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Installation [12/2023 - ]: Procedure

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  1. INSTALL NO. 2 CYLINDER HEAD GASKET 
    1. GTY1233113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Cylinder Head Gasket - -
      *a Lot No. *b 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *c 3.0 to 5.0 mm (0.118 to 0.197 in.) *d 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *e 40 mm (1.57 in.) *f 112.1 mm (4.41 in.)
      Front of Engine Seal Packing
      1. Place a new No. 2 cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
        NOTE:
        • Remove any oil from the contact surfaces.
        • Pay attention to the installation direction.
      2. Apply seal packing to the No. 2 cylinder head gasket as shown in the illustration.

        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.
  2. INSTALL CYLINDER HEAD LH 
    Refer to PROCEDURE - Step 7
  3. INSTALL CYLINDER HEAD GASKET 
    1. GTY1239586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Gasket - -
      *a Lot No. *b 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *c 3.0 to 5.0 mm (0.118 to 0.197 in.) *d 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *e 39.4 mm (1.55 in.) *f 143.5 mm (5.65 in.)
      Front of Engine Seal Packing
      1. Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
        NOTE:
        • Remove any oil from the contact surfaces.
        • Pay attention to the installation direction.
      2. Apply seal packing to the cylinder head gasket as shown in the illustration.

        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.
  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 9
  5. INSTALL VALVE STEM CAP 
    Refer to PROCEDURE - Step 12
  6. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    Refer to PROCEDURE - Step 13
  7. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 14
  8. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 15
  9. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 16
  10. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 
    Refer to PROCEDURE - Step 17
  11. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 
    Refer to PROCEDURE - Step 18
  12. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) 
    Refer to PROCEDURE - Step 19
  13. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 
    Refer to PROCEDURE - Step 8
  14. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 
    Refer to PROCEDURE - Step 9
  15. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 
    Refer to PROCEDURE - Step 22
  16. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 
    Refer to PROCEDURE - Step 23
  17. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 
    Refer to PROCEDURE - Step 24
  18. INSTALL CAMSHAFT 
    Refer to PROCEDURE - Step 25
  19. INSTALL NO. 2 CAMSHAFT 
    Refer to PROCEDURE - Step 26
  20. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 
    Refer to PROCEDURE - Step 27
  21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 
    Refer to PROCEDURE - Step 28
  22. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) 
    Refer to PROCEDURE - Step 29
  23. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 
    Refer to PROCEDURE - Step 21
  24. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 
    Refer to PROCEDURE - Step 22
  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    Refer to PROCEDURE - Step 32
  26. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 
    Refer to PROCEDURE - Step 33
  27. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 
    Refer to PROCEDURE - Step 34
  28. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 38

  30. INSTALL CHAIN SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 40
  31. INSTALL CHAIN TENSIONER SLIPPER 
  32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    Refer to PROCEDURE - Step 42
  33. INSPECT VALVE TIMING 
    Refer to PROCEDURE - Step 43
  34. INSTALL TIMING CHAIN COVER ASSEMBLY 
    Refer to PROCEDURE - Step 1
  35. INSTALL TIMING CHAIN CASE OIL SEAL 
    See step  1
  36. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Fig 1: Oil Pan Sub-Assembly Tightening Sequence
      GTY1240478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing *b Torque
      *c Bolt and Nut Tightening Order - -
      Bolt Nut
      Wipe off the Seal Packing - -
      1. Install 2 new oil pan gaskets to the timing chain cover 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

        Seal Packing Diameter

        3.0 to 4.0 mm (0.118 to 0.157 in.)

        NOTE:
        • Remove any oil from the contact surfaces.
        • Install the oil pan sub-assembly within 3 minutes of applying seal packing.
        • Do not start the engine for at least 2 hours after installation.
      3. Install the oil pan sub-assembly with the 16 bolts and 2 nuts in the order shown in the illustration.

