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Reassembly [11/2021 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus IS 500, 2023 Lexus IS 500, and 2022 Lexus IS 500. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.

    1. Using a plastic-faced hammer, tap in 6 new straight pins to the timing chain cover assembly.
      GTY1084141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Protrusion Height

      5.5 to 6.5 mm (0.217 to 0.256 in.)

  2. INSTALL RING PIN 
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.

    1. Using a plastic-faced hammer, tap in new ring pins to the timing chain cover assembly.
      GTY511305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Protrusion Height

      Item Specified Condition
      Ring Pin (A) 7.5 to 8.5 mm (0.295 to 0.335 in.)
      Ring Pin (B) 3.6 to 4.6 mm (0.142 to 0.181 in.)
  3. INSTALL STUD BOLT 
    NOTE:

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

    1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the oil pan sub-assembly.

      Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

      GTY504545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the timing chain cover assembly.

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

      GTY1084295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the oil drain pipe sub-assembly.
    3. Install the oil drain pipe sub-assembly with the bolt.

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

      GTY505935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL ENGINE REAR OIL SEAL 
    1. Apply MP grease to the lip of a new engine rear oil seal.
    2. Place the engine rear oil seal retainer on wooden blocks.
    3. Using SST and a hammer, tap in the engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge.
      GTY465486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Standard Depth
      • SST: 09223-1503009950-70010 
        1. 09951-07100

      Standard Depth

      -1.0 to 0 mm (-0.0394 to 0 in.)

      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap in the engine rear oil seal at an angle.
  6. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY508181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Packing Diameter

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      Application Position from Inside Edge of Engine Rear Oil Seal Retainer

      3.5 mm (0.138 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the engine rear oil seal retainer within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
    2. Install the engine rear oil seal retainer with the 6 bolts.

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

      GTY496704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the oil strainer sub-assembly.
    3. Install the oil strainer sub-assembly with the 2 bolts.

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

      NOTE:

      Make sure that the O-ring is not twisted or damaged.

      GTY517320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. Install the No. 1 oil pan baffle plate with the 8 bolts.

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

      GTY499825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY1082725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Packing Diameter

      2.8 to 3.8 mm (0.110 to 0.150 in.)

      Application Position from Inside Edge of Oil Pan Sub-assembly

      6.0 mm (0.236 in.)

      NOTE:
      • Check and clean the bolts and bolt holes.
      • Remove any oil from the contact surfaces.
      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of 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 the oil pan sub-assembly with the 14 bolts and 2 nuts.
      GTY515098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut

      Bolt (A) 

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

      Bolt (B) 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      Nut 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

  10. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY504218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Packing Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      NOTE:
      • Check and clean the bolts and bolt holes.
      • Remove any oil from the contact surfaces.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      • Do not add engine oil for at least 2 hours after installation.
    2. Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts.

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

      GTY509328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
  11. INSTALL VENTILATION PIPE GASKET 
    1. Using SST and a hammer, evenly tap in a new ventilation pipe gasket until its surface is flush with the edge of the ventilation pipe gasket.
      • SST: 09950-6001009950-70010 

      HINT: 

      • Do not tap in the ventilation pipe gasket at an angle.
      • Do not tap in the ventilation pipe gasket excessively.
      GTY517594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL HEAT EXCHANGER ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.

      Seal Packing

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

      Standard Seal Packing Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      NOTE:

      Remove any oil from the contact surfaces.

      GTY510051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the heat exchanger assembly with the 11 bolts and 2 nuts.

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

      NOTE:
      • Install the heat exchanger assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      GTY496647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
    3. Install the oil return pipe sub-assembly with the bolt.

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

      GTY502453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the 2 cylinder block water jacket spacers to the cylinder block sub-assembly as shown in the illustration.

      HINT: 

      • Face the cutouts away from the center of the engine.
      • Face each UP mark as shown in the illustration.
      GTY518101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a UP Mark
  14. INSTALL NO. 2 CYLINDER HEAD GASKET 

    See step  4

  15. INSTALL CYLINDER HEAD LH 

    See step  5

  16. INSTALL CYLINDER HEAD GASKET 

    See step  2

  17. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    See step  3

  18. INSTALL CYLINDER HEAD VALVE ROCKER ARM PIVOT RH 
    1. Install the 16 cylinder head valve rocker arm pivots RH to the cylinder head sub-assembly.

