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Reassembly [09/2016 - ]: Procedure

  1. INSTALL OIL PAN STUD BOLT 
    NOTE:

    If a stud bolt is deformed or the threads are damaged, replace it.

    1. for 2WD:
      GTY102860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    2. for AWD:
      GTY121116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  2. INSTALL NO. 1 VENTILATION CONNECTOR 
    1. Install the No. 1 ventilation connector as shown in the illustration.
      GTY634676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Acceptable angle (A)

      -5 to 5°

      Tap-in depth (B)

      0.2 to 3.2 mm (0.008 to 0.126 in.)

      NOTE:

      After the installation of the ventilation connector, do not rotate it.

      HINT: 

      Connect the No. 1 ventilation connector so that its flat surface faces the rear part of the engine.

  3. INSTALL OIL DRAIN PIPE SUBASSEMBLY 
    1. Apply a light coat of engine oil to a new O-ring.
      GTY685747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  4. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY538885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      2.0 to 3.0 mm (0.079 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 pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
      • 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.
      GTY496704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  5. INSTALL OIL STRAINER SUBASSEMBLY 
    1. Apply a light coat of engine oil to a new O-ring.
      GTY615405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the O-ring to the oil strainer.
    3. Install the oil strainer with the 2 bolts.

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

      NOTE:

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

  6. INSTALL NO. 2 OIL PAN BAFFLE PLATE (for AWD) 
    1. Install the baffle plate with the 4 bolts.
      GTY685885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. for 2WD:

      Install the baffle plate with the 8 bolts.

      GTY626461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. for AWD:

      Install the baffle plate with the 4 bolts.

      GTY685104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  8. INSTALL OIL PAN SUBASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY636891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.)

      Application position from inside edge of oil pan

      6.0 mm (0.236 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.
    2. Install the oil pan with the 14 bolts and 2 nuts.
      GTY628109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A 

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

      for bolt B and nut 

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

      NOTE:

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

  9. INSTALL OIL PAN PROTECTOR (for 2WD) 
    1. Install the protector with the 2 nuts.
      GTY260345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      HINT: 

      Install the oil pan protector with its protrusion facing the bottom of the engine.

  10. INSTALL NO. 2 OIL PAN SUBASSEMBLY 
    1. for 2WD:
      1. Apply seal packing in a continuous line as shown in the illustration.
        GTY105229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        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 10 minutes after applying seal packing.
        • Do not start the engine for at least 2 hours after installing.
      2. Install the oil pan with the 15 bolts and 2 nuts.
        GTY652235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. for AWD:
      1. Apply seal packing in a continuous line as shown in the illustration.
        GTY129009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        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 10 minutes after applying seal packing.
      2. Install the oil pan with the 13 bolts and 2 nuts.
        GTY615252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

        NOTE:

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

  11. INSTALL VENTILATION PIPE GASKET 
    1. Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.
      GTY678865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00360
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:
      • Do not tap the gasket at an angle.
      • Do not tap the gasket excessively.
  12. INSTALL NO. 1 HEAT EXCHANGER COVER 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY105228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 10 minutes after applying seal packing.
    2. Install the heat exchanger cover with the 11 bolts and 2 nuts.
      GTY640574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

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

    3. Install the bolt.
      GTY651611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  13. INSTALL OIL RETURN PIPE GASKET 
    1. Install a new oil return pipe gasket.
      GTY105338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the 2 water jacket spacers as shown in the illustration.
      GTY651284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • Face the cutouts (indicated by arrows in illustration) away from the engine.
      • Face the "UP" mark as shown in the illustration.
  15. INSTALL CYLINDER HEAD SUBASSEMBLY (for Bank 1) 

    See step  3

  16. INSTALL CYLINDER HEAD SUBASSEMBLY (for Bank 2) 

    See step  3

  17. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem caps.
    2. Install the 32 valve stem caps to the cylinder head.
  18. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    1. Be sure to inspect the valve lash adjuster before installing it (See step  2).
    2. Install the 32 valve lash adjusters to the cylinder head.
      NOTE:

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

  19. INSTALL NO. 1 VALVE ROCKER ARM SUBASSEMBLY 
    1. Apply engine oil to the lash adjuster tips and valve stem cap ends.
      TEXT IN ILLUSTRATION

      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      GTY657886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Make sure that the 32 valve rocker arms are installed as shown in the illustration.
  20. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 

