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Engine Unit: Reassembly

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .
  1. INSTALL STRAIGHT PIN 
    1. Using a plastic hammer, tap in new straight pins to the cylinder block.
      Fig 1: Identifying Positions Of Straight Pin
      G04056214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard protrusion 

      STANDARD PROTRUSION

      Item Protrusion
      Pin A 6 mm (0.236 in.)
      Pin B 23 mm (0.906 in.)
      Pin C 11 mm (0.433 in.)
      Pin D 9 mm (0.354 in.)
  2. INSTALL STUD BOLT 
    1. Using an E8 "torx" socket, install the stud bolts.
      Fig 2: Identifying Positions Of Stud Bolt
      G04056215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  3. INSTALL TIGHT PLUG 
    NOTE: If water leaks from the tight plug or the plug corrodes, replace it.
    1. Apply adhesive around the tight plugs.
      Fig 3: Applying Adhesive Around Tight Plugs
      G04056216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. 

    2. Using SST and a hammer, tap in new tight plugs as shown in the illustration.
      Fig 4: Taping In Tight Plugs
      G04056217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST, tap in the 2 tight plugs A.

        SST 09950-60010 (09951-00340), 09950- 70010 (09951-07100) 

      2. Using SST, tap in the tight plug B.

        SST 09950-60010 (09951-00200), 09950-70010 (09951-07100) 

  4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, install the oil nozzles.
      Fig 5: Identifying Oil Nozzles
      G04056218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  5. INSTALL CONNECTING ROD SMALL END BUSH 
    1. Align the oil holes of a new bush and the connecting rod.
      Fig 6: Identifying Oil Holes Of Bush And Connecting Rod
      G04056219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the bush.

      SST 09222-30010 

      Fig 7: Pressing Rod Small End Bushing Using SST And Press
      G04056220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin.
      Fig 8: Honing Bush
      G04056221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance: -0.002 to 0.004 mm (-0.00007 to 0.0001 in.) 

    4. Check that the piston pin fits at normal room temperature.
    5. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
      Fig 9: Fitting Piston Pin
      G04056222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL PISTON SUB-ASSEMBLY WITH PIN 
    1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
      Fig 10: Identifying Snap Ring
      G04056223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

    2. Gradually heat the piston to approximately 80°C (176°F).
    3. Coat the piston pin with engine oil.
      Fig 11: Heating Piston
      G04056224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

      Front Mark 

      FRONT MARK REFERENCE

      Item Front Mark
      Piston LH 1
      Piston RH 2
      Fig 12: Identifying Front Marks Of Piston And Connecting Rod
      G04056225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      The piston and pin are a matched set.

    5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
      Fig 13: Checking Fitting Condition Between Piston And Piston Pin
      G04056226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.
      Fig 14: Identifying Snap Ring
      G04056227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

  7. INSTALL PISTON RING SET 
    1. Install the oil ring expander by hand.
    2. Using a piston ring expander, install the oil ring rail as shown in the illustration.
      Fig 15: Identifying Piston Ring Set
      G04056228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

      HINT:

      • Install the compression ring No. 1 with the code mark (1N) facing upward.
      • Install the compression ring No. 2 with the code mark (2N) facing upward.
        Fig 16: Identifying 2 Compression Rings
        G04056229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Position the piston rings so that the ring ends are as shown in the illustration.
      Fig 17: Positioning Piston Rings
      G04056230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not align the ring ends.
  8. INSTALL CRANKSHAFT BEARING 
    1. Clean the main journal and the both surfaces of the bearing.
      Fig 18: Identifying Main Bearings Widths
      G04056231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.
    2. Install the upper bearing.
      1. Install the upper bearings to the cylinder block as shown in the illustration.
        Fig 19: Identifying Upper Bearing
        G04056232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Do not apply engine oil to the bearings and the contact surfaces.
        • Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.
        • Do not allow coolant to come into contact with the bearing inner surface.
        • If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
    3. Install the lower bearing.
      1. Install the lower bearings to the bearing caps.
      2. Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
        Fig 20: Identifying Lower Bearing
        G04056233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Dimension (A - B): 0.7 mm (0.0276 in.) or less 

        NOTE:
        • Do not apply engine oil to the bearings and the contact surfaces.
        • Do not allow coolant to come into contact with the bearing inner surface.
        • If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
  9. INSTALL CRANKSHAFT THRUST WASHER SET 
    1. Apply engine oil to the crankshaft thrust washer.
    2. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
      Fig 21: Identifying Oil Grooves
      G04056234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL CRANKSHAFT 
    1. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
    2. Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.

