CAMSHAFT INSTALLATION


  1. 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. 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. 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.

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

  4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

    Tech Tips

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

    A01NM40E01
    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
      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

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

    2. A01NK20E01
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      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
      Text in Illustration
      *1 Knock Pin
      *2 Camshaft

      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. A01NME8E02

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

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

  5. 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. 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. 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.

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

  8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Tech Tips

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

    A01NM40E01
    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
      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

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

    2. A01NK2GE01
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      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
      Text in Illustration
      *1 Knock Pin
      *2 Camshaft

      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 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.

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

  9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01NJ89E03
      Text in Illustration
      *1 Plunger
      *2 Pin

      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.

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


    1. A01NKJRE01
      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 sprocket LH with the No. 2 chain sub-assembly installed.

    4. A01NJE6E01
      Text in Illustration
      *1 Turn
      *2 Hold

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

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

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

  11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01NMS5E04
      Text in Illustration
      *1 Plunger
      *2 Pin

      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.

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


    1. A01NK4WE01
      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 sprocket with the No. 2 chain sub-assembly installed.

    4. A01NMVGE01
      Text in Illustration
      *1 Turn
      *2 Hold

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

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

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

  13. INSTALL IDLE SPROCKET ASSEMBLY


    1. A01NIEPE04
      Text in Illustration
      *a 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 assembly with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block sub-assembly.

      Note

      Be careful of the idle gear installation position.

      Tech Tips

      Check that no foreign matter is 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 assembly turns smoothly.

  14. INSTALL CHAIN SUB-ASSEMBLY


    1. A01NJDHE02
      Text in Illustration
      *a Timing Mark
      *b Mark Plate

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

      Tech Tips

      The camshaft mark plates are orange.

    2. A01NK9J

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

    3. A01NI4RE04

      Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain sub-assembly 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 sub-assembly between the banks.

    4. A01NMMZE06
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

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

      Tech Tips

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the pulley set bolt.

    6. A01NN2QE04
      Text in Illustration
      *a Center Line
      *b Timing Mark
      *c Sensor Plate

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

  15. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01NJLPE06
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner.

    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.

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

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

  17. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

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

      A01NK0SE04
      Text in Illustration
      *a Timing Mark - -

      Tech Tips

      For the intake camshaft:

      Be sure to check mark A at the point where marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      A01NMLGE01

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

    4. Remove the pulley set bolt.

  18. 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.

      SST
      09223-22010
      09506-35010
      Oil Seal Tap in Depth
      -1.0 to 1.0 mm (-0.0394 to 0.0394)

      Note


      • Keep the lip free of foreign matter.

      • Do not tap in the timing chain case oil seal at an angle.

      • Make sure that the timing chain case oil seal edge does not stick out of the timing chain cover sub-assembly.

    2. Apply MP grease to the timing chain case oil seal lip.

  19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

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

      A01NMULE01
    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.) or more

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain cover sub-assembly 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 timing chain cover sub-assembly.

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

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

      A01NMEGE10
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain cover sub-assembly 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 installation.

      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) 1.0 to 2.0 mm (0.0394 to 0.0787 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 0.157 in.)
      Diagonal Line Area 6.0 mm or more (0.236 in. or more) 5.0 mm (0.197 in.)
    6. A01NKBYE09
      Text in Illustration
      *1 Crankshaft
      *a Drive Rotor Spline

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

    7. Type X:


      1. A01NL7HE01

        Temporarily tighten the timing chain cover sub-assembly 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 (0.984 in.)

        Note

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

    8. Type Y:


      1. A01NL7HE01

        Temporarily tighten the timing chain cover sub-assembly 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 28 mm (1.102 in.)

        Note

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

    9. A01NIHS

      Fully tighten the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    10. A01NJMP

      Fully tighten the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    11. A01NI1J

      Fully tighten the 7 bolts and 2 nuts.

      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.

    12. A01NLLQE01

      Fully tighten the 12 bolts.

      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.

    13. 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 }

  20. INSTALL INLET WATER HOUSING


    1. A01NIWIE01

      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. A01NLDBE02

      Install the 2 stud bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A01NNCAE03
      Text in Illustration
      *a Bolt
      *b Nut

      Install the inlet water 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 to the inlet water housing.

    5. Apply adhesive around the drain cock assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the drain cock assembly to the inlet water 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. A01NJO8E01

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

      Tech Tips

      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.

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

  21. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01NI75E05

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

      Torque:
      54 N*m  { 550 kgf*cm, 40 ft.*lbf }

      Note


      • Install the inlet water and No. 1 engine mounting bracket LH within 15 minutes after installing the timing chain cover sub-assembly.

