Engine Unit: Reassembly

WARNING: This page is about a different car, the 2007 Lexus ES 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 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

STRAIGHT PIN DIAMETER

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.
  
  Fig 2: Identifying Stud Bolt Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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
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: Identifying Bolt And Oil Nozzle
  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.
  HINT:
  
  Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
  
  Fig 4: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston to approximately 80°C (176°F).
3. Coat the piston pin with engine oil.
  
  Fig 5: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
  HINT:
  
  The piston and pin are a matched set.
  
  Fig 6: Aligning Front Marks Of Piston And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 And 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.
  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.
  
  Fig 8: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, install the oil ring rail as shown in the illustration.
  
  Fig 9: Installing Piston Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Position the piston rings so that the ring ends are as shown in the illustration.
  NOTE: do not align the ring ends.
  
  Fig 10: Identifying Piston Rings Gap Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT BEARING
1. Clean the main journal and both surfaces of the bearing.
  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.
  
  Fig 11: Identifying Journal Bearings Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the upper bearing.
  1. Install the upper bearings to the cylinder block as shown in the illustration.
    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.
    
    Fig 12: Identifying Upper Bearing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the lower bearing.
  1. Install the lower bearings to the bearing caps.
  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.
  
  Fig 13: Identifying Lower Bearing To Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.

INSTALL CRANKSHAFT

Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

Fig 14: Identifying Oil Grooves
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.
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.

Fig 15: Identifying Main Bearing Caps Installation Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

Fig 17: Tapping Bearing Cap To Ensure Proper Fit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 8 main bearing cap bolts to the outside positions.
Install the crankshaft bearing cap bolts.
HINT:

The main bearing cap bolts are tightened in 2 progressive steps.

Fig 18: Identifying Main Bearing Cap Bolt Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Step 1
1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
  Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
  
  If any of the main bearing cap bolts does not meet the specified torque, replace it.
  
  Fig 19: Locating Main Bearing Cap Bolts Loosening 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: Identifying Paint Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

Bolt length

BOLT LENGTH SPECIFICATION

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

Check that the crankshaft turns smoothly.

Fig 21: Locating Main Bearing Cap Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Measuring Distance Between Connecting Rod And Bearing Cap Edges And Connecting Rod Bearing Edge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Position the piston rings so that the ring ends are as shown in the illustration.
  NOTE: do not align the ring ends.
  
  Fig 23: Identifying Piston Rings Gap Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  NOTE: Match the numbered connecting rod cap with the connecting rod.
  
  Fig 24: Pushing Piston And Connecting Rod Assembly Into Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
6. Install the connecting cap bolts.
  HINT:
  
  The connecting cap bolts are tightened in 2 progressive steps.
  
  Fig 25: Identifying Front Mark Of Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 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° as shown in the illustration.
  3. Check that 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 ).
  
  Fig 27: Identifying Retightening Angle Of Connecting Rod Cap Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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).

GUIDE BUSH 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.)

Fig 28: Checking Bush Bore Diameter Of Cylinder Head

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 an 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).

GUIDE BUSH 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.)

Fig 31: Checking Bush Bore Diameter Of Cylinder Head

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Locating Ring Pin
  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)
INSTALL STUD BOLT
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.

Fig 36: Locating No. 2 Straight Screw Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 as shown in the illustration.
  
  Fig 38: Identifying Straight Pin Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Protrusion height:
  
  17.5 to 19.5 mm (0.689 to 0.768 in.)
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: Identifying Intake And Exhaust Valve 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 shown in the illustration.
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 41: 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 42: 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.
  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 shown in the illustration.
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.
  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.
  
  Fig 46: Tapping Valve Stem Tip To Ensure Proper Fit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
  SST 09223-15030, 09950-70010 (09951-07100)
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the oil seal at an angle.
    
    Fig 47: Tapping Engine Rear Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE REAR OIL SEAL RETAINER
1. Apply seal packing in a continuous line as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal diameter:
  
  2.0 to 3.0 mm (0.079 to 0.118 in.)
  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.
    
    Fig 48: Applying Seal Packing In Continuous Line
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Locating Oil Seal Retainer
  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)
2. Install the No. 1 water by-pass hose.
  
  Fig 50: Locating Water Bypass Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder 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.
  
  Fig 51: Placing Cylinder Head Gasket On Cylinder Block Surface With Lot No. Stamp Upward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 and in the sequence shown in the illustration.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
    
    Fig 52: Locating Cylinder Head Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Step 2
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  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.
    
    Fig 53: Identifying Painted Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder 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.
  
  Fig 54: Placing Cylinder Head Gasket On Cylinder Block Surface With Front Face
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 and in the sequence shown in the illustration.
    Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
    
    Fig 55: Locating Cylinder Head Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Step 2
  1. Mark the cylinder head bolt head with paint as shown in the illustration.
  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.
    
    Fig 56: Identifying Painted Mark
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Tighten the 2 bolts in the order shown in the illustration.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
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.
  
  Fig 57: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 as shown in the illustration. If the check ball is not pressed, air will not be bled.
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.
  
  Fig 58: Checking Movement Of Plunger And Bleed Air
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Make sure that the valve rocker arms are installed as shown in the illustration.
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.
  
  Fig 59: Applying Engine Oil To Lash Adjuster Tips And Valve Stem Cap Ends
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 61: Tightening Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
1. Make sure that the valve rocker arm is installed as shown in the illustration.
  
  Fig 62: Applying Engine Oil To Lash Adjuster Tips And Valve Stem Cap Ends
  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.)
  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.
    
    Fig 63: Applying Seal Packing In Continuous Bead
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the camshaft housing RH and tighten the 12 bolts in the order shown in the illustration.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  NOTE:
  - When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. 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.
    
    Fig 64: Tightening Bolts In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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)
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.
  