      HINT:

      A number is marked on each main bearing cap to indicate the installation position.

    3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
    4. Temporarily install the 8 main bearing cap bolts to the inside positions.
      Fig 22: Identifying Projection And Number Mark
      G04056235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
      Fig 23: Identifying Clearance Between Main Bearing Cap And Cylinder Block
      G04056236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt length: 100 to 102 mm (3.94 to 4.02 in.) 

    6. Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
    7. Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
      Fig 24: Taping Bearing Cap
      G04056237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the 8 main bearing cap bolts to the outside positions.

      Bolt length 

      BOLT LENGTH

      Item Length
      Bolt A 100 to 102 mm (3.94 to 4.02 in.)
      Except bolt A 105.5 to 107.5 mm (4.15 to 4.23 in.)
      Fig 25: Identifying Main Bearing Cap Bolts
      G04056238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the crankshaft bearing cap bolts.

      HINT:

      The main bearing cap bolts are tightened in 2 progressive steps.

    10. Step 1
      1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
        Fig 26: Identifying Main Bearing Cap Bolts Tightening Sequence
        G04056239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) 

        If any of the main bearing cap bolts does not meet the torque specified, replace it.

    11. Step 2
      1. Mark the front of the bearing cap bolts with paint.
      2. Retighten the bearing cap bolts by 90° in the order above.
      3. Check that the painted mark is now at a 90° angle to the front.
        Fig 27: Identifying Paint Mark
        G04056240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.

      Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

      Bolt length 

      BOLT LENGTH SPECIFICATIONS

      Item Length
      Bolt A 45 mm (1.77 in.)
      Except bolt A 30 mm (1.18 in.)
    13. Check that the crankshaft turns smoothly.
    14. Check the crankshaft thrust clearance (See INSPECTION  ).
      Fig 28: Identifying Main Bearing Cap Bolts Tightening Sequence
      G04056241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL CONNECTING ROD BEARING 
    1. Install the connecting rod bearing to the connecting rod and bearing cap.
    2. Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.

      Dimension (A - B): 0.7 mm (0.0276 in.) or less 

      Fig 29: Measuring Distance Between Connecting Rod's And Bearing Cap's Edges And Connecting Rod Bearing's Edge
      G04056242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply engine oil to the bearings and the contact surfaces.
      • Do not allow coolant to come into contact with the bearing inner surface.
      • If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
  12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
    2. Position the piston rings so that the ring ends are as shown in the illustration.
      Fig 30: Positioning Piston Rings
      G04056243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not align the ring ends.
    3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
      NOTE: Match the numbered connecting rod cap with the connecting rod.

      Front Mark 

      FRONT MARK REFERENCE

      Item Front Mark
      Piston LH 1
      Piston RH 2
      Fig 31: Pushing Correctly Numbered Piston And Connecting Rod Assembly Into Cylinder
      G04056244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the front mark of the connecting rod cap is facing forward.
    5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
    6. Install the connecting cap bolts.
      Fig 32: Checking Front Mark Of Connecting Rod Cap Facing Forward
      G04056245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      The connecting cap bolts are tightened in 2 progressive steps.

