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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.
      Fig 1: Measuring Plastigage At Camshaft Widest Point
      G04974706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 2: Installing 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 in the illustration.

      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 3: Identifying Engine Rear Oil Seal Retainer
        G06112853Courtesy 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 4: Installing Oil Seal Retainer
      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) 

    2. Install the No. 1 water by-pass hose.
      Fig 5: Locating Water Inlet Pipe Bolts
      G06112816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 6: Placing Cylinder Head Gasket On Cylinder Block Surface With Front Face
        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 and in the sequence shown in the illustration.

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

        Fig 7: Installing Cylinder Head Bolts
        G04974784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Step 2
      1. Mark the cylinder head bolt head with paint as shown in the illustration.
      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 8: Tightening Cylinder Head Bolts
        G04974785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 9: Placing Cylinder Head Gasket On Cylinder Block Surface With Front Face
        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 in the sequence shown in the illustration.

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

        Fig 10: Installing Cylinder Head Bolts
        G04974787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Step 2
      1. Mark the cylinder head bolt head with paint as shown in the illustration.
      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 11: Tightening Cylinder Head Bolts
        G04974785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Tighten the 2 bolts in the order shown in the illustration.

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

  6. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the lash adjuster free of dirt and foreign objects.
    • Only use clean engine oil.
      Fig 12: Tightening 2 Bolts
      G04974789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the lash adjuster into a container filled with engine oil.
    2. Insert the tip of SST 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 in the illustration. 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.

    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: Inserting Tip Of SST Into Lash Adjuster's Plunger
      G06030521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Make sure that the 24 No. 1 valve rocker arms are installed as shown in the illustration.
  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.
      Fig 14: Identifying Valve Rocker Arm, Lash Adjuster And Valve Stem
      G06112864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Make sure to install camshaft bearing caps in each proper position and direction according to the painted marks and numbers.
      Fig 15: Identifying Marks And Numbers On Camshaft Bearing Caps
      G04974792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.

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

      Fig 16: Tightening Bolts In 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 in the illustration.
      Fig 17: Applying Engine Oil To Lash Adjuster Tips And Valve Stem Cap Ends
      G04974791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 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 18: Identifying Camshaft Housing Seal Area
        G06112868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

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

      NOTE:
      • When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. 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.
        Fig 19: Tightening Bolts In Sequence
        G04974796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 8 bolts in the order shown in the illustration.

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

  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.
      Fig 20: Tightening Bolts In Sequence
      G04974797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Make sure to install camshaft bearing caps in each proper position and direction according to the painted marks and numbers.
      Fig 21: Identifying Marks And Numbers On Camshaft Bearing Caps
      G04974798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the 8 bolts in the order shown in the illustration.

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

      Fig 22: Tightening Bolts In 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 in the illustration.
      Fig 23: Applying Engine Oil To Lash Adjuster Tips And Valve Stem Cap Ends
      G04974791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 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 24: Identifying Camshaft Housing Seal Area
        G06112874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

      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 in the illustration. 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 25: Tightening Bolts In Sequence
        G04974802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 8 bolts in the order shown in the illustration.

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

      Fig 26: Locating 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) 

    2. While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix it.
      Fig 27: Installing No 2 Chain Tensioner
      G04974804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.
    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 assembly LH with the No. 2 chain subassembly installed.
      Fig 28: Identifying Timing Mark
      G05136867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

      SST 09922-10010 

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

    5. Remove the pin from the No. 2 chain tensioner assembly.
      Fig 29: Loosening Flange Bolts Of Camshaft Timing Gear Assembly
      G05998373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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) 

    2. While pushing in the tensioner, insert a pin of 1.0 mm diameter (0.0394 in.) into the hole to hold it.
      Fig 30: Installing No 3 Chain Tensioner
      G04974807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) 
    1. Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.
    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 31: Identifying Timing Mark
      G05136870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

      SST 09922-10010 

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

    5. Remove the pin from the No. 3 chain tensioner assembly.
      Fig 32: Tightening Flange Bolts Of Camshaft Timing Gear Assembly
      G05998171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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) 

  17. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 No. 2 chain vibration dampers.
      Fig 33: Identifying No.1 Chain Vibration Damper Bolts
      G04974810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the 2 keys and crankshaft timing sprocket as shown in the illustration.
      Fig 34: Installing Crankshaft Timing Sprocket
      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.
      Fig 35: Locating Idle Sprocket Assembly
      G04974812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

      HINT:

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

  20. INSTALL CHAIN SUB-ASSEMBLY 
    1. Align the mark plate and timing marks as shown in the illustration and install the chain.

      HINT:

      The camshaft mark plates are orange.

      Fig 36: Identifying Timing Mark On Marking Plate
      G04974813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.
      Fig 37: Identifying Chain Set
      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 38: Turning Camshaft Timing Gear Assembly
      G04974815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.

      HINT:

      The crankshaft mark plate is yellow.