        Bolt (A) 

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

        Bolt (B), (C), (D) 

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

        Nut 

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

        Bolt Length

        Item Length
        Bolt (A) 16 mm (0.630 in.)
        Bolt (B) 45 mm (1.77 in.)
        Bolt (C) 25 mm (0.984 in.)
        Bolt (D) 70 mm (2.76 in.)
      4. Wipe off any excess seal packing with a clean piece of cloth.
  37. INSTALL OIL STRAINER SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 52
  38. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 53
  39. INSTALL SPARK PLUG TUBE GASKET 
  40. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    Refer to PROCEDURE - Step 70
  41. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2) 
    Refer to PROCEDURE - Step 7
  42. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2) 
    Refer to PROCEDURE - Step 1
  43. INSTALL SPARK PLUG TUBE GASKET 
  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 71
  45. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1) 
    Refer to PROCEDURE - Step 2
  46. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1) 
    Refer to PROCEDURE - Step 1
  47. INSTALL WATER OUTLET 

    Refer to PROCEDURE - Step 57

  48. INSTALL OIL COOLER PIPE 

    Refer to PROCEDURE - Step 59

  49. INSTALL NO. 5 WATER BY-PASS HOSE 
  50. INSTALL NO. 4 WATER BY-PASS HOSE 
  51. INSTALL OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  52. CONNECT NO. 5 WATER BY-PASS HOSE 
  53. CONNECT NO. 4 WATER BY-PASS HOSE 
  54. INSTALL SENSOR WIRE 

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

  55. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR 

    Refer to PROCEDURE - Step 67

  56. INSTALL WATER HOSE CLAMP 

    Refer to PROCEDURE - Step 68

  57. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  58. INSTALL WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 77

  59. INSTALL ENGINE MOUNTING BRACKET RH 
    Refer to PROCEDURE - Step 78
  60. INSTALL CRANKSHAFT PULLEY 
    See step  2
  61. INSTALL WATER PUMP PULLEY 
    Refer to PROCEDURE - Step 2
  62. INSTALL SENSOR WIRE 

    Refer to PROCEDURE - Step 84

  63. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to INSTALLATION [12/2023 - ]

  64. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    Refer to PROCEDURE - Step 39
  65. INSTALL IGNITION COIL ASSEMBLY 
    Refer to PROCEDURE - Step 2
  66. INSTALL FUEL HOSE BRACKET 

    Refer to PROCEDURE - Step 3

  67. INSTALL WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 4

  68. INSTALL NO. 2 VENTILATION HOSE 
  69. INSTALL VENTILATION HOSE 
  70. INSTALL NO. 1 ENGINE COVER 
  71. INSTALL FUEL PUMP LIFTER ASSEMBLY 
    Refer to PROCEDURE - Step 1
  72. INSTALL FUEL PUMP SPACER GASKET 
  73. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    Refer to PROCEDURE - Step 3
  74. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 4
  75. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    Refer to PROCEDURE - Step 5
  76. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 6
  77. INSTALL FUEL PUMP PROTECTOR 

    Refer to PROCEDURE - Step 9

  78. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    Refer to PROCEDURE - Step 1
  79. INSTALL INTAKE MANIFOLD 
    Refer to PROCEDURE - Step 2
  80. INSTALL REAR ENGINE MOUNTING STAY RH 

    Refer to PROCEDURE - Step 19

  81. CONNECT WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 20

  82. INSTALL NO. 1 FUEL HOSE 
    Refer to PROCEDURE - Step 21
  83. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET 
  84. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    Refer to PROCEDURE - Step 14
  85. INSTALL NO. 2 SURGE TANK STAY 
    Refer to PROCEDURE - Step 15
  86. INSTALL WATER BY-PASS HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 25

  87. CONNECT VENTILATION HOSE 
    Refer to PROCEDURE - Step 18
  88. INSTALL WATER BY-PASS HOSE 
  89. INSTALL NO. 2 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 28

  90. INSTALL THROTTLE BODY GASKET 
    Refer to PROCEDURE - Step 1
  91. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 
    Refer to PROCEDURE - Step 2
  92. CONNECT NO. 2 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 3
  93. CONNECT WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 4
  94. INSTALL NO. 5 CYLINDER BLOCK INSULATOR 
  95. INSTALL NO. 4 CYLINDER BLOCK INSULATOR 
  96. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET 
    Refer to PROCEDURE - Step 35
  97. INSTALL HV WATER PUMP BRACKET 
    Refer to PROCEDURE - Step 36
  98. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 
    Refer to PROCEDURE - Step 2
  99. INSTALL V-RIBBED BELT 
    Refer to PROCEDURE - Step 1
  100. INSTALL ENGINE HANGERS 
    See step  63
  101. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 

    Refer to INSTALLATION [12/2023 - ] 

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