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Engine Unit: Reassembly

WARNING: This page is about a different car, the 2008 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 Straight Pin Dimension
      G05823728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard protrusion 

      ITEM SPECIFICATION

      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 Stud Bolt Dimension
      G05823729Courtesy 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 is corroded, replace it.
    1. Apply adhesive around the tight plugs.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 3: Applying Adhesive To Tight Plugs
      G05823730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap in new tight plugs as shown in the illustration.
      Fig 4: Locating Tight Plug Location
      G05823731Courtesy 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.

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

      Fig 5: Locating Oil Nozzles Bolts
      G05823732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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
      G05823733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the bush.

      SST 09222-30010 

      Fig 7: Pressing Out Bush
      G05823734Courtesy 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.

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

      Fig 8: Identifying Clearance Between Bush And Piston Pin
      G05823735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: Checking Piston Pin
      G05823736Courtesy 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.

      HINT:

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

      Fig 10: Installing Piston Sub-Assembly With Pin
      G05823737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to approximately 80°C (176°F).
    3. Coat the piston pin with engine oil.
      Fig 11: Heating Piston
      G05823738Courtesy 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 

      ITEM SPECIFICATION

      Item Front Mark
      Piston LH 1
      Piston RH 2

      HINT:

      The piston and pin are a matched set.

      Fig 12: Identifying Front Marks Of Piston And Connecting Rod
      G05823739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      G05823740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

      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.
      Fig 14: Identifying Service Hole
      G05823741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a piston ring expander, install the oil ring rail as shown in the illustration.
      Fig 15: Installing Oil Ring Rail
      G05823742Courtesy 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 Piston Ring Expander
        G05823743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Position the piston rings so that the ring ends are as shown in the illustration.
      NOTE: Do not align the ring ends.
      Fig 17: Identifying Piston Rings Front Mark
      G05823744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL CRANKSHAFT BEARING 
    1. Clean the main journal and the both surfaces of the bearing.
      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.
      Fig 18: Identifying Crankshaft Bearing
      G05823745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the upper bearing.
      1. Install the upper bearings to the cylinder block as shown in the illustration.
        NOTE:
        • Do not apply engine oil to the bearings or 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.
          Fig 19: Installing Upper Bearing
          G05823746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

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

        NOTE:
        • Do not apply engine oil to the bearings or 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.
          Fig 20: Installing Lower Bearing
          G05823747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  10. INSTALL CRANKSHAFT 
    1. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
      Fig 21: Identifying Grooves
      G05823748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Numbers Of Main Bearing Caps
      G05823749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Insert the main bearing cap by 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.

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

      Fig 23: Identifying Bearing Cap Bolts Dimension
      G05823750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: Tapping Bearing Cap
      G05823751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the 8 main bearing cap bolts to the outside positions.

      Bolt length 

      BOLT LENGTH SPECIFICATION

      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.)
    9. Install the crankshaft bearing cap bolts.

      HINT:

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

      Fig 25: Identifying Main Bearing Cap Bolts Dimension
      G05823752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Step 1
      1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.

        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.

        Fig 26: Identifying Main Bearing Cap Bolts Tighten Sequence
        G05823753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Mark Of Bearing Cap Bolts With Paint
        G05823754Courtesy 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 SPECIFICATION

      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 j ).
      Fig 28: Identifying Main Bearing Cap Bolts Tighten Sequence
      G05823755Courtesy 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 

      NOTE:
      • Do not apply engine oil to the bearings or 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.
      Fig 29: Measuring Distance Between Connecting Rod's And Bearing Cap's Edges
      G05823756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Position the piston rings so that the ring ends are as shown in the illustration.
      NOTE: Do not align the ring ends.
      Fig 30: Positioning Piston Rings
      G05823757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 CHART

      Item Front Mark
      Piston LH 1
      Piston RH 2
      Fig 31: Pushing Connecting Rod Assembly Into Cylinder
      G05823758Courtesy 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 rod cap bolts.

      HINT:

      The connecting rod cap bolts are tightened in 2 progressive steps.

      Fig 32: Identifying Front Mark Of Connecting Rod Cap
      G05823759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Step 1
      1. Install and alternately tighten the connecting rod cap bolts in several steps.

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

        Fig 33: Locating Connecting Rod Cap Bolts
        G05823760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Step 2
      1. Mark the front side of each connecting rod 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: Identifying Connecting Rod Cap Bolts Mark Position
      G05823761Courtesy 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 SPECIFICATION

      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: Installing Intake Valve Guide Bush
      G05823762Courtesy 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 an 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.

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

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

      Fig 36: Tapping Valve Guide Bushes
      G05823763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a sharp 5.5 mm reamer, ream the valve guide bushes to obtain the specified clearance.