  Fig 65: Tightening Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 And Numbers On Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily tighten the 8 bolts in the order shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 67: Tightening Bolts In 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: Applying Engine Oil To Lash Adjuster Tips And Valve Stem Cap Ends
  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.)
  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.
    
    Fig 69: Applying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  NOTE:
  - When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. 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.
    
    Fig 70: Tightening Bolts In Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 8 bolts in the order shown in the illustration.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 71: Locating Bolts
  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 (J) 1.0 mm (0.039 in.) into the hole to fix it.
  
  Fig 72: Locating No 2 Chain Tensioner
  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 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.
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.
  
  Fig 73: Aligning Mark Plate (Yellow) With Timing Marks (1-Dot Mark) Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
5. Remove the pin from the chain tensioner.
  
  Fig 74: Tightening Camshaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Locating No 3 Chain Tensioner
  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 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.
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.
  
  Fig 76: Aligning Mark Plate (Yellow) With Timing Marks (2-Dot Mark) Of Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
5. Remove the pin from the chain tensioner.
  
  Fig 77: Holding Hexagonal Portion Of Camshaft Using Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
INSTALL NO. 2 CHAIN VIBRATION DAMPER
1. Install the 2 chain vibration dampers.
  
  Fig 78: Identifying No.1 Chain Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING SPROCKET
1. Install the 2 timing gear set keys and timing sprocket as shown in the illustration.
  
  Fig 79: Identifying Crankshaft Timing Sprocket Installation Position
  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 sure to install the idle gear shaft in 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.
  
  Fig 80: Locating Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHAIN SUB-ASSEMBLY
1. Align the mark plate and timing marks as shown in the illustration and install the chain.
  HINT:
  
  The color of the camshaft mark plate is orange.
  
  Fig 81: Identifying Timing Mark On Marking Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  HINT:
  
  The color of the crankshaft mark plate is yellow.
5. Temporarily tighten the pulley set bolt.
  
  Fig 84: Aligning Mark Plate And Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
INSTALL CHAIN TENSIONER SLIPPER
1. Install the chain tensioner slipper.
  
  Fig 85: Turning Crankshaft Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
  
  Fig 86: Moving Stopper Plate Upward To Release Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the chain tensioner with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 87: Locating Chain Tensioner With 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.
5. Remove the pulley set bolt.
  
  Fig 88: Identifying Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  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.
    
    Fig 89: Tapping Timing Chain Case Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  NOTE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
  
  Fig 90: Locating Water Pump With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Fig 91: Applying Seal Packing
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 as shown in the following illustration.

Fig 92: Identifying Timing Chain Cover Dimension

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 Short 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 And Crankshaft

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

Fig 95: Identifying Timing Chain Cover With Bolts

Bolt length

BOLT LENGTH SPECIFICATION

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) in the illustration before installing it.
  
  Fig 96: Locating O-Ring
  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)
  
  NOTE: Be careful that the O-ring does not get caught between the parts.
  
  Fig 98: Locating Bolts, Nut, And Water Inlet Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Locating Water Inlet With 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)
  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)
  
  Fig 101: Identifying Stud Bolt Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  HINT:
  
  Temporarily tighten the 7 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.
  
  Fig 102: Locating Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN SUB-ASSEMBLY
1. When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.
  
  Fig 103: Identifying Lower Cylinder Block And Timing Chain Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install 2 new O-rings.
  
  Fig 104: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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.)
  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.
    
    Fig 105: Applying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 106: Locating Oil Pan With Bolts And 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 107: Locating Stud Bolts And Length
  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 108: Locating Gasket And Oil Strainer With Bolt
  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 109: Locating No. 2 Oil Pan Sub-Assembly
  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.)
  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.
    
    Fig 110: Applying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil pan with the 16 bolts and 2 nuts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 111: Identifying Oil Pan With Bolts And 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 112: Locating Oil Pan drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Apply seal packing as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  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.
    
    Fig 113: Applying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 3 new gaskets as shown in the illustration.
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
  
  HINT:
  
  After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
  
  Fig 115: Identifying Head Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Apply seal packing as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  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.
    
    Fig 116: Applying Seal Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 3 new gaskets as shown in the illustration.
3. Install a new gasket to the head cover.
  
  Fig 117: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  
  HINT:
  
  After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
  
  Fig 118: Locating Head Cover With Bolts And Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER OUTLET
1. Install 2 new gaskets and a new O-ring.
  HINT:
  
  Apply soapy water to the O-ring.
  
  Fig 119: Locating Gaskets And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  
  NOTE: Be careful that the O-ring does not get caught between the parts.
  
  Fig 120: Locating Bolts, Nuts And Water Outlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide it 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 121: Identifying Crankshaft Pulley Bolt Using SST
  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.
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.
    
    Fig 122: Identifying Oil Filler Element And O-Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, tighten the oil filter cap.
  SST 09228-06501
  
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  NOTE: Make sure that the oil filter is installed securely as shown in the illustration.
  
  Fig 123: Tightening Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  NOTE: Make sure that the O-ring does not get caught between the parts.
  
  Fig 124: Locating Oil Filter Drain Plug To Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 125: Applying Adhesive Around drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water drain cocks as shown in the illustration.
  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 plugs to the water drain cocks.
  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)
  
  NOTE: If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.
  
  Fig 127: Locating Oil Pipe Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 128: Locating 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 129: Locating Crankshaft Position Sensor
  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 130: Locating Camshaft Timing Oil Control Valves With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT POSITION SENSOR
1. Install the 4 sensors with the 4 bolts.
  Torque: 1b N*m (102 kgf*cm, 7 ft.*lbf)
Fig 131: Locating Camshaft Position Sensors With 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 132: Identifying Oil Filler Cap
  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.