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Reassembly [04/2013 - 08/2015]: Procedure

WARNING: This page is about a different car, the 2015 Lexus IS 250 and 2014 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.

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

        for stud bolt A 

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

        for stud bolt B 

        Torque: 4.4 N.m (45 kgf/cm, 39 in.lbf) 

        GTY456371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Timing Chain Or Belt Cover Sub-assembly Lower *b Cylinder Block Sub-assembly Lower
        *c 9.0 mm (0.354 in.) *d 19 mm (0.748 in.)
        *e 16 mm (0.630 in.) *f 27 mm (1.06 in.)
    2. for AWD:
      1. Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

        for stud bolt A 

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

        for stud bolt B 

        Torque: 4.4 N.m (45 kgf/cm, 39 in.lbf) 

        GTY466411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Timing Chain Or Belt Cover Sub-assembly Lower *b Oil Pan Sub-assembly Lower
        *c 9.0 mm (0.354 in.) *d 19 mm (0.748 in.)
        *e 16 mm (0.630 in.) *f 27 mm (1.06 in.)
    3. Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

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

      GTY461534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for 2WD *B for AWD
      *a 9.0 mm (0.354 in.) *b 19 mm (0.748 in.)
    4. Using an E8 "TORX" socket wrench, install the stud bolts as shown in the illustration.
      GTY459286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      * 1 Cylinder Head Cover Sub-assembly
      *a 19 mm (0.748 in.)
      *b 16 mm (0.630 in.)
      *c 44 mm (1.73 in.)

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

  2. INSTALL RING WITH HEAD PIN 
    NOTE:

    It is not necessary to remove a ring with head pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in new ring with head pins to the camshaft housing sub-assembly.

      Standard protrusion height

      2.7 to 3.3 mm (0.106 to 0.130 in.)

      GTY459009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 2 *b for Bank 1
      *c Protrusion Height - -
  3. INSTALL NO. 1 STRAIGHT PIN 
    NOTE:

    It is not necessary to remove a No. 1 straight pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in new No. 1 straight pins to the camshaft housing sub-assemblies.

      Standard Protrusion Height

      Item Specified Condition
      Straight pin A 7.7 to 8.3 mm (0.303 to 0.327 in.)
      Straight pin B 5.7 to 6.3 mm (0.224 to 0.248 in.)
      GTY459910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 2 *b for Bank 1
      *c Protrusion Height - -
  4. INSTALL ENGINE REAR OIL SEAL 
    1. Place the engine rear oil seal retainer on wooden blocks.
    2. Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge.
      GTY465487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Standard depth
      • SST: 09223-1503009950-70010 
        1. 09951-07100

      Standard depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap in the engine rear oil seal at an angle.
      • Do not tap in the engine rear oil seal more than necessary.
      • Do not deform the engine rear oil seal.
  5. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Apply MP grease to the lip of the engine rear oil seal.
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY673497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Packing

      Seal packing

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

      Seal diameter

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the engine rear oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    3. Apply adhesive 1324 to the 2 bolts A.
      GTY469891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Tighten the bolts within 3 minute after applying adhesive.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the engine rear oil seal retainer with the 6 bolts.

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

      NOTE:
      • Thoroughly wipe clean any seal packing.
      • Do not add engine oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
  6. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY 
    1. Install the water outlet pipe sub-assembly with the 2 bolts.

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

  7. INSTALL CYLINDER BLOCK WATER JACKET SPACER RH 
    1. Install the cylinder block water jacket spacer RH as shown in the illustration.
      GTY462475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL CYLINDER BLOCK WATER JACKET SPACER LH 
    1. Install the cylinder block water jacket spacer LH as shown in the illustration.
      GTY462476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  10. INSTALL NO. 5 ENGINE WIRE 
    1. Install the No. 5 engine wire with the clamp.
  11. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1

  12. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  13. INSTALL NO. 2 CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 3

  14. INSTALL CYLINDER HEAD LH 

    Refer to PROCEDURE - Step 4

  15. INSTALL VALVE STEM CAP 

    Refer to PROCEDURE - Step 11

  16. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 12

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

    Refer to PROCEDURE - Step 13

  18. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 16

  19. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 17

  20. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 

    Refer to PROCEDURE - Step 18

  21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 19

  22. INSTALL CAMSHAFT 

    Refer to PROCEDURE - Step 20

  23. INSTALL NO. 2 CAMSHAFT 

    Refer to PROCEDURE - Step 21

  24. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 

    Refer to PROCEDURE - Step 22

  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 23

  26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 26

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

    Refer to PROCEDURE - Step 27

  28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 24

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

    Refer to PROCEDURE - Step 25

  30. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

      Torque: 22.5 N.m (229 kgf/cm, 17 ft.lbf) 

