ENGINE UNIT REASSEMBLY


  1. INSTALL REAR ENGINE OIL SEAL


    1. Place the rear engine oil seal retainer on wooden blocks.

    2. A01NIO7E01

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

      SST
      09223-15030
      09950-70010   ( 09951-07100 )
      Oil Seal Tap in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197)

      Note


      • Keep the lip free of foreign matter.

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

    3. Apply MP grease to the rear engine oil seal lip.

  2. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. A01NL2OE04

      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 rear engine oil seal retainer within 3 minutes after applying seal packing.

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

    2. A01NJJHE01

      Install the rear engine 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 (A) before installing them.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

  3. INSTALL INLET WATER PIPE


    1. A01NK4VE01
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

      Install the inlet water pipe with the 2 bolts.

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

    2. Install the No. 1 water by-pass hose with the clamp and slide the clip to secure it.

  4. INSTALL CYLINDER HEAD GASKET RH


    1. A01NKPYE02
      Text in Illustration
      *1 Lot No.
      *2 Engine Front

      Place a new cylinder head gasket 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. A01NM8DE02

        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, 26 ft.*lbf }
    4. A01NJJZE01
      Text in Illustration
      *1 Painted Mark
      *2 Engine Front

      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. A01NI5ZE03
      Text in Illustration
      *1 Lot No.
      *2 Engine Front

      Place a new No. 2 cylinder head gasket 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. A01NINWE02

        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, 26 ft.*lbf }
    4. A01NILBE01
      Text in Illustration
      *1 Painted Mark
      *2 Engine Front

      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. A01NLUOE02

      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. A01NJ3ME01
      Text in Illustration
      *1 Tapered Part
      *2 Plunger
      *3 Low Pressure Chamber
      *4 Check Ball

      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. 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

      Install the 24 No. 1 valve rocker arm sub-assemblies 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. 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 }

  14. 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 }

  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. 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 }

  18. 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 }

  19. 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.

  20. 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.

  21. 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.

  22. 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.

  23. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01NI89

      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. A01NN3B

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

  26. 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.

  27. 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).

  28. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  29. 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.

  30. 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.

  31. 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.

  32. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. A01NLM9E01

      Install a new water pump gasket and the engine 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. 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 }

  34. 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 }

  35. 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 }

  36. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01NMRDE01

      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 the 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.

      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 }

  38. 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 }

  39. 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 }

  40. INSTALL OIL PAN DRAIN PLUG


    1. A01NIEH

      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. 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.

  42. 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.

  43. INSTALL OUTLET WATER


    1. A01NL0H

      Install 2 new gaskets and a new O-ring.

      Tech Tips

      Apply soapy water to the O-ring.

    2. A01NJ0EE02
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System
      *a Nut
      *b Bolt

      Install the outlet water 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. 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 }

  45. 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 }

  46. INSTALL OIL FILTER ELEMENT


    1. A01NJAZE23
      Text in Illustration
      *1 Oil Filter Element
      *a O-ring

      Clean the inside of the oil filter cap sub-assembly, 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 assembly.

    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. A01NJR1E02

      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 element is installed securely as shown in the illustration.

    7. A01NLC9E04
      Text in Illustration
      *a O-ring

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

      Note

      Remove all dirt and foreign matter from the installation surfaces.

    8. Install the 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.

  47. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. for Bank 1:


      1. A01NJ8JE23
        Text in Illustration
        *a Adhesive

        Apply adhesive around the cylinder block water drain cock sub-assembly.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      2. A01NILOE02
        Text in Illustration
        *A for Bank 1

        Install the cylinder block water drain cock sub-assembly to the cylinder block sub-assembly as shown in the illustration.

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

        Note

        Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assembly to the specified torque.

      3. Install the cylinder block water drain cock plug to the cylinder block water drain cock sub-assembly.

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

    2. for Bank 2:

      Tech Tips

      Perform this operation only when a cylinder block water drain cock sub-assembly is installed.


      1. A01NJ8JE18
        Text in Illustration
        *a Adhesive

        Apply adhesive to the cylinder block water drain cock sub-assembly.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      2. A01NMJ0E03
        Text in Illustration
        *A for Bank 2

        Install the cylinder block water drain cock sub-assembly to the cylinder block sub-assembly as shown in the illustration.

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

        Note

        Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assembly to the specified torque.

      3. Install the cylinder block water drain cock plug to the cylinder block water drain cock sub-assembly.

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

  48. INSTALL TAPER SCREW PLUG

    Tech Tips

    Perform this operation only when a taper screw plug is installed.


    1. Apply adhesive to the taper screw plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01NMZ1

      Install the taper screw plug to the cylinder block sub-assembly.

      Torque:
      13 N*m  { 133 kgf*cm, 9 ft.*lbf }

  49. 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.

  50. 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.

  51. 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.

  52. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1)


    1. A01NMXPE01
      Text in Illustration
      *1 New O-ring

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

    2. A01NK8B

      Install the camshaft timing oil control valve assembly with the bolt.

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

      Note

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

    3. Connect the camshaft timing oil control valve assembly connector.

  53. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2)


    1. A01NMXPE01
      Text in Illustration
      *1 New O-ring

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

    2. A01NKP1

      Install the camshaft timing oil control valve assembly with the bolt.

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

      Note

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

    3. Connect the camshaft timing oil control valve assembly connector.

  54. INSTALL VVT SENSOR (for Bank 1)


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

    2. A01NJ8U

      Install the sensor with the bolt.

      Note

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

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

    3. Connect the sensor connector.

  55. INSTALL VVT SENSOR (for Bank 2)


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

    2. A01NK8Q

      Install the sensor with the bolt.

      Note

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

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

    3. Connect the sensor connector.

  56. 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. A01NLKS

      Install the ventilation valve sub-assembly.

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

  57. INSTALL SPARK PLUG


    1. A01NLZO

      Install the 6 spark plugs.

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

  58. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new oil filler cap gasket.

    2. Install the oil filler cap sub-assembly.