ENGINE UNIT REASSEMBLY


  1. INSTALL ENGINE REAR OIL SEAL


    1. Place the oil seal retainer on wooden blocks.

    2. A019LB3E01

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

      SST
      09223-15030
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free of foreign matter.

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

  2. INSTALL ENGINE REAR OIL SEAL RETAINER


    1. A019PBAE04

      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 surfaces.

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

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

    2. A019OV2E01

      Install the engine rear 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

  3. INSTALL WATER INLET PIPE


    1. A019L3X

      Install the water inlet pipe with the 2 bolts.

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

    2. Install the No. 1 water by-pass hose.

  4. INSTALL CYLINDER HEAD GASKET RH


    1. A019K68E01

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

      Note


      • Be careful of the installation direction.

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

  5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


    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. A019LPYE02

        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. A019NW3E02

      Step 2


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

      2. Tighten the cylinder head bolts another 90°.

    5. Step 3


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

      2. Check that the painted mark is now facing rearward.

  6. INSTALL CYLINDER HEAD GASKET LH


    1. A019O2UE02

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

      Note


      • Be careful of the installation direction.

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

  7. INSTALL CYLINDER HEAD SUB-ASSEMBLY 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. A019O57E02

        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. A019NW3E02

      Step 2


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

      2. Tighten the cylinder head bolts another 90°.

    5. Step 3


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

      2. Check that the painted mark is now facing rearward.

    6. A019LQRE02

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

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

  8. INSTALL VALVE STEM CAP


    1. Install the 24 valve stem caps.

  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the lash adjuster free of dirt and foreign objects.

    • Only use clean engine oil.


    1. Place the lash adjuster into a container filled with engine oil.

    2. A019NF8E06

      Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed the air.

      OK
      Plunger moves up and down.

      Note

      When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

    5. After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly by hand.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster.

    6. Install the valve lash adjusters.

      Note

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

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


    1. Apply engine oil to the lash adjuster tip and valve stem cap end.

    2. A019LN3E06
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Install the valve rocker arms as shown in the illustration.

  11. 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.

  12. 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.

  13. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A019KCK

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

    3. A019JOHE01

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

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

  14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A019LN3E06
      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.

    2. A019KJME07

      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.

    3. A019OD8E01

      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. A019JLWE02

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

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

  15. 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.

  16. 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.

  17. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A019OMR

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

    3. A019N6XE01

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

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

  18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A019LN3E06
      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.

    2. A019M2XE08

      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.

    3. A019PLQE01

      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.

    4. A019PC0E02

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

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

  19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A019MGNE02

      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.

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


    1. A019KJJE08
      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. A019OU8E02

      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.

  21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A019MRQE02

      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.

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


    1. A019OO6E11
      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. A019JXNE02

      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.

  23. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A019MJ7

      Install the No. 1 chain vibration damper with the 2 bolts.

      Torque:
      23 N*m  { 230 kgf*cm, 17 ft.*lbf }

  24. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. Install the 2 No. 2 chain vibration dampers.

  25. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A019OAV

      Install the 2 keys and crankshaft timing sprocket as shown in the illustration.

  26. INSTALL IDLE SPROCKET ASSEMBLY


    1. A019OZHE02
      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.

  27. INSTALL CHAIN SUB-ASSEMBLY


    1. A019OCDE03
      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.

    2. A019LNR

      Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.

    3. A019NRRE09

      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.

    4. A019L2EE04
      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.

    5. Temporarily tighten the pulley set bolt.

    6. A019NZBE01
      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).

  28. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A019K8NE03
      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. A019OCS

      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.

  30. 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.

      A019O4JE01

      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.

      A019NP0E01

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

    4. Remove the pulley set bolt.

  31. INSTALL TIMING CHAIN CASE OIL SEAL


    1. A019OKQE04

      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.

  32. INSTALL WATER PUMP ASSEMBLY


    1. A019L4HE01

      Install a new water pump gasket and the water pump assembly with the 8 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note

      Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

      A019LSNE09
      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.

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

      A019JUME10
      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.)
    3. A019N1L

      Install a new gasket.

    4. A019PKHE06
      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.

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

      A019PH5E06
      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.

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

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

    7. 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.

    8. 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.

