REASSEMBLY

PROCEDURE

1. INSTALL ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.

(b) Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge. SST: 09223-15030 SST: 09950-70010 09951-07100 Text in Illustration *a Depth NOTICE: Keep the lip free of foreign matter. Do not tap on the engine rear oil seal at an angle.

2. INSTALL ENGINE REAR OIL SEAL RETAINER

(a) Apply seal packing in a continuous line as shown in the illustration. Text in Illustration *a Seal Packing Diameter (2.0 to 3.0 mm (0.0787 to 0.118 in.)) 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.) NOTICE: Remove any oil from the contact surfaces. Install the oil seal retainer within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation.

(b) Install the engine rear oil seal retainer with the 6 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} NOTICE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

3. INSTALL WATER INLET PIPE

Text in Illustration

(a) Install the water inlet pipe with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Install the No. 1 water by-pass hose.

4. INSTALL CYLINDER HEAD GASKET RH

5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

6. INSTALL CYLINDER HEAD GASKET LH

7. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

8. INSTALL VALVE STEM CAP

9. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

11. INSTALL NO. 3 CAMSHAFT

12. INSTALL NO. 4 CAMSHAFT

13. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

15. INSTALL CAMSHAFT

16. INSTALL NO. 2 CAMSHAFT

17. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

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

21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

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

23. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) 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

(a) Install the 2 No. 2 chain vibration dampers.

25. INSTALL CRANKSHAFT TIMING SPROCKET

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

26. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. Text in Illustration *1 Knock Pin

(b) 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.

NOTICE:

Be careful of the idle gear installation position.

HINT:

Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.

(c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

Torque:

60 N·m {612 kgf·cm, 44 ft·lbf}

HINT:

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

27. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plates and timing marks as shown in the illustration and install the chain. Text in Illustration *1 Mark Plate *a Timing Mark HINT: The camshaft mark plates are orange.

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

(c) Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks. Text in Illustration *1 Mark Plate *a Turn *b When the idle sprocket is reused *c Mark *d Align NOTICE: 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.

(d) Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket. Text in Illustration *1 Mark Plate *a Timing Mark HINT: The crankshaft mark plate is yellow.

(e) Temporarily tighten the pulley set bolt.

(f) Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression). Text in Illustration *1 Center Line *2 Timing Mark *3 Sensor Plate

28. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. Text in Illustration *1 Stopper Plate *2 Plunger

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

(c) Install the No. 1 chain tensioner assembly with the 2 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Remove the hexagon wrench from the No. 1 chain tensioner assembly.

30. INSPECT VALVE TIMING

(a) Check the camshaft timing marks.

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

Text in Illustration

HINT:

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.

(c) If the valve timing is misaligned, reinstall the timing chain.

(d) Remove the pulley set bolt.

31. INSTALL TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge. Text in Illustration *a Depth SST: 09223-22010 SST: 09506-35010 Oil seal tap in depth: 0 to 1.0 mm (0 to 0.0394 in.) NOTICE: Keep the lip free of foreign matter. Do not tap on the oil seal at an angle. Make sure that the oil seal edge does not stick out of the timing chain case.

32. INSTALL WATER PUMP ASSEMBLY

(a) Install a new water pump gasket and the water pump assembly with the 8 bolts. Torque: 11 N·m {112 kgf·cm, 8 ft·lbf} NOTICE: 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

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

Text in Illustration

*a	Seal Diameter: 3.0 mm or more		Seal Packing
	Be sure to clean and grease the contact surface	-	-

Seal packing:

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

Seal diameter:

3.0 mm (0.118 in.)

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

Text in Illustration

*a	Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)	*b	Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
*c	Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)	*d	Diagonal line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
	Be sure to apply seal packing	-	-

Seal packing:

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

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

Seal Packing Application Chart

(c) Install a new gasket.

(d) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft. Text in Illustration *1 Drive Rotor Spline *2 Crankshaft

(e) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts. Text in Illustration *1 Nut Bolt Length Item Length Bolt A 40 mm (1.57 in.) Bolt B 55 mm (2.17 in.) Bolt C 28 mm (1.10 in.) NOTICE: Make sure that there is no oil on the bolt and nut threads.

(f) Fully tighten the bolts in this order: Area 1 and Area 2. Text in Illustration *a Area 1 *b Area 2 *c Area 3 *d Area 4 Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

(g) Fully tighten the bolts in Area 3.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

HINT:

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

(h) Fully tighten the bolts in Area 4.

Torque:

Bolt A :

43 N·m {438 kgf·cm, 32 ft·lbf}

Torque:

Except bolt A :

21 N·m {214 kgf·cm, 15 ft·lbf}

HINT:

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

(i) Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.

Torque:

9.1 N·m {93 kgf·cm, 81 in·lbf}

34. INSTALL WATER INLET HOUSING

(a) Install 2 new O-rings. HINT: Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.

(b) Install the 2 stud bolts. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) Install the water inlet housing with the 2 bolts and nut. Text in Illustration *1 Nut *2 Bolt Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} NOTICE: Be careful that the O-ring does not get caught between the parts.

(d) Connect the No. 1 water by-pass hose.