  31. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 No. 2 chain vibration dampers.
  32. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Install the 2 crankshaft timing gear keys to the crankshaft.
  33. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Install the crankshaft timeng gear or sprocket to the crankshaft.
  34. INSTALL IDLE SPROCKET ASSEMBLY 
    1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
      GTY465384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Idle Gear Shaft
      *2 No. 2 Idle Gear Shaft
      *3 Idle Sprocket Assembly
      *4 Knock Pin
      Apply Engine Oil
    2. Temporarily install the No. 1 idle gear shaft and idle sprocket assembly with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block sub-assembly.
      NOTE:

      Make sure that the idle sprocket assembly is facing the correct direction.

      HINT: 

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

    3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

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

      HINT: 

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

  35. INSTALL CHAIN SUB-ASSEMBLY 
    1. Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly.
      GTY468202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Mark Plate (Orange)
      *2 Timing Mark

      HINT: 

      The camshaft mark plates are orange.

    2. Rest the chain sub-assembly on top of the crankshaft.
      GTY467456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain sub-assembly between the banks.
      GTY459635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inner Chain Plate
      *2 Outer Chain Plate
      *a Chain sub-assembly between banks
      *b When idle sprocket assembly is reused
      *c Mark
      Turn
      NOTE:

      When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain sub-assembly between the banks.

    4. Align the mark plate and timing mark as shown in the illustration and install the chain sub-assembly onto the crankshaft timeng gear or sprocket.
      GTY464828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Mark Plate (Yellow)
      *2 Timing Mark

      HINT: 

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the crankshaft pulley set bolt.
    6. Turn the crankshaft clockwise to set the timing mark to the bank 1 cylinder block bore center line (TDC/compression).
      GTY461467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Mark
      *a Bank 1 Cylinder block Bore Center Line (TDC/compression)
      Turn
  36. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
      GTY465992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Stopper Plate
      *2 Plunger
      *3 Hexagon Wrench
      *a Move Stopper Plate upward
      *b Move Stopper Plate downward
    2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
    3. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.
  38. INSPECT VALVE TIMING 
    1. Check the camshaft timing marks.
      NOTE:
      • Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.
      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
    2. Check that each camshaft timing mark is positioned as shown in the illustration.
      GTY468526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Mark - -
      *a Viewpoint - -

      HINT: 

      For the intake camshaft:

      Be sure to check mark A at the point when marks B, C, and D are positioned in line.

      GTY470127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the marks are checked from any other viewpoint, they cannot be checked correctly.

    3. If the valve timing is misaligned, reinstall the chain sub-assembly.
    4. Remove the crankshaft pulley set bolt.
  39. INSTALL ENGINE WATER PUMP ASSEMBLY 
    1. Install a new water pump gasket and the engine water pump assembly with the 7 bolts.
      GTY469195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 11 N.m (112 kgf/cm, 8 ft.lbf) 

      NOTE:
      • Be sure to replace the 2 bolts (A) with new ones or reuse them after applying adhesive.
      • Tighten the bolts within 3 minute after applying adhesive.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  40. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  41. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 

    Refer to PROCEDURE - Step 1

  42. INSTALL TIMING CHAIN COVER PLATE 

    Refer to PROCEDURE - Step 13

  43. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. for 2WD:
      1. Temporarily install the No. 1 oil pan baffle plate with the 8 bolts.
        GTY461686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Tighten the 2 bolts A shown in the illustration.

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

      3. Tighten the other 6 bolt.

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

    2. for AWD:
      1. Temporarily install the No. 1 oil pan baffle plate with the 7 bolts.
        GTY457161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Tighten the 2 bolts A shown in the illustration.

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

      3. Tighten the other 5 bolt.

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

  44. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. for 2WD:
      1. Install a new oil strainer gasket and the oil strainer sub-assembly with the 3 nuts.

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

    2. for AWD:
      1. Install a new oil strainer gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

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

  45. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Install 2 new O-rings.
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY466122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for 2WD
      *B for AWD
      *a Seal Packing

      Seal packing

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

      Seal diameter

      3.0 to 4.0 mm (0.118 to 0.156 in.)