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

  19. INSTALL CYLINDER HEAD VALVE ROCKER ARM PIVOT LH 
    1. Install the 16 cylinder head valve rocker arm pivots LH to the cylinder head LH.

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

  20. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the cylinder head valve rocker arm pivots and valve adjusting shims.
    2. Install the 32 No. 1 valve rocker arm sub-assemblies to the cylinder head LH and cylinder head sub-assembly.
    3. Make sure that the 32 No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY1084013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Valve Adjusting Shim
      *2 Cylinder Head Valve Rocker Arm Pivot
  21. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 

    See step  5

  22. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 

    See step  6

  23. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 

    See step  7

  24. INSTALL CAMSHAFT 

    See step  1

  25. INSTALL NO. 2 CAMSHAFT 

    See step  2

  26. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 

    See step  3

  27. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Install the 2 crankshaft timing gear keys.
      GTY502486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the crankshaft pulley set bolt, and set the crankshaft timing gear key in the position as shown in the illustration.
      GTY511187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
    3. Remove the crankshaft pulley set bolt.
  28. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 2 chain tensioner assembly with the 2 bolts.

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

      GTY506268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Push
      *b Plunger
      *c Pin
    2. While pushing up the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to secure it in place.
  29. INSTALL NO. 1 CHAIN SUB-ASSEMBLY (for Bank 2) 

    HINT: 

    The crankshaft timing gear, camshaft timing intake gear assembly RH and camshaft timing exhaust gear assembly RH will be installed with the No. 1 chain sub-assembly and No. 2 chain sub-assembly attached to the gears.

    1. Align the mark plates (pink) of the No. 1 chain sub-assembly with the timing mark of the camshaft timing intake gear assembly RH, and attach the chain to the gear as shown in the illustration.
      GTY505851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    2. Align the mark plate (pink) of the No. 1 chain sub-assembly with the timing mark of the crankshaft timing gear, and attach the chain to the gear as shown in the illustration.
      GTY504567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    3. Align the mark plates (yellow) of the No. 2 chain sub-assembly with the timing marks of the camshaft timing intake gear assembly RH and camshaft timing exhaust gear assembly RH, and attach the No. 2 chain sub-assembly to the gears as shown in the illustration.
      GTY505423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    4. Install the crankshaft timing gear to the crankshaft.
    5. Align and fit the knock pin of the camshaft to the pin hole of the camshaft timing intake gear assembly RH.
    6. Using a wrench, hold the hexagonal portion of the No. 2 camshaft, align and fit the knock pin of the No. 2 camshaft to the pin hole of the camshaft timing exhaust gear assembly RH.
      NOTE:

      Because the timing mark positions of the gears may shift due to looseness of the No. 1 chain sub-assembly, using a wrench, hold the hexagonal portion of the camshaft to hold the No. 2 camshaft in place until the No. 1 chain tensioner assembly RH is installed.

    7. Remove the pin from the No. 2 chain tensioner assembly.
  30. INSTALL CHAIN VIBRATION DAMPER RH 
    1. Install the chain vibration damper RH with the 2 bolts.

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

      GTY499770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL CHAIN TENSIONER SLIPPER RH 
    1. Install the chain tensioner slipper RH.

      HINT: 

      If it is difficult to install the chain tensioner slipper RH due to the tension of the No. 1 chain sub-assembly, using a wrench, hold the hexagonal portion of the camshaft to loosen the No. 1 chain sub-assembly, and then install the chain tensioner slipper RH.

      GTY499801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH 
    1. Turn the stopper plate clockwise to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly RH.
      GTY498053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Stopper Plate
      *c Plunger
    2. Turn the stopper plate counterclockwise to set the lock, and insert a pin of 1.0 mm (0.0394 in.) diameter into the stopper plate hole.
    3. Install the No. 1 chain tensioner assembly RH with the 2 bolts.

