Click here

CAMSHAFT INSTALLATION

Click here
Click here Click here
  1. Click here

    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 to the camshaft housing sub-assembly LH.

  2. Click here

    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 to the camshaft housing sub-assembly LH.

  3. Click here

    INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01NMA1

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

    3. A01NJV1E01

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

      10 N*m 102 kgf*cm 7 ft.*lbf
  4. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

    A01NM40E01
    Tip:

    Type A and Type B can be distinguished by the shape of the compression spring.

    Table 1. Text in Illustration
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Inner Compression Spring
    *a Valve Spring Retainer Diameter
    *b No. 1 Valve Rocker Arm Sub-assembly Roller Width
    Type No. 1 Valve Rocker Arm Sub-assembly Roller Width Valve Spring Retainer Diameter Inner Compression Spring Shape
    A 10.7 mm (0.421 in.) 23.4 mm (0.921 in.) Straight
    B 8.0 mm (0.315 in.) 18.9 mm (0.744 in.) Taper

    1. A01NJZOE01

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

      Table 2. Text in Illustration
      *A Type A
      *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    2. A01NK20E01

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

      Table 3. Text in Illustration
      *1 Seal Packing
      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. A01NM3ME02

      Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

      Table 4. Text in Illustration
      *1 Knock Pin
      *2 Camshaft
      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. A01NME8E02

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

      16 N*m 163 kgf*cm 12 ft.*lbf
  5. Click here

    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.

  6. Click here

    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.

  7. Click here

    INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Apply engine oil to the camshaft bearing caps.

    2. A01NMO3

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

    3. A01NJ7CE01

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

      10 N*m 102 kgf*cm 7 ft.*lbf
  8. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

    A01NM40E01
    Tip:

    Type A and Type B can be distinguished by the shape of the compression spring.

    Table 5. Text in Illustration
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Inner Compression Spring
    *a Valve Spring Retainer Diameter
    *b No. 1 Valve Rocker Arm Sub-assembly Roller Width
    Type No. 1 Valve Rocker Arm Sub-assembly Roller Width Valve Spring Retainer Diameter Inner Compression Spring Shape
    A 10.7 mm (0.421 in.) 23.4 mm (0.921 in.) Straight
    B 8.0 mm (0.315 in.) 18.9 mm (0.744 in.) Taper

    1. A01NJZOE01

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

      Table 6. Text in Illustration
      *A Type A
      *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    2. A01NK2GE01

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

      Table 7. Text in Illustration
      *1 Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.5 to 4.0 mm (0.138 to 0.157 in.)
      Note:

      • Remove any oil from the contact surface.

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

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

    3. A01NL0JE01

      Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

      Table 8. Text in Illustration
      *1 Knock Pin
      *2 Camshaft
      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 is 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 is loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

    4. A01NJ64E02

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

      16 N*m 163 kgf*cm 12 ft.*lbf
  9. Click here

    INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01NJ89E03

      Install the No. 3 chain tensioner assembly with the bolt.

      Table 9. Text in Illustration
      *1 Plunger
      *2 Pin
      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.

  10. Click here

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


    1. A01NKJRE01

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

      Table 10. Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

    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 sprocket LH with the No. 2 chain sub-assembly installed.

    4. A01NJE6E01

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

      Table 11. Text in Illustration
      *1 Turn
      *2 Hold
      09922-10010
      100 N*m 1020 kgf*cm 74 ft.*lbf

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

  11. Click here

    INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01NMS5E04

      Install the No. 2 chain tensioner assembly with the bolt.

      Table 12. Text in Illustration
      *1 Plunger
      *2 Pin
      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.

  12. Click here

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


    1. A01NK4WE01

      Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

      Table 13. Text in Illustration
      *1 Timing Mark
      *2 Mark Plate

    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 sprocket with the No. 2 chain sub-assembly installed.

    4. A01NMVGE01

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

      Table 14. Text in Illustration
      *1 Turn
      *2 Hold
      09922-10010
      100 N*m 1020 kgf*cm 74 ft.*lbf

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

  13. Click here

    INSTALL IDLE SPROCKET ASSEMBLY


    1. A01NIEPE02

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

      Table 15. Text in Illustration
      *1 Knock Pin

    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.

      Tip:

      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.

      60 N*m 612 kgf*cm 44 ft.*lbf
      Tip:

      After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.

  14. Click here

    INSTALL CHAIN SUB-ASSEMBLY


    1. A01NJDHE01

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

      Table 16. Text in Illustration
      *1 Timing Mark
      *2 Mark Plate
      Tip:

      The camshaft mark plates are orange.