    7. Step 1
      1. Install and alternately tighten the bolts of the connecting rod cap in several steps.
        Fig 33: Tightening Bolts Of Connecting Rod Cap
        G04056246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

    8. Step 2
      1. Mark the front side of each connecting cap bolt with paint.
      2. Retighten the cap bolts by 90° as shown in the illustration.
      3. Check the painted mark is now at a 90° angle to the front.
    9. Check that the crankshaft turns smoothly.
    10. Check the connecting rod thrust clearance (See INSPECTION  ).
      Fig 34: Retightening Cap Bolts By 90°
      G04056247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL INTAKE VALVE GUIDE BUSH 
    1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) 

      Select a new guide bush (STD or O/S 0.05) 

      BUSH DIAMETER SPECIFICATIONS

      Bush size Bush bore diameter
      Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
      Fig 35: Measuring Bush Bore Diameter Of Cylinder Head
      G04056248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.

      If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

    2. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    3. Place the cylinder head on wooden blocks.
    4. Using SST, tap in new valve guide bushes to the specified protrusion height.
      Fig 36: Taping In Valve Guide Bushes
      G04056249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 

      Protrusion height: 9.1 to 9.9 mm (0.3583 to 0.3898 in.) 

    5. Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
      Fig 37: Reaming Valve Guide Bushings
      G04056250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0023 in.) 

  14. INSTALL EXHAUST VALVE GUIDE BUSH 
    1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) 

      Select a new guide bush (STD or O/S 0.05) 

      BUSH BORE DIAMETER SPECIFICATIONS

      Bush size Bush bore diameter
      Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
      Fig 38: Measuring Bush Bore Diameter Of Cylinder Head
      G04056251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.

      If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

    2. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    3. Place the cylinder head on wooden blocks.
    4. Using SST, tap in new valve guide bushes to the specified protrusion height.
      Fig 39: Taping In Valve Guide Bushes
      G04056252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 

      Protrusion height: 9.1 to 9.9 mm (0.3583 to 0.3898 in.) 

    5. Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
      Fig 40: Reaming Valve Guide Bushings
      G04056253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) 

  15. INSTALL RING PIN 
    1. Using a plastic hammer, tap in new ring pins to the specified protrusion height.
      Fig 41: Identifying Protrusion Height
      G04056254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified protrusion height: 2.5 to 3.8 mm (0.098 to 0.150 in.) 

  16. INSTALL NO. 1 STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
      Fig 42: Identifying 4 Gaskets
      G04056255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

  17. INSTALL NO. 2 STRAIGHT SCREW PLUG 
    1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

  18. INSTALL STUD BOLT 
    Fig 43: Identifying No.2 Straight Screw Plug
    G04056256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
    1. Using E6 and E8 "torx" sockets, install the stud bolts.
      Fig 44: Identifying Stud Bolts Specifications
      G04056257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      • 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts A, B and C 
      • 4.0 N*m (41 kgf*cm, 35 in.*lbf) for bolt D 
  19. INSTALL UNION 
    1. Apply adhesive to the union of the cylinder head.

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. 

    2. Using SST, install the union to the cylinder head as shown in the illustration.
      Fig 45: Applying Adhesive To Union Of Cylinder Head
      G04056258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 46: Installing Union To Cylinder Head
      G04056259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09023-38201 

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

  20. INSTALL STRAIGHT PIN 
    1. Using a plastic hammer, tap in new straight pins as shown in the illustration.
      Fig 47: Taping In Straight Pins
      G04056260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Protrusion height: 17.5 to 19.5 mm (0.689 to 0.768 in.) 

  21. INSTALL VALVE SPRING SEAT 
    1. Install the valve spring seats to the cylinder head.
  22. INSTALL VALVE STEM OIL SEAL 
    1. Apply a light coat of engine oil to new oil seals.
      NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

      HINT:

      The intake valve oil seals are gray and the exhaust valve oil seals are black.

      Fig 48: Identifying Intake And Exhaust Valve Oil Seals
      G04056261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, push in the oil seals.

