Engine Unit: Reassembly

WARNING: This page is about a different car, the 2008 Lexus RX 350. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .

INSTALL STRAIGHT PIN

Using a plastic hammer, tap in new straight pins to the cylinder block.

Fig 1: Identifying Straight Pin Installation Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard protrusion

STANDARD PROTRUSION

Item	Protrusion
Pin A	23 mm (0.906 in.)
Pin B	6 mm (0.236 in.)
Pin C	11 mm (0.433 in.)
Pin D	9 mm (0.354 in.)

INSTALL STUD BOLT
1. Using E8 and E10 "torx" sockets, install the stud bolts.
  Torque:
  
  10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
  
  17 N*m (173 kgf*cm, 13 ft.*lbf) for bolt B
  
  Fig 2: Identifying Stud Bolt Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, install the oil nozzles.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 3: Using Hexagon Wrench To Install Nozzles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON SUB-ASSEMBLY WITH PIN
1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.
  
  Fig 4: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
2. Gradually heat the piston to approximately 80°C (176°F).
  
  Fig 5: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the piston pin with engine oil.
4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
  
  Fig 6: Aligning Front Marks Of Piston & Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The piston and pin are a matched set.
5. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
  
  Fig 7: Checking Fitting Condition Between Piston & Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.
  
  Fig 8: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
INSTALL PISTON RING SET
1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the oil ring rail.
  
  Fig 9: Using Piston Ring Expander To Install Oil Ring Rail
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends.
  
  Fig 10: Identifying Piston Rings Gap Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not align the ring ends.
INSTALL CRANKSHAFT BEARING
1. Clean the main journal and both surfaces of the bearing.
  
  Fig 11: Identifying Journal Bearings Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.
2. Install the upper bearing.
  1. Install the upper bearings to the cylinder block.
    
    Fig 12: Identifying Upper Bearings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Do not apply engine oil to the bearings and the contact surfaces.
    
    Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.
3. Install the lower bearing.
  1. Install the lower bearings to the bearing caps.
    
    Fig 13: Installing Lower Bearing To Bearing Cap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
    Dimension (A - B): 0.7 mm (0.0276 in.) or less
    
    NOTE: Do not apply engine oil to the bearings and the contact surfaces.
INSTALL CRANKSHAFT THRUST WASHER SET
1. Apply engine oil to the crankshaft thrust washer.
2. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
  
  Fig 14: Identifying Oil Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CRANKSHAFT

Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.

Fig 15: Confirming Projection And Numbers Of Main Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

A number is marked on each main bearing cap to indicate the installation position.
Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
Temporarily install the 8 main bearing cap bolts to the inside positions.
Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
Bolt length: 100 to 102 mm (3.94 to 4.02 in.)

Fig 16: Identifying Bolt Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.

Fig 17: Tapping Bearing Cap To Ensure Proper Fit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
Install the 8 main bearing cap bolts to the outside positions.

Fig 18: Identifying Main Bearing Cap Bolt Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the crankshaft bearing cap bolts.
HINT:

The main bearing cap bolts are tightened in 2 progressive steps.
Step 1
1. Install and uniformly tighten the 16 main bearing cap bolts.
  Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
  
  If any of the main bearing cap bolts does not meet the torque specified, replace it.
  
  Fig 19: Tightening Main Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Step 2
1. Mark the front of the bearing cap bolts with paint.
2. Retighten the bearing cap bolts 90° in the order above.
3. Check that the painted mark is now at a 90° angle to the front.
  
  Fig 20: Retightening Bearing Cap Bolts An Additional 90 Degrees
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps.

Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf)

Fig 21: Tightening Main Bearing Cap Bolts In Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length

BOLT LENGTH

Item	Length
Bolt A	45 mm (1.77 in.)
Except bolt A	30 mm (1.18 in.)

Check that the crankshaft turns smoothly.
Check the crankshaft thrust clearance (See INSPECTION ).

INSTALL CONNECTING ROD BEARING
1. Install the connecting rod bearing to the connecting rod and bearing cap.
2. Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.
  Dimension (A - B): 0.7 mm (0.0276 in.) or less
  
  NOTE: Do not apply engine oil to the bearings and the contact surfaces.
INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
  
  Fig 22: Identifying Distance Between Connecting Rod's & Bearing Cap's Edges & Connecting Rod Bearing's Edge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Position the piston rings so that the ring ends.
  