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

      GTY498147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the pin from the No. 1 chain tensioner assembly RH.
  33. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 3 chain tensioner assembly with the 2 bolts.

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

      GTY520816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Plunger
      *c Push
    2. While fully pushing the plunger into the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to secure it in place.
  34. INSTALL NO. 1 CHAIN SUB-ASSEMBLY (for Bank 1) 

    HINT: 

    The crankshaft timing sprocket LH, camshaft timing intake gear assembly LH and camshaft timing exhaust gear assembly LH will be installed with the No. 1 chain sub-assembly and No. 2 chain sub-assembly attached to the gears.

    1. Align the mark plates (pink) of the No. 1 chain sub-assembly with the timing mark of the camshaft timing intake gear assembly LH, and attach the chain to the gear as shown in the illustration.
      GTY511283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    2. Align the mark plate (pink) of the No. 1 chain sub-assembly with the timing mark of the crankshaft timing sprocket LH, and attach the chain to the gear as shown in the illustration.
      GTY502493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    3. Align the mark plates (yellow) of the No. 2 chain sub-assembly with the timing marks of the camshaft timing intake gear assembly LH and camshaft timing exhaust gear assembly LH, and attach the No. 2 chain sub-assembly to the gears as shown in the illustration.
      GTY503281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    4. Install the crankshaft timing sprocket LH to the crankshaft.
    5. Align and fit the knock pin of the No. 3 camshaft sub-assembly to the pin hole of the camshaft timing intake gear assembly LH.
    6. Using a wrench, hold the hexagonal portion of the No. 4 camshaft sub-assembly, align and fit the knock pin of the No. 4 camshaft sub-assembly with the pin hole of the camshaft timing exhaust gear assembly LH.
      NOTE:

      Because the timing mark positions of the gears may shift due to looseness of the No. 1 chain sub-assembly, using a wrench, hold the hexagonal portion of the No. 4 camshaft sub-assembly to hold the No. 3 camshaft sub-assembly in place until the No. 1 chain tensioner assembly LH is installed.

    7. Remove the pin from the No. 3 chain tensioner assembly.
  35. INSTALL CHAIN VIBRATION DAMPER LH 
    1. Install the chain vibration damper LH with the 2 bolts.

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

      GTY518598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL CHAIN TENSIONER SLIPPER LH 
    1. Install the chain tensioner slipper LH.

      HINT: 

      If it is difficult to install the chain tensioner slipper LH due to the tension of the No. 1 chain sub-assembly, using a wrench, hold the hexagonal portion of the No. 3 camshaft sub-assembly to loosen the No. 1 chain sub-assembly and install the chain tensioner slipper LH.

      GTY518001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH 
    1. Turn the stopper plate clockwise to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly LH.
      GTY498052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Stopper Plate
      *c Plunger
    2. Turn the stopper plate counterclockwise to set the lock, and insert a pin of 1.0 mm (0.0394 in.) diameter into the stopper plate hole.
    3. Install a new chain tensioner gasket and the No. 1 chain tensioner assembly LH with the 2 bolts.

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

      GTY496687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the pin from the No. 1 chain tensioner assembly LH.
  38. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1) 
    1. Using a wrench, hold the hexagonal portion of the No. 3 camshaft sub-assembly.
    2. Using a 12 mm hexagon socket wrench, tighten a new bolt of the camshaft timing intake gear assembly LH.
      GTY500773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold

      Torque: 79 N.m (806 kgf/cm, 58 ft.lbf) 

    3. Using a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly, tighten the bolt of the camshaft timing exhaust gear assembly LH.

      Torque: 100 N.m (1020 kgf/cm, 74 ft.lbf) 

      GTY520443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
  39. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 2) 
    1. Using a wrench, hold the hexagonal portion of the camshaft.
    2. Using a 12 mm hexagon socket wrench, tighten a new bolt of the camshaft timing intake gear assembly RH.

      Torque: 79 N.m (806 kgf/cm, 58 ft.lbf) 

      GTY514244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
    3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt of the camshaft timing exhaust gear assembly RH.