      SST 09201-41020 

      Fig 49: Pushing In Oil Seals Using SST
      G04056262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
  23. INSTALL EXHAUST VALVE 
    1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
    2. Install the valve, compression spring and spring retainer to the cylinder head.
      Fig 50: Identifying Tip Area Of Intake Valve
      G04056263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the same parts in the same combination to the original locations.
    3. Using SST, compress the spring and install the 2 retainer locks.
      Fig 51: Installing Retainer Locks Using SST
      G04056264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09202-70020 (09202-00010) 

    4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
      Fig 52: Taping Valve Stem Tip
      G04056265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the retainer.
  24. INSTALL INTAKE VALVE 
    1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.
    2. Install the valve, compression spring and spring retainer to the cylinder head.
      Fig 53: Identifying Tip Area Of Intake Valve
      G04056266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the same parts in the same combination to the original locations.
    3. Using SST, compress the spring and install the 2 retainer locks.
      Fig 54: Identifying 2 Retainer Locks And SST
      G04056267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09202-70020 (09202-00010) 

    4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
      NOTE: Be careful not to damage the retainer.
      Fig 55: Taping Valve Stem Tip
      G04056268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem caps.
    2. Install the valve stem caps on the valves.
  26. INSTALL ENGINE REAR OIL SEAL 
    1. Place the oil seal retainer on wooden blocks.
    2. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
      Fig 56: Identifying Engine Rear Oil Seal
      G04056269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap on the oil seal at an angle.
  27. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Apply seal packing in a continuous line as shown in the illustration.

      Seal packing: Part No. 08826-00080 or equivalent 

      Apply seal packing as follows 

      SEAL PACKING DIAMETER SPECIFICATIONS

      Area Seal Packing Diameter
      Continuous Line Area 2.0 to 3.0 mm (0.0079 to 0.118 in.)
      Dashed Line Area 7.0 to 9.0 mm (0.276 to 0.354 in.)
      Fig 57: Applying Seal Packing In Continuous Line
      G04056270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil seal retainer within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    2. Install the oil seal retainer with the 6 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 58: Identifying Oil Seal Retainer With 6 Bolts
      G04056271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

  28. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY 
    1. Install the water outlet pipe with the 2 bolts.
      Fig 59: Identifying Water Outlet Pipe With 2 Bolts
      G04056272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  29. INSTALL KNOCK SENSOR 
    1. Install the 2 knock sensors with the 2 bolts as shown in the illustration.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    2. Connect the 2 knock sensor connectors.
    3. Connect the knock sensor wire clamp.
      Fig 60: Identifying Knock Sensor
      G04056273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH 
    1. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.
      Fig 61: Applying Continuous Line Of Seal Packing To Cylinder Head Gasket
      G04056274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: Part No. 08826-00080 or equivalent 

      Seal diameter: 2.5 to 3.0 mm (0.098 to 0.118 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head gasket within 3 minutes after applying the seal packing.
      • Do not apply engine oil within 2 hours of installation.
    2. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
      Fig 62: Identifying Lot No
      G04056275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful of the installation direction.
      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
    3. 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.

      HINT:

      The cylinder head bolts are tightened in 3 progressive steps.

    4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
    5. Step 1
      1. 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.
        Fig 63: Identifying Cylinder Head Bolts Tightening Sequence
        G04056276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

    6. Step 2
      1. Mark the cylinder head bolt head with paint as shown in the illustration.
      2. Tighten the cylinder head bolts another 90°.
    7. Step 3
      1. Tighten the cylinder head bolts by an additional 90°.
      2. Check that the painted mark is now facing rearward.
        Fig 64: Tightening Cylinder Head Bolts
        G04056277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.
      Fig 65: Identifying Wipe Clean
      G04056278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH 
    1. Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.
      Fig 66: Applying Continuous Line Of Seal Packing To Cylinder Head Gasket
      G04056279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: Part No. 08826-00080 or equivalent 

      Seal diameter: 2.5 to 3.0 mm (0.098 to 0.118 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head gasket within 3 minutes after applying the seal packing.
      • Do not apply engine oil within 2 hours of installation.
    2. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
      NOTE:
      • Be careful of the installation direction.
      • Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
    3. Place the cylinder head on the cylinder block.
      Fig 67: Identifying Lot No
      G04056280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      HINT:

      The cylinder head bolts are tightened in 3 progressive steps.