  Fig 23: Identifying Piston Rings Gap Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not align the ring ends.
3. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.
  
  Fig 24: Pushing Piston And Connecting Rod Assembly Into Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Match the numbered connecting rod cap with the connecting rod.
4. Check that the front mark of the connecting rod cap is facing forward.
5. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
  
  Fig 25: Identifying Connecting Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the connecting cap bolts.
  HINT:
  
  The connecting cap bolts are tightened in 2 progressive steps.
7. Step 1
  1. Install and alternately tighten the bolts of the connecting rod cap in several steps.
    Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
    
    Fig 26: Tightening Connecting Rod Cap Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Step 2
  1. Mark the front side of each connecting cap bolt with paint.
  2. Retighten the cap bolts 90°.
    
    Fig 27: Retightening Cap Bolts 90 Degrees
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Check the painted mark is now at a 90° angle to the front.
9. Check that the crankshaft turns smoothly.
10. Check the connecting rod thrust clearance (See INSPECTION ).

INSTALL INTAKE VALVE GUIDE BUSH

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Select a new guide bush (STD or O/S 0.05)

Fig 28: Measuring Bush Bore Diameter Of Cylinder Head Using Caliper Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

BUSH BORE DIAMETER

Bush size	Bush bore diameter
STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.

If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

Heat the cylinder head to 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
Using SST, tap in new valve guide bushes to the specified protrusion height.
SST 09201 -10000 (09201-01050), 09950-70010 (09951-07100)

Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.)

Fig 29: Tapping In Intake Valve Guide Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0023 in.)

Fig 30: Reaming Valve Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL EXHAUST VALVE GUIDE BUSH

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Select a new guide bush (STD or O/S 0.05)

Fig 31: Measuring Bush Bore Diameter Of Cylinder Head Using Caliper Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

BUSH BORE DIAMETER

Bush size	Bush bore diameter
STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)

If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

Heat the cylinder head to 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
Using SST, tap in new valve guide bushes to the specified protrusion height.
SST 09201 -10000 (09201-01050), 09950-70010 (09951-07100)

Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.)

Fig 32: Tapping Valve Guide Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Fig 33: Reaming Valve Guide Bushing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL RING PIN
1. Using a plastic hammer, tap in new ring pins to the specified protrusion height.
  Specified protrusion height: 2.5 to 3.5 mm (0.098 to 0.138 in.)
  
  Fig 34: Identifying Ring Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
  Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
  
  Fig 35: Identifying No. 1 Straight Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 STRAIGHT SCREW PLUG
1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
  Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)
  
  Fig 36: Identifying No. 2 Straight Screw Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STUD BOLT
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
1. Using E6 and E8 "torx" sockets, install the stud bolts.
  
  Fig 37: Identifying Stud Bolts Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque:
  
  10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts A and B
  
  4.0 N*m (41 kgf*cm, 35 in.*lbf) for bolt C
INSTALL STRAIGHT PIN
1. Using a plastic hammer, tap in new straight pins.
  Protrusion height: 17.5 to 19.5 mm (0.689 to 0.768 in.)
  
  Fig 38: Identifying Straight Pin Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE SPRING SEAT
1. Install the valve spring seats to the cylinder head.
INSTALL VALVE STEM OIL SEAL
1. Apply a light coat of engine oil to new oil seals.
  NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.
  
  HINT:
  
  The intake valve oil seals are gray and the exhaust valve oil seals are black.
  
  Fig 39: Applying Coat Of Engine Oil To Oil Seals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, push in the oil seals.
  SST 09201-41020
  
  NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
  
  Fig 40: Pushing In Oil Seals Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST VALVE
1. Apply a sufficient coat of engine oil to the tip area of the intake valve.
2. Install the valve, compression spring and spring retainer to the cylinder head.
  NOTE: Install the same parts in the same combination to the original locations.
3. Using SST, compress the spring and install the 2 retainer locks.
  SST 09202-70020(09202-00010)
  
  Fig 42: Compressing Spring Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  NOTE: Be careful not to damage the retainer.
  
