
5. Apply adhesive around the drain cock.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
6. Install the drain cock assembly to the water inlet housing.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
7. Install the drain cock plug to the drain cock assembly.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
8. Install a new gasket to the thermostat.
9. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.
  
  Tech Tips
  
  The jiggle valve may be set within 10° of either side of the prescribed position.
10. Install the water inlet with the 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Install the No. 1 front engine mounting bracket LH with the 6 bolts.
  
  Torque:
  
  54 N*m { 550 kgf*cm, 40 ft.*lbf }
  Note
  - Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
  - Do not start the engine for at least 2 hours after installation.
INSTALL OIL PAN SUB-ASSEMBLY
1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.
  
  Torque:
  
  Bolt A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Bolt B
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Install 2 new O-rings.
3. Apply seal packing in a continuous line as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.0 to 4.0 mm (0.118 to 0.157 in.)
  Note
  
  Remove any oil from the contact surface.
  
  Install the oil pan within 3 minutes after applying seal packing.
  
  Do not start the engine for at least 2 hours after installing.
4. Text in Illustration
  
  *1 Nut
  
  Install the oil pan with the 16 bolts and 2 nuts.
  
  Torque:
  
  Bolts A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Except bolts A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Text in Illustration
  
  *1 Nut
  
  Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
1. Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Apply seal packing in a continuous line as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter
  
  3.0 to 4.0 mm (0.118 to 0.157 in.)
  Note
  
  Remove any oil from the contact surface.
  
  Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
  
  Do not start the engine for at least 2 hours after installing.
3. Text in Illustration
  
  *1 Nut
  
  Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. 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 installing.
2. Install 3 new gaskets as shown in the illustration.
3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
4. Install the head cover with the 12 bolts and a new seal washer.
  
  Torque:
  
  Bolts A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Except bolts A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Tech Tips
  
  After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. 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 after applying seal packing.
  
  Do not start the engine for at least 2 hours after installing.
2. Install 3 new gaskets as shown in the illustration.
3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH.
4. Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.
  
  Torque:
  
  Bolts A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Except bolts A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Tech Tips
  
  After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the pulley bolt.
  
  SST
  
  09213-70011 ( 09213-70020 )
  
  09330-00021
  
  Torque:
  
  250 N*m { 2550 kgf*cm, 184 ft.*lbf }
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. Text in Illustration
  
  *1 Oil Pipe Union
  
  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) with the union.
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.
4. Tighten the oil pipe union (on the head cover side).
  
  Torque:
  
  65 N*m { 663 kgf*cm, 48 ft.*lbf }
5. Tighten the oil pipe union (on the cylinder head side).
  
  Torque:
  
  65 N*m { 663 kgf*cm, 48 ft.*lbf }
  
  Note
  
  If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
INSTALL OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
  
  Note
  
  Do not touch the mesh when installing the oil control valve filter.
2. Text in Illustration
  
  *1 Oil Pipe Union
  
  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) with the union.
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.
4. Install the bolt (A) to the cylinder head.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
5. Tighten the oil pipe union (on the head cover side).
  
  Torque:
  
  65 N*m { 663 kgf*cm, 48 ft.*lbf }
6. Tighten the oil pipe union (on the cylinder head side).
  
  Torque:
  
  65 N*m { 663 kgf*cm, 48 ft.*lbf }
  
  Note
  
  If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
INSTALL CRANK POSITION SENSOR
1. Text in Illustration
  
  *1 O-ring
  
  Apply a light coat of engine oil to the O-ring on the crank position sensor.
2. Install the crank position sensor with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the crank position sensor connector.
INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
1. Install the No. 1 vacuum switching valve assembly with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL WATER PUMP PULLEY
1. Temporarily install the water pump pulley with the 4 bolts.
2. Using SST, hold the water pump pulley.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-00700 )
3. Tighten the 4 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.
  
  Torque:
  
  54 N*m { 550 kgf*cm, 40 ft.*lbf }
INSTALL NO. 2 TIMING GEAR COVER
1. Install the No. 2 timing gear cover with the 2 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.
2. Install the engine oil level dipstick guide.
INSTALL NO. 1 OIL COOLER BRACKET
1. Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Text in Illustration
  
  *1 Nut
  
  *2 Bolt
  
  Install a new gasket to the No. 1 oil cooler bracket.
3. Install the oil cooler pipe with the bolt and 2 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 16 ft.*lbf }
4. Install a new gasket to the No. 1 oil pan.
5. Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 16 ft.*lbf }
INSTALL OIL COOLER ASSEMBLY
1. Install a new O-ring.
2. Install the oil cooler assembly with the union bolt.
  