    4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
    5. Step 1
      1. 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.
        Fig 68: Identifying Cylinder Head Bolts Tightening Sequence
        G04056281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

    6. Step 2
      1. Mark the cylinder head bolt head with paint as shown in the illustration.
      2. Tighten the cylinder head bolts by 90°.
    7. Step 3
      1. Tighten the cylinder head bolts by an additional 90°.
      2. Check that the painted mark is now facing rearward.
        Fig 69: Identifying Painted Mark
        G04056282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Tighten the 2 bolts in the order shown in the illustration.
      Fig 70: Identifying Bolts Tightening Order
      G04056283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

    9. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.
  32. 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.
      Fig 71: Identifying Wipe Clean
      G04056284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

      SST 09276-75010 

    3. Squeeze the 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 high-pressure air from the compression chamber, make sure that the tip of the 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 quickly and firmly press the plunger with a finger.

      OK: Plunger is very difficult to move. 

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

    6. Install the lash adjusters.
      NOTE: Install the lash adjuster to the same place it was removed from.
  33. INSTALL NO. 1 VALVE ROCKER ARM SUBASSEMBLY 
    1. Apply engine oil to the lash adjuster tip and valve stem cap end.
      Fig 72: Inserting SST Tip Into Lash Adjuster's Plunger
      G04056285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Make sure that the valve rocker arms are installed as shown in the illustration.
      Fig 73: Installing Positions Of Valve Rocker Arms
      G04056286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 
    1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
    2. Install the camshaft and camshaft No. 2 to the camshaft housing RH.
    3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
      Fig 74: Identifying Marks And Numbers On Camshaft Bearing Caps
      G04056287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the 9 bolts in the order shown in the illustration.
      Fig 75: Identifying Camshaft Bearing Caps Bolts Tightening Order
      G04056288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  35. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
      Fig 76: Identifying Positions Of Valve Rocker Arm
      G04056289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing in a continuous line as shown in the illustration.
      Fig 77: Applying Seal Packing In Continuous Line
      G04056290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: Part No. 08826-00080 or equivalent 

      Seal diameter: 3.5 to 4.0 mm (0.138 to 0.158 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. Install the camshaft housing RH and tighten the 14 bolts in the order shown in the illustration.
      Fig 78: Identifying Camshaft Housing Bolts Tightening Order
      G04056291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

      NOTE:
      • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
      • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing 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. Tighten the 9 bolts in the order shown in the illustration.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

      Fig 79: Identifying Bolts Tightening Order
      G04056292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 
    1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
    2. Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing LH.
    3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
      Fig 80: Identifying Marks And Numbers On Camshaft Bearing Caps
      G04056293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the 8 bolts in the order shown in the illustration.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 81: Identifying Bolts Tightening Order
      G04056294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
      Fig 82: Identifying Positions Of Valve Rocker Arm
      G04056295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing in a continuous line as shown in the illustration.
      Fig 83: Applying Seal Packing In Continuous Line
      G04056296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: Part No. 08826-00080 or equivalent 

      Seal diameter: 5.0 to 5.5 mm (0.197 to 0.217 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. Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration.
      Fig 84: Identifying Camshaft Housing Bolts Tightening Order
      G04056297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

      NOTE:
      • When installing the camshaft housing 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, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing 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. Tighten the 8 bolts in the order shown in the illustration.
      Fig 85: Identifying 8 Bolts Tightening Order
      G04056298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

  38. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 2 chain tensioner 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 (0.039 in.) into the hole to fix it.
      Fig 86: Identifying No.2 Chain Tensioner Assembly
      G04056299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) 
    CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .
    1. Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears 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. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed.
      Fig 87: Identifying Timing Marks And Mark Plate
      G04056300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

      Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) 