  Fig 43: Tapping Valve Stem Tip To Ensure Proper Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE VALVE
1. Apply a sufficient coat of engine oil to the tip area of the intake valve.
2. Install the valve, compression spring and spring retainer to the cylinder head.
  NOTE: Install the same parts in the same combination to the original locations.
  
  Fig 44: Identifying Intake Valve Tip Area Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, compress the spring and install the 2 retainer locks.
  SST 09202-70020(09202-00010)
  
  Fig 45: Compressing Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.
  
  Fig 46: Tapping Valve Stem Tip To Ensure Proper Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the retainer.
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the valve stem caps on the valves.
INSTALL ENGINE REAR OIL SEAL
1. Place the oil seal retainer on wooden blocks.
2. Using SST and hammer, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
  SST 09223-15030, 09950-70010 (09951-07100)
  
  Fig 47: Tapping Engine Rear Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the oil seal at an angle.
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Apply seal packing in a continuous line.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal Diameter: 2.0 to 3.0 mm (0.079 to 0.118 in.)
  
  Fig 48: Identifying Oil Seal Retainer Seal Packing Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
2. Install the oil seal retainer with the 6 bolts.
  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
  
  Fig 49: Identifying Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER INLET PIPE
1. Install the water inlet pipe with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 50: Identifying Water Inlet Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 water by-pass hose.
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
  
  Fig 51: Placing Cylinder Head Gasket On Cylinder Block Surface With Lot No. Stamp Upward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful of the installation direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
2. Place the cylinder head on the cylinder block.
  NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
4. Step 1
  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
    
    Fig 52: Tightening Cylinder Head Bolts And Plate Washer In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Step 2
  1. Mark the cylinder head bolt head with paint.
    
    Fig 53: Identifying Cylinder Head Bolt Head Paint Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Tighten the cylinder head bolts another 90°.
6. Step 3
  1. Tighten the cylinder head bolts an additional 90°.
  2. Check that the painted mark is now facing rearward.
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
  
  Fig 54: Placing Cylinder Head Gasket On Cylinder Block Surface With Lot No. Stamp Upward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful of the installation direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
2. Place the cylinder head on the cylinder block.
  NOTE: Be careful not to allow oil to adhere to the bottom part of the cylinder head.
  
  HINT:
  
  The cylinder head bolts are tightened in 3 progressive steps.
3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
4. Step 1
  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
    
    Fig 55: Tightening Cylinder Head And Plate Washers In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Step 2
  1. Mark the cylinder head bolt head with paint.
  2. Tighten the cylinder head bolts another 90°.
6. Step 3
  1. Tighten the cylinder head bolts an additional 90°.
  2. Check that the painted mark is now facing rearward.
7. Tighten the 2 bolts.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  Fig 57: Identifying Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.
1. Place the lash adjuster into a container filled with engine oil.
2. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
  SST 09276-75010
3. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed the air.
  OK: Plunger moves up and down.
  
  NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually pressing the check ball. If the check ball is not pressed, air will not bleed.
  
  Fig 58: Inspecting Valve Lash Adjuster Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. After bleeding the air, remove the SST. Then, try to press the plunger quickly and firmly with a finger.
  OK: Plunger is very difficult to move.
  
  If the result is not as specified, replace the lash adjuster.
6. Install the lash adjusters.
  NOTE: Install the lash adjuster to the same place where it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Apply engine oil to the lash adjuster tip and valve stem cap end.
2. Make sure that the valve rocker arms are installed.
  
  Fig 59: Identifying Valve Rocker Arms
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP (for Bank 1)
1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
2. Install the camshaft and No. 2 camshaft to the camshaft housing RH.
3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
  
  Fig 60: Identifying Marks And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 8 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 61: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
1. Make sure that the valve rocker arm is installed.
  
  Fig 62: Identifying Valve Rocker Arm
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.)
  
