Installation [11/2017 - ]: Procedure
- INSTALL CYLINDER HEAD GASKET
- Apply seal packing to a new cylinder head gasket as shown in the illustration.
*1 Cylinder Head Gasket *a 5.0 to 7.0 mm (0.197 to 0.276 in.) *b 3.0 to 5.0 mm (0.118 to 0.197 in.) *c 7.0 to 9.0 mm (0.276 to 0.354 in.) *d 38.6 mm (1.52 in.) *e 142.7 mm (5.62 in.) Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTE:- Remove any oil from the contact surfaces.
- Install the cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying seal packing.
- Place the cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
*a Lot No. Front of Engine NOTE:- Remove any oil from the contact surfaces.
- Make sure to install the cylinder head gasket in the correct direction.
- Apply seal packing to a new cylinder head gasket as shown in the illustration.
- INSTALL CYLINDER HEAD SUB-ASSEMBLY
HINT:
Perform inspection after repairs after replacing the cylinder head sub-assembly.
Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]
- Place the cylinder head sub-assembly onto the cylinder block sub-assembly.NOTE:
- Do not allow oil to adhere to the bottom of the cylinder head sub-assembly.
- Gently lower the cylinder head sub-assembly in order not to damage the cylinder head gasket with the bottom of the cylinder head sub-assembly.
HINT:
The cylinder head set bolts are tightened in 3 progressive steps.
- Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
- Step 1:
- Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 8 cylinder head set bolts with 8 cylinder head set plate washers in several steps and in the order shown in the illustration.
Torque: 36 N.m (367 kgf/cm, 27 ft.lbf)
- Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 8 cylinder head set bolts with 8 cylinder head set plate washers in several steps and in the order shown in the illustration.
- Step 2:
*a Turn 90° *b Paint Mark Front of Engine - Mark each cylinder head set bolt head with paint as shown in the illustration.
- Tighten the cylinder head set bolts 90° in the order shown in step 2.
- Step 3:
- Tighten the cylinder head set bolts an additional 90° in the order shown in step 1.
- Check that the paint marks are now facing rearward.
- Thoroughly wipe off the seal packing that has seeped out onto the front side of the engine.
*1 Cylinder Head Sub-assembly *2 Cylinder Head Gasket *3 Cylinder Block Sub-assembly *a Wipe Off
- Place the cylinder head sub-assembly onto the cylinder block sub-assembly.
- INSTALL NO. 2 CYLINDER HEAD GASKET
- Apply seal packing to a new No. 2 cylinder head gasket as shown in the illustration.
*1 No. 2 Cylinder Head Gasket *a 5.0 to 7.0 mm (0.197 to 0.276 in.) *b 3.0 to 5.0 mm (0.118 to 0.197 in.) *c 7.0 to 9.0 mm (0.276 to 0.354 in.) *d 39.3 mm (1.55 in.) *e 111.3 mm (4.38 in.) Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTE:- Remove any oil from the contact surfaces.
- Install the No. 2 cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying seal packing.
- Place the No. 2 cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
*a Lot No. Front of Engine NOTE:- Remove any oil from the contact surfaces.
- Make sure to install the No. 2 cylinder head gasket in the correct direction.
- Apply seal packing to a new No. 2 cylinder head gasket as shown in the illustration.
- INSTALL CYLINDER HEAD LH
HINT:
Perform inspection after repairs after replacing the cylinder head LH.
Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]
- Place the cylinder head LH onto the cylinder block sub-assembly.NOTE:
- Do not allow oil to adhere to the bottom of the cylinder head LH.
- Gently lower the cylinder head LH in order not to damage the No. 2 cylinder head gasket with the bottom of the cylinder head LH.
HINT:
The cylinder head set bolts are tightened in 3 progressive steps.
- Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
- Step 1:
- Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 8 cylinder head set bolts with 8 cylinder head set plate washers in several steps in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 36 N.m (367 kgf/cm, 27 ft.lbf)
- Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 8 cylinder head set bolts with 8 cylinder head set plate washers in several steps in the order shown in the illustration.
- Step 2:
*a Turn 90° *b Paint Mark Front of Engine - Mark each cylinder head set bolt head with paint as shown in the illustration.