    2. A01NK9J

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

    3. A01NI4RE01

      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. A01NMMZE04

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

      Table 17. Text in Illustration
      *1 Mark Plate
      *2 Timing Plate
      Tip:

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the pulley set bolt.

    6. A01NN2QE01

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

      Table 18. Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate
  15. Click here

    INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  16. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01NJLPE03

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

      Table 19. Text in Illustration
      *1 Stopper Plate
      *2 Plunger

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

    3. A01NKOO

      Install the No. 1 chain tensioner assembly with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.

  17. Click here

    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. A01NK0SE01

      Check that each camshaft timing mark is positioned as shown in the illustration.

      Table 20. Text in Illustration
      *1 Timing Mark - -
      A01NMLGE01
      Tip:

      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.

  18. Click here

    INSTALL TIMING CHAIN CASE OIL SEAL


    1. A01NLRRE04

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

      09223-22010
      09506-35010
      Oil seal tap in depth
      -1.0 to 1.0 mm (-0.0393 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.

  19. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

    2. A01NMULE01

      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.

    3. A01NLH0

      Install a new gasket.

    4. A01NJM5E01

      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:

      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not 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. A01NMEGE10

      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 10 minutes after applying seal packing.

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

      Table 21. 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. or more) 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. or more) 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm or more (0.138 in. or more) 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Diagonal Line Area 6.0 mm or more (0.236 in. or more) 5.0 mm (0.197 in.)
    6. A01NKBYE06

      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.

      Table 22. Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft
    7. A01NL7HE01

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

      Table 23. Bolt Length
      Item Length
      Bolt A 40 mm (1.57 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 25 mm (0.984 in.)
      Note:

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

    8. A01NIHS

      Fully tighten the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
    9. A01NJMP

      Fully tighten the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
    10. A01NI1J

      Fully tighten the 7 bolts and 2 nuts.

      21 N*m 214 kgf*cm 15 ft.*lbf
      Tip:

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

    11. A01NLLQE01

      Fully tighten the 12 bolts.

      Bolt A
      43 N*m 438 kgf*cm 32 ft.*lbf
      Except bolt A
      21 N*m 214 kgf*cm 15 ft.*lbf
      Tip:

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

    12. Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.

      9.1 N*m 93 kgf*cm 81 in.*lbf
  20. Click here

    INSTALL INLET WATER HOUSING


    1. A01NIWIE01

      Install 2 new O-rings.

      Tip:

      Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.

    2. A01NLDBE02

      Install the 2 stud bolts.

      4.0 N*m 41 kgf*cm 35 in.*lbf
    3. A01NNCAE01

      Install the inlet water housing with the 2 bolts and nut.

      Table 24. Text in Illustration
      *1 Bolt
      *2 Nut
      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 inlet water housing.

      30 N*m 306 kgf*cm 22 ft.*lbf

    7. Install the drain cock plug to the drain cock assembly.

      13 N*m 130 kgf*cm 9 ft.*lbf

    8. Install a new gasket to the thermostat.

    9. A01NJO8E01

      Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the inlet water housing.

      Tip:

      The jiggle valve may be set within 10° of either side of the prescribed position.

    10. A01NKT1

      Install the inlet water with the 2 nuts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  21. Click here

    INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01NI75E01

      Install the front No. 1 engine mounting bracket LH with the 6 bolts.

      54 N*m 550 kgf*cm 40 ft.*lbf
      Note:

      • Install the inlet water and mounting bracket within 15 minutes after installing the chain cover.

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

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

      10 N*m 102 kgf*cm 7 ft.*lbf
  22. Click here

    INSTALL OIL PAN SUB-ASSEMBLY


    1. A01NJAAE09

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

      10 N*m 102 kgf*cm 7 ft.*lbf
    2. A01NKDV

      Install 2 new O-rings.

    3. A01NJB1E05

      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 surfaces.

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

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

    4. A01NIIFE04

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

      Table 25. Text in Illustration
      *1 Nut
      Bolts A
      10 N*m 102 kgf*cm 7 ft.*lbf
      Except bolts A
      21 N*m 214 kgf*cm 15 ft.*lbf
  23. Click here

    INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01NKE6E06

      Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration.

      4.0 N*m 41 kgf*cm 35 in.*lbf
    2. A01NK8VE02

      Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

      Table 26. Text in Illustration
      *1 Nut
      10 N*m 102 kgf*cm 7 ft.*lbf
  24. Click here

    INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01NL2KE02

      Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration.