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

      Fig 37: Laying Strip Of Camshaft Journals
      G05823764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 SPECIFICATION

      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
      G05823765Courtesy 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 an 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.

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

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

      Fig 39: Tapping Valve Guide Bushes
      G05823766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a sharp 5.5 mm reamer, ream the valve guide bushes to obtain the specified clearance.

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

      Fig 40: Reaming Valve Guide Bushes
      G05823767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL RING PIN 
    1. Using a plastic hammer, tap in new ring pins to the specified protrusion height.

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

      Fig 41: Locating Ring Pin
      G05823768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL NO. 1 STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.

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

      Fig 42: Locating No. 1 Straight Screw Plug
      G05823769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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) 

      Fig 43: Locating No. 2 Straight Screw Plug
      G05823770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL STUD BOLT 
    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: Stud Bolts Dimension Chart
      G05823771Courtesy 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. 

      Fig 45: Applying Adhesive To Union
      G05823772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the union to the cylinder head as shown in the illustration.
      Fig 46: Union Dimension Chart
      G05823773Courtesy 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: Straight Pins Dimension Chart
      G05823774Courtesy 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 Valve Stem Oil Seal
      G05823775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, push in the oil seals.

      SST 09201-41020 

      NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
      Fig 49: Pushing Oil Seals
      G05823776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      NOTE: Install the same parts in the same combination to the original locations.
      Fig 50: Identifying Exhaust Valve Dimension
      G05823777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, compress the spring and install the 2 retainer locks.

      SST 09202-70020 (09202-00010) 

      Fig 51: Installing Retainer Locks
      G05823778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 52: Tapping Valve Stem Tip
      G05823779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      NOTE: Install the same parts in the same combination to the original locations.
      Fig 53: Identifying Tip Area Of Intake Valve
      G05823780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, compress the spring and install the 2 retainer locks.

      SST 09202-70020 (09202-00010) 

      Fig 54: Compressing Spring
      G05823781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
      NOTE: Be careful not to damage the retainer.
  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.
      Fig 55: Tapping Valve Stem
      G05823782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.

      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.
        Fig 56: Installing Engine Rear Oil Seal
        G05823783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Apply seal packing in a continuous line as shown in the illustration.

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

      Apply seal packing as follows 

      SEAL PACKING SPECIFICATION

      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.)
      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.
        Fig 57: Identifying Engine Rear Oil Seal Retainer Dimension
        G05823784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 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 in the places indicated by A before installing them.

      Adhesive: Part No. 08833-00070, Three Bond 1324 or equivalent 

      Fig 58: Locating Oil Seal Retainer Bolts
      G05823785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY 
    1. Install the water outlet pipe with the 2 bolts.

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

      Fig 59: Locating Water Outlet Pipe Sub-Assembly
      G05823786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 Sensors With Bolts
      G05823787Courtesy 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.

      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.
        Fig 61: Identifying Continuous Line Of Seal Packing To Cylinder Head Gasket
        G05823788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.
      Fig 62: Identifying Cylinder Head Gasket
      G05823789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

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

        Fig 63: Locating Cylinder Head Bolts
        G05823790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: Identifying Mark Of Cylinder Head Bolt
        G05823791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
      Fig 65: Identifying Wipe Off Seal Packing
      G05823792Courtesy 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.

      Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B 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 start the engine for at least 2 hours after installing.
        Fig 66: Locating Cylinder Head Sub-Assembly
        G05823793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      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.

      Fig 67: Identifying Cylinder Head Gasket
      G05823794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

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

        Fig 68: Locating Cylinder Head Bolts
        G05823795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Mark Of Cylinder Head Bolt
        G05823796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Tighten the 2 bolts in the order shown in the illustration.

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

      Fig 70: Locating Cylinder Head Bolts Tightening Sequence
      G05823797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
  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 Off Seal Packing
      G05823798Courtesy 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 position it was removed from.
    Fig 72: Checking Plunger Movement
    G05823799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the lash adjuster tip and valve stem cap end.
    2. Make sure that the valve rocker arms are installed as shown in the illustration.
  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.
      Fig 73: Identifying Valve Rocker Arms And Valve Lash Adjuster
      G05823800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the marks and numbers on the camshaft bearing caps and place each of them in the proper position and direction.
      Fig 74: Checking Marks And Numbers On Camshaft Bearing Caps
      G05823801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the 9 bolts in the order shown in the illustration.

