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Reassembly [10/2015 - ]: Procedure

  1. INSTALL RING PIN 
    NOTE:

    It is not necessary to remove a ring pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in new ring pins to the camshaft housing.

      Standard protrusion height

      2.7 to 3.3 mm (0.106 to 0.130 in.)

      GTY614822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a LH *b RH
      *c Protrusion Height - -
  2. INSTALL NO. 1 STRAIGHT PIN 
    NOTE:

    It is not necessary to remove a No. 1 straight pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in new No. 1 straight pins to the camshaft housing.

      Standard protrusion height

      7.7 to 8.3 mm (0.303 to 0.327 in.)

      GTY662646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a LH *b RH
      *c Protrusion Height - -
  3. INSTALL REAR CRANKSHAFT OIL SEAL 
    1. Place the oil seal retainer on wooden blocks.
    2. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
      GTY145954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-1503009950-70010 
        1. 09951-07100
      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap on the oil seal at an angle.
  4. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Apply MP grease to the lip of the oil seal.
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY674720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing

      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 engine rear oil seal retainer within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    3. Install the engine rear oil seal retainer with the 6 bolts.

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

      GTY540193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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

  5. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the 2 water jacket spacers as shown in the illustration.
      GTY647763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front Side
  6. INSTALL NO. 1 WATER OUTLET PIPE 
    1. Install the water outlet pipe with the 2 bolts.

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

  7. INSTALL KNOCK SENSOR 

    Refer to PROCEDURE - Step 1

  8. INSTALL NO. 5 ENGINE WIRE 
    1. Install the No. 5 engine wire with the clamp.
  9. INSTALL CYLINDER HEAD GASKET 

    See step  1

  10. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    See step  2

  11. INSTALL NO. 2 CYLINDER HEAD GASKET 

    See step  3

  12. INSTALL CYLINDER HEAD LH 

    See step  4

  13. INSTALL VALVE STEM CAP 

    See step  11

  14. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    See step  12

  15. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    See step  13

  16. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET 
    1. Install the camshaft bearing cap oil hole gasket to the No. 6 camshaft bearing cap.
    2. Install the camshaft bearing cap oil hole gasket to the No. 7 camshaft bearing cap.
  17. INSTALL OIL CONTROL VALVE FILTER LH 
    1. Install the oil control valve filter LH to the camshaft bearing cap.
      GTY628809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Camshaft Installation Surface
      NOTE:

      Make sure the oil control valve filter does not protrude past the camshaft installation surface shown in the illustration.

  18. INSTALL OIL CONTROL VALVE FILTER RH 

    HINT: 

    Use the same procedure described for the LH side.

  19. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 

    See step  16

  20. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 

    See step  17

  21. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 

    See step  18

  22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 

    See step  23

  23. INSTALL CAMSHAFT 

    See step  25

  24. INSTALL NO. 2 CAMSHAFT 

    See step  26

  25. INSTALL FUEL PUMP LIFTER HOUSING 

    See step  27

  26. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 

    See step  28

  27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 

    See step  33

  28. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 

    See step  29

  29. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) 

    See step  30

  30. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 

    See step  31

  31. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 

    See step  32

  32. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 1) 

    See step  34

  33. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 

    See step  19

  34. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) 

    See step  20

  35. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 

    See step  21

  36. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 

    See step  22

  37. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Bank 2) 

    See step  24

  38. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the No. 1 chain vibration damper with the 2 bolts.

      Torque: 22.5 N*m (229 kgf*cm, 17 ft.*lbf) 

  39. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 No. 2 chain vibration dampers.
  40. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Install the 2 timing gear set keys and timing sprocket to the crankshaft.
  41. INSTALL IDLE SPROCKET ASSEMBLY 
    1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
      GTY669376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Idle Gear Shaft
      *2 Idle Sprocket
      *3 No. 2 Idle Gear Shaft
      *4 Knock Pin
      Apply Engine Oil
    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 with the knock pin groove of the cylinder block.
      NOTE:

      Make sure that the idle gear is facing the correct direction.

      HINT: 

      Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.

    3. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

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

      HINT: 

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

  42. INSTALL CHAIN SUB-ASSEMBLY 
    1. Check that the camshaft timing gear position on the RH bank and the timing marks on the LH bank and crankshaft are positioned as shown in the illustration.
      GTY668400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b Center Line
      *c Approximately 10° - -
    2. Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly.
      GTY662946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Yellow)
      *b Timing Mark

      HINT: 

      The camshaft mark plates are yellow.

    3. Rest the chain sub-assembly on top of the crankshaft.
      GTY616778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain sub-assembly between the banks.
      GTY669614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a When idle sprocket is reused
      *b Mark
      *c Align
      *d Chain Plate
      Turn
      NOTE:

      When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain sub-assembly between the banks.