      4.0 N*m 41 kgf*cm 35 in.*lbf
    2. A01NI6IE04

      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 surfaces.

      • 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. A01NINKE02

      Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

      Table 27. Text in Illustration
      *1 Nut
      10 N*m 102 kgf*cm 7 ft.*lbf
  25. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01NKU9

      Install 3 new gaskets as shown in the illustration.

    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

    3. A01NN51E01

      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 head cover within 3 minutes after applying seal packing.

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

    4. A01NKHVE01

      Install the head cover with the 12 bolts and a new seal washer.

      Bolts A
      21 N*m 214 kgf*cm 15 ft.*lbf
      Except bolts A
      10 N*m 102 kgf*cm 7 ft.*lbf
      Tip:

      After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

  26. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01NJET

      Install 3 new gaskets as shown in the illustration.

    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH.

    3. A01NIXCE01

      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.

    4. A01NJ5XE02

      Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.

      Bolts A
      21 N*m 214 kgf*cm 15 ft.*lbf
      Except bolts A
      10 N*m 102 kgf*cm 7 ft.*lbf
      Tip:

      After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

  27. Click here

    INSTALL CRANKSHAFT PULLEY


    1. A01NIP4E02

      Using SST, install the pulley bolt.

      Table 28. Text in Illustration
      *1 Hold
      *2 Turn
      09213-70011 09213-70020
      09330-00021
      250 N*m 2550 kgf*cm 184 ft.*lbf
  28. Click here

    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. A01NJXCE02

      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.

      Table 29. Text in Illustration
      *1 Oil Pipe 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).

      65 N*m 663 kgf*cm 48 ft.*lbf

    5. Tighten the oil pipe union (on the cylinder head side).

      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.

  29. Click here

    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. A01NLAEE05

      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.

      Table 30. Text in Illustration
      *1 Oil Pipe 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.

      10 N*m 102 kgf*cm 7 ft.*lbf

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

      65 N*m 663 kgf*cm 48 ft.*lbf

    6. Tighten the oil pipe union (on the cylinder head side).

      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.

  30. Click here

    INSTALL CRANK POSITION SENSOR


    1. A01NLRYE03

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

      Table 31. Text in Illustration
      *1 O-ring
    2. A01NLKU

      Install the crank position sensor with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf

    3. Connect the crank position sensor connector.

  31. Click here

    INSTALL NO. 1 VACUUM SWITCHING VALVE


    1. A01NL9T

      Install the No. 1 vacuum switching valve with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
  32. Click here

    INSTALL RADIO SETTING CONDENSER


    1. A01NK3C

      Install the 2 radio setting condensers with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  33. Click here

    INSTALL WATER PUMP PULLEY


    1. A01NJ49E01

      Temporarily install the water pump pulley with the 4 bolts.

    2. Using SST, hold the water pump pulley.

      09960-10010 09962-01000 09963-00700

    3. Tighten the 4 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
  34. Click here

    INSTALL NO. 2 TIMING GEAR COVER


    1. A01NL08

      Install the No. 2 timing gear cover with the 2 bolts.

      6.0 N*m 61 kgf*cm 53 in.*lbf
  35. Click here

    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01NKI8E01

      Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.

      Tip:

      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.

      43 N*m 438 kgf*cm 32 ft.*lbf

    3. Tighten the other bolts.

      43 N*m 438 kgf*cm 32 ft.*lbf
  36. Click here

    INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01NJDOE04

      Install a new gasket as shown in the illustration.

      Table 32. Text in Illustration
      *1 Front
    2. A01NKCYE01

      Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf
  37. Click here

    INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01NKQ9

      Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      8.5 N*m 87 kgf*cm 75 in.*lbf
    2. A01NMZK

      Connect the sensor wire to the radiator pipe clamp.

    3. Connect the air fuel ratio sensor connector (for Bank 2 Sensor 1).

  38. Click here

    INSTALL NO. 2 MANIFOLD STAY


    1. A01NMNYE01

      Install the No. 2 manifold stay by tightening the bolt and nut in the order shown in the illustration.

      34 N*m 347 kgf*cm 25 ft.*lbf
  39. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01NN7Z

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

    2. A01NJ1W

      Install the engine oil level dipstick guide with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  40. Click here

    INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01NJ6G

      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. A01NJEY

      Install the No. 2 engine oil level dipstick guide with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf

    5. Install the engine oil level dipstick.

  41. Click here

    INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01NKK4E03

      Install a new gasket as shown in the illustration.

