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Engine Unit: Reassembly

CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE VALVE TIMING PROCEDURE .
  1. INSTALL ENGINE REAR OIL SEAL 
    1. Place the oil seal retainer on wooden blocks.
    2. Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge.

      SST 09223-15030, 09950-70010 (09951-07100) 

      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap on the engine rear oil seal at an angle.
      Fig 1: Using SST & Hammer To Install Engine Rear Oil Seal
      G04974779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Apply seal packing in a continuous line as shown below.

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

      Seal diameter: 2.0 to 3.0 mm (0.079 to 0.118 in.) 

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the oil seal retainer within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      Fig 2: Identifying Seal Packing In Continuous Line
      G05414642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine rear oil seal retainer with the 6 bolts.

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

      NOTE: Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 3: Identifying Engine Rear Oil Seal Retainer Bolts
      G04974781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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 4: Identifying Water Inlet Pipe Bolts
      G05414605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 water by-pass hose.
  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH 
    1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
      NOTE:
      • Be careful of the installation direction.
      • Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
      Fig 5: Placing Cylinder Head Gasket On Cylinder Block Surface
      G04974783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the cylinder head on the cylinder block.
      NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      HINT:

      The cylinder head bolts are tightened in 3 progressive steps.

    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
    4. 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 shown below.

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

        Fig 6: Identifying Cylinder Head Bolts
        G04974784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Step 2
      1. Mark the cylinder head bolt head with paint as shown below.
      2. Tighten the cylinder head bolts another 90°.
        3. Fig 7: Identifying Painted Mark
        G04974785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Step 3
      1. Tighten the cylinder head bolts an additional 90°.
      2. Check that the painted mark is now facing rearward.
  5. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH 
    1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
      NOTE:
      • Be careful of the installation direction.
      • Gently lower the cylinder head in order not to damage the gasket with the bottom part of the head.
      Fig 8: Placing Cylinder Head Gasket On Cylinder Block Surface
      G04974786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the cylinder head on the cylinder block.
      NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.

      HINT:

      The cylinder head bolts are tightened in 3 progressive steps.

    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
    4. 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 shown below.

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

        Fig 9: Identifying Cylinder Head Bolts
        G04974787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Step 2
      1. Mark the cylinder head bolt head with paint as shown below.
      2. Tighten the cylinder head bolts another 90°.
    6. Step 3
      1. Tighten the cylinder head bolts an additional 90°.
      2. Check that the painted mark is now facing rearward.
      Fig 10: Identifying Painted Mark
      G04974785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Tighten the 2 bolts in the order shown below.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      Fig 11: Identifying Tightening Sequence Of Bolts
      G04974789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the lash adjuster free of dirt and foreign objects.
    • Only use clean engine oil.
    1. Place the lash adjuster into a container filled with engine oil.
    2. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

      SST 09276-75010 

    3. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.
    4. Check the movement of the plunger and bleed the air.

      OK: Plunger moves up and down. 

      NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown below. If the check ball is not pressed, air will not bleed.
    5. After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly with by hand.

      OK: Plunger is very difficult to move. 

      If the result is not as specified, replace the lash adjuster.

      Fig 12: Inserting SST Tip Into Lash Adjuster Plunger
      G05414207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the lash adjusters.
      NOTE: Install the lash adjuster to the same place where it was removed from.
  7. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the lash adjuster tip and valve stem cap end.
      Fig 13: Applying Engine Oil To Lash Adjuster Tips & Valve Stem Cap Ends
      G05414653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Make sure that the 24 No. 1 valve rocker arms are installed.
  8. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 
    1. Apply engine oil to the camshaft journals, camshaft housing sub-assembly RH and camshaft bearing caps.
    2. Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly RH.
    3. Make sure to install camshaft bearing caps in each proper position and direction according to the painted marks and numbers.
      Fig 14: Identifying Marks & Numbers On Camshaft Bearing Caps
      G04974792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the 8 bearing cap bolts in the order shown below.