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

      Fig 75: Locating Camshaft Bearing Bolts Sequence
      G05823802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 Valve Rocker Arm Correct And Incorrect Position
      G05823803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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: 3.5 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.
        Fig 77: Identifying Cylinder Head Bolts Tightening Sequence
        G05823804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the camshaft housing RH and tighten the 14 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 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.
        Fig 78: Locating Camshafts Housing Bolts Tighten Sequence
        G05823805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 9 bolts in the order shown in the illustration.

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

  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.
      Fig 79: Locating Camshafts Bearing Bolts With Tighten Sequence
      G05303022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the marks and numbers on the camshaft bearing caps and place each of them in the proper position and direction.
      Fig 80: Identifying Camshaft Bearing Caps In Proper Position And Direction
      G05286267Courtesy 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 Camshaft Bearing Caps Bolts With Tightening Sequence
      G05303025Courtesy 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 Valve Lash Adjuster
      G05823803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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: 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.
        Fig 83: Identifying Seal Packing In Continuous Line
        G05823810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the camshaft housing 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 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.
        Fig 84: Identifying Camshaft Housing Bolts With Tightening Sequence
        G05303027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 8 bolts in the order shown in the illustration.

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

      Fig 85: Identifying Camshaft Housing Bolt Tightening Sequence
      G05814115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Installing No. 2 Chain Tensioner With Bolt
      G04974804Courtesy 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: Aligning Mark Plate With Timing Marks
      G04974805Courtesy 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: Holding Hexagonal Portion Of Camshaft
      G04974806Courtesy 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: Installing Chain Tensioner With Bolt
      G04974807Courtesy 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 Mark Plate With Timing Marks
      G04974808Courtesy 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
      G04974809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the chain vibration damper with the 2 bolts.

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

      Fig 92: Locating Vibration Damper And Bolts
      G04974810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 chain vibration dampers.
      Fig 93: Locating Vibration Dampers
      G05286058Courtesy 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
      G04974612Courtesy 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.
      NOTE: Make sure that the idle gear is facing the correct 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) 

      Fig 95: Locating Idle Sprocket Assembly
      G05303039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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: Identifying Mark Plate And Timing Marks
      G05303040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rest the chain on top of the crankshaft.
      Fig 97: Identifying Chain On Top Of Crankshaft
      G05286284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.
      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.
      Fig 98: Turning Camshaft Timing Gear Assembly
      G04974815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: Identifying Mark Plate And Timing Mark
      G05286286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
  47. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
      Fig 100: Turning Crankshaft
      G05286287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Installing No. 1 Chain Tensioner Assembly
      G05286288Courtesy 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: Locating Chain Tensioner And Bolts
      G05286289Courtesy 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 Mark Of Crankshaft
      G05303046Courtesy 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.

      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.
        Fig 104: Tapping Oil Seal
        G04974821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL WATER PUMP ASSEMBLY 
    1. Install a new gasket and the water pump with the 16 bolts.

      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 Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent.
      Fig 105: Locating Water Pump With Bolts
      G05823832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Identifying Timing Chain Cover Sub-Assembly Seal Location
      G05805990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Seal diameter: 

      A: 3.0 to 4.0 mm (0.118 to 0.158 in.) 

      B: 3.0 mm (0.118 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: Identifying Timing Chain Cover Seal Packing Area
      G05805991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Toyota Genuine Seal Packing 1282B, Three Bond 1282B 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.

      Seal Packing Application Chart 

      SEAL PACKING APPLICATION CHART

      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Diagonal Line Area 6.0 mm (0.236 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Alternate Long and Dashed Line Area 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.079 to 0.118 in.)
      Dashed Line Area 3.5 mm (0.138 in.) or more 1.0 to 2.0 mm (0.039 to 0.079 in.)
    3. Install a new gasket.
      Fig 108: Locating Gasket
      G05287612Courtesy 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
      G05287627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

      Bolt length 

      BOLT LENGTH SPECIFICATION

      Item Length
      Bolt A 50 mm (1.97 in.)
      Bolt B 25 mm (0.98 in.)
      Bolt C 55 mm (2.17 in.)
      NOTE: Make sure that there is no oil on the bolt threads.
      Fig 110: Locating Timing Chain Cover Bolts And Nuts
      G05287628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Fully tighten the 3 bolts as shown in the illustration.

      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 

      Fig 111: Locating Timing Chain Cover Bolts
      G05287629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Fully tighten the 3 bolts as shown in the illustration.

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

      Fig 112: Locating Timing Chain Cover Bolts
      G05287630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Fully tighten the 7 bolts and 2 nuts as shown in the illustration.

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

      HINT:

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

      Fig 113: Locating Timing Chain Cover Bolts And Nuts
      G05287631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Fully tighten the 12 bolts as shown in the illustration.