      NOTE:
      • Check the bolts and bolt holes and clean them.
      • Remove any oil from the contact surface.
      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
      • Do not add engine oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
    3. for 2WD:
      1. Install the oil pan sub-assembly and temporarily tighten the 16 bolts and 2 nuts in several steps.
        Fig 1: Oil Pan Sub-Assembly Temporary Tightening Sequence - 2WD
        GTY460587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
        STANDARD BOLT:

        Item Length
        Bolt A 25 mm (0.984 in.)
        Bolt B 45 mm (1.77 in.)
        Bolt C 16 mm (0.630 in.)
      2. Tighten the 16 bolts and 2 nuts in the order shown in the illustration.

        for bolt A, B and nut 

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

        for bolt C 

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

        Fig 2: Oil Pan Sub-Assembly Tightening Sequence - 2WD
        GTY469498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
    4. for AWD:
      1. Install the oil pan sub-assembly and temporarily tighten the 16 bolts and 2 nuts in several steps.

        HINT: 

        STANDARD BOLT:

        Item Length
        Bolt A 25 mm (0.984 in.)
        Bolt B 45 mm (1.77 in.)
        Bolt C 93 mm (3.66 in.)
        Bolt D 16 mm (0.630 in.)
        Fig 3: Oil Pan Sub-Assembly Temporary Tightening Sequence - AWD
        GTY466196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
      2. Tighten the 16 bolts and 2 nuts in the order shown in the illustration.

        for bolt A, B, C and nut 

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

        for bolt D 

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

        Fig 4: Oil Pan Sub-Assembly Tightening Sequence - AWD
        GTY470724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
  46. INSTALL OIL STRAINER WITH PIPE SUB-ASSEMBLY (for AWD) 
    1. Install a new oil strainer gasket and the oil strainer with pipe sub-assembly with the 3 nuts.

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

  47. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY460147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for 2WD
      *B for AWD
      *a Seal Packing

      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:
      • Check the bolts and bolt holes and clean them.
      • Remove any oil from the contact surface.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
      • Do not add engine oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
    2. for 2WD:
      1. Install the No. 2 oil pan sub-assembly and tighten the 15 bolts and 2 nuts in several steps in the order shown in the illustration.
        Fig 5: No. 2 Oil Pan Sub-Assembly Bolts And Nuts Tightening Sequence (2WD)
        GTY517313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut

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

    3. for AWD:
      1. Install the No. 2 oil pan sub-assembly and tighten the 14 bolts and 2 nuts in several steps in the order shown in the illustration.

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

        Fig 6: No. 2 Oil Pan Sub-Assembly Bolts And Nuts Tightening Sequence (AWD)
        GTY511976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
  48. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug.

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

  49. INSTALL SPARK PLUG TUBE GASKET 
    1. Using a cutter, cut off the sealing part of the removed spark plug tube gasket.
      GTY463658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Before cutting off
      *b After cutting off
      Area to be cut off
    2. Using a spark plug tube gasket which has had the sealing part cut off, uniformly press in a new spark plug tube gasket all the way.
      GTY458718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Spark Plug Tube Gasket without Sealing Part
      *2 New Spark Plug Tube Gasket
      *3 Claw
      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap in the spark plug tube gasket at an angle.

      HINT: 

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

    3. Return the claws of the ventilation baffle plate to their original positions.
  50. POUR ENGINE OIL 

    HINT: 

    Before installing the cylinder head cover sub-assemblies, pour engine oil into the locations shown in the illustration.

    GTY101239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Apply seal packing as shown in the illustration.
      GTY469076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 timing chain cover sub-assembly
      *2 camshaft housing sub-assembly RH
      *a 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *b 5.0 to 10.0 mm (0.197 to 0.394 in.)
      Seal Packing

      Seal packing

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      • Do not add engine oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
    2. Install 3 new gaskets to the No. 1, No. 2 and No. 7 camshaft bearing caps.
    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
    4. Apply adhesive 1324 to the threads of the 11 bolts indicated by the black arrows in the illustration.
      GTY462888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt with cylinder head cover seal washer
      Apply adhesive 1324 to these bolts

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      Tighten the bolts within 3 minute after applying adhesive.

    5. Install the cylinder head cover sub-assembly and 2 new seal washers with the 14 bolts.

      for bolt A 

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

      except bolt A 

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

  52. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Apply seal packing as shown in the illustration.
      GTY461469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 timing chain cover sub-assembly
      *2 camshaft housing sub-assembly LH
      *a 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *b 5.0 to 10.0 mm (0.197 to 0.394 in.)
      Seal Packing

      Seal packing

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      • Do not add engine oil for at least 2 hours after installation.
      • Do not start the engine for at least 2 hours after installation.
    2. Install 3 new gaskets to the No. 3, No. 4 and No. 7 camshaft bearing caps.
    3. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.
    4. Apply adhesive 1324 to the threads of the 10 bolts indicated by the black arrows in the illustration.
      GTY457648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt with cylinder head cover seal washer
      Apply adhesive 1324 to these bolts

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      Tighten the bolts within 3 minute after applying adhesive.