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

      Fig 15: Identifying Bearing Cap Bolts Tightening Sequence
      G04974793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    1. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown below.
      Fig 16: Identifying Valve Rocker Arm
      G04974791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing in a continuous line as shown below.

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

      Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.) 

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the camshaft housing sub-assembly RH within 3 minutes.
      • Do not start the engine for at least 2 hours after installing.
      Fig 17: Applying Seal Packing
      G05414657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown below.

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

      Fig 18: Identifying Camshaft Housing RH Bolts Tightening Sequence
      G04974796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown below. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
      • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing sub-assembly is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
    4. Tighten the 8 bolts in the order shown below.

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

      Fig 19: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
      G04974797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 
    1. Apply engine oil to the camshaft journals, camshaft housing sub-assembly LH and camshaft bearing caps.
    2. Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing sub-assembly LH.
    3. Make sure to install camshaft bearing caps in each proper position and direction according to the painted marks and numbers.
      Fig 20: Identifying Marks & Numbers On Camshaft Bearing Caps
      G04974798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the 8 bolts in the order shown below.

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

      Fig 21: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
      G04974799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 
    1. Make sure that the valve rocker arm is installed as shown below.
      Fig 22: Identifying Valve Rocker Arm
      G04974791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing in a continuous line as shown below.

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

      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 sub-assembly LH within 3 minutes.
      • Do not start the engine for at least 2 hours after installing.
      Fig 23: Applying Seal Packing
      G05414663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown below.

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

      NOTE:
      • When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown below. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
      • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
      Fig 24: Identifying Camshaft Housing Bolts Tightening Sequence
      G04974802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 8 bolts in the order shown below.

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

      Fig 25: Identifying Bolts
      G04974803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 2 chain tensioner assembly with the bolt.

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

      Fig 26: Identifying No. 2 Chain Tensioner Assembly Bolt
      G04974804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) diameter into the hole to fix it.
  13. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) 
    1. Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gear assemblies as shown below.
    2. Apply a light coat 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 assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear RH with the No. 2 chain sub-assembly installed.
      Fig 27: Identifying Timing Mark
      G05136867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts and camshaft timing gear assemblies.

      Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 

      Fig 28: Holding Hexagonal Portion Of Camshaft With Wrench
      G04974806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the pin from the No. 2 chain tensioner assembly.
  14. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 3 chain tensioner assembly with the bolt.

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

      Fig 29: Identifying No. 3 Chain Tensioner Assembly Bolt
      G04974807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While pushing in the tensioner, insert a pin of 1.0 mm diameter (0.039 in.) into the hole to hold it.
  15. 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 gear assemblies as shown below.
    2. Apply a light coat 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 assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.
      Fig 30: Identifying Timing Mark
      G05136870Courtesy 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 (1020 kgf*cm, 74 ft.*lbf) 

      Fig 31: Holding Hexagonal Portion Of Camshaft Using Wrench
      G04974809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the pin from the No. 3 chain tensioner assembly.
  16. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

      Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf) 

      Fig 32: Identifying No. 1 Chain Vibration Damper Bolts
      G04974810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 No. 2 chain vibration dampers.
  18. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the 2 keys and crankshaft timing sprocket as shown below.
      Fig 33: Identifying Crankshaft Timing Sprocket & Keys
      G04974612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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 installation position.

      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.

      Fig 34: Identifying Idle Sprocket Assembly
      G04974812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL CHAIN SUB-ASSEMBLY 
    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 and timing marks as shown below and install the chain.

      HINT:

      The camshaft mark plates are orange.

      Fig 35: Identifying Timing Mark On Marking Plate
      G04974813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Do not pass the chain over the crankshaft, just temporally place it on the crankshaft.
      Fig 36: Identifying Crankshaft Timing Sprocket
      G04974608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks.
      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 between the banks.
      Fig 37: Turning Camshaft Timing Gear Assembly
      G04974815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the mark plate and timing marks as shown below and install the chain onto the crankshaft timing sprocket.

