Engine Unit: Reassembly: Reassembly

Fig 1: Locating Timing Chain Cover Stud Bolt

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1. Install the timing chain cover stud bolt.
   1. 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) 

Fig 2: Locating Oil Pan Stud Bolt
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2. Install the oil pan stud bolt.
   1. 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) 

Fig 3: Locating Ring Pin

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1. Using a plastic-faced hammer, tap in new ring pins to the timing chain cover.

   Standard Protrusion

   Item	Ring Pin Diameter	Specified Condition
   Ring pin A	13 mm (0.512 in.)	7.5 to 8.5 mm (0.295 to 0.335 in.)
   Ring pin B	11 mm (0.433 in.)	3.6 to 4.6 mm (0.142 to 0.181 in.)

Fig 4: Installing Rear Crankshaft Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
• Keep the lip free from foreign matter.
• Do not tap on the oil seal at an angle.
1. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
   • SST: 09223-15030 
   • SST: 09950-70010 
     • 09951-07100

   Standard depth

   0 to 1.0 mm (0 to 0.0394 in.)

Fig 5: Locating Oil Drain Pipe Bolt

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1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the drain pipe.
3. Install the oil drain pipe with the bolt.

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

Fig 6: Applying Seal Packing In Continuous Line

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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

   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.
Fig 7: Locating Engine Rear Oil Seal Retainer Bolts
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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.
2. Install the oil seal retainer with the 6 bolts.

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

Fig 8: Locating Oil Strainer Bolts

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1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the oil strainer.
3. Install the oil strainer with the 2 bolts.

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

   NOTE:

   Make sure the O-ring is not twisted or damaged.

Fig 9: Locating No. 1 Oil Pan Baffle Plate Bolts

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1. Install the baffle plate with the 7 bolts.

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

Fig 10: Identifying Standard Seal Diameter

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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

   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.
Fig 11: Locating Oil Pan Bolts And Nuts
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NOTE:

Do not start the engine for at least 2 hours after installing.

2. 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) 

   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.)

Fig 12: Applying Seal Packing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   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.
Fig 13: Locating No. 2 Oil Pan Sub-Assembly Bolts And Nuts
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NOTE:

Do not start the engine for at least 2 hours after installing.

2. Install the oil pan with the 14 bolts and 2 nuts.

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

Fig 14: Applying Seal Packing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. 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.
Fig 15: Locating Heat Exchanger Cover Bolts And Nuts
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NOTE:

Do not start the engine for at least 2 hours after installing.

2. Install the heat exchanger cover with the 12 bolts and 2 nuts.

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

   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.)

Fig 16: Installing Ventilation Pipe Gasket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. 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.

Fig 17: Identifying Cylinder Block Water Jacket Spacer

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1. 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.

1. Apply a light coat of engine oil to the valve stem caps.
2. Install the 32 valve stem caps to the cylinder heads.

1. Inspect the valve lash adjuster before installing it See step  3.
2. Install the 32 valve lash adjusters to the cylinder heads.
   NOTE:

   Install the lash adjuster to the same place it was removed from.

1. Apply engine oil to the lash adjuster tips and valve stem cap ends.
Fig 18: Identifying Valve Rocker Arm And Valve Stem Cap
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2. Install the 32 valve rocker arms as shown in the illustration.

Fig 19: Identifying Timing Gear Key

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1. Install the timing gear key.

   HINT: 

   The other timing gear key will be installed at a later step.

1. Temporarily install the crankshaft pulley bolt.
2. 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.

3. Remove the crankshaft pulley bolt.
   Fig 20: Identifying Timing Marks Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 21: Installing No. 2 Chain Tensioner Assembly

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1. Install the chain tensioner with the 2 bolts.

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

2. 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.

Fig 22: Aligning No. 1 Chain's Orange Mark Plate With Camshaft Timing Gear's Timing Mark

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1. 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.
Fig 23: Identifying No. 1 Chain Orange Mark Plate And Crankshaft Timing Sprocket Timing Mark
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2. 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.
Fig 24: Identifying No. 2 Chain Yellow Mark Plates And Timing Marks Of Camshaft Timing Gear Assembly
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3. 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.

   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.

4. Install the crankshaft timing sprocket RH to the crankshaft.
5. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.
6. 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.
7. Remove the pin from the No. 2 chain tensioner.
8. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, temporarily install the bolt.
9. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, temporarily install the bolt.

Fig 25: Identifying Bolts And Vibration Damper

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1. Install the vibration damper with the 2 bolts.

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

Fig 26: Identifying No. 1 Chain Tensioner Slipper (RH)

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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.

Fig 27: Installing No. 1 Chain Tensioner Assembly (RH)

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1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
Fig 28: Locating Chain Tensioner Bolts
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3. Install the chain tensioner with the 2 bolts.

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

4. Remove the hexagon wrench from the chain tensioner.

Fig 29: Installing No. 3 Chain Tensioner Assembly

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1. Install the chain tensioner with the 2 bolts.

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

2. 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.