  Torque:
  
  68 N*m { 693 kgf*cm, 50 ft.*lbf }
3. Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.
  
  Tech Tips
  
  Each bolt length is as follows:
  
  A: 70 mm (2.76 in.)
  
  B: 33 mm (1.30 in.)
2. Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
3. Tighten the other bolts.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Install a new gasket as shown in the illustration.
2. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
2. Connect the sensor wire to the radiator pipe clamp.
3. Connect the air fuel ratio sensor connector (for Bank 2 Sensor 1).
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay by tightening the bolt and nut in the order shown in the illustration.
  
  Torque:
  
  34 N*m { 347 kgf*cm, 25 ft.*lbf }
INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
1. Install a new O-ring to the No. 2 engine oil level dipstick guide.
2. Apply a light coat of engine oil to the O-ring.
3. Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.
4. Install the No. 2 engine oil level dipstick guide with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
5. Install the engine oil level dipstick.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Install a new gasket as shown in the illustration.
2. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL INTAKE MANIFOLD
1. Set the new No. 1 and No. 2 intake manifold to head gaskets on each cylinder head.
  Note
  
  Align the port holes of the gasket and cylinder head.
  
  Make sure that the gasket is installed in the correct direction.
2. Set the intake manifold on the cylinder heads.
3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Install the fuel hose protector with the 2 bolts and nut.
  
  Torque:
  
  Bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Nut
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL NO. 2 ENGINE MOUNTING STAY RH
1. Install the No. 2 engine mounting stay RH with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL IGNITION COIL ASSEMBLY
1. Install the 6 ignition coils with the 6 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the 6 ignition coil connectors.
3. Connect the 3 wire harness clamps.
INSTALL THROTTLE BODY BRACKET
1. Install the throttle body bracket with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 SURGE TANK STAY
1. Install the No. 1 surge tank stay with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }

Text in Illustration
*1	Nut
*2	Bolt

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Seal diameter
3.0 to 4.0 mm (0.118 to 0.157 in.)

Text in Illustration
*1	Nut

Text in Illustration
*1	Nut

Seal diameter
3.0 to 4.0 mm (0.118 to 0.157 in.)

Text in Illustration
*1	Nut

Text in Illustration
*1	Oil Pipe Union

Text in Illustration
*1	Oil Pipe Union

Text in Illustration
*1	O-ring

Text in Illustration
*1	Nut
*2	Bolt

INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE

DO NOT apply oil to the bolts listed below:

Tightening Part
Surge Tank and Intake Manifold
No. 1 Surge Tank Stay and Surge Tank
Throttle Body Bracket and Surge Tank

Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.
Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

Torque:

Bolt

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

Nut

16 N*m { 163 kgf*cm, 12 ft.*lbf }
Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Connect the connector to the intake air control valve assembly.
Connect the ventilation hose and vacuum hose.
Connect the 2 water by-pass hoses to the throttle body assembly.
Connect the vacuum hose clamp and fuel vapor feed hose.
Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.
Text in Illustration

*1 for RHD:

*2 for LHD:

Connect the union to check valve hose.

Text in Illustration
*1	for RHD:
*2	for LHD:

INSTALL ENGINE HANGERS

Text in Illustration
*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger

Install the No. 1 and No. 2 engine hangers with the 4 bolts as shown in the illustration.

Part No.
No. 1 engine hanger 12281-31120
No. 2 engine hanger 12282-31100
Bolts 91671-10825

Torque:: 33 N*m { 337 kgf*cm, 24 ft.*lbf }

Attach the engine sling device and hang the engine with the chain block.

REMOVE ENGINE STAND
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
1. Using SST, hold the crankshaft pulley.
  
  SST
  
  09213-70011 ( 09213-70020 )
  
  09330-00021
2. Clean the 8 bolts and 8 bolt holes.
3. Install the front drive plate spacer.
  
  Tech Tips
  
  Align the pin of the front drive plate spacer with the pin hole of the crankshaft.
4. Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft.
5. Text in Illustration
  
  *1 Adhesive
  
  Apply adhesive to 2 or 3 threads of the 8 bolts.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
6. In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
  
  Torque:
  
  83 N*m { 846 kgf*cm, 61 ft.*lbf }
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

Tech Tips

See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle" Click here.