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Reassembly [10/2017 - ]: Procedure

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  1. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

    It is not necessary to remove a camshaft bearing cap setting ring pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in 20 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

      Standard protrusion height

      2.7 to 3.3 mm (0.106 to 0.130 in.)

      GTY777615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 2 *b for Bank 1
      *c Protrusion Height - -
  2. INSTALL STRAIGHT PIN 
    NOTE:

    It is not necessary to remove a straight pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing sub-assembly.

      Standard protrusion height

      7.7 to 8.3 mm (0.303 to 0.327 in.)

      GTY818592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 2 *b for Bank 1
      *c Protrusion Height - -
  3. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the 2 cylinder block water jacket spacers as shown in the illustration.
      GTY804690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front Side
  4. INSTALL REAR ENGINE OIL SEAL 
    1. Place the rear engine oil seal retainer on wooden blocks.
    2. Using SST, tap in a new rear engine oil seal until its surface is flush with the rear engine oil seal retainer edge.
      GTY803435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-15030 
      • SST: 09950-70010 
        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 on the rear engine oil seal at an angle.
  5. INSTALL REAR ENGINE OIL SEAL RETAINER 
    1. Apply MP grease to the lip of the rear engine oil seal.
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY783260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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 0.1181 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the rear engine oil seal retainer within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    3. Install the rear engine oil seal retainer with the 6 new bolts.
      GTY540193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:
      • Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.
      • Install the bolt within 3 minutes after applying adhesive.
  6. INSTALL NO. 1 WATER OUTLET PIPE 
    1. Install the No. 1 water outlet pipe with the 2 bolts.

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

      GTY616802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  8. INSTALL NO. 5 ENGINE WIRE 
    1. Install the No. 5 engine wire with the 2 clamps.
      GTY814103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 connectors.
  9. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1

  10. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  11. INSTALL NO. 2 CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 3

  12. INSTALL CYLINDER HEAD LH 

    Refer to PROCEDURE - Step 4

  13. INSTALL VALVE STEM CAP 

    Refer to PROCEDURE - Step 11

  14. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 12

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

    Refer to PROCEDURE - Step 13

  16. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET LH 
    1. Install the camshaft bearing cap oil hole gasket LH to the No. 6 camshaft bearing cap.
      GTY616796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET RH 
    1. Install the camshaft bearing cap oil hole gasket RH to the No. 7 camshaft bearing cap.
      GTY673434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL OIL CONTROL VALVE FILTER (for Bank 1) 
    1. Install the 2 oil control valve filters to the No. 1 and No. 2 camshaft bearing caps.
      GTY789238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Camshaft Installation Surface
      NOTE:

      Make sure the oil control valve filter does not protrude past the camshaft installation surface shown in the illustration.

  19. INSTALL OIL CONTROL VALVE FILTER (for Bank 2) 

    HINT: 

    Use the same procedure described for the Bank 1.

  20. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 16

  21. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 17

  22. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 

    Refer to PROCEDURE - Step 18

  23. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 19

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

    Refer to PROCEDURE - Step 20

  25. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 21

  26. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 22

  27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 23

  28. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 2) 

    Refer to PROCEDURE - Step 24

  29. INSTALL CAMSHAFT 

    Refer to PROCEDURE - Step 25

  30. INSTALL NO. 2 CAMSHAFT 

    Refer to PROCEDURE - Step 26

  31. INSTALL FUEL PUMP LIFTER HOUSING 

    Refer to PROCEDURE - Step 27

  32. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 

    Refer to PROCEDURE - Step 28

  33. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 29

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

    Refer to PROCEDURE - Step 30

  35. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 31

  36. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 32

  37. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 33

  38. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 1) 

    Refer to PROCEDURE - Step 24

  39. 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) 

      GTY616783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 No. 2 chain vibration dampers.
      GTY616791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Install the 2 timing gear set keys and crankshaft timing gear or sprocket to the crankshaft.
      GTY835822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL IDLE SPROCKET ASSEMBLY 
    1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
      GTY831878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Idle Gear Shaft
      *2 Idle Sprocket Assembly
      *3 No. 2 Idle Gear Shaft
      *a 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.
      NOTE:

      Make sure that the idle gear 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 turns smoothly.

  43. INSTALL CHAIN SUB-ASSEMBLY 
    1. Check that the camshaft timing gear position on the bank 2 and the timing marks on the bank 1 and crankshaft are positioned as shown in the illustration.
      GTY821067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b Center Line
      *c Timing Gear Set Key *d Flat Surface

      HINT: 

      The flat surface on the camshaft timing exhaust gear assembly must be positioned as shown in the illustration.

    2. Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly.
      GTY818881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Yellow)
      *b Timing Mark

      HINT: 

      The camshaft mark plates are yellow.

    3. Rest the chain sub-assembly on top of the crankshaft.
      GTY616778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the camshaft timing gear assembly on the bank 2 counterclockwise to tighten the chain sub-assembly between the banks.
      GTY824825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a When idle sprocket is reused
      *b Mark
      *c Align
      *d Chain Plate
      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.