    5. Temporarily tighten the pulley set bolt.
      Fig 39: Identifying Timing Mark
      G05136878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).
  21. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
      Fig 40: Identifying Timing Mark
      G05136879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
    2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
      Fig 41: Moving Stopper Plate Upward To Release Lock
      G04974818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.
    5. Check the camshaft timing marks.
      NOTE:
      • Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.
      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
        Fig 42: Installing Chain Tensioner With Bolts
        G04974606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Check that each camshaft timing mark is positioned as shown in the illustration.
      Fig 43: Identifying Camshaft Timing Mark Position
      G05998387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 44: Identifying Timing Mark Of Camshaft Position
      G05998386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      For the intake camshaft:

      Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

    7. If the valve timing is misaligned, reinstall the timing chain.
    8. Remove the pulley set bolt.
  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 45: Installing 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: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
      Fig 46: Locating Water Pump With 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 in the following illustration.
      Fig 47: Applying Seal Packing
      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 in the illustration.
      • 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 in the following illustration.
      Fig 48: Identifying Timing Chain Cover Seal Packing Area
      G06112898Courtesy 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 DIAMETER CHART

      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 0.157 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 0.157 in.)
      Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.)
    3. Install a new gasket.
      Fig 49: Installing Gasket
      G04974825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.
    5. Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.
      Fig 50: Identifying Drive Rotor Spline And Crankshaft
      G06112900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 51: Locating Timing Chain Cover Bolts And Nuts
      G06112901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 in the illustration.

    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 in the illustration.

    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) 

  26. INSTALL WATER INLET HOUSING 
    1. Install 2 new O-rings.

      HINT:

      Apply a small amount of water or soapy water to CD-ring (A) in the illustration before installation.

      Fig 52: Locating O-Ring
      G04974828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 stud bolts.

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

      Fig 53: 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.
    4. Connect the No. 1 water by-pass hose.
    5. Apply adhesive around the drain cock.
      Fig 54: Removing Bolts, Nut, And Water Inlet Housing
      G04974580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 55: 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 56: Locating Water Inlet With 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.
    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) 

      Fig 57: Identifying Stud Bolt Length
      G04974833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. Install the No. 1 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 in the illustration before tightening the other bolts.

      Fig 58: Locating 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.
      Fig 59: Locating Stud Bolt
      G06112909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt B 

    2. Install 2 new O-rings.
      Fig 60: Locating O-Rings
      G04974593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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 diameter: 

      3.0 to 4.0 mm (0.118 to 0.157 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 61: Identifying Oil Pan Seal Packing Area
        G06112911Courtesy 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 except bolt A 

      Fig 62: Locating Oil Pan Bolts And Nuts
      G06112912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.

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

      Fig 63: Locating Stud Bolts And 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 64: Installing Gasket And Oil Strainer With Bolt And 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 in the illustration.

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

      Fig 65: Installing No. 2 Oil Pan Sub-Assembly
      G04974841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 diameter: 

      3.0 to 4.0 mm (0.118 to 0.157 in.) 

      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.
        Fig 66: Identifying No. 2 Oil Pan Sub-Assembly Seal Packing Area
        G06112916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 67: Identifying Oil Pan With Bolts And 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 68: Locating Oil Pan Drain Plug
      G04974564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) 
    1. Apply seal packing as shown in the illustration.

      Seal packing: 

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the head cover within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
        Fig 69: Applying Seal Packing
        G04974845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 3 new gaskets as shown in the illustration.
    3. Install a new gasket to the head cover.
      Fig 70: Identifying Gaskets
      G04974585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 except bolt A 

      HINT:

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

      Fig 71: Identifying Head Cover With Bolts
      G04974847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) 
    1. Apply seal packing 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 cover sub-assembly within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
        Fig 72: Applying Seal Packing
        G04974848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 3 new gaskets as shown in the illustration.
    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
      Fig 73: Identifying Gaskets
      G04974587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 except bolt A 

      HINT:

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

      Fig 74: Installing Head Cover With Bolts And 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 75: Locating Gaskets And 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 76: Removing Bolts, Nuts And 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 77: Locating No. 1 Engine Oil Level Dipstick Guide
      G06030685Courtesy 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 78: Locating No. 2 Dipstick Guide And Bolt
      G06112928Courtesy 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 in the illustration.

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

      Fig 79: Installing 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 80: Removing Bolt, Nuts, No. 1 Oil Cooler Bracket, And 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 81: Removing Bolts, Nuts, And 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 82: Removing Union Bolt, Oil Cooler Assembly, And 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) 

  39. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
      Fig 83: Removing Bolt, Clamps, And Clips
      G05136636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 84: Installing Crankshaft Pulley Bolt Using SST
      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.
      Fig 85: Applying Light Coat Of Engine Oil To O-Ring
      G04974575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful that the O-ring does not get caught between any parts.
      • The O-ring must not be twisted on the groove.
    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 in the illustration.
      Fig 86: Tightening Oil Filter Cap
      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.
    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.
      Fig 87: Locating Oil Filter Drain Plug To Oil Filter Cap
      G04996989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 88: Applying Adhesive To 2 Or 3 Threads Of Drain Cocks
      G04943675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water drain cocks as shown in the illustration.

      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.
    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.
      Fig 89: Installing Water Drain Cocks
      G05136925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union bolt.
    3. 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).
    4. 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 90: Removing Oil Control Valve Filter LH And Gaskets
      G04974569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the oil pipe union (on the head cover side).

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

  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 a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union bolt.
    3. 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).
    4. Tighten the oil pipe union (on the cylinder head side).

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

      Fig 91: Locating Oil Pipe Union
      G06112941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
    5. Tighten the oil pipe union (on the head cover side).

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

    6. Install the bolt (A) to the cylinder head.

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

  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 92: Locating Crankshaft Position Sensor
      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 93: Installing 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) 

  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 

      Fig 94: Removing Bolts And Camshaft Position Sensors
      G05136624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the ventilation valve sub-assembly.

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

  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 the oil filler gasket.
    2. Install the oil filler cap sub-assembly.
      Fig 95: Identifying Ventilation Valve Sub-Assembly
      G04974565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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