    5. Install the cylinder head cover sub-assembly LH and a new seal washer with the 12 bolts.

      for bolt A 

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

      except bolt A 

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

  53. INSTALL REAR WATER BY-PASS JOINT 
    1. Install 2 new water outlet gaskets and a new water outlet pipe O-ring.

      HINT: 

      Apply water to the water outlet pipe O-ring.

    2. Install the rear 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 water outlet pipe O-ring does not get caught between the parts.

  54. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT 
    1. Install a new No. 1 water inlet housing gasket and water inlet sub-assembly with thermostat with the 3 nuts.

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

  55. INSTALL WATER INLET SUB-ASSEMBLY 
    1. Connect the No. 3, No. 4 and No. 6 water by-pass hoses on engine side.
      GTY460380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 4 Water By-pass Hose
      *2 No. 6 Water By-pass Hose
      *3 No. 3 Water By-pass Hose
      *a RH Side

      HINT: 

      • Install the water by-pass hoses so that the paint marks are positioned on the cylinder head side.
      • Attach the No. 4 water by-pass hose clamp as shown in the illustration.
    2. Install a new No. 1 water inlet housing gasket and water outlet pipe O-ring.
    3. Install the water inlet sub-assembly with the 4 bolts and nut.

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

      NOTE:

      Be careful not to allow the No. 1 water inlet housing gasket and water outlet pipe O-ring to get caught between the parts.

    4. Connect the No. 3, No. 4 and No. 6 water by-pass hoses to the water inlet sub-assembly.
  56. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 3

  57. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for AWD) 
    1. Install a new gasket.
    2. Install the oil filter bracket sub-assembly with the bolt and 2 nuts.

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

  58. INSTALL OIL FILTER CAP ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 6

  59. INSTALL OIL FILTER CAP ASSEMBLY (for 2WD) 

    Refer to PROCEDURE - Step 5

  60. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  61. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads at the end of the cylinder block water drain cock sub-assembly.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      GTY467076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Adhesive
      NOTE:

      Install the cylinder block water drain cock sub-assembly within 3 minutes after applying adhesive.

    2. Install the cylinder block water drain cock sub-assemblies as shown in the illustration.
      GTY465353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 1
      *b for Bank 2

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

      NOTE:
      • Do not rotate the cylinder block water drain cock sub-assembly by more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assembly to the specified torque.
      • Do not loosen the cylinder block water drain cock sub-assembly after setting it correctly.
    3. Install the 2 water drain cock plugs to the 2 cylinder block water drain cock sub-assemblies.

      Torque: 12.7 N.m (130 kgf/cm, 9 ft.lbf) 

  62. INSTALL NO. 1 OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
      NOTE:

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

    2. Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe on the cylinder head cover sub-assembly LH side.
      GTY456939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pipe Union
      *2 Oil Check Valve Bolt
    3. Install a new gasket and temporarily install the No. 1 oil pipe on the cylinder head LH side with the oil check valve bolt.
    4. Tighten the oil pipe union on the cylinder head cover sub-assembly LH side.

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

    5. Tighten the oil check valve bolt on the cylinder head LH 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.

  63. 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 RH.

    2. Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 2 oil pipe on the cylinder head cover sub-assembly side.
      GTY465885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pipe Union
      *2 Oil Check Valve Bolt
    3. Install a new gasket and temporarily install the No. 2 oil pipe on the cylinder head sub-assembly side with the oil check valve bolt.
    4. Tighten the oil pipe union on the cylinder head cover sub-assembly side.

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

    5. Tighten the oil check valve bolt on the cylinder head sub-assembly 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.

  64. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  65. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  66. INSTALL ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 1

  67. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 2

  68. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 1

  69. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  70. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 4

  71. INSTALL VVT SENSOR (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 1

  72. INSTALL VVT SENSOR (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 2

  73. INSTALL VVT SENSOR (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  74. INSTALL VVT SENSOR (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 4

  75. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 1

  76. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  77. INSTALL RADIATOR CAP SUB-ASSEMBLY 
    1. Install the radiator cap sub-assembly.
  78. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install a new gasket.
    2. Install the oil filler cap sub-assembly.
  79. INSTALL FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 1

  80. INSTALL FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  81. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  82. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

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