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

      HINT:

      Tighten the bolts in the order from 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) 

      Fig 114: Locating Timing Chain Cover Nuts Tighten Position
      G05287632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Stud Bolt Dimension Chart
      G05823842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the baffle plate with the 8 bolts.

      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.

      Fig 116: Locating Baffle Plate With Bolts
      G05286300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new gasket and the oil strainer with the 3 nuts.

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

      Fig 117: Locating Oil Strainer With Nuts
      G05303052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install 2 new O-rings.
      Fig 118: Locating O-Rings
      G05823845Courtesy 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.

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

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

      Fig 119: Identifying Stud Bolt Dimension
      G05303054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 Oil Pan Seal Packing Area
        G05823847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil pan with the 16 bolts and 2 nuts.

      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 

      Fig 121: Locating Oil Pan Bolts And Nuts
      G05286303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. 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: 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.
        Fig 122: Identifying Seal Packing In Continuous Line
        G05823849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

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

      Fig 123: Locating Oil Pan With Bolts And Nuts
      G05286035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL SPARK PLUG TUBE GASKET 
    1. Using a cutter, cut off the sealing part of the removed plug tube gasket.
      Fig 124: Identifying Spark Plug Tube Gasket
      G05823851Courtesy 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.
      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.
      Fig 125: Tapping Oil Seal
      G05286313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) 
    1. 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 surface.
      • Install the head cover within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
        Fig 126: Installing Cylinder Head Cover Sub-Assembly (For Bank 1)
        G05286314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 3 new gaskets as shown in the illustration.
    3. Install a new gasket to the head cover.
      Fig 127: Locating Cylinder Head Cover And Gasket
      G05286063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the head cover with the 14 bolts.

      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 

      Fig 128: Locating Head Cover With Bolts
      G05286315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) 
    1. 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 surface.
      • Install the head cover within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
        Fig 129: Installing Cylinder Head Cover Sub-Assembly (For Bank 2)
        G05286316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 3 new gaskets as shown in the illustration.
    3. Install a new gasket to the head cover.
      Fig 130: Locating Gaskets
      G05286071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the head cover with the 12 bolts.

      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 

      Fig 131: Locating Head Cover With Bolts
      G05286317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL REAR WATER BY-PASS JOINT 
    1. Install 2 new gaskets and a new O-ring.

      HINT:

      Apply soapy water to the O-ring.

      Fig 132: Locating Gaskets And O-Ring
      G05286030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water by-pass joint 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.
      Fig 133: Locating Water By-Pass Joint With Bolts And Nuts
      G05286319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 
    1. Install a new gasket and water inlet with thermostat with the 3 nuts.

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

      Fig 134: Locating Water Inlet With Thermostat Sub-Assembly
      G05286028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL WATER INLET SUB-ASSEMBLY 
    1. Install the 3 water by-pass hoses.
      Fig 135: Locating Water By-Pass Hoses
      G05286027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 2 new O-rings.

      HINT:

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

      Fig 136: Locating O-Rings
      G05286322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the water inlet with the 4 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.
      Fig 137: Locating Water Inlet, Bolts And Nut
      G05286025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 3 water by-pass hoses.
  61. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
      Fig 138: Locating Water By-Pass Hoses
      G05286024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the pulley bolt.

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

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

      Fig 139: Installing Pulley Bolt
      G04974853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      NOTE: Be careful that the O-ring does not get caught between the parts.
      Fig 140: Identifying Oil Filter Element And O-Ring
      G04974575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST, tighten the oil filter cap.

      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.
      Fig 141: Tightening Oil Filter Cap
      G05823868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply adhesive around the drain cocks.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 142: Applying Adhesive Around Drain Cocks
      G04943675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water drain cocks as shown in the illustration.

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

      NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to 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.
      Fig 143: Identifying Water Drain Cock Plugs To Water Drain Cocks
      G05823870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Check Valve Bolt And Oil Pipe Union
      G05286325Courtesy 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).

      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.
      Fig 145: Locating Oil Pipe Union And Oil Pipe
      G05286326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Install the sensor with the bolt.

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

      Fig 146: Locating Sensor With Bolt
      G05286086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Install the 4 oil control valves with the 4 bolts.

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

      Fig 147: Identifying Oil Control Valves And Bolts
      G05823561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSTALL CAMSHAFT POSITION SENSOR 
    1. Install the 4 sensors with the 4 bolts.

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

  69. INSTALL VENTILATION VALVE SUB-ASSEMBLY 
    1. Apply adhesive around the ventilation valve.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 148: Locating Camshaft Position Sensor Bolts
      G05286019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the ventilation valve.

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

  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.
      Fig 149: Locating Ventilation Valve
      G05286018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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