Reassembly [08/2015 - 08/2016]: Procedure
- INSTALL STUD BOLT
- Install the timing chain cover stud bolt.
- Using an E10 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
- Using an E10 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
Install the oil pan stud bolt.
- Using an E6 and E7 "TORX" socket wrench, install the 3 stud bolts as shown in the illustration.
for stud bolt A
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
for stud bolt B
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
- Using an E6 and E7 "TORX" socket wrench, install the 3 stud bolts as shown in the illustration.
- Install the timing chain cover stud bolt.
- INSTALL RING PIN
- INSTALL REAR CRANKSHAFT OIL SEAL
- INSTALL OIL DRAIN PIPE SUBASSEMBLY
- Apply a light coat of engine oil to a new O-ring.
- Install the O-ring to the drain pipe.
- Install the oil drain pipe with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- INSTALL ENGINE REAR OIL SEAL RETAINER
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard Seal diameter
2.0 to 3.0 mm (0.0787 to 0.118 in.)
Application position from inside edge of retainer
3.5 mm (0.138 in.)
NOTE:- Remove any oil from the contact surface.
- Install the oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Install the oil seal retainer with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NOTE:- Do not start the engine for at least 2 hours after installing.
- When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.
- When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.
- Apply seal packing in a continuous line as shown in the illustration.
- INSTALL OIL STRAINER SUBASSEMBLY
- Apply a light coat of engine oil to a new O-ring.
- Install the O-ring to the oil strainer.
- Install the oil strainer with the 2 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
NOTE:Make sure the O-ring is not twisted or damaged.
- INSTALL NO. 1 OIL PAN BAFFLE PLATE
- Install the baffle plate with the 7 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
- Install the baffle plate with the 7 bolts.
- INSTALL NO. 1 OIL PAN SUBASSEMBLY
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard 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 and tighten the bolts and nuts within 15 minutes after applying seal packing.
Install the oil pan with the 14 bolts and 2 nuts.
for bolt A
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
for bolt B
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
for nut
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
NOTE:Do not start the engine for at least 2 hours after installing.
Standard Bolt
Item Length Thread Diameter Bolt A 92 mm (3.62 in.) 6 mm (0.236 in.) Bolt B 30 mm (1.18 in.) 10 mm (0.394 in.)
- Apply seal packing in a continuous line as shown in the illustration.
- INSTALL NO. 2 OIL PAN SUBASSEMBLY
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard 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 and tighten the bolts and nuts within 15 minutes after applying seal packing.
Install the oil pan with the 14 bolts and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NOTE:Do not start the engine for at least 2 hours after installing.
- Apply seal packing in a continuous line as shown in the illustration.
- INSTALL NO. 1 HEAT EXCHANGER COVER
- Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Standard seal diameter
3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTE:- Remove any oil from the contact surface.
- Install the heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
Install the heat exchanger cover with the 12 bolts and 2 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
NOTE:Do not start the engine for at least 2 hours after installing.
Standard Bolt
Item Length Thread Diameter Bolt A 20 mm (0.787 in.) 8 mm (0.315 in.) Bolt B 70 mm (2.76 in.) 8 mm (0.315 in.) Bolt C 16 mm (0.630 in.) 6 mm (0.236 in.)
- Apply seal packing in a continuous line as shown in the illustration.
- INSTALL VENTILATION PIPE GASKET
- Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.
- SST: 09950-60010
- 09951-00360
- SST: 09950-70010
- 09951-07100
NOTE:- Do not tap the gasket at an angle.
- Do not tap the gasket excessively.
- SST: 09950-60010
- Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.
- INSTALL CYLINDER BLOCK WATER JACKET SPACER
- Install the 2 water jacket spacers as shown in the illustration.
HINT:
- Face the cutouts indicated by the arrows in illustration away from the engine.
- Face the "UP" mark as shown in the illustration.
- Install the 2 water jacket spacers as shown in the illustration.