      HINT:

      The crankshaft mark plate is yellow.

      Fig 38: Identifying Timing Mark
      G05136878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Temporarily tighten the pulley set bolt.
    6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).
      Fig 39: Identifying Timing Mark & Center Line
      G05136879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
  22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
      Fig 40: Moving Stopper Plate Upward To Release Lock
      G04974818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 No. 1 chain tensioner assembly with the 2 bolts.

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

      Fig 41: Identifying No. 1 Chain Tensioner With Bolts
      G04974606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly. Check that each timing mark is aligned with the crankshaft at the TDC/compression.
    5. Remove the pulley set bolt.
      6. Fig 42: Identifying Timing Mark Alignment
      G05136882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL TIMING CHAIN CASE OIL SEAL 
    1. Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge.

      SST 09223-22010, 09506-35010 

      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap on the oil seal at an angle.
      • Make sure that the oil seal edge does not stick out of the timing chain case.
      Fig 43: Using SST To Install New Timing Chain Case Oil Seal
      G04974821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL WATER PUMP ASSEMBLY 
    1. Install a new water pump gasket and the water pump assembly with the 8 bolts.

      Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 

      NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
      Fig 44: Identifying Water Pump Assembly Bolts
      G04974822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line to the engine unit as shown below.
      Fig 45: Applying Seal Packing To Engine Unit
      G04974823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Seal diameter: 3.0 mm (0.118 in.) 

      NOTE:
      • Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C shown below.
      • If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • Install the chain cover within 3 minutes.
      • Do not start the engine for at least 2 hours after installing.
    2. Apply seal packing in a continuous line to the timing chain cover as shown below.
      Fig 46: Applying Seal Packing To Timing Chain
      G05414686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent 

      NOTE:
      • If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • install the chain cover 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 installing.

      Apply seal packing as follows 

      SEAL PACKING SPECIFICATION

      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm or more (0.177 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Alternate Long and Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.)
      Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.)
    3. Install a new gasket.
      Fig 47: Identifying New Gasket
      G04974825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the oil pump's drive rotor spline and the crankshaft as shown below. Install the spline and chain cover to the crankshaft.
      Fig 48: Identifying Driver Rotor Spline & Crankshaft
      G05414688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

      Bolt length 

      BOLT LENGTH SPECIFICATION

      Item Length
      Bolt A 40 mm (1.57 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 25 mm (0.98 in.)
      NOTE: Make sure that there is no oil on the bolt and nut threads.
    6. Fully tighten the bolts in this order: Area 1 and Area 2.

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

    7. Fully tighten the bolts in Area 3.

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

      HINT:

      First tighten the upper bolts and nuts followed by lower bolts and nuts as shown below.

    8. Fully tighten the bolts in Area 4.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A 

      21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except bolt A 

      HINT:

      Tighten the bolts in the order of lower to upper as shown below.

    9. Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.

      Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 

      Fig 49: Identifying Timing Chain Cover With Bolts & Nuts
      G05414689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL WATER INLET HOUSING 
    1. Install 2 new O-rings.

      HINT:

      Apply a small amount of water or soapy water to O-ring (A) shown below before installation.

      Fig 50: Identifying Water Inlet Housing O-Rings
      G04974828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 stud bolts.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      Fig 51: Identifying Stud Bolt Length
      G04974829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the water inlet housing with the 2 bolts and nut.

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

      NOTE: Be careful that the O-ring does not get caught between the parts.
      Fig 52: Identifying Water Inlet Housing With Bolts & Nut
      G04974580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the No. 1 water by-pass hose.
    5. Apply adhesive around the drain cock.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    6. Install the drain cock assembly to the water inlet housing.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

    7. Install the drain cock plug to the drain cock assembly.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

    8. Install a new gasket to the thermostat.
    9. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

      HINT:

      The jiggle valve may be set within 10° of either side of the prescribed position.

      Fig 53: Identifying Jiggle Valve Angles
      G04974831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the water inlet with the 2 nuts.