  Fig 63: Identifying Camshaft Housing Sub-Assembly Seal Packing Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing sub-assembly RH within 3 minutes.
  - Do not start the engine for at least 2 hours after installing.
3. Install the camshaft housing RH and tighten the 12 bolts.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 64: Tightening Camshaft Housing Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - When installing the camshaft housing RH, it is necessary to correctly position the camshafts. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
  - If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
4. Tighten the 8 bolts.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 65: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT BEARING CAP (for Bank 2)
1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
2. Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing LH.
3. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
  
  Fig 66: Identifying Marks & Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 8 bolts in order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 67: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
1. Make sure that the valve rocker arm is installed as shown in the illustration.
  
  Fig 68: Identifying Valve Rocker Arm
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown in the illustration.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.)
  
  Fig 69: Identifying Camshaft Housing Sub-Assembly Seal Packing Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the camshaft housing sub-assembly LH within 3 minutes.
  - Do not start the engine for at least 2 hours after installing.
3. Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 70: Tightening Camshaft Housing Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - When installing the camshaft housing LH, it is necessary to correctly position the camshafts. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
  - If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
  - If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
4. Tighten the 8 bolts in the order shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 71: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
1. Install the No. 2 chain tensioner with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of ø 1.0 mm (0.039 in.) into the hole to fix it.
  
  Fig 72: Inserting Pin Into Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .
1. Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.
  
  Fig 73: Aligning Mark Plate (Yellow) With Timing Marks (1-Dot Mark) Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed.
4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
  
  Fig 74: Tightening Camshaft Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the pin from the chain tensioner.
INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
1. Install the chain tensioner with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. While pushing in the tensioner, insert a pin of ø 1.0 mm (0.039 in.) into the hole to hold it.
  
  Fig 75: Inserting Pin Into Hole To Hold It
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .
1. Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration.
  
  Fig 76: Aligning Mark Plate (Yellow) With Timing Marks (2-Dot Mark) Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
3. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed.
4. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
  
  Fig 77: Tightening Camshaft Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the pin from the chain tensioner.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
1. Install the chain vibration damper with the 2 bolts.
  Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
  
  Fig 78: Identifying No. 1 Chain Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN VIBRATION DAMPER
1. Install the 2 chain vibration dampers.
INSTALL CRANKSHAFT TIMING SPROCKET
1. Install the 2 timing gear set keys and timing sprocket as shown in the illustration.
  
  Fig 79: Identifying Timing Gear Set Keys & Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL IDLE SPROCKET ASSEMBLY
1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
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: Be careful of the idle gear 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)
  
  Fig 80: Tightening No. 2 Idle Gear Shaft Using Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
INSTALL CHAIN SUB-ASSEMBLY
1. Align the mark plate and timing marks as shown in the illustration and install the chain.
  
  Fig 81: Identifying Mark Plate & Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The camshaft mark plate is orange.
2. Do not pass the chain over the crankshaft, just put it on it.
  
  Fig 82: Identifying Chain Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.
  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.
  
  Fig 83: Turning Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.
  
  Fig 84: Aligning Mark Plate & Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  The crankshaft mark plate is yellow.
5. Temporarily tighten the pulley set bolt.
6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
  
  Fig 85: Turning Crankshaft Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
  
  Fig 86: Moving Stopper Plate Upward To Release Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
3. Install the chain tensioner with the 2 bolts.
  Torque: 10 N*m (102 kgf cm, 7 ft.*lbf)
  
  Fig 87: Identifying Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the hexagon wrench of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression.
  
  Fig 88: Identifying Timing Mark Aligning Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the pulley set bolt.
INSTALL TIMING CHAIN CASE OIL SEAL
1. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
  SST 09223-22010,09506-35010
  
  Fig 89: Using SST To Install Timing Chain Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the oil seal at an angle.
  - Make sure that the oil seal edge does not stick out of the timing chain case.
INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket and the water pump with the 8 bolts.
  Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
  
  Fig 90: Identifying Water Pump Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Apply seal packing in a continuous line to the engine unit.

Fig 91: Applying Seal Packing In Continuous Line To Engine Unit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Seal diameter: 3.0 mm (0.118 in.)
NOTE:
- Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
- When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain cover within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

Apply seal packing in a continuous line to the timing chain cover.

Fig 92: Applying Seal Packing In Continuous Line To Timing Chain Cover

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

Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent

NOTE:

When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
Install the chain 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 installing.