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

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

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

  22. INSTALL OIL PAN SUB-ASSEMBLY


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

      A01NJAAE09
      Torque:
      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 sub-assembly within 3 minutes after applying seal packing.

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

    4. A01NIIFE06
      Text in Illustration
      *a Nut

      Install the oil pan sub-assembly 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 }

  23. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01NKE6E06

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01NK8VE04
      Text in Illustration
      *a Bolt
      *b 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 }

  24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01NL2KE02

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

      Torque:
      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 installation.

    3. A01NINKE03
      Text in Illustration
      *a 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 }

  25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01NKU9

      Install 3 new gaskets 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 cylinder head cover sub-assembly within 3 minutes after applying seal packing.

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

    4. A01NKHVE01

      Install the cylinder head cover sub-assembly 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.

  26. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01NJET

      Install 3 new gaskets 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 installation.

    4. A01NJ5XE02

      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.

  27. INSTALL CRANKSHAFT PULLEY


    1. A01NIP4E02
      Text in Illustration
      *1 Hold
      *2 Turn

      Using SST, install the pulley bolt.

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

  28. 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 LH.

    2. A01NJXCE05
      Text in Illustration
      *a 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 cylinder head cover sub-assembly side) with the union.

    3. Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head sub-assembly side) with the union.

    4. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    5. Tighten the oil pipe union (on the cylinder head sub-assembly 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.

  29. 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 RH.

    2. A01NLAEE10
      Text in Illustration
      *a Oil Pipe Union
      *b Bolt

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

    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head sub-assembly side) with the union.

    4. Install the bolt to the cylinder head sub-assembly.

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

    5. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    6. Tighten the oil pipe union (on the cylinder head sub-assembly 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.

  30. INSTALL CRANK POSITION SENSOR


    1. A01NLRYE03
      Text in Illustration
      *1 O-ring

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

    2. A01NLKU

      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.

  31. INSTALL NO. 1 VACUUM SWITCHING VALVE


    1. A01NL9T

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

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

  32. INSTALL RADIO SETTING CONDENSER


    1. A01NK3C

      Install the 2 radio setting condensers with the 2 bolts.

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

  33. INSTALL WATER PUMP PULLEY


    1. A01NJ49E01

      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 }

  34. INSTALL NO. 2 TIMING GEAR COVER


    1. A01NL08

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

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  35. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01NKI8E01

      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 }

  36. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01NJDOE04
      Text in Illustration
      *1 Front

      Install a new gasket as shown in the illustration.

    2. A01NKCYE01

      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 }

  37. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01NKQ9

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

      Torque:
      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. 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.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  39. 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.

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

  40. 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.

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

    5. Install the engine oil level dipstick.

  41. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01NKK4E03
      Text in Illustration
      *1 Front

      Install a new gasket as shown in the illustration.

    2. A01NKBZE01

      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 }

  42. 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.

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

  43. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A01NIQU

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

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

  44. INSTALL IGNITION COIL ASSEMBLY


    1. A01NJQ9E01

      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.

  45. INSTALL NO. 1 SURGE TANK STAY


    1. A01NLTG

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

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

  46. INSTALL EGR DELIVERY CHAMBER


    1. A01NMF8

      Set a new No. 2 intake manifold gasket.

    2. A01NJDUE01
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

      Install the EGR delivery chamber.

    3. A01NJGE

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

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


    1. A01NN16

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

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

  48. INSTALL EGR COOLER ASSEMBLY (w/ EGR System)


    1. A01NIUO

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

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

    2. Connect the 2 water hoses.

  49. 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.

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

  50. INSTALL THROTTLE BODY BRACKET


    1. A01NJVB

      Install the throttle body bracket with the bolt.

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

  51. 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
      Text in Illustration
      *1 Bolt
      *2 Nut

      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 }
    3. A01NJD4

      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 }
    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. INSTALL ENGINE HANGERS


    1. A01NL1FE13
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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

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


    1. Remove the engine assembly from the engine stand.

  54. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A01NMXIE01

      Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021

    2. Clean the 8 bolts and 8 bolt holes.

    3. A01NJOVE06
      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

    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.

      Torque:
      83 N*m  { 846 kgf*cm, 61 ft.*lbf }

      Note

      Do not start the engine within 1 hour after installing.

  55. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY


    1. A01NMXIE01

      Using SST, hold the crankshaft pulley.

      SST
      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.

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

      Note

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

  56. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Tech Tips

    Click here.