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

      Fig 54: Identifying Water Inlet Nuts
      G04974579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    1. Install the No. 1 front engine mounting bracket LH with the 6 bolts.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      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 installation.
      Fig 55: Identifying No. 1 Front Engine Mounting Bracket Bolts
      G04974833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.

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

  28. INSTALL OIL PAN BAFFLE PLATE NO.1 
    1. Install the oil pan baffle plate with the 7 bolts.

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

      HINT:

      Temporarily tighten the 7 bolts. Fully tighten 2 bolts (A) as shown below before tightening the other bolts.

      Fig 56: Identifying Oil Pan Baffle Plate Bolts
      G04974834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL OIL PAN SUB-ASSEMBLY 
    1. When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.

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

      Fig 57: Identifying Stud Bolt Installation Procedure
      G05136897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 2 new O-rings.
      Fig 58: Identifying New O-Rings
      G04974593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply seal packing in a continuous line as shown below.

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

      Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
      Fig 59: Applying Seal Packing
      G05414699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the oil pan with the 16 bolts and 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A 

      21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A 

      Fig 60: Identifying Oil Pan With Bolts & Nuts
      G05414566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Using an E6 "TORX" socket, install the stud bolts as shown below.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      Fig 61: Identifying Stud Bolts & Length
      G04974839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

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

      Fig 62: Identifying Gasket & Oil Strainer Sub-Assembly With Bolt & Nuts
      G04974840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Using an E6 "TORX" socket, install the stud bolts as shown below.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      Fig 63: Identifying No. 2 Oil Pan Sub-Assembly Stud Bolts
      G04974841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing in a continuous line as shown below.

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

      Seal diameter: 3.0 to 4.0 mm (0.118 to 0.158 in.) 

      Fig 64: Applying Seal Packing
      G05414704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
    3. Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

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

      Fig 65: Identifying No. 2 Oil Pan With Bolts & Nuts
      G04974588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new oil pan drain plug gasket and the oil pan drain plug.

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

      Fig 66: Identifying Oil Pan Drain Plug & Gasket
      G04974564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) 
    1. Apply seal packing as shown below.

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the head cover within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
      Fig 67: Applying Seal Packing
      G04974845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 3 new gaskets as shown below.
      Fig 68: Identifying New Gaskets
      G04974585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new gasket to the head cover.
    4. Install a head cover with the 12 bolts and a new seal washer.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 

      10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A 

      HINT:

      After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

      Fig 69: Identifying Head Cover Bolts
      G04974847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) 
    1. Apply seal packing as shown below.

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

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
      Fig 70: Applying Seal Packing
      G04974848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 3 new gaskets as shown below.
      Fig 71: Identifying New Gaskets
      G04974587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
    4. Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A 

      10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A 

      HINT:

      After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

      Fig 72: Identifying Cylinder Head Cover With Bolts & Seal Washer
      G04974850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL WATER OUTLET 
    1. Install 2 new gaskets and a new O-ring.

      HINT:

      Apply soapy water to the O-ring.

      Fig 73: Identifying Gaskets & O-Ring
      G04974583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water outlet with the 2 bolts and 4 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts 

      10 N*m (102 kgf*cm, 7 ft.*lbf) for nuts 

      NOTE: Be careful that the O-ring does not get caught between the parts.
      Fig 74: Identifying Bolts, Nuts & Water Outlet
      G04974582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring and install it to the No. 1 engine oil level dipstick guide.
      Fig 75: Identifying No. 1 Engine Oil Level Dipstick Guide
      G05414552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt and No. 2 dipstick guide.

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

      Fig 76: Identifying No. 2 Dipstick Guide Bolt
      G05414716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL NO. 1 OIL COOLER BRACKET (w/ OIL COOLER) 
    1. Using an E8 "TORX" socket, install the 2 stud bolts as shown below.