    5. Remove the pin from the chain tensioner.
      Fig 88: Identifying Camshaft Bolt
      G04056301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Install the chain tensioner 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 (0.039 in.) into the hole to hold it.
      Fig 89: Identifying No.3 Chain Tensioner Assembly
      G04056302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) 
    CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .
    1. Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears 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. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed.
      Fig 90: Identifying Timing Marks And Mark Plate
      G04056303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

      Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) 

    5. Remove the pin from the chain tensioner.
      Fig 91: Holding Hexagonal Portion Of Camshaft Using Wrench
      G04056304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the chain vibration damper with the 2 bolts.
      Fig 92: Identifying No.1 Chain Vibration Damper
      G04056305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf) 

  43. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 chain vibration dampers.
      Fig 93: Identifying No.2 Chain Vibration Damper
      G04056306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the 2 timing gear set keys and timing sprocket as shown in the illustration.
      Fig 94: Identifying Crankshaft Timing Sprocket
      G04056307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL IDLE SPROCKET ASSEMBLY 
    1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
    2. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.
      Fig 95: Identifying Idle Sprocket Assembly
      G04056308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful of the idle gear direction.

      HINT:

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

    3. 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.

  46. INSTALL CHAIN SUB-ASSEMBLY 
    1. Align the mark plate and timing marks as shown in the illustration and install the chain.

      HINT:

      The camshaft mark plate is orange.

      Fig 96: Aligning Mark Plate And Timing Marks
      G04056309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Do not pass the chain over the crankshaft, just put it on it.
      Fig 97: Locating Chain
      G04056310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.
      Fig 98: Turning Camshaft Timing Gear Assembly
      G04056311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.
    4. Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing sprocket.

      HINT:

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the pulley set bolt.
      Fig 99: Aligning Mark Plate And Timing Mark
      G04056312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
      Fig 100: Turning Crankshaft Clockwise
      G04056313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
  48. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
    2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.050 in.) into the hole of the stopper plate.
      Fig 101: Pushing Plunger
      G04056314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the chain tensioner with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 102: Identifying Chain Tensioner With 2 Bolts
      G04056315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the lock pin of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression.
    5. Remove the pulley set bolt.
      Fig 103: Identifying Timing Marks
      G04056316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL TIMING CHAIN CASE OIL SEAL 
    1. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
      Fig 104: Identifying Timing Chain Case Oil Seal
      G04056317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09223-22010, 09506-35010 

      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap on the oil seal at an angle.
      • Make sure that the oil seal edge does not stick out of the timing chain case.
  50. INSTALL WATER PUMP ASSEMBLY 
    1. Install a new gasket and the water pump with the 16 bolts.
      Fig 105: Identifying Gasket And Water Pump With 16 Bolts
      G04056318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 

      NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
  51. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line to the engine unit as shown in the following illustration.
      Fig 106: Applying Seal Packing In Continuous Line To Engine Unit
      G04056319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: Part No. 08826-00080 or equivalent 

      Seal diameter: 5.0 to 5.5 mm (0.197 to 0.217 in.) 

      NOTE:
      • Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • Install the chain cover within 3 minutes.
      • Do not start the engine for at least 2 hours after installing.
    2. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.
      Fig 107: Applying Seal Packing In Continuous Line To Timing Chain Cover
      G04056320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: 

      • 08826-00080 or equivalent 
      • 08826-00100 or equivalent 
      NOTE:
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.

      Apply seal packing as follows 

      SEAL PACKING APPLYING REFERENCE

      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 to 5.0 mm (0.177 to 0.197 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Alternate Long and Dashed Line Area 4.5 to 5.0 mm (0.177 to 0.197 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.)
      Dashed Line Area 3.5 to 4.0 mm (0.138 to 0.158 in.) 1.0 to 2.0 mm (0.039 to 0.079 in.)
      Diagonal Line Area 6.0 to 6.5 mm (0.236 to 0.256 in.) 4.5 mm (0.177 in.)
    3. Install a new gasket.
      Fig 108: Locating Gasket
      G04057866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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.
      Fig 109: Aligning Oil Pump's Drive Rotor Spline And Crankshaft
      G04056322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

