Engine Unit: Reassembly

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INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the 3 oil nozzles with the bolts.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 1: Identifying No. 1 Oil Nozzle Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive around the drain cocks.
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
  
  Fig 2: Applying Adhesive Around Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cylinder block water drain cocks.
  1. Temporarily install the drain cocks.
    Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  2. Within one full rotation, tighten the drain cock to the angle shown in the figure below.
    Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
    
    NOTE: Do not loosen the drain cock to adjust it. If an adjustment is necessary, remove the drain cock and reinstall it.
    
    Fig 3: Tightening Drain Cock
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the water drain cock plug to the water drain cocks.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
INSTALL PISTON WITH PIN SUB-ASSEMBLY
1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
  HINT:
  
  Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
  
  Fig 4: Installing Piston Pin Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston to approximately 80°C (176°F).
  
  Fig 5: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the piston pin with engine oil.
4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
  HINT:
  
  The piston and pin are a matched set.
  
  Fig 6: Aligning Front Marks Of Piston And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
  
  Fig 7: Checking Fitting Condition Between Piston And Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.
  HINT:
  
  Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
  
  Fig 8: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON RING SET
1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.
  
  Fig 9: Installing Piston Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown in the illustration.
  NOTE: Do not align the ring ends.
  
  Fig 10: Positioning Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT BEARING
NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

Fig 11: Identifying No. 1 & No. 4 Cylinder Block Journal And No. 2 & No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Clean the main journal and both surfaces of the bearing.
2. Install the upper bearing.
  1. Install the upper bearing to the cylinder block as shown in the illustration.
    NOTE: Do not apply engine oil to the bearing and its contact surface.
    
    Fig 12: Installing Upper Bearing To Cylinder Block
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the lower bearing.
  1. Install the lower bearing to the bearing cap.
  2. Using a vernier caliper, measure the distance between the bearing cap's edge and the lower bearing's edge.
    Dimension (A - B): 0.7 mm (0.028 in.) or less.
    
    NOTE: Do not apply engine oil to the bearing's contact area and underside.
    
    Fig 13: Installing Lower Bearing To Bearing Cap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT
1. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
  
  Fig 14: Identifying Oil Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
3. Confirm the front marks and numbers of the main bearing caps and install the bearing caps on the cylinder block. See Fig 15.
  HINT:
  
  A number is marked on each main bearing cap to indicate the installation position.
4. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
5. Temporarily install the 8 main bearing cap bolts to the inside positions.
  
  Fig 15: Installing Bearing Caps On Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
  Bolt length: 100.0 to 102.0 mm (3.937 to 4.016 in.)
  
  Fig 16: Inserting Main Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
  
  Fig 17: Tapping Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
9. Install the 8 main bearing cap bolts to the outside positions.
  Bolt length: 105.5 to 107.5 mm (4.154 to 4.232 in.)
  
  Fig 18: Installing Crankshaft Bearing Cap Bolts To Outside Positions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the crankshaft bearing cap bolts.
  HINT:
  
  The main bearing cap bolts are tightened in 2 progressive steps.
11. Step 1
  1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
    Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
    
    If any of the main bearing cap bolts does not meet the specified torque, replace it.
    
    Fig 19: Tightening Main Bearing Cap Bolts In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Step 2
  1. Mark the front of the bearing cap bolts with paint.
  2. Tighten the bearing cap bolts another 90° in the order shown in step 1.
  3. Check that the painted mark is now at a 90° angle to the front.
13. Check that the crankshaft turns smoothly.
14. Install and uniformly tighten the 8 main bearing cap bolts in several steps, in the sequence shown in the illustration.
  Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
  
  Bolt length:
  
  45 mm (1.77 in.) for bolt A
  
  30 mm (1.18 in.) for except bolt A
15. Check that the crankshaft turns smoothly.
  
  Fig 21: Tightening Main Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearing to the connecting rod and bearing cap.
2. Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges, and each connecting rod bearing's edge.
  Dimension (A - B): 0.7 mm (0.028 in.) or less
  
  NOTE: Do not apply engine oil to the bearing's contact area and underside.
  
  Fig 22: Measuring Distance Between Connecting Rod'S And Bearing Cap'S Edges
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
2. Position the piston rings so that the ring ends are as shown in the illustration.
  NOTE: Do not align the ring ends.
  
