Reassembly [09/2014 - 10/2015]: Procedure

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.)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Protrusion Height	-	-
   *a	LH	*b	RH

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

   Standard Protrusion Height

   Item	Specified Condition
   Straight pin A	7.7 to 8.3 mm (0.303 to 0.327 in.)
   Straight pin B	5.7 to 6.3 mm (0.224 to 0.248 in.)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Protrusion Height	-	-
   *a	LH	*b	RH

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09223-15030 
   • SST: 09950-70010 
     1. 09951-07100
   NOTE:

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

1. Apply MP grease to the lip of the oil seal.
2. Apply seal packing in a continuous line as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.)

   TEXT IN ILLUSTRATION
   
   

   *1	Seal Packing

   NOTE:

   • Remove any oil from the contact surface.
   • Install the 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 oil seal retainer with the 6 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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

1. Install the water outlet pipe with the 2 bolts.

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

Refer to PROCEDURE - Step 1

1. Install the No. 5 engine wire with the clamp.

See step  1

See step  2

See step  3

See step  4

See step  11

See step  12

See step  13

1. Install the oil check valve to the camshaft bearing cap.

1. Install the oil control valve filter LH to the camshaft bearing cap.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

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

   TEXT IN ILLUSTRATION
   
   

   *a	Camshaft Installation Surface

HINT: 

Use the same procedure described for the LH side.

See step  16

See step  17

See step  18

See step  19

See step  20

See step  21

See step  22

See step  23

See step  24

See step  27

See step  28

See step  25

See step  26

1. Install the No. 1 chain vibration damper with the 2 bolts.

   Torque: 23 N*m (229 kgf*cm, 17 ft.*lbf) 

1. Install the 2 No. 2 chain vibration dampers.

1. Install the 2 timing gear set keys and timing sprocket to the crankshaft.

1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *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 idle gear shafts No. 1 and No. 2.

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.

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Timing Mark	*2	Center Line
   *a	Approximately 10°	-	-

2. Align the mark plates and timing marks as shown in the illustration and install the chain.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Mark Plate (Pink)
   *2	Timing Mark

   HINT: 

   The camshaft mark plates are pink.

3. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Rest the chain on top of the crankshaft.

4. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Chain Plate
   *a	When idle sprocket is reused
   *b	Mark
   *c	Align
   	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 between the banks.

5. Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing sprocket.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Mark Plate (Yellow)
   *2	Timing Mark

   HINT: 

   The crankshaft mark plate is yellow.

6. Temporarily install the pulley set bolt.
7. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Timing Mark
   *a	Center Line
   	Turn

1. Install the chain tensioner slipper.

1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Stopper Plate
   *2	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 with the 2 bolts.

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

4. Remove the lock pin of the chain tensioner.

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Timing Mark	-	-
   *a	Viewpoint	-	-

   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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. If the valve timing is misaligned, reinstall the timing chain.
4. Remove the pulley set bolt.

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 1

See step  1

1. When replacing a stud bolt, install it by using an E6 "TORX" socket wrench, as shown in the illustration.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a

   Timing Chain Cover

   *b

   Cylinder Block Lower

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Install the 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.

3. Install a new gasket and the oil strainer with the 3 nuts.

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

4. Install 2 new O-rings.

1. When replacing a stud bolt, install it by using an E6 "TORX" socket wrench.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Apply seal packing in a continuous line as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing

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

   Seal diameter

   3.0 to 4.0 mm (0.118 to 0.156 in.)

   TEXT IN ILLUSTRATION
   
   

   *1	Seal Packing

   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 installation.
3. Install the oil pan with the 16 bolts and 2 nuts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   for bolt A, B and nut 

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

   for bolt C 

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

   Standard Bolt

   Item	Length
   Bolt A	25 mm (0.984 in.)
   Bolt B	45 mm (1.77 in.)
   Bolt C	16 mm (0.630 in.)

   TEXT IN ILLUSTRATION
   
   

   	Bolt A
   	Bolt B
   	Bolt C
   	Nut

1. Apply seal packing in a continuous line as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Seal packing

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

   Seal diameter

   4.0 to 6.0 mm (0.156 to 0.236 in.)

   TEXT IN ILLUSTRATION
   
   

   *1	Seal Packing

   NOTE:

   • Remove any oil from the contact surface.
   • Install the No. 2 oil pan within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installation.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Install the oil pan with the 15 bolts and 2 nuts.

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

   TEXT IN ILLUSTRATION
   
   

   	Bolt
   	Nut

1. Install a new gasket and the oil pan drain plug.

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

1. Using a cutter, cut off the sealing part of the removed plug tube gasket.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a	Before cutting off
   *b	After cutting off
   	Area to be cut off

2. Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Plug tube gasket without sealing part
   *2	New plug tube gasket
   *3	Claw

   NOTE:

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

   HINT: 

   If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

3. Return the claws of the ventilation baffle plate to their original positions.

See step  15

See step  16

See step  17

1. Install a new fuel pump spacer gasket to the cylinder head cover.

1. Install 2 new gaskets and a new O-ring.

   HINT: 

   Apply water to the O-ring.

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

1. Install a new gasket and the water inlet with thermostat with the 3 nuts.

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

1. Install the 3 water by-pass hoses.
2. Install 2 new O-rings.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Apply a small amount of water to the O-ring (A) shown in the illustration before installing it.

3. Install the water inlet with the 4 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. Install the 3 water by-pass hoses.

See step  3

Refer to PROCEDURE - Step 4

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   TEXT IN ILLUSTRATION
   
   

   *a	RH Side:
   *b	LH Side:

   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 plugs to the water drain cocks.

   Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

See step  21

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Apply a light coat of engine oil to a new O-ring and install it to the No. 2 separator case.

   TEXT IN ILLUSTRATION
   
   

   *1	New O-Ring

2. Install the No. 2 separator case with the bolt and 2 nuts as shown in the illustration.

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

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 1

1. Install the gasket.
2. Install the oil filler cap.