    9. 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 }

  34. INSTALL WATER INLET HOUSING


    1. A019JNWE01

      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. A019P0QE02

      Install the 2 stud bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A019NN5E03
      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. A019NC5E01

      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. A019KNL

      Install the water inlet with the 2 nuts.

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

  35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A019K15E02

      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.

  36. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A019KO2E01

      Install the No. 1 oil pan baffle plate with the 7 bolts.

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

      Tech Tips

      Temporarily tighten the 7 bolts. Fully tighten 2 bolts (A) shown in the illustration before tightening the other bolts.

  37. INSTALL OIL PAN SUB-ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

      A019MJFE07
      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. A019L7R

      Install 2 new O-rings.

    3. A019NO1E05

      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. A019M3AE01
      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 }

  38. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A019PK9E05

      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. A019MXTE02
      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 }

  39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A019O0OE02

      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. A019LWDE04

      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. A019MZHE02
      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 }

  40. INSTALL OIL PAN DRAIN PLUG


    1. A019KAW

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

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

  41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A019LQ5E01

      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. A019N77

      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. A019N8QE01

      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.

  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A019NXAE01

      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. A019KNZ

      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. A019MR5E04

      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.

  43. INSTALL WATER OUTLET


    1. A019O0X

      Install 2 new gaskets and a new O-ring.

      Tech Tips

      Apply soapy water to the O-ring.

    2. A019KAME02
      Text in Illustration
      *1 Nut
      *2 Bolt

      Install the water outlet 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.

  44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A019LNN

      Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

    2. A019MTB

      Install the engine oil level dipstick guide.

  45. INSTALL NO. 1 OIL COOLER BRACKET


    1. A019NJLE03

      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. A019P83E02
      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. A019K3V

      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 }

  46. INSTALL OIL COOLER ASSEMBLY


    1. A019KI8

      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. A019KN7

      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 }

  47. INSTALL CRANKSHAFT PULLEY


    1. A019KY0

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

    2. A019N80E01

      Using SST, install the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      250 N*m  { 2550 kgf*cm, 184 ft.*lbf }

  48. INSTALL OIL FILTER ELEMENT


    1. A019KBGE12
      Text in Illustration
      *1 Oil Filter Element
      *2 O-ring

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

    2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap sub-assembly.

    3. Set a new oil filter element to the oil filter cap sub-assembly.

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

    5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap sub-assembly.

      Note


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

      • The O-ring must not be twisted on the groove.

    6. A019MIPE02

      Using SST, tighten the oil filter cap sub-assembly.

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

      Note

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

    7. A019LK6E02
      Text in Illustration
      *1 O-ring

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

      Note

      Remove all dirt and foreign matter from the installation surfaces.

    8. Install the oil filter drain plug to the oil filter cap sub-assembly.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      Make sure that the O-ring does not get caught between the parts.

  49. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A019NUZE06
      Text in Illustration
      *1 Adhesive

      Apply adhesive around the drain cock sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A019MBLE04

      Install the water drain cocks as shown in the illustration.

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

      Note

      Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with 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 }

  50. 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. A019JMNE02
      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.

  51. 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. A019O2ME05
      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.

  52. INSTALL CRANK POSITION SENSOR


    1. A019KVKE03
      Text in Illustration
      *1 O-ring

      Apply a light coat of engine oil to the O-ring on the crank position sensor.

    2. A019L97

      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.

  53. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A019KC6E07
      Text in Illustration
      *1 O-ring

      Apply a light coat of engine oil to 4 new O-rings and install them to the 4 camshaft timing oil control valve assemblies.

    2. A019KU2E02

      Install the 4 oil control valves with the 4 bolts.

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

      Note

      Make sure that each O-ring is not cracked or does not jump out of position during installation.

    3. Connect the 4 oil control valve connectors.

    4. A019OAR

      Install the bolt and connect the wire harness clamp to install the engine wire.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  54. INSTALL VVT SENSOR


    1. A019O9ME01

      Install the 4 sensors with the 4 bolts.

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

    2. Connect the 4 sensor connectors.

  55. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. Apply adhesive around the ventilation valve sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A019L7N

      Install the ventilation valve sub-assembly.

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

  56. INSTALL SPARK PLUG


    1. A019KMA

      Install the 6 spark plugs.

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

  57. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new oil filler gasket.

    2. Install the oil filler cap sub-assembly.