  Fig 23: Positioning Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward.
  NOTE: Match the numbered connecting rod cap with the connecting rod.
  
  Fig 24: Pushing Piston And Connecting Rod Into Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the front mark of the connecting rod cap is facing forward.
  
  Fig 25: Checking Front Mark Of Connecting Rod Cap Is Facing Forward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
6. Install the connecting cap bolts.
  HINT:
  
  The connecting cap bolts are tightened in 2 progressive steps.
7. Step 1
  1. Install and alternately tighten the bolts of the connecting rod cap in several steps.
    Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
    
    Fig 26: Tightening Connecting Cap Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Step 2
  1. Mark the front side of each connecting cap bolt with paint.
  2. Tighten the cap bolts another 90° as shown in the illustration in the order in step 1.
  3. Check that the painted mark is now at a 90° angle to the front.
    
    Fig 27: Checking Painted Mark On Connecting Cap Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Check that the crankshaft turns smoothly.
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the crankshaft position sensor with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 28: Identifying Crankshaft Position Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 STRAIGHT SCREW PLUG
1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
  Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
  
  Fig 29: Identifying Straight Screw Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
  
  Fig 30: Identifying No. 1 Straight Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE SPRING SEAT
1. Install the valve spring seats to the cylinder head.
INSTALL INTAKE VALVE STEM OIL SEAL
1. Apply a light coat of engine oil to new oil seals.
  NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.
  
  HINT:
  
  The intake valve oil seals are white and the exhaust valve oil seals are black.
  
  Fig 31: Identifying Valve Stem Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, push in the oil seals.
  SST 09201-41020
  
  NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
  
  Fig 32: Installing Valve Stem Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE VALVE
1. Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.
  
  Fig 33: Identifying Area to Apply Oil On Intake Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the valve, compression spring and spring retainer to the cylinder head.
  NOTE: Install the same parts in the same combination to original locations.
3. Using SST and wooden blocks, compress the spring and install the retainer lock.
  SST 09202-70020 (09202-00010)
  
  Fig 34: Installing Retainer Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
  NOTE: Be careful not to damage the retainer.
  
  Fig 35: Tapping Valve Stem Tip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST VALVE
1. Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.
2. Install the valve, compression spring and spring retainer to the cylinder head.
  NOTE: Install the same parts in the same combination to their original locations.
3. Using SST and wooden blocks, compress the spring and install the retainer lock.
  SST 09202-70020 (09202-00010)
  
  Fig 37: Installing Retainer Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
  NOTE: Be careful not to damage the retainer.
  
  Fig 38: Tapping Valve Stem Tip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the valve stem caps to the cylinder head.
INSTALL WATER INLET PIPE
1. Install the water inlet pipe with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 39: Identifying Water Inlet Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water by-pass hose.
INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)
1. Check the piston protrusions for each cylinder.
  1. Clean the cylinder block with solvent.
  2. Set the piston of the cylinder to be measured to slightly before TDC.
2. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
  
  Fig 40: Placing Cylinder Head Gasket On Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful of the installation direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
3. Place the cylinder head on the cylinder block.
  NOTE: Ensure that no oil is on the mounting surface of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
5. Step 1
  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps, in the sequence shown in the illustration.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
    
    Fig 41: Identifying Cylinder Head Bolts In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Step 2
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  2. Tighten the cylinder heads bolts another 90° in the sequence shown in step e.
7. Step 3
  1. Tighten the cylinder head bolts by an additional 90° in the sequence shown in step e.
  2. Check that the painted mark is now facing rearward.
INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2)
1. Check the piston protrusions for each cylinder.
  1. Clean the cylinder block with solvent.
  2. Set the piston of the cylinder to be measured to slightly before TDC.
2. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
  
  Fig 43: Placing Cylinder Head Gasket On Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful of the installation direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
3. Place the cylinder head on the cylinder block.
  NOTE: Ensure that no oil is on the mounting surface of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
5. Step 1
  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps, in the sequence shown in the illustration.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
    
    Fig 44: Identifying Cylinder Head Bolts In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Step 2
  1. Mark the cylinder head bolt heads with paint as shown in the figure below.
    