      Table 33. Text in Illustration
      *1 Front
    2. A01NKBZE01

      Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf
  42. Click here

    INSTALL INTAKE MANIFOLD

    Note:

    DO NOT apply oil to the bolts listed below:

    Tightening Part
    Intake Manifold and Cylinder Head Sub-assembly RH
    Intake Manifold and Cylinder Head Sub-assembly LH

    1. A01NNEE

      Set a new gasket 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.

      21 N*m 214 kgf*cm 15 ft.*lbf
  43. Click here

    INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A01NIQU

      Install the No. 2 engine mounting stay RH with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  44. Click here

    INSTALL IGNITION COIL ASSEMBLY


    1. A01NJQ9E01

      Install the 6 ignition coils with the 6 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Connect the 6 ignition coil connectors.

  45. Click here

    INSTALL NO. 1 SURGE TANK STAY


    1. A01NLTG

      Install the No. 1 surge tank stay with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  46. Click here

    INSTALL EGR DELIVERY CHAMBER


    1. A01NMF8

      Set a new No. 2 intake manifold gasket.

    2. A01NJDUE01

      Install the EGR delivery chamber.

      Table 34. Text in Illustration
      *A w/ EGR System
      *B w/o EGR System
    3. A01NJGE

      Connect the 2 water hoses and connector (w/ EGR System).

  47. Click here

    INSTALL NO. 1 EGR COOLER BRACKET (w/ EGR System)


    1. A01NN16

      Install the No. 1 EGR cooler bracket with the 3 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
  48. Click here

    INSTALL EGR COOLER ASSEMBLY (w/ EGR System)


    1. A01NIUO

      Install a new gasket and the EGR cooler assembly with the 4 nuts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    2. Connect the 2 water hoses.

  49. Click here

    INSTALL NO. 2 EGR PIPE (w/ EGR System)


    1. A01NI88

      Install 2 new gaskets and the No. 2 EGR pipe with the 2 nuts and 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
  50. Click here

    INSTALL THROTTLE BODY BRACKET


    1. A01NJVB

      Install the throttle body bracket with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  51. Click here

    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

    1. A01NLFD

      Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.

    2. A01NKFUE01

      Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

      Table 35. Text in Illustration
      *1 Bolt
      *2 Nut
      Bolt
      18 N*m 184 kgf*cm 13 ft.*lbf
      Nut
      16 N*m 163 kgf*cm 12 ft.*lbf
    3. A01NJD4

      Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
    4. A01NM5B

      Connect the connector to the manifold absolute pressure sensor.

    5. A01NMP3

      Connect the ventilation hose.

    6. A01NI9Z

      Install the 5 clamps and connect the main wire to the body.

    7. A01NLNY

      Connect the 2 water by-pass hoses to the throttle body assembly.

    8. A01NLHF

      Connect the fuel vapor feed hose.

    9. A01NL6X

      Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.

  52. Click here

    INSTALL ENGINE HANGERS


    1. A01NL1FE13

      Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Table 36. Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      33 N*m 337 kgf*cm 24 ft.*lbf
      Table 37. Part No.
      Item Part No.
      No. 1 Engine Hanger 12281-31120
      No. 2 Engine Hanger 12282-31100
      Bolt 91671-10825

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

  53. Click here

    REMOVE ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  54. Click here

    INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A01NMXIE01

      Using SST, hold the crankshaft pulley.

      09213-70011 09213-70020
      09330-00021

    2. Clean the 8 bolts and 8 bolt holes.

    3. A01NJOVE06

      Apply adhesive to 2 or 3 threads of the 8 bolts.

      Table 38. Text in Illustration
      *1 Adhesive
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the flywheel sub-assembly.

    5. A01NLW7E01

      In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      83 N*m 846 kgf*cm 61 ft.*lbf
      Note:

      Do not start the engine within 1 hour after installing.

  55. Click here

    INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY


    1. A01NMXIE01

      Using SST, hold the crankshaft pulley.

      09213-70011 09213-70020
      09330-00021

    2. Install the transmission input damper.

    3. A01NLZVE01

      In several steps, uniformly install and tighten the 6 bolts in the sequence shown in the illustration.

      30 N*m 306 kgf*cm 22 ft.*lbf
      Note:

      Take care not to insert the transmission input damper in a wrong direction.

  56. Click here

    INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Tip:

    Click here.