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Installation [02/2014 - 11/2016]: Procedure

  1. INSTALL NO. 3 CAMSHAFT 
    1. Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH.
    2. Install the No. 3 camshaft to the camshaft housing sub-assembly LH.

      HINT: 

      Perform "Inspection After Repair" after replacing the No. 3 camshaft.

      Refer to INITIALIZATION [02/2014 - 11/2016]

  2. INSTALL NO. 4 CAMSHAFT 
    1. Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.
    2. Install the No. 4 camshaft to the camshaft housing sub-assembly LH.

      HINT: 

      Perform "Inspection After Repair" after replacing the No. 4 camshaft.

      Refer to INITIALIZATION [02/2014 - 11/2016]

  3. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 
    1. Apply engine oil to the 5 camshaft bearing caps.
    2. Confirm the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
      GTY429837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily tighten the 8 bolts in the order shown in the illustration.
      Fig 1: Tightening Sequence Of 8 Camshaft Bearing Cap Bolts (For Bank 2)
      GTY431631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 
    GTY479604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Inner Compression Spring
    *a Valve Spring Retainer Diameter
    *b No. 1 Valve Rocker Arm Sub-assembly Roller Width

    HINT: 

    Type A and Type B can be distinguished by the shape of the compression spring.

    Type No. 1 Valve Rocker Arm Sub-assembly Roller Width Valve Spring Retainer Diameter Inner Compression Spring Shape
    A 10.7 mm (0.421 in.) 23.4 mm (0.921 in.) Straight
    B 8.0 mm (0.315 in.) 18.9 mm (0.744 in.) Taper
    1. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY472310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A
      *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY453918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Continuous Line Area (Seal Packing)
      *b Dashed Line Area (Seal Packing)

      Seal Packing

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

      Seal Packing Application Chart

      Area Seal Packing Diameter
      Continuous Line Area 2.7 to 4.5 mm (0.107 to 0.177 in.)
      Dashed Line Area 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 and tighten the bolts within 3 minutes.
      • Do not start the engine for at least 2 hours after installation.
    3. Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.
      Fig 2: Tightening Sequence Of Camshaft Housing Sub-Assembly LH
      GTY440573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Front View

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

      NOTE:
      • When installing the camshaft housing sub-assembly LH, correctly position the camshafts as shown in the illustration. Failure to do so may result in damage due to contact between the pistons and valves. If a camshaft is rotated, valve contact with a piston at TDC may occur.
      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing sub-assembly LH 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 in the illustration.
      Fig 3: Tightening Sequence Of Camshaft Housing Sub-Assembly LH
      GTY440175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  5. INSTALL CAMSHAFT 
    1. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH.
    2. Install the camshaft to the camshaft housing sub-assembly RH.

      HINT: 

      Perform "Inspection After Repair" after replacing the camshaft.

      Refer to INITIALIZATION [02/2014 - 11/2016]

  6. INSTALL NO. 2 CAMSHAFT 
    1. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH.
    2. Install the No. 2 camshaft to the camshaft housing sub-assembly RH.

      HINT: 

      Perform "Inspection After Repair" after replacing the No. 2 camshaft.

      Refer to INITIALIZATION [02/2014 - 11/2016]

  7. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 
    1. Apply engine oil to the camshaft bearing caps.
    2. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.
      GTY451712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily tighten the 8 bolts in the order shown in the illustration.
      Fig 4: Tightening Sequence Of Camshaft Bearing Cap Bolts (For Bank 1)
      GTY436917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  8. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    GTY479604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Inner Compression Spring
    *a Valve Spring Retainer Diameter
    *b No. 1 Valve Rocker Arm Sub-assembly Roller Width

    HINT: 

    Type A and Type B can be distinguished by the shape of the compression spring.

    Type No. 1 Valve Rocker Arm Sub-assembly Roller Width Valve Spring Retainer Diameter Inner Compression Spring Shape
    A 10.7 mm (0.421 in.) 23.4 mm (0.921 in.) Straight
    B 8.0 mm (0.315 in.) 18.9 mm (0.744 in.) Taper
    1. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
      GTY472310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A
      *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY442728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Continuous Line Area (Seal Packing)
      *b Dashed Line Area (Seal Packing)

      Seal Packing

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

      Seal Packing Application Chart

      Area Seal Packing Diameter
      Continuous Line Area 2.7 to 4.5 mm (0.107 to 0.177 in.)
      Dashed Line Area 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 RH and tighten the bolts within 3 minutes.
      • Do not start the engine for at least 2 hours after installation.
    3. Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.
      Fig 5: Tightening Sequence Of Camshaft Housing Sub-Assembly RH
      GTY427652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Front View

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

      NOTE:
      • When installing the camshaft housing sub-assembly RH, correctly position the camshafts as shown in the illustration.