    Fig 45: Checking Painted Mark On Cylinder Head Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Tighten the cylinder head bolts another 90° in the sequence shown in step e.
7. Step 3
  1. Tighten the cylinder head bolts by an additional 90° in the sequence shown in step e.
  2. Check that the painted mark is now facing rearward.
8. Install the 2 bolts in the order shown in the figure below.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  Fig 46: Identifying Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE LASH ADJUSTER ASSEMBLY
1. Be sure to inspect the valve lash adjuster before installing it (see INSPECTION ).
2. Install the lash adjusters.
  NOTE: Install the lash adjuster at the same place it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Apply engine oil to the lash adjuster tips and valve stem cap ends.
2. Make sure that the valve rocker arms are installed as shown in the illustration.
  
  Fig 47: Identifying Valve Rocker Arms
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP (for Bank 1)
1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
2. Install the No. 1 camshaft and No. 2 camshaft to the camshaft housing.
3. Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper position and direction.
  
  Fig 48: Identifying No. 1 Camshaft And No. 2 Camshaft & Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install the 8 bolts in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 49: Identifying Camshaft Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1)
1. Apply seal packing in a continuous line as shown in the figure below.
  Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
  
  Standard seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after the installation.
    
    Fig 50: Applying Seal Packing In Camshaft Housing Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshaft housing, and install the 12 bolts in the order shown in the illustration.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  NOTE: Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.
  
  Fig 51: Identifying Tightening Sequence Of Camshaft Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tighten the 8 bolts in the order shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 52: Tightening Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Thoroughly wipe clean any seal packing.
4. Install 3 new gaskets.
  
  Fig 53: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP (for Bank 2)
1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
2. Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing.
3. Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper position and direction.
4. Temporarily install the 8 bolts in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 55: Identifying Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2)
1. Apply seal packing in a continuous line as shown in the figure below.
  Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
  
  Standard seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after the installation.
    
    Fig 56: Applying Seal Packing On Camshaft Housing Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshaft housing and tighten the 13 bolts in the order shown in the illustration.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 57: Identifying Tightening Sequence Of Camshaft Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.
3. Tighten the 8 bolts in the order shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 58: Tightening Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Thoroughly wipe clean any seal packing.
4. Install 3 new gaskets.
  
  Fig 59: Installing Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
1. Install the chain tensioner with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) diameter into the hole to fix it in place.
  
  Fig 60: Identifying Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE VALVE TIMING PROCEDURE .
1. Align the mark plate (yellow) with the timing marks (1 dot mark) of the camshaft timing gears as shown in the illustration.
2. Apply a small amount of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear with the No. 2 chain installed.
  
  Fig 61: Aligning Mark Plate With Timing Marks Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
  
  Fig 62: Tightening Camshaft Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the pin from the No. 2 chain tensioner.
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
1. Install the chain tensioner with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) diameter into the hole to fix it in place.
  
  Fig 63: Identifying Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE VALVE TIMING PROCEDURE .
1. Align the mark plate (yellow) with the timing marks (2 dot mark) of the camshaft timing gears as shown in the illustration.
2. Apply a small amount of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear with the No. 2 chain installed.
  
  Fig 64: Aligning Mark Plate With Timing Marks Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
  
  Fig 65: Tightening Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the pin from the No. 2 chain tensioner.
INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
1. Install the timing gear set keys and timing gear as shown in the illustration.
  
  Fig 66: Identifying Timing Gear Set Keys And Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper with the 2 bolts.
  Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
  
  Fig 67: Identifying Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN VIBRATION DAMPER
1. Install the 2 chain vibration damper.
INSTALL IDLE SPROCKET ASSEMBLY
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 with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.
  NOTE: Be careful of the idle gear direction.
  
  Fig 68: Installing Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
  Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
INSTALL CHAIN SUB-ASSEMBLY
1. Align the mark plate and timing mark as shown in the figure below and install the chain.
  NOTE: Do not pass the chain over the crankshaft, just put it on it.
  
  HINT:
  
  The chain mark plate is orange.
  
  Fig 69: Aligning Mark Plate And Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the camshaft timing gear on the bank 1 counterclockwise to tighten the chain between the banks.
  NOTE: If reusing the idle sprocket, align one of the idle sprocket's chain plate marks with one of the chain's chain plates when installing the idle sprocket.
  