Apply seal packing as follows

SEAL PACKING DIAMETER

Area	Seal Packing Diameter	Application Position from Inside Seal Line
Continuous Line Area	4.5 mm or more (0.177 in.)	3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Dashed Line Area	3.5 mm or more (0.138 in.)	2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area	3.5 mm or more (0.138 in.)	3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area	6.0 mm or more (0.236 in.)	5.0 mm (0.197 in.)

Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Fig 94: Aligning Oil Pump Drive Rotor Spline & Crankshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Fig 95: Identifying Timing Chain Cover Bolts & Nuts

Bolt length

BOLT LENGTH

Item	Length
Bolt A	40 mm (1.57 in.)
Bolt B	55 mm (2.17 in.)
Bolt C	25 mm (0.98 in.)

NOTE: Make sure that there is no oil on the bolt and nut threads.

Fully tighten the bolts in this order: Area 1 and Area 2.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
Fully tighten the bolts in Area 3.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

HINT:

Tighten the bolts and nuts in the order of upper to lower as shown in the illustration.
Fully tighten the bolts in Area 4.
Torque:

43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A

21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except bolt A

HINT:

Tighten the bolts in the order of lower to upper as shown in the illustration.
Install a new gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)

INSTALL WATER INLET HOUSING
1. Install 2 new O-rings.
  HINT:
  
  Apply a small amount of water or soapy water to O-ring (A) the illustration before installing it.
  
  Fig 96: Identifying Water Inlet Housing O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the stud bolts.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 97: Identifying Stud Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the water inlet with the 2 bolts and nut.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 98: Identifying Water Inlet Housing Bolts & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful that the O-ring does not get caught between the parts.
4. Connect the No. 1 water by-pass hose.
5. Apply adhesive around the drain cock.
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
6. Install the drain cock to the water inlet housing.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
7. Install the drain cock plug to the water drain cock.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
8. Install a new gasket to the thermostat.
9. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.
  HINT:
  
  The jiggle valve may be set within 10° of either side of the prescribed positions.
  
  Fig 99: Identifying Jiggle Valve Angles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the water inlet with the 2 nuts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 100: Identifying Water Inlet Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT ENGINE MOUNTING BRACKET NO. 1 LH
1. Install the engine mounting bracket with the 6 bolts.
  Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
  
  Fig 101: Identifying Stud Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
  - Do not start the engine for at least 2 hours after installation.
2. When replacing a stud bolt, install it by using an E8 "torx" socket wrench.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL OIL PAN BAFFLE PLATE
1. Install the oil pan baffle plate with the 7 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 102: Identifying Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Temporarily tighten the 7 bolts. Fully tighten 2 bolts A before tightening the other bolts.
INSTALL OIL PAN SUB-ASSEMBLY
1. When replacing a stud bolt, install it by using an E8 "torx" socket wrench (without oil cooler).
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 103: Identifying Stud Bolt Length (Without Oil Cooler)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. When replacing a stud bolt, install it by using an E8 "torx" socket wrench (with oil cooler).
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 104: Identifying Stud Bolt Length (With Oil Cooler)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install 2 new O-rings.
  
  Fig 105: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply seal packing in a continuous line.
  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.)
  
  Fig 106: Identifying Seal Packing Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 installing.
5. Install the oil pan with the 16 bolts and 2 nuts.
  Torque:
  
  10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
  
  21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A
  
  Fig 107: Identifying Oil Pan Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Using an E6 "torx" socket, install the stud bolts as shown in the illustration.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 108: Identifying Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new gasket and the oil strainer with the bolt and 2 nuts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 109: Identifying Oil Strainer Bolt & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
1. Using an E6 "torx" socket, install the stud bolts as shown in the illustration.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 110: Identifying No. 2 Oil Pan Sub-Assembly Stud Bolts Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing in a continuous line as shown in the illustration.
  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.)
  
  Fig 111: Identifying Seal Packing Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan No. 2 within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
3. Install the oil pan with the 16 bolts and 2 nuts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 112: Identifying Oil Pan Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN DRAIN PLUG
1. Install a new gasket and the drain plug.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
  
  Fig 113: Identifying Oil Pan Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Apply seal packing.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Fig 114: Identifying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install 3 new gaskets as shown in the illustration.
  