(e) Apply adhesive around the drain cock.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(f) Install the drain cock assembly to the water inlet housing.

Torque:

30 N·m {306 kgf·cm, 22 ft·lbf}

(g) Install the drain cock plug to the drain cock assembly.

Torque:

13 N·m {130 kgf·cm, 9 ft·lbf}

(h) Install a new gasket to the thermostat.

(i) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 10° of either side of the prescribed position.

(j) Install the water inlet with the 2 nuts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH

Text in Illustration

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

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

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

Torque:

54 N·m {550 kgf·cm, 40 ft·lbf}

36. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate with the 7 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} HINT: 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

(a) Using an E8 "TORX" socket wrench, install the 4 stud bolts.

Text in Illustration

Torque:

Bolt A :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt B :

9.0 N·m {92 kgf·cm, 80 in·lbf}

(b) Install 2 new O-rings.

(c) Apply seal packing in a continuous line as shown in the illustration. Text in Illustration *a Seal Diameter 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.) NOTICE: Remove any oil from the contact surface. Install the oil pan within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

(d) Install the oil pan with the 16 bolts and 2 nuts. Text in Illustration *1 Nut *a w/o Oil Cooler *b w/ Oil Cooler 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

(a) Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration. Text in Illustration *a Timing Chain Cover Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

(b) Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts. Text in Illustration *1 Nut Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

(b) Apply seal packing in a continuous line as shown in the illustration. Text in Illustration *a Seal Diameter 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.) NOTICE: Remove any oil from the contact surface. Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

(c) Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts. Text in Illustration *1 Nut Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

40. INSTALL OIL PAN DRAIN PLUG

(a) 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

(a) Apply seal packing as shown in the illustration.

Text in Illustration

Seal Packing

Seal packing:

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

(b) Install 3 new gaskets as shown in the illustration.

(c) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

(d) Install the head cover with the 12 bolts and a new seal washer. Torque: Bolts A : 21 N·m {214 kgf·cm, 15 ft·lbf} Except bolts A : 10 N·m {102 kgf·cm, 7 ft·lbf} HINT: 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

(a) Apply seal packing as shown in the illustration.

Text in Illustration

Seal Packing

Seal packing:

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

(b) Install 3 new gaskets as shown in the illustration.

(c) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH.

(d) 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} HINT: After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

43. INSTALL WATER OUTLET

(a) Install 2 new gaskets and a new O-ring. HINT: Apply soapy water to the O-ring.

(b) Install the water outlet with the 2 bolts and 4 nuts. Text in Illustration *1 Nut *2 Bolt Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} NOTICE: Be careful that the O-ring does not get caught between the parts.

44. INSTALL ENGINE OIL DIPSTICK GUIDE (w/ Oil Cooler)

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

(b) Install the engine oil dipstick guide.

45. INSTALL ENGINE OIL DIPSTICK GUIDE (w/o Oil Cooler)

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

(b) Install the engine oil dipstick guide with the bolt. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

46. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)

(a) Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Install a new gasket to the No. 1 oil cooler bracket. Text in Illustration *1 Nut *2 Bolt

(c) Install the oil cooler pipe with the bolt and 2 nuts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Install a new gasket to the No. 1 oil pan.

(e) Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

47. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)

(a) Install a new O-ring.

(b) Install the oil cooler assembly with the union bolt.

Torque:

68 N·m {693 kgf·cm, 50 ft·lbf}

(c) Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

48. INSTALL CRANKSHAFT PULLEY

49. INSTALL OIL FILTER ELEMENT

50. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cock sub-assembly. Text in Illustration *1 Adhesive Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the water drain cocks as shown in the illustration. Text in Illustration *a for Bank 1 *b for Bank 2 Torque: 25 N·m {255 kgf·cm, 18 ft·lbf} NOTICE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.

Torque:

13 N·m {130 kgf·cm, 9 ft·lbf}

51. INSTALL NO. 1 OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

NOTICE:

Do not touch the mesh when installing the oil control valve filter.

(b) 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. Text in Illustration *1 Oil Pipe Union

(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.

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

Torque:

65 N·m {663 kgf·cm, 48 ft·lbf}

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

Torque:

65 N·m {663 kgf·cm, 48 ft·lbf}

NOTICE:

If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

52. INSTALL OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

NOTICE:

Do not touch the mesh when installing the oil control valve filter.

(b) 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. Text in Illustration *1 Oil Pipe Union

(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.

(d) Install the bolt (A) to the cylinder head.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

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

Torque:

65 N·m {663 kgf·cm, 48 ft·lbf}

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

Torque:

65 N·m {663 kgf·cm, 48 ft·lbf}

NOTICE:

If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

53. INSTALL CRANKSHAFT POSITION SENSOR

54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(See page )

55. INSTALL VVT SENSOR

(See page )

56. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive around the ventilation valve sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Using a deep socket wrench 19 mm, install the ventilation valve sub-assembly. Torque: 27 N·m {275 kgf·cm, 20 ft·lbf}

57. INSTALL SPARK PLUG

58. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install a new oil filler gasket.

(b) Install the oil filler cap sub-assembly.