    5. Align the mark plate and timing mark as shown in the illustration and install the chain sub-assembly onto the crankshaft timing sprocket.
      GTY648147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark Plate (Pink)
      *b Timing Mark

      HINT: 

      The crankshaft mark plate is pink.

    6. Temporarily install the pulley set bolt.
    7. Turn the crankshaft clockwise 10° to set it to the RH block bore center line (TDC/compression).
      GTY626252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
      *b Center Line
      Turn
  43. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
  44. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
      GTY640799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper Plate
      *b Plunger
    2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.0500 in.) diameter into the hole of the stopper plate.
    3. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

    4. Remove the lock pin of the No. 1 chain tensioner assembly.
  45. INSPECT VALVE TIMING 
    1. 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.
    2. Check that each camshaft timing mark is positioned as shown in the illustration.
      GTY632723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b Viewpoint

      HINT: 

      For the intake camshaft:

      GTY565856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

    3. If the valve timing is misaligned, reinstall the timing chain.
    4. Remove the pulley set bolt.
  46. INSTALL ENGINE WATER PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  47. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 2 (10/2015 - 09/2016) or PROCEDURE - Step 2 (09/2016 -)

  48. INSTALL TIMING CHAIN CASE OIL SEAL 

    Refer to PROCEDURE - Step 1 (10/2015 - 09/2016) or PROCEDURE - Step 1 (09/2016 -)

  49. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. for 2WD:
      GTY621298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the No. 1 oil pan baffle plate with the 8 bolts.

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

      HINT: 

      Temporarily install the 8 bolts. Tighten the 2 bolts A shown in the illustration before tightening the other bolts.

    2. for AWD:

      Install the No. 1 oil pan baffle plate with the 7 bolts.

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

      HINT: 

      Temporarily install the 8 bolts. Tighten the 2 bolts A shown in the illustration before tightening the other bolts.

      GTY634412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL OIL STRAINER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3 (10/2015 - 09/2016) or PROCEDURE - Step 3 (09/2016 -)

  51. INSTALL OIL PAN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 (10/2015 - 09/2016) or PROCEDURE - Step 4 (09/2016 -)

  52. INSTALL OIL LEVEL SENSOR BRACKET 

    Refer to PROCEDURE - Step 1

  53. INSTALL ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 6 (10/2015 - 09/2016) or PROCEDURE - Step 6 (09/2016 -)

  54. INSTALL OIL WITH STRAINER PIPE SUB-ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 7 (10/2015 - 09/2016) or PROCEDURE - Step 7 (09/2016 -)

  55. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8 (10/2015 - 09/2016) or PROCEDURE - Step 8 (09/2016 -)

  56. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug.

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

  57. INSTALL SPARK PLUG TUBE GASKET 
    1. Install 6 new spark plug tube gaskets to the cylinder head cover sub-assembly.
  58. INSTALL OIL FILLER STUD BOLT 
    1. Install the 2 oil filler stud bolts to the cylinder head cover sub-assembly LH.

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

  59. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10 (10/2015 - 09/2016) or PROCEDURE - Step 10 (09/2016 -)

  60. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 11 (10/2015 - 09/2016) or PROCEDURE - Step 11 (09/2016 -)

  61. INSTALL FUEL PUMP SPACER GASKET 
    1. Install a new fuel pump spacer gasket to the cylinder head cover.
  62. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  63. INSTALL REAR WATER BY-PASS JOINT 
    1. Install a new O-ring and 2 new gaskets.
      GTY616895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Apply water to the O-ring.

    2. Install the water by-pass joint with the 4 bolts and 2 nuts.

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

      NOTE:

      Be careful that the O-ring does not get caught between the parts.

  64. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 
    1. Install a new gasket and the water inlet with thermostat with the 2 bolts and nut.

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

  65. INSTALL WATER OUTLET 
    1. Install a new O-ring to the water outlet pipe sub-assembly.
      GTY617833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water outlet with the 2 bolts.

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

      NOTE:

      Be careful that the O-ring does not get caught between the parts.

  66. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 16 (10/2015 - 09/2016) or PROCEDURE - Step 16 (09/2016 -)

  67. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 17 (10/2015 - 09/2016) or PROCEDURE - Step 17 (09/2016 -)

  68. INSTALL OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 4

  69. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply adhesive around the drain cocks.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the water drain cocks as shown in the illustration.
      GTY659159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a RH Side:
      *b LH Side:

      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 to the specified torque.

    3. Install the water drain cock plug to the water drain cock.

      Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf) 

    4. Install the taper screw plug.

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

  70. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  71. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 1

  72. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 2

  73. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 3

  74. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 4

  75. INSTALL PCV VALVE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  76. INSTALL NO. 1 FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  77. INSTALL NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 15 (10/2015 - 09/2016) or PROCEDURE - Step 15 (09/2016 -)

  78. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

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