      Bolt length 

      BOLT LENGTH SPECIFICATIONS

      Item Length
      Bolt A 50 mm (1.97 in.)
      Bolt B 25 mm (0.98 in.)
      Bolt C 55 mm (2.17 in.)
      Fig 110: Identifying Timing Chain Cover Installing Bolt And Nuts
      G04056323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that there is no oil on the bolt threads.
    6. Fully tighten the 3 bolts as shown in the illustration.
      Fig 111: Tightening 3 Bolts
      G04056324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      • 43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A 
      • 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A 
    7. Fully tighten the 3 bolts as shown in the illustration.
      Fig 112: Tightening 3 Bolts
      G04056325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    8. Fully tighten the 7 bolts and 2 nuts as shown in the illustration.
      Fig 113: Identifying Nuts
      G04056326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      HINT:

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

    9. Fully tighten the 12 bolts as shown in the illustration.
      Fig 114: Tightening 12 Bolts
      G04056327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 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.

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

      Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 

  52. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Using an E6 "torx" socket, install the stud bolts as shown in the illustration.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      Fig 115: Identifying Stud Bolts
      G04056328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the baffle plate with the 8 bolts.
      Fig 116: Identifying Baffle Plate With 8 Bolts
      G04056329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT:

      Temporarily tighten the 8 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.

    3. Install a new gasket and the oil strainer with the 3 nuts.
      Fig 117: Identifying Oil Strainer With 3 Nuts
      G04056330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    4. Install 2 new O-rings.
      Fig 118: Identifying O-Rings
      G04056331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL OIL PAN SUB-ASSEMBLY 
    1. When replacing a stud bolt, install it by using an E6 "torx" socket wrench.
      Fig 119: Identifying Stud Bolt Dimensions
      G04056332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

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

      Seal packing: Part No. 08826-00080 or equivalent 

      Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
        Fig 120: Identifying Seal Diameter
        G04056333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil pan with the 16 bolts and 2 nuts.
      Fig 121: Identifying Oil Pan With 16 Bolts And 2 Nuts
      G04056334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      • 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 
      • 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A 
  54. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      Fig 122: Applying Seal Packing In Continuous Line
      G04056335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: Part No. 08826-00080 or equivalent 

      Seal diameter: 4.0 to 6.0 mm (0.156 to 0.236 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan No. 2 within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
    2. Install the oil pan with the 15 bolts and 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    3. Install a new gasket and the drain plug.
      Fig 123: Identifying Oil Pan With 15 Bolts And 2 Nuts
      G04056336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  55. INSTALL SPARK PLUG TUBE GASKET 
    1. Using a cutter, cut off the sealing part of the removed plug tube gasket.
      Fig 124: Identifying Area To Be Cut Off
      G04056337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.
      Fig 125: Identifying Spark Plug Tube Gasket
      G04056338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap on the oil seal at an angle.

      HINT:

      If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

    3. Return the claws of the ventilation baffle plate to their original positions.
  56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) 
    1. Apply seal packing as shown in the illustration.
      Fig 126: Applying Seal Packing
      G04056339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the head cover within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
    2. Install 3 new gaskets as shown in the illustration.
    3. Install a new gasket to the head cover.
      Fig 127: Identifying Gaskets
      G04056340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a head cover with the 14 bolts.
      Fig 128: Identifying Head Cover With 14 Bolts
      G04056341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 

      10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A 

  57. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) 
    1. Apply seal packing as shown in the illustration.
      Fig 129: Applying Seal Packing
      G04056342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the head cover within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
    2. Install 3 new gaskets as shown in the illustration.
    3. Install a new gasket to the head cover.
      Fig 130: Identifying Gaskets
      G04056343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the head cover with the 12 bolts.
      Fig 131: Identifying Head Cover With 12 Bolts
      G04056344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      • 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 
      • 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A 
  58. INSTALL REAR WATER BY-PASS JOINT 
    1. Install 2 new gaskets and a new O-ring.
      Fig 132: Identifying Rear Water By-Pass Joint
      G04056345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply soapy water to the O-ring.