- INSTALL CYLINDER HEAD SUBASSEMBLY RH
See step 3
- INSTALL CYLINDER HEAD SUBASSEMBLY LH
See step 4
- INSTALL VALVE STEM CAP
- Apply a light coat of engine oil to the valve stem caps.
- Install the 32 valve stem caps to the cylinder heads.
- INSTALL VALVE LASH ADJUSTER ASSEMBLY
- Inspect the valve lash adjuster before installing it (See step 3).
- Install the 32 valve lash adjusters to the cylinder heads.NOTE:
Install the lash adjuster to the same place it was removed from.
- INSTALL NO. 1 VALVE ROCKER ARM SUBASSEMBLY
- INSTALL CAMSHAFT BEARING CAP RH
See step 1
- INSTALL CAMSHAFT HOUSING SUBASSEMBLY RH
See step 2
- INSTALL CAMSHAFT BEARING CAP LH
See step 3
- INSTALL CAMSHAFT HOUSING SUBASSEMBLY LH
See step 4
- INSTALL CRANKSHAFT TIMING GEAR KEY
- Install the timing gear key.
HINT:
The other timing gear key will be installed at a later step.
- Install the timing gear key.
- SET NO. 1 CYLINDER TO TDC/COMPRESSION
- Temporarily install the crankshaft pulley bolt.
- Rotate the crankshaft so that the timing gear key is as shown in the illustration. Then using a wrench, rotate each camshaft so that the timing marks are as shown in the illustration.NOTE:
When the crankshaft or a camshaft is rotated excessively, the valves and pistons may interfere with each other.
- Remove the crankshaft pulley bolt.
- INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
- Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.
- Install the chain tensioner with the 2 bolts.
- INSTALL NO. 1 CHAIN SUBASSEMBLY RH
- Align the No. 1 chain orange mark plate with the camshaft timing gear timing mark, and attach the chain to the gear as shown in the illustration.
Align the No. 1 chain orange mark plate with the crankshaft timing sprocket timing mark, and attach the chain to the gear as shown in the illustration.
Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.
NOTE:The camshaft timing exhaust gear has 2 grooves. Align the mark plates of the No. 2 chain with the first groove.
HINT:
The crankshaft timing sprocket RH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.
- Install the crankshaft timing sprocket RH to the crankshaft.
- Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.
- Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.
- Remove the pin from the No. 2 chain tensioner.
- Using a wrench to hold the hexagonal portion of the No. 1 camshaft, temporarily install the bolt.
- Using a wrench to hold the hexagonal portion of the No. 2 camshaft, temporarily install the bolt.
- INSTALL NO. 1 CHAIN VIBRATION DAMPER RH
- Install the vibration damper with the 2 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Install the vibration damper with the 2 bolts.
- INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH
HINT:
If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.
- INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH
- Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.
- Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Remove the hexagon wrench from the chain tensioner.
- INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
- Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- While pushing down the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.
- Install the chain tensioner with the 2 bolts.
- INSTALL NO. 1 CHAIN SUBASSEMBLY LH
- Align the No. 1 chain orange mark plate with the camshaft timing gear timing mark, and attach the chain to the gear as shown in the illustration.
Align the No. 1 chain orange mark plate with the crankshaft timing sprocket timing mark, and attach the chain to the gear as shown in the illustration.
Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.
NOTE:The camshaft timing exhaust gear has 2 grooves. Align the mark plates of the No. 2 chain with the first groove.
HINT:
The crankshaft timing sprocket LH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.
- Install the crankshaft timing sprocket LH to the crankshaft.
- Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear.
- Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear.NOTE:
Because the timing mark positions of the gears may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.
- Remove the pin from the No. 3 chain tensioner.
- Using a wrench to hold the hexagonal portion of the No. 3 camshaft, temporarily install the bolt.
- Using a wrench to hold the hexagonal portion of the No. 4 camshaft, temporarily install the bolt.
- INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH
HINT:
If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and install the chain tensioner slipper.
- INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH
- Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.
- Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
Install a new gasket and the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- INSTALL NO. 1 CHAIN VIBRATION DAMPER LH
- Install the vibration damper with the 2 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Remove the hexagon wrench from the No. 1 chain tensioner.
- Install the vibration damper with the 2 bolts.
- TIGHTEN CAMSHAFT TIMING GEAR
for Bank 1:
- Using a wrench, hold the hexagonal portion of the No. 3 camshaft.
- Tighten the bolt of the camshaft timing gear.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the bolt of the camshaft timing exhaust gear.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
for Bank 2:
- Using a wrench, hold the hexagonal portion of the No. 1 camshaft.
- Tighten the bolt of the camshaft timing gear.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt of the camshaft timing exhaust gear.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
- CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
- INSTALL WATER INLET PIPE
Refer to PROCEDURE - Step 1
- INSTALL TIMING CHAIN COVER SUBASSEMBLY
Refer to PROCEDURE - Step 2
- INSTALL WATER PUMP ASSEMBLY
Refer to PROCEDURE - Step 1
- INSTALL FRONT CRANKSHAFT OIL SEAL
- INSTALL CRANKSHAFT TIMING GEAR KEY
- INSTALL CRANKSHAFT PULLEY
Refer to PROCEDURE - Step 9
- INSTALL SPARK PLUG TUBE GASKET
- Using a cutter knife, cut off the seal part of the removed gasket.
Using the removed gasket and a hammer, tap in a new gasket until it stops.
HINT:
If the removed gasket does not fit on the new one, correct the removed one with pliers.
- Apply a light coat of MP grease to the lip of the gasket.
- Return the 4 ventilation baffle plate claws to the original positions.
- INSTALL OIL CONTROL VALVE FILTER
- LH:
- Install the filter in the cylinder head.
- Install a new gasket and the cylinder head cover spacer with the 3 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
RH:
- Install the filter in the cylinder head.
- Install a new gasket and the cylinder head cover spacer with the 3 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- LH:
- INSTALL CYLINDER HEAD COVER SUBASSEMBLY RH
Refer to PROCEDURE - Step 5
- INSTALL CYLINDER HEAD COVER SUBASSEMBLY LH
Refer to PROCEDURE - Step 4
- INSTALL NO. 1 IDLER PULLEY SUBASSEMBLY
Refer to PROCEDURE - Step 10
- INSTALL WATER PUMP PULLEY
Refer to PROCEDURE - Step 2
- INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY
for Bank 1:
- Apply a light coat of engine oil to 2 new O-rings.
- Install the 2 O-rings to the 2 oil control valves.
- Install the 2 oil control valves with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
for Bank 2:
- Apply a light coat of engine oil to 2 new O-rings.
- Install the 2 O-rings to the 2 oil control valves.
- Install the 2 oil control valves with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- INSTALL ENGINE OIL LEVEL SENSOR
Refer to PROCEDURE - Step 1
- INSTALL CRANKSHAFT POSITION SENSOR
- Install the crankshaft position sensor with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the crankshaft position sensor with the bolt.
- INSTALL CRANK POSITION SENSOR PROTECTOR
- Install the sensor protector with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the sensor protector with the 2 bolts.
- INSTALL CAMSHAFT POSITION SENSOR
- Install the camshaft position sensor with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the camshaft position sensor with the bolt.
- INSTALL VVT SENSOR
- INSTALL SPARK PLUG
- Using a 16 mm plug wrench, install the 8 spark plugs.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Using a 16 mm plug wrench, install the 8 spark plugs.
- INSTALL OIL FILLER CAP HOUSING
- INSTALL OIL FILLER CAP SUBASSEMBLY
- INSTALL OIL FILTER BRACKET (w/o Oil Cooler)
Refer to PROCEDURE - Step 23
- INSTALL OIL FILTER BRACKET (w/ Oil Cooler)
Refer to PROCEDURE - Step 3
- INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)
Refer to PROCEDURE - Step 4
- INSTALL OIL FILTER ELEMENT
Refer to PROCEDURE - Step 5
- INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY
Refer to PROCEDURE - Step 1