      Torque: 100 N.m (1020 kgf/cm, 74 ft.lbf) 

      GTY496054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
  40. INSPECT NO. 1 CYLINDER TO TDC / COMPRESSION 
    1. Temporarily install the crankshaft pulley set bolt.
    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket LH, camshaft timing intake gear assembly LH, camshaft timing intake gear assembly RH, camshaft timing exhaust gear assembly LH and camshaft timing exhaust gear assembly RH are as shown in the illustration.
      GTY1084005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b Timing Mark Position
      *c Knock Pin Position *d Approximately 2°
      *e Approximately 45° *f Approximately 16°
      *g Upward *h Approximately 20°
      *i Approximately 33° *j Crankshaft Timing Gear Key
    3. Remove the crankshaft pulley set bolt.
  41. INSPECT VALVE CLEARANCE 

    See step  9

  42. ADJUST VALVE CLEARANCE 

    See step  10

  43. INSTALL OIL REFLECTOR PLATE LH 
    1. Install the oil reflector plate LH to the cylinder head LH with the 2 bolts.

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

  44. INSTALL OIL REFLECTOR PLATE RH 
    1. Install the oil reflector plate RH to the cylinder head sub-assembly with the 2 bolts.

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

  45. INSTALL SCAVENGING PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  46. INSTALL NO. 3 OIL PIPE 

    Refer to PROCEDURE - Step 2

  47. INSTALL NO. 2 OIL PIPE 

    Refer to PROCEDURE - Step 3

  48. INSTALL NO. 1 OIL PIPE 

    Refer to PROCEDURE - Step 4

  49. INSTALL INLET WATER PIPE 
    1. Apply soapy water to 2 new O-rings and install them to the inlet water pipe.
    2. Install the inlet water pipe to the heat exchanger assembly.
  50. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 

    See step  1

  51. INSTALL OIL PUMP RELIEF VALVE PLUG 
    1. Install a new gasket and oil pump relief valve plug to the timing chain cover assembly.
      GTY947608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 46 N.m (469 kgf/cm, 34 ft.lbf) 

  52. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 7

  53. INSTALL ENGINE WATER PUMP ASSEMBLY 
    1. Install a new water pump gasket and the engine water pump assembly to the timing chain cover assembly with the 5 bolts.
      GTY502467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  54. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Install the V-ribbed belt tensioner assembly with the bolt and 6 mm hexagon bolt.

      Torque: 23 N.m (235 kgf/cm, 17 ft.lbf) 

  55. INSTALL OIL CONTROL VALVE FILTER LH 
    1. Install the oil control valve filter LH to the cylinder head cover spacer LH.
    2. Install a new gasket and the cylinder head cover spacer LH with the 2 bolts.

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

      GTY1082722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Control Valve Filter LH
      *2 Gasket
      *3 Cylinder Head Cover Spacer LH
  56. INSTALL OIL CONTROL VALVE FILTER RH 
    1. Install the oil control valve filter RH to the cylinder head cover spacer RH.
    2. Install a new gasket and the cylinder head cover spacer RH with the 2 bolts.

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

      GTY1082711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Control Valve Filter RH
      *2 Gasket
      *3 Cylinder Head Cover Spacer RH
  57. INSTALL SPARK PLUG TUBE GASKET 
    1. Install 8 new spark plug tube gaskets to the cylinder head LH and cylinder head sub-assembly.
      NOTE:
      • Make sure to install the spark plug tube gaskets in the correct orientation.
      • Push in each spark plug tube gasket until its bottom surface contacts the cylinder head LH and cylinder head sub-assembly.
      GTY509726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bottom
  58. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.
      GTY502575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.
      NOTE:

      Remove any oil from the contact surfaces.

    3. Apply seal packing as shown in the illustration.

      Seal Packing

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

      Standard Seal Packing Diameter

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly LH.
      GTY508104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Seal Packing
    4. Install the cylinder head cover sub-assembly LH with 3 new seal washers and the 16 bolts in the order shown in the illustration.