    2. Install the water by-pass joint with the 2 bolts and 4 nuts.
      Fig 133: Identifying Water By-Pass Joint With 2 Bolts And 4 Nuts
      G04056346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      NOTE: Be careful that the O-ring does not get caught between the parts.
  59. INSTALL WATER INLET WITH THERMOSTAT SUBASSEMBLY 
    1. Install a new gasket and water inlet with thermostat with the 3 nuts.
      Fig 134: Identifying Water Inlet With Thermostat Subassembly
      G04056347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  60. INSTALL WATER INLET SUB-ASSEMBLY 
    1. Install the 3 water by-pass hoses.
      Fig 135: Identifying Water By-Pass Hoses
      G04056348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 2 new O-rings.
      Fig 136: Identifying O-Rings
      G04056349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply a small amount of water or soapy water to Oring (A) in the illustration before installing it.

    3. Install the water inlet with the 4 bolts and nut.
      Fig 137: Identifying Water Inlet With 4 Bolts And Nut
      G04056350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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. Install the 3 water by-pass hoses.
      Fig 138: Identifying 3 Water By-Pass Hoses
      G04056351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
    2. Using SST, install the pulley bolt.
      Fig 139: Installing Crankshaft Pulley Bolt Using SST
      G04056352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf) 

  62. INSTALL OIL FILTER ELEMENT 
    1. Clean the inside of the oil filter cap, the threads and O-ring groove.
    2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
    3. Set a new oil filter element to the oil filter cap.
    4. Remove dirt or foreign matter from the installation surface of the engine.
    5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
      Fig 140: View Of Oil Filter Element And O-Ring
      G04018936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful that the O-ring does not get caught between the parts.
    6. Using SST, tighten the oil filter cap.
      Fig 141: Tightening Oil Filter Cap Using SST
      G04056354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09228-06501 

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      NOTE: Make sure that the oil filter is installed securely as shown in the illustration.
  63. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply adhesive around the drain cocks.
      Fig 142: Applying Adhesive Around Drain Cocks
      G04056355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

    2. Install the water drain cocks as shown in the illustration.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      Fig 143: Identifying Water Drain Cocks
      G04056356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
    3. Install the water drain cock plugs to the water drain cocks.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

  64. INSTALL NO. 1 OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
      NOTE: Do not touch the mesh when installing the oil control valve filter.
    2. 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).
    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
    4. Tighten the oil pipe union (on the head cover side).

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

    5. Tighten the oil check valve bolt (on the cylinder head side).

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

      Fig 144: Identifying Oil Pipe Union And Oil Check Valve Bolt
      G04056357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
  65. INSTALL NO. 2 OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
      NOTE: Do not touch the mesh when installing the oil control valve filter.
    2. 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).
    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
    4. Tighten the oil pipe union (on the head cover side).

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

    5. Tighten the oil check valve bolt (on the cylinder head side).
      Fig 145: Identifying Oil Check Valve Bolt
      G04056358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

      NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
  66. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Install the sensor with the bolt.
      Fig 146: Identifying Crankshaft Position Sensor With Bolt
      G04056359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  67. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Install the 4 oil control valves with the 4 bolts.
      Fig 147: Identifying Oil Control Valves
      G04056360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  68. INSTALL CAMSHAFT POSITION SENSOR 
    1. Install the 4 sensors with the 4 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 148: Identifying Camshaft Position Sensor
      G04056361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. INSTALL VENTILATION VALVE SUB-ASSEMBLY 
    1. Apply adhesive around the ventilation valve.

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

    2. Install the ventilation valve.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      Fig 149: Identifying Ventilation Valve
      G04056362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL SPARK PLUG 
    1. Install the spark plugs.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

  71. INSTALL RADIATOR CAP SUB-ASSEMBLY 
    1. Install the radiator cap.
  72. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install a new gasket.
    2. Install the oil filler cap.
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