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

      Fig 77: Identifying Stud Bolts
      G05136915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket to the No. 1 oil cooler bracket.
    3. Install the oil cooler pipe with the bolt and 2 nuts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 78: Identifying Bolt, Nuts, No. 1 Oil Cooler Bracket & Gasket
      G05136639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new gasket to the No. 1 oil pan.
    5. Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 79: Identifying Bolts, Nuts & Oil Cooler Pipe With No. 1 Oil Cooler Bracket
      G05136638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL OIL COOLER ASSEMBLY (w/ OIL COOLER) 
    1. Install a new O-ring.
    2. Install the oil cooler assembly with the union bolt.

      Torque: 68 N*m (693 kgf*cm, 50 ft.*lbf) 

      Fig 80: Identifying Union Bolt, Oil Cooler Assembly & O-Ring
      G05136637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.

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

      Fig 81: Identifying Bolt, Clamps & Clips
      G05136636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. 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 (2550 kgf*cm, 184 ft.*lbf) 

      Fig 82: Using SST To Install Crankshaft Pulley Bolt
      G04974853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL OIL FILTER ELEMENT 
    1. Clean the inside of the oil filter cap sub-assembly, the threads and O-ring groove.
    2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap sub-assembly.
    3. Set a new oil filter element to the oil filter cap sub-assembly.
    4. Remove dirt and foreign matter from the installation surface of the engine.
    5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap sub-assembly.
      NOTE:
      • Be careful that the O-ring does not get caught between any parts.
      • The O-ring must not be twisted on the groove.
      Fig 83: Identifying Oil Filter Element & O-Ring
      G04974575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST, tighten the oil filter cap sub-assembly.

      SST 09228-06501 

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

      NOTE: Make sure that the oil filter is installed securely as shown below.
      Fig 84: Tightening Oil Filter Cap Sub-Assembly Using SST
      G04974855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
      NOTE: Remove all dirt and foreign matter from the installation surfaces.
      Fig 85: Identifying O-Ring Location
      G04996989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the oil filter drain plug to the oil filter cap sub-assembly.

      Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) 

      NOTE: Make sure that the O-ring does not get caught between the parts.
  41. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply adhesive around the drain cock sub-assembly.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 86: Applying Adhesive Around Drain Cocks
      G04943675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water drain cocks as shown below.

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

      NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
      Fig 87: Identifying Water Drain Cocks
      G05136925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the water drain cock plugs to the water drain cocks.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

  42. INSTALL NO. 1 OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
      NOTE: Do not touch the mesh when installing the oil control valve filter.
    2. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
    4. Tighten the oil pipe union (on the head cover side).

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

    5. Tighten the oil pipe union (on the cylinder head side).

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

      NOTE: If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
      Fig 88: Identifying Oil Pipe Union (1 Of 2)
      G04974569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
      NOTE: Do not touch the mesh when installing the oil control valve filter.
    2. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
    4. Install the bolt (A) to the cylinder head.

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

    5. Tighten the oil pipe union (on the head cover side).

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

    6. Tighten the oil pipe union (on the cylinder head side).

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

      NOTE: If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
      Fig 89: Identifying Oil Pipe Union (2 Of 2)
      G04974860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Install the crankshaft position sensor with the bolt.

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

      Fig 90: Identifying Crankshaft Position Sensor Bolt
      G04974861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. 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 91: Identifying Camshaft Timing Oil Control Valves With Bolts
      G05136929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL CAMSHAFT POSITION SENSOR 
    1. Install the 4 camshaft position sensors with the 4 bolts.

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

      Fig 92: Identifying Camshaft Position Sensors & Bolts
      G05136624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL VENTILATION VALVE SUB-ASSEMBLY 
    1. Apply adhesive around the ventilation valve sub-assembly.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    2. Install the ventilation valve sub-assembly.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      Fig 93: Identifying Ventilation Valve Sub-Assembly
      G04974565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL SPARK PLUG 
    1. Install the 6 spark plugs.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

  49. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install a new oil filler gasket.
    2. Install the oil filler cap sub-assembly.
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