        Failure to do so may result in damage due to contact between the pistons and valves. If a camshaft is rotated, valve contact with a piston at TDC may occur.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces, and reapply seal packing.
      • If the camshaft housing sub-assembly RH 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 in the illustration.
      Fig 6: Tightening Sequence Of Camshaft Housing Sub-Assembly RH
      GTY449575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  9. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 3 chain tensioner assembly with the bolt.
      GTY448244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
      *b Pin
      *c Push

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

    2. While pushing down the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure it.
  10. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING SPROCKET AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing sprocket as shown in the illustration.
      GTY436597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    2. Apply a light coat of engine oil to the bolt threads and bolt seating surface.
    3. Align the knock pin of the No. 3 camshaft and No. 4 camshaft with the pin hole of the camshaft timing gear assembly and camshaft timing sprocket. Install the camshaft timing gear assembly and camshaft timing sprocket with the No. 2 chain sub-assembly installed.
    4. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing sprocket.
      • SST: 09922-10010 

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

    5. Remove the pin from the No. 3 chain tensioner assembly.

      HINT: 

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

      Refer to INITIALIZATION [02/2014 - 11/2016]

  11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Install the No. 2 chain tensioner assembly with the bolt.
      GTY445187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
      *b Pin
      *c Push

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

    2. While pushing up the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure it.
  12. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING SPROCKET AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) 
    1. Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing sprocket as shown in the illustration.
      GTY452385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Mark Plate
    2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
    3. Align the knock pin of the camshaft and No. 2 camshaft with the pin hole of the camshaft timing gear assembly and camshaft timing sprocket. Install the camshaft timing gear assembly and camshaft timing sprocket with the No. 2 chain sub-assembly installed.
    4. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing sprocket.
      • SST: 09922-10010 

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

    5. Remove the pin from the No. 2 chain tensioner assembly.

      HINT: 

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

      Refer to INITIALIZATION [02/2014 - 11/2016]

  13. INSTALL IDLE SPROCKET ASSEMBLY 

    See step  26

  14. INSTALL CHAIN SUB-ASSEMBLY 

    See step  27

  15. INSTALL CHAIN TENSIONER SLIPPER 

    See step  28

  16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    See step  29

  17. INSPECT VALVE TIMING 

    See step  30

  18. INSTALL TIMING CHAIN CASE OIL SEAL 

    Refer to PROCEDURE - Step 1

  19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  20. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Install 2 new O-rings.
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY433683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing

      Seal Packing

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

      Seal Packing Diameter

      2.5 to 3.5 mm (0.0985 to 0.1377 in.)

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

      Bolt (A) 

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

      Except Bolt (A) 

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

      GTY539166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A
      *B Type B
      Bolt
      Nut
  21. INSTALL OIL STRAINER SUB-ASSEMBLY 

    See step  39

  22. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 

    See step  40

  23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    See step  42

  24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 

    See step  43

  25. INSTALL WATER INLET HOUSING 

    See step  35

  26. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH 

    See step  36

  27. INSTALL CRANKSHAFT PULLEY 

    See step  2

  28. INSTALL NO. 1 OIL PIPE 

    See step  52

  29. INSTALL OIL PIPE 

    See step  53

  30. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  31. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  32. INSTALL WATER PUMP PULLEY 

    See step  6

  33. INSTALL NO. 2 TIMING GEAR COVER 

    See step  7

  34. INSTALL NO. 1 OIL COOLER BRACKET 

    See step  46

  35. INSTALL OIL COOLER ASSEMBLY 

    See step  47

  36. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 

    See step  8

  37. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH 

    Refer to PROCEDURE - Step 1

  38. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 2

  39. INSTALL NO. 2 MANIFOLD STAY 

    Refer to PROCEDURE - Step 3

  40. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

  41. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    See step  45

  42. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 

    See step  19

  43. INSTALL EXHAUST MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 9

  44. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 10

  45. INSTALL NO. 1 EGR PIPE 

    Refer to PROCEDURE - Step 11

  46. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 2

  47. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side) 

    Refer to PROCEDURE - Step 5

  48. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  49. INSTALL EGR DELIVERY CHAMBER 

    Refer to PROCEDURE - Step 7

  50. INSTALL EGR COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  51. INSTALL NO. 2 EGR PIPE 

    Refer to PROCEDURE - Step 2

  52. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 11

  53. INSTALL ENGINE MOUNTING BRACKET RH 

    See step  14

  54. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  55. INSTALL V-RIBBED BELT 

    See step  1

  56. INSTALL ENGINE HANGERS 

    See step  50 , or see step  50

  57. REMOVE ENGINE FROM ENGINE STAND 

    Refer to INSTALLATION [02/2014 - 11/2015] , or refer to INSTALLATION [11/2015 - 11/2016] 

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