  Fig 70: Turning Camshaft Timing Gear On Bank 1 Counterclockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing gear.
  HINT:
  
  The chain mark plate is yellow.
  
  Fig 71: Aligning Mark Plate And Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the pulley set bolt.
5. Turn the crankshaft clockwise to set it to the bank 1 block bore center line (TDC / compression).
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner (see the figure below).
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
3. Install the chain tensioner with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 74: Identifying Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the lock pin of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression.
  
  Fig 75: Aligning Timing Mark With Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the pulley set bolt.
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/Oil Pump) (See REASSEMBLY )
INSTALL WATER PUMP ASSEMBLY (See INSTALLATION )
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Apply seal packing in a continuous line as shown in the figure below.
  Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
  
  Standard seal diameter: 2.0 to 3.0 mm (0.079 to 0.118 in.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the crankcase within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after the installation.
  Fig 76: Applying Seal Packing In Engine Rear Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil seal retainer with the 6 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  NOTE: Apply adhesive 1324 to the 2 bolts labeled A.
  
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
  
  Fig 77: Identifying Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the pulley bolt.
  SST 09213-70011 (09213-70020), 09330-00021
  
  Torque: 250 N*m (2,549 kgf*cm, 184 ft.*lbf)
  
  Fig 78: Installing Crankshaft Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN BAFFLE PLATE
1. Temporarily install the 7 bolts.
2. Tighten the 7 bolts in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 79: Identifying Oil Pan Baffle Plate No. 1 Bolts With Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN SUB-ASSEMBLY (see appropriate step(s) under INSTALLATION )
INSTALL OIL STRAINER SUB-ASSEMBLY (see appropriate step(s) under INSTALLATION )
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (see appropriate step(s) under INSTALLATION )
INSTALL OIL FILTER ELEMENT (see appropriate step(s) under REPLACEMENT )
INSTALL OIL FILTER CAP SUB-ASSEMBLY (see appropriate step(s) under REPLACEMENT )
INSTALL WATER INLET HOUSING (See appropriate step(s) under INSTALLATION )
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET
1. Install the engine mounting bracket with the 6 bolts.
  Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
  
  Fig 80: Identifying Engine Mounting Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
  - Do not start the engine for at least 2 hours after the installation.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Apply seal packing as shown in the figure below.
  Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the crankcase within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after the installation.
  Fig 81: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the gasket to the head cover.
3. Install the head cover with the 12 bolts in the order shown in the illustration.
  Torque:
  
  21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
  
  10 N*m (102 kgf*cm, 7 ft.*lbf) for except bolt A
  
  HINT:
  
  Make sure the tightening torque of bolt 1 and 11 in correct.
INSTALL OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter.
2. Install the oil control valve filter to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the head cover side) with the oil pipe union.
  NOTE: Remove any oil from the contact surface.
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.
  
  Fig 83: Identifying Oil Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Remove any oil from the contact surface.
4. Install bolt A to the cylinder head.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
5. Tighten the 2 oil pipe union bolts.
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Apply seal packing as shown in the figure below.
  Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the crankcase within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after the installation.
  Fig 84: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the gasket to the head cover.
3. Install the head cover with the 12 bolts in the order in the illustration.
  Torque:
  
  21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
  
  10 N*m (102 kgf*cm, 7 ft.*lbf) for except bolt A
  
  HINT:
  
  Make sure the tightening torque of bolts 1 and 10 is correct.
  
  Fig 85: Identifying Head Cover Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter.
2. Install the oil control valve filter to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the head cover side) with the oil pipe union.
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.
  NOTE: Remove any oil from the contract surface.
  
  Fig 86: Identifying No. 1 Oil Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 2 oil pipe union bolts.
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
INSTALL WATER OUTLET
1. Install 2 new gaskets and a new O-ring.
2. Apply soapy water to the O-ring.
3. Install the water outlet with the 2 bolts and 4 nuts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 88: Identifying Water Outlet Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Install the 4 camshaft timing oil control valves with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 89: Identifying Camshaft Timing Oil Control Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VVT SENSOR
1. Install the 4 VVT sensors with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 90: Identifying VVT Sensors Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG
1. Install the 6 spark plugs.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)