    5. Align the mark plate and timing mark as shown in the illustration and install the chain sub-assembly onto the crankshaft timing gear or sprocket.
      GTY805006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Pink)
      *b Timing Mark

      HINT: 

      The crankshaft mark plate is pink.

    6. Temporarily install the crankshaft pulley set bolt.
    7. Turn the crankshaft clockwise 10° to set it to the bank 2 block bore center line (TDC/compression).
      GTY777137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Gear Set Key
      *b Center Line
      *c 10°
  44. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
  45. 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.
      GTY798875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper Plate
      *b Plunger
    2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.0500 in.) diameter 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 lock pin of the No. 1 chain tensioner assembly.
  46. INSPECT VALVE TIMING 
    1. Check the camshaft timing marks.
      NOTE:
      • Check each timing mark from a viewpoint directly in line 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.
      GTY831089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b 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. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      GTY565856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. If the valve timing is misaligned, reinstall the chain sub-assembly.
    4. Remove the crankshaft pulley set bolt.
  47. INSTALL ENGINE WATER PUMP ASSEMBLY 
    1. Install the new water pump gasket.
    2. Install the engine water pump assembly with the 7 bolts.
      GTY799605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Be sure to apply adhesive to the 2 bolts labeled A before reusing them, or replace them with new ones if necessary.
      • Install the bolt within 3 minutes after applying adhesive.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  48. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  49. INSTALL TIMING CHAIN COVER PLATE 

    Refer to PROCEDURE - Step 30

  50. INSTALL TIMING CHAIN CASE OIL SEAL 

    Refer to PROCEDURE - Step 2

  51. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. for 2WD:
      1. Install the No. 1 oil pan baffle plate with the 8 bolts.
        GTY621298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

        HINT: 

        Temporarily install the 8 bolts. Tighten the 2 bolts A shown in the illustration before tightening the other bolts.

    2. for AWD:
      GTY634412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the No. 1 oil pan baffle plate with the 7 bolts.

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

        HINT: 

        Temporarily install the 7 bolts. Tighten the 2 bolts A shown in the illustration before tightening the other bolts.

  52. INSTALL OIL STRAINER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  53. INSTALL OIL PAN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  54. INSTALL OIL LEVEL SENSOR BRACKET 

    Refer to PROCEDURE - Step 1

  55. INSTALL ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 2

  56. INSTALL OIL PIPE WITH STRAINER SUB-ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 8

  57. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  58. 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) 

  59. INSTALL SPARK PLUG TUBE GASKET 
    1. Install 6 new spark plug tube gaskets to the cylinder head cover sub-assembly.
      GTY664457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  61. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 12

  62. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  63. INSTALL REAR WATER BY-PASS JOINT 
    1. Install a new O-ring to the No. 1 water outlet pipe.

      HINT: 

      Apply water to the O-ring.

      GTY616895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 2 new water by-pass joint gaskets to the rear water by-pass joint.
      GTY814105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the rear water by-pass joint with the 4 bolts and 2 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.

      GTY797878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  64. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 1

  65. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 2

  66. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 3

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

    Refer to PROCEDURE - Step 4

  68. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 
    1. Install a new water inlet housing gasket and the water inlet with thermostat sub-assembly with the 2 bolts and nut.

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

      GTY777287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  69. INSTALL WATER OUTLET SUB-ASSEMBLY 
    1. Install a new O-ring to the No. 1 water outlet pipe.
      GTY617833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water outlet sub-assembly with the 2 bolts.

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

      NOTE:

      Be careful that the O-ring does not get caught between the parts.

      GTY664461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 14

  71. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  72. INSTALL OIL FILTER CAP ASSEMBLY 
  73. INSTALL CYLINDER BLOCK WATER DRAIN COCK PLUG (w/ Water Drain Cock Plug) 
    1. Apply adhesive around the cylinder block water drain cock plug.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the cylinder block water drain cock plug.

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

      GTY814113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Install the cylinder block water drain cock plug within 3 minutes after applying adhesive.

  74. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply adhesive around the cylinder block water drain cock sub-assembly.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the cylinder block water drain cock sub-assembly as shown in the illustration.
      GTY801797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 80°

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

      NOTE:
      • Install the cylinder block water drain cock sub-assembly within 3 minutes after applying adhesive.
      • Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening the drain cock to the specified torque.
      • Do not loosen the cylinder block water drain cock sub-assembly after setting it correctly.
      • Do not add engine coolant for at least 1 hours after installing the cylinder block water drain cock sub-assembly.
    3. Install the water drain cock plug to the cylinder block water drain cock sub-assembly.

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

  75. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  76. INSTALL VENTILATION VALVE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  77. INSTALL VENTILATION HOSE ASSEMBLY 
    1. Install the ventilation hose assembly to the cylinder head cover sub-assembly LH with the hose clamp.
      GTY835826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. INSTALL NO. 1 FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 37

  79. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 38

  80. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

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