      Bolt (A) 

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

      except Bolt (A) 

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

      Fig 1: Cylinder Head Cover Sub-Assembly LH Bolts Tightening Sequence
      GTY1084015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install a new fuel pump spacer gasket.
  59. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.
    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
      NOTE:

      Remove any oil from the contact surfaces.

    3. Apply seal packing as shown in the illustration.

      Seal Packing

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

      Standard Seal Packing Diameter

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly.
      GTY515500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Seal Packing
    4. Install the cylinder head cover sub-assembly with 3 new seal washers and the 16 bolts in the order shown in the illustration.

      Bolt (A) 

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

      except Bolt (A) 

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

      Fig 2: Cylinder Head Cover Sub-Assembly Bolts Tightening Sequence
      GTY1084003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install a new fuel pump spacer gasket.
  60. INSTALL V-BANK COVER BOLT (for Bank 1) 
    1. Install the V-bank cover bolt to the cylinder head cover sub-assembly LH.

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

      GTY502572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL V-BANK COVER BOLT (for Bank 2) 
    1. Install the V-bank cover bolt to the cylinder head cover sub-assembly.

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

      GTY499788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL CRANKSHAFT PULLEY 

    See step  3

  63. INSTALL OIL FILTER BRACKET 
    1. Install 2 new gaskets to the timing chain cover assembly.
      GTY796107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Install the oil filter bracket with the 2 bolts and 2 nuts.

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

    3. Install the oil filter bracket stay with the 2 bolts.

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

      GTY795660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  65. INSTALL OIL FILTER CAP ASSEMBLY 
    1. Clean the inside of the oil filter cap assembly, the threads and O-ring groove.
      GTY514981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Filter Element
      *2 O-Ring
      *3 Oil Filter Cap Assembly
    2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap assembly.
    3. Install a new oil filter element to the oil filter cap assembly.
    4. Remove any dirt and foreign matter from the installation surface of the oil filter bracket.
    5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap assembly.
    6. Using SST, tighten the oil filter cap assembly.
      • SST: 09228-06502 

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

      NOTE:
      • Make sure that the oil filter cap assembly is installed securely as shown in the illustration.
      • Make sure that the O-ring does not get caught between the parts.
      GTY515700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No Clearance
  66. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the cylinder block water drain cock sub-assembly.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      GTY514662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive
    2. Install each cylinder block water drain cock sub-assembly to the cylinder block sub-assembly as shown in the illustration.

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

      NOTE:
      • Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening to the specified torque.
      • Do not loosen the cylinder block water drain cock sub-assembly to adjust it. If an adjustment is necessary, remove the cylinder block water drain cock sub-assembly and reinstall it.
      GTY1082707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 2
      *b for Bank 1
    3. Install each cylinder block water drain cock plug to each cylinder block water drain cock sub-assembly.

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

  67. INSTALL FRONT WATER BY-PASS JOINT 
    1. Install the front water by-pass joint and 2 new gaskets with the 4 nuts.

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

  68. INSTALL CAMSHAFT TIMING CONTROL MOTOR WITH EDU ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  69. INSTALL CAMSHAFT TIMING CONTROL MOTOR WITH EDU ASSEMBLY RH 

    Refer to PROCEDURE - Step 1

  70. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH 

    Refer to PROCEDURE - Step 4

  71. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH 

    Refer to PROCEDURE - Step 1

  72. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  73. INSTALL CAMSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 7

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

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 3

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

    Refer to PROCEDURE - Step 6

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

    Refer to PROCEDURE - Step 5

  78. INSTALL OIL PAN DRAIN PLUG 
    1. Install the oil pan drain plug and a new gasket to the No. 2 oil pan sub-assembly.

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

  79. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  80. INSTALL OIL FILLER CAP HOUSING 
    1. Align the protrusion of a new oil filler cap housing gasket with the cutout of the oil filler cap housing, and install the oil filler cap housing gasket to the oil filler cap housing.
      GTY1082715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Install the oil filler cap housing with the 2 bolts.
      GTY502609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  81. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install a new oil filler cap gasket to the oil filler cap sub-assembly.
    2. Install the oil filler cap sub-assembly to the oil filler cap housing.
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