  Fig 115: Identifying Head Cover Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket to the head cover.
4. Install a head cover with the 12 bolts and a new washer.
  Torque:
  
  21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
  
  10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A
  
  Fig 116: Identifying Head Cover Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Apply seal packing.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Fig 117: Identifying Cylinder Head Cover Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the head cover within 3 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after installing.
2. Install 3 new gaskets.
  
  Fig 118: Identifying Head Cover Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket to the head cover.
4. Install the head cover with the 12 bolts and a new washer.
  Torque:
  
  21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
  
  10 N*m (102 kgf*cm, 7 ft.*lbf) for bolts except A
  
  Fig 119: Identifying Head Cover Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
INSTALL WATER OUTLET
1. Install 2 new gaskets and a new O-ring.
  
  Fig 120: Identifying Water Outlet Gaskets & O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply soapy 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) for bolts
  
  10 N*m (103 kgf*cm, 7 ft.*lbf) for nuts
  
  Fig 121: Identifying Water By-Pass Joint Outlet Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful that the O-ring does not get caught between the parts.
INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)
1. Using an E8 "torx" socket, install the stud bolts as shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 122: Identifying No. 1 Oil Cooler Bracket Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new gasket to the No. 1 oil cooler bracket.
3. Install the oil cooler pipe with the bolt and 2 nuts.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
  
  Fig 123: Identifying Oil Cooler Pipe Bolt & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a new gasket to the No. 1 oil pan.
5. Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
  
  Fig 124: Identifying No. 1 Oil Cooler Bracket With Oil Cooler Pipe Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)
1. Install a new O-ring.
2. Install the oil cooler assembly with the union bolt.
  Torque: 68 N*m (693 kgf*cm, 50 ft.*lbf)
  
  Fig 125: Identifying Oil Cooler Assembly Union Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 126: Identifying Water By-Pass Hoses Bolt, Clamps & Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the pulley bolt.
  SST 09213-70011 (09213-70020), 09330-00021
  
  Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf)
  
  Fig 127: Using SST To Install Crankshaft Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER ELEMENT
1. Clean the inside of the oil filter cap, the threads and O-ring groove.
2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
3. Set a new oil filter element to the oil filter cap.
  
  Fig 128: Identifying Oil Filter Element & O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove dirt or foreign matter from the installation surface of the engine.
5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
  NOTE:
  - Be careful that the O-ring does not get caught between the parts.
  - The O-ring must not be twisted on the groove.
6. Using SST, tighten the oil filter cap.
  SST 09228-06501
  
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 129: Tightening Oil Filter Cap Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure that the oil filter is installed securely.
7. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
  NOTE: Remove all dirt and foreign matter from the installation surface.
8. Install the oil filter drain plug to the oil filter cap.
  Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf)
  
  Fig 130: Identifying Oil Filter Drain Plug & Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure that the O-ring does not get caught between the parts.
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
  
  Fig 131: Applying Adhesive Around Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water drain cocks.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 132: Identifying Water Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
3. Install the water drain cock plugs to the water drain
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
INSTALL NO. 1 OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
  NOTE: Do not touch the mesh when installing the oil control valve filter.
2. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
4. Tighten the oil pipe union (on the head cover side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
5. Tighten the oil pipe union (on the cylinder head side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
  
  Fig 133: Identifying Oil Pipe Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
INSTALL OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
  NOTE: Do not touch the mesh when installing the oil control valve filter.
2. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
4. Install the bolt (A) to the cylinder head.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
5. Tighten the oil pipe union (on the head cover side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
6. Tighten the oil pipe union (on the cylinder head side).
  Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf)
  
  Fig 134: Identifying Oil Pipe Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the sensor with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 135: Identifying Crankshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Install the 4 oil control valves with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 136: Identifying Camshaft Timing Oil Control Valve Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT POSITION SENSOR
1. Install the 4 sensors with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 137: Identifying Camshaft Position Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VENTILATION VALVE SUB-ASSEMBLY
1. Apply adhesive around the ventilation valve.
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
2. Install the ventilation valve.
  Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
  
  Fig 138: Identifying Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPARK PLUG
1. Install the 6 spark plugs.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install a new gasket.
2. Install the oil filler cap.