- Tighten the cylinder head set bolts 90° in the order shown in step 2.
- Step 3:
- Tighten the cylinder head set bolts an additional 90° in the order shown in step 1.
- Check that the paint marks are now facing rearward.
- Tighten the 2 bolts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 30 N.m (306 kgf/cm, 22 ft.lbf)
- Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.
*1 Cylinder Head LH *2 No. 2 Cylinder Head Gasket *3 Cylinder Block Sub-assembly *a Wipe Clean
- Place the cylinder head LH onto the cylinder block sub-assembly.
- INSTALL FUEL INJECTOR SEAL
Refer to PROCEDURE - Step 1
- INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)
Refer to PROCEDURE - Step 2
- INSTALL FUEL DELIVERY PIPE RH
Refer to PROCEDURE - Step 3
- INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH
Refer to PROCEDURE - Step 4
- INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY
Refer to PROCEDURE - Step 5
- INSTALL REAR WATER BY-PASS JOINT
Refer to PROCEDURE - Step 63
- INSTALL VALVE STEM CAP
- Apply a light coat of engine oil to the 24 valve stem caps.
- Install the 24 valve stem caps.NOTE:
Install each part to its original position.
- INSTALL VALVE LASH ADJUSTER ASSEMBLY
- Inspect the valve lash adjuster assembly.
Refer to PROCEDURE - Step 2
- Install the 24 valve lash adjuster assemblies.NOTE:
Install each part to its original position.
- Inspect the valve lash adjuster assembly.
- INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
- Apply engine oil to the valve lash adjuster assembly tip and valve stem cap end.
- Install the 24 No. 1 valve rocker arm sub-assemblies as shown in the illustration.NOTE:
Install each part to its original position.
*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap
- INSTALL NO. 1 CHAIN VIBRATION DAMPER
Refer to PROCEDURE - Step 39
- INSTALL NO. 2 CHAIN VIBRATION DAMPER
Refer to PROCEDURE - Step 40
- INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
HINT:
Perform inspection after repair after replacing the No. 3 camshaft sub-assembly.
Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]
- Apply a light coat of engine oil to the No. 3 camshaft sub-assembly journals and camshaft housing sub-assembly LH.
- Install the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH.
- INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
HINT:
Perform inspection after repair after replacing the No. 4 camshaft sub-assembly.
Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]
- Apply a light coat of engine oil to the No. 4 camshaft sub-assembly journals and camshaft housing sub-assembly LH.
- Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH.
- INSTALL CAMSHAFT BEARING CAP (for Bank 2)
- Apply engine oil to the 5 camshaft bearing caps.
- Make sure of the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.
- Temporarily install and tighten the 8 bolts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
- INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
- SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)
HINT:
Perform inspection after repair after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly LH.
Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]
- Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH as shown in the illustration.
*a Timing Mark *b Mark Plate (yellow) - Align the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly with the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH with the No. 2 chain sub-assembly installed.NOTE:
Be careful not to damage the contact surface of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH with the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly.
- Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH as shown in the illustration.
- TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
See step 8
- TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
See step 9
- INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
- Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap *a Correct *b Incorrect - Apply seal packing as shown in the illustration.
*a Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) *b Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.) *c Separated by 4.0 to 6.0 mm (0.157 to 0.236 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 camshaft housing sub-assembly LH within 3 minutes and tighten the bolts 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.
- Install the camshaft housing sub-assembly LH and tighten the 15 bolts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
*a Types of bolt *b Tightening order *c Intake Side *d Exhaust Side *e Knock Pin - - Torque: 28 N.m (286 kgf/cm, 21 ft.lbf)
NOTE:- When installing the camshaft housing sub-assembly LH, correctly position the camshafts as shown in the illustration. Failure to do so may result in damage due to contact between the pistons and valves. If a camshaft is rotated, valve contact with a piston at TDC may occur.
- Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed.
- If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.
- If it is necessary to remove the camshaft housing sub-assembly LH during installation, make sure that the previously applied seal packing does not enter any oil passages.
Bolt Length
Item Length Bolt (A) 48 mm (1.89 in.) Bolt (B) 68 mm (2.68 in.) - Tighten the 8 bolts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 16 N.m (163 kgf/cm, 12 ft.lbf)
- Remove any protruding seal packing.NOTE:
Be careful not to drop seal packing into the cylinder head LH.
- Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
- TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
- Using a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.
*a Hold Turn Torque: 95 N.m (969 kgf/cm, 70 ft.lbf)
NOTE:Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with the wrench.
- Using a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.
- TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
- Using a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.
*a Hold Turn Torque: 95 N.m (969 kgf/cm, 70 ft.lbf)
NOTE:Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with the wrench.
- Remove the pin from the No. 3 chain tensioner assembly.
- Using a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.
- INSTALL CAMSHAFT
HINT:
Perform inspection after repair after replacing the camshaft.
Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]
- Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH.
- Install the camshaft to the camshaft housing sub-assembly RH.
- INSTALL NO. 2 CAMSHAFT
HINT:
Perform inspection after repair after replacing the No. 2 camshaft.
Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]
- Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH.
- Install the No. 2 camshaft to the camshaft housing sub-assembly RH.
- INSTALL FUEL PUMP LIFTER HOUSING
- Install the fuel pump lifter housing.
- INSTALL CAMSHAFT BEARING CAP (for Bank 1)
- Apply engine oil to the 5 camshaft bearing caps.
- Make sure of the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.
- Temporarily install and tighten the 9 bolts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Bolt (A) Bolt (B) Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
Bolt Length
Item Length Bolt (A) 40 mm (1.57 in.) Bolt (B) 58 mm (2.28 in.)
- INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
- SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)
HINT:
Perform inspection after repair after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly RH.
Refer to INITIALIZATION [11/2017 - 10/2018] , or refer to INITIALIZATION [10/2018 - 09/2020] , or refer to INITIALIZATION [09/2020 - ]
- Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH as shown in the illustration.
*a Timing Mark *b Mark Plate - Align the straight pins of the camshaft and No. 2 camshaft with the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH with the No. 2 chain sub-assembly installed.NOTE:
Be careful not to damage the contact surface of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH with the straight pins of the camshaft and No. 2 camshaft.
- Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH as shown in the illustration.
- TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
See step 21
- TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
See step 22
- INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
- Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap *a Correct *b Incorrect - Apply seal packing as shown in the illustration.
*a Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.) *b Separated by 4.0 to 6.0 mm (0.157 to 0.236 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 camshaft housing sub-assembly RH within 3 minutes and tighten the bolts 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.
- Install the camshaft housing sub-assembly RH and tighten the 15 bolts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
*a Types of bolt *b Tightening order *c Exhaust Side *d Intake Side *e Knock Pin - - Torque: 28 N.m (286 kgf/cm, 21 ft.lbf)
NOTE:- When installing the camshaft housing sub-assembly RH, correctly position the camshafts as shown in the illustration. Failure to do so may result in damage due to contact between the pistons and valves. If a camshaft is rotated, valve contact with a piston at TDC may occur.
- Make sure that the No. 1 valve rocker arm sub-assemblies are correctly installed.
- If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.
- If it is necessary to remove the camshaft housing sub-assembly RH during installation, make sure that the previously applied seal packing does not enter any oil passages.
Bolt Length
Item Length Bolt (A) 48 mm (1.89 in.) Bolt (B) 68 mm (2.68 in.) - Tighten the 9 bolts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 16 N.m (163 kgf/cm, 12 ft.lbf)
- Remove any protruding seal packing.NOTE:
Be careful not to drop seal packing into the cylinder head sub-assembly.
- Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
- TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
- TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
- Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.
*a Hold Turn Torque: 95 N.m (969 kgf/cm, 70 ft.lbf)
NOTE:Be careful not to damage the camshaft housing sub-assembly RH or spark plug tube with the wrench.
- Remove the pin from the No. 2 chain tensioner assembly.
- Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.
- INSTALL CHAIN SUB-ASSEMBLY
Refer to PROCEDURE - Step 43
- INSTALL CHAIN TENSIONER SLIPPER
Refer to PROCEDURE - Step 44
- INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
Refer to PROCEDURE - Step 45
- INSPECT VALVE TIMING
Refer to PROCEDURE - Step 46
- INSTALL TIMING CHAIN COVER ASSEMBLY
Refer to INSTALLATION [11/2017 - ]