    See step  1

  21. INSTALL CAMSHAFT HOUSING SUBASSEMBLY (for Bank 1) 

    See step  2

  22. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 

    See step  1

  23. INSTALL CAMSHAFT HOUSING SUBASSEMBLY (for Bank 2) 

    See step  2

  24. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Install the 2 timing gear keys.
      GTY122372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. SET NO. 1 CYLINDER TO TDC / COMPRESSION 

    See step  1

  26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 

    See step  2

  27. INSTALL CHAIN SUBASSEMBLY (for Bank 2) 

    See step  4

  28. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2) 

    See step  5

  29. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2) 

    See step  6

  30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2) 

    See step  7

  31. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 

    See step  8

  32. INSTALL CHAIN SUBASSEMBLY (for Bank 1) 

    See step  10

  33. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1) 

    See step  11

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) 

    See step  12

  35. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) 

    See step  13

  36. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY 

    See step  14

  37. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION 

    See step  15

  38. INSTALL WATER INLET PIPE 

    Refer to PROCEDURE - Step 1

  39. INSTALL ENGINE WATER PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  40. INSTALL TIMING CHAIN COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 2

  41. INSTALL OIL CONTROL VALVE FILTER 
    1. for Bank 1:
      1. Install the valve filter in the cylinder head.
        GTY654968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install a new gasket and the cylinder head cover spacer with the 2 bolts.

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

    2. for Bank 2:
      1. Install the valve filter in the cylinder head.
        GTY630678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install a new gasket and the cylinder head cover spacer with the 2 bolts.

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

  42. INSTALL CYLINDER HEAD COVER SUBASSEMBLY LH 
    1. Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3, No. 7).
      GTY626457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket to the cylinder head cover.
      NOTE:

      Remove any oil from the contact surface.

    3. Apply seal packing as shown in the illustration.
      GTY102557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after the installation.
    4. Install the cylinder head cover with 2 new seal washers and the 15 bolts.
      GTY634323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A 

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

      except bolt A 

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

    5. Install a new fuel pump spacer gasket.
  43. INSTALL CYLINDER HEAD COVER SUBASSEMBLY RH 
    1. Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 1, No. 3, No. 6).
      GTY685844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket to the cylinder head cover.
      NOTE:

      Remove any oil from the contact surface.

    3. Apply seal packing as shown in the illustration.
      GTY102400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after the installation.
    4. Install the cylinder head cover with 2 new seal washers and the 15 bolts.
      GTY628095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A 

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

      except bolt A 

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

    5. Install a new fuel pump spacer gasket.
  44. INSTALL SPARK PLUG TUBE GASKET 
    1. Perform a visual inspection on the spark plug tube gasket.
      GTY636326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

      Area Specified Condition
      Upper surface No scratches or deformation
      Outer lip No scratches or deformation
      Inner lip No scratches
    2. Install the 8 plug tube gaskets to the cylinder head covers.
      GTY147517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL TIMING CHAIN CASE OIL SEAL 

    See step  6

  46. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 6

  47. INSTALL FRONT WATER BY-PASS JOINT 
    1. Install the 2 new gaskets and water by-pass joint with the 4 nuts.
      GTY625803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  48. INSTALL OIL FILTER BRACKET (for 2WD) 

    Refer to PROCEDURE - Step 8

  49. INSTALL OIL FILTER BRACKET (for AWD) 

    Refer to PROCEDURE - Step 9

  50. INSTALL OIL FILTER ELEMENT (for 2WD) 

    Refer to PROCEDURE - Step 4

  51. INSTALL OIL FILTER ELEMENT (for AWD) 

    Refer to PROCEDURE - Step 4

  52. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUBASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the drain cock.
      GTY570588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the water drain cocks as shown in the illustration.
      GTY278824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
      • Do not loosen the drain cocks to adjust them. If an adjustment is necessary, remove the drain cocks and reinstall them.
    3. Install the water drain cock plugs to the water drain cocks.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  53. INSTALL CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  54. INSTALL CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY RH 

    Refer to PROCEDURE - Step 2

  55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) 

    Refer to PROCEDURE - Step 2

  56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) 

    Refer to PROCEDURE - Step 1

  57. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  58. INSTALL CAMSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  59. INSTALL VVT SENSOR 

    Refer to PROCEDURE - Step 1

  60. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  61. INSTALL OIL FILLER CAP HOUSING 
    1. Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing.
      GTY105208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cap housing with the 2 bolts.
      GTY147452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  62. INSTALL OIL FILLER CAP SUBASSEMBLY 
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