Reassembly [10/2023 - ]: Procedure

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for Bank 1	*B	for Bank 2
   *a	Protrusion Height	-	-

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

      Standard protrusion height

      2.7 to 3.3 mm (0.106 to 0.130 in.)

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

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Rear Engine Oil Seal Retainer	-	-
   *a	0 to 0.5 mm (0 to 0.0197 in.)	-	-

   1. Apply MP grease to the lip of a new rear engine oil seal.
      NOTE:

      Keep the lip free of foreign matter.

   2. Using SST, tap in a new rear engine oil seal until its surface is flush with the rear engine oil seal retainer edge.
      • SST: 09223-56010 

      Oil Seal Protrusion Height

      0 to 0.5 mm (0 to 0.0197 in.)

      NOTE:

      Do not tap on the rear engine oil seal at an angle.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Standard Seal Packing Diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.)	*b	Wide Seal Packing Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)
   *c	Seal Packing Width 28 mm (1.10 in.)	*d	Seal Packing Width 18 mm (0.709 in.)
   	Bolt A (Do not reuse)		Bolt B
   	Seal Packing	-	-

   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

      NOTE:

      • Remove any oil from the contact surface.
      • Install the rear engine oil seal retainer within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      • Do not add the engine oil for at least 2 hours after the installation.
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   2. Install the rear engine oil seal retainer with 6 new bolts and the 4 bolts.

      for bolt A 

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

      for bolt B 

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Temporarily install the No. 1 oil pan baffle plate with the 4 bolts.

      HINT: 

      After temporarily installing the 4 bolts, install the oil strainer sub-assembly.

1. Fig 1: Oil Strainer Sub-Assembly Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Install a new gasket with the oil strainer sub-assembly.
      NOTE:

      Check that the gasket is securely fitted into the installation groove.

   2. Temporarily install the oil strainer sub-assembly to the crankshaft bearing cap sub-assembly with the 3 bolts.
   3. Tighten the 7 bolts in the order shown in the illustration.

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

1. Fig 2: No. 1 Oil Pan Sub-Assembly Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Standard Seal Packing Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)	*b	Wide Seal Packing Diameter 5.5 to 6.5 mm (0.216 to 0.255 in.)
   *c	Thick Coating Cross-section	*d	Seal Packing Width 38 mm (1.49 in.)
   *e	Seal Packing Width 60 mm (2.36 in.)	*f	3.0 mm (0.118 in.) or more
   *g	8.0 to 12 mm (0.315 to 0.472 in.)	-	-
   	Bolt A		Bolt B
   	Bolt C	-	-

   1. Remove any remaining seal packing material and be careful not to drop any oil on the contact surfaces of the No. 1 oil pan sub-assembly and crankshaft bearing cap sub-assembly.
   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

      NOTE:

      • Remove any oil from the contact surface.
      • Install the No. 1 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      • Do not add the engine oil for at least 2 hours after the installation.
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   3. Install the No. 1 oil pan sub-assembly with the 12 bolts. Tighten the bolts uniformly in several steps.

      for bolt A and C 

      Torque: 43 N.m (438 kgf/cm, 32 ft.lbf) 

      for bolt B 

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

      Standard Bolt

      Item	Length
      Bolt A	30 mm (1.18 in.)
      Bolt B	92 mm (3.62 in.)
      Bolt C	50 mm (1.97 in.)

1. Fig 3: No. 2 Oil Pan Sub-Assembly Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	Type A	*B	Type B
   *a	3.0 to 4.0 mm (0.118 to 0.157 in.)	-	-
   	Bolt		Nut
   	Seal Packing	-	-

   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

      Standard seal diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      NOTE:

      • Check the bolts and bolt holes, and clean and degrease them.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   2. Install the No. 2 oil pan sub-assembly with the 9 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

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

      NOTE:

      • Do not start the engine for at least 2 hours after the installation.
      • Do not add the engine oil for at least 2 hours after the installation.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install a new gasket to the oil pan drain plug.
   2. Install the oil pan drain plug.

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

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

HINT:  Remove any remaining seal packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover assembly and cylinder block sub-assembly and cylinder head sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	3.0 to 4.0 mm (0.118 to 0.157 in.)	-	-
   	Seal Packing	-	-

   1. Cylinder Block Sub-assembly Side:

      Install 3 new oil pump gaskets to the cylinder block sub-assembly.

   2. Timing Chain Cover Assembly Side:

      Install 2 new oil pump gaskets and 2 new water pump gaskets to the timing chain cover assembly.

   3. Apply seal packing in a continuous line to the engine unit as shown in the illustration.

      Seal packing

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

      Seal diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      NOTE:

      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
2. Fig 4: Timing Chain Cover Assembly Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Temporarily install the timing chain cover assembly with the 27 bolts.
      NOTE:

      Make sure that there is no oil on the bolt threads.

   2. Tighten the bolts in the order shown in the illustration.

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

      NOTE:

      • Do not add the engine oil for at least 2 hours after the installation.
      • Do not start the engine for at least 2 hours after the installation.

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

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

1. Courtesy 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	-	-

   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 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 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: 56 N.m (571 kgf/cm, 41 ft.lbf) 

      HINT: 

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for Bank 1	*B	for Bank 2
   *1	Crankshaft Pulley Set Key	-	-
   *a	60°	*b	Timing Mark

   1. Turn the crankshaft 60° counterclockwise and set it as shown in the illustration.
   2. Check that the camshaft timing gear position on the bank 1 is as shown in the illustration.
   3. Check that the camshaft timing gear position on the bank 2 is as shown in the illustration.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Mark Plate (Pink)

   *b

   Timing Mark

   1. Align the mark plates and timing marks as shown in the illustration and install the No. 1 chain sub-assembly.

      HINT: 

      The camshaft mark plates are pink.

3. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	When idle sprocket is reused	*b	Mark
   *c	Align	*d	Chain Plate
   *e	Chain sub-assembly between the banks	-	-
   	Turn	-	-

   1. Rest the No. 1 chain sub-assembly on top of the crankshaft.
   2. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain sub-assembly 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 sub-assembly between the banks.

4. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Crankshaft Pulley Set Key	-	-
   *a	Mark Plate (Orange)	*b	Timing Mark
   *c	Center Line	-	-

   1. Align the mark plate and timing mark as shown in the illustration and install the No. 1 chain sub-assembly onto the crankshaft timing sprocket.

      HINT: 

      The crankshaft mark plate is orange.

   2. Temporarily install the crankshaft pulley set bolt.
   3. Turn the crankshaft clockwise to set it to the block bore center line RH (TDC/compression).

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Stopper Plate	*b	Plunger
   *c	Pin	-	-

   1. Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
   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 a new gasket to the No. 1 chain tensioner assembly.
   4. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

   5. Remove the lock pin of the No. 1 chain tensioner assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Timing Mark (Camshaft Timing Intake Gear Assembly Side)

   *b

   Timing Mark (Camshaft Timing Exhaust Gear Assembly Side)

   1. for Bank 1 Side:

      Check that each camshaft timing mark is positioned as shown in the illustration.

      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. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Timing Mark (Camshaft Timing Intake Gear Assembly Side)

   *b

   Timing Mark (Camshaft Timing Exhaust Gear Assembly Side)

   1. for Bank 2 Side:

      Check that each camshaft timing mark is positioned as shown in the illustration.

      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.
3. If the valve timing is misaligned, reinstall the timing chain.
4. Remove the crankshaft pulley set bolt.

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 9

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 10

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

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 14