Fig 30: Aligning No. 1 Chain's Orange Mark Plate With Camshaft Timing Gear's Timing Mark

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1. 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.
Fig 31: Identifying No. 1 Chain Orange Mark Plate And Crankshaft Timing Sprocket Timing Mark
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2. 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.
Fig 32: Identifying No. 2 Chain Yellow Mark Plates And Timing Marks Of Camshaft Timing Gear Assembly
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3. 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.

   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.

4. Install the crankshaft timing sprocket LH to the crankshaft.
5. Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear.
6. 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.

7. Remove the pin from the No. 3 chain tensioner.
8. Using a wrench to hold the hexagonal portion of the No. 3 camshaft, temporarily install the bolt.
9. Using a wrench to hold the hexagonal portion of the No. 4 camshaft, temporarily install the bolt.

Fig 33: Identifying No. 1 Chain Tensioner Slipper (LH)

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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.

Fig 34: Pushing Plunger Deep Into Tensioner

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1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
Fig 35: Locating Chain Tensioner Bolts
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3. Install a new gasket and the chain tensioner with the 2 bolts.

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

Fig 36: Locating Vibration Damper Bolts

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1. Install the vibration damper with the 2 bolts.

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

2. Remove the hexagon wrench from the No. 1 chain tensioner.

Fig 37: Holding Hexagonal Portion Of No. 3 Camshaft
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1. for Bank 1:
   1. Using a wrench, hold the hexagonal portion of the No. 3 camshaft.
   2. Tighten the bolt of the camshaft timing gear.

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

   Fig 38: Holding Hexagonal Portion Of No. 4 Camshaft
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. 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) 

Fig 39: Holding Hexagonal Portion Of No. 1 Camshaft
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2. for Bank 2:
   1. Using a wrench, hold the hexagonal portion of the No. 1 camshaft.
   2. Tighten the bolt of the camshaft timing gear.

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

   Fig 40: Holding Hexagonal Portion Of No. 2 Camshaft
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. 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) 

1. Temporarily install the crankshaft pulley bolt.
2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.
3. Remove the crankshaft pulley bolt.
   Fig 41: Identifying Timing Marks On Crankshaft Timing Sprocket And Camshaft Timing Gears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 42: Installing Front Crankshaft Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply MP grease to the lip of a new oil seal.
2. Using SST and a hammer, tap in the oil seal to a depth between 0 and 1.0 mm (0 and 0.0394 in.) from the timing chain cover edge.
   • SST: 09223-22010 
   • SST: 09506-35010 
   NOTE:

   • Keep the lip free from foreign matter.
   • Do not tap the oil seal at an angle.

Fig 43: Identifying Crankshaft Timing Gear Key
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1. Install the crankshaft timing gear key to the crankshaft.

Fig 44: Identifying Gasket Cut Off Area

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1. Using a cutter knife, cut off the seal part of the removed gasket.
Fig 45: Installing Spark Plug Tube Gasket
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2. 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.

3. Apply a light coat of MP grease to the lip of the gasket.
4. Return the 4 ventilation baffle plate claws to the original positions.

Fig 46: Identifying Bolts, Cylinder Head Cover Spacer, Gasket And Valve Filter

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1. LH:
   1. Install the filter in the cylinder head cover.
   2. Install a new gasket and the cylinder head cover spacer with the 3 bolts.

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

Fig 47: Identifying Oil Control Valve Filter, Gasket And Cylinder Head Cover Spacer (RH)
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2. RH:
   1. Install the filter in the cylinder head cover.
   2. Install a new gasket and the cylinder head cover spacer with the 3 bolts.

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

Fig 48: Identifying Oil Control Valves And Bolts
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1. for Bank 1:
   1. Apply a light coat of engine oil to 2 new O-rings.
   2. Install the 2 O-rings to the 2 oil control valves.
   3. Install the 2 oil control valves with the 2 bolts.

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

Fig 49: Locating Oil Control Valves With Bolts
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2. for Bank 2:
   1. Apply a light coat of engine oil to 2 new O-rings.
   2. Install the 2 O-rings to the 2 oil control valves.
   3. Install the 2 oil control valves with the 2 bolts.

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

Fig 50: Locating Crankshaft Position Sensor Bolt

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1. Install the crankshaft position sensor with the bolt.

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

Fig 51: Locating Crank Position Sensor Protector Bolts

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1. Install the sensor protector with the 2 bolts.

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

Fig 52: Locating Camshaft Position Sensor Bolt

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1. Install the camshaft position sensor with the bolt.

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

Fig 53: Identifying Bolts And VVT Sensors
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1. for Bank 1:

   Install the 2 VVT sensors with the 2 bolts.

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

Fig 54: Identifying Bolts And VVT Sensors
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2. for Bank 2:

   Install the 2 VVT sensors with the 2 bolts.

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

1. Using a 16 mm plug wrench, install the 8 spark plugs.

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

Fig 55: Identifying Oil Filler Cap Housing
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1. Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing.
Fig 56: Locating Cap Housing With Bolts
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2. Install the cap housing with the 2 bolts.

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