FixVault
Home › Toyota › 2009 › Avalon XLS › Repair and Diagnosis › External Pages › Different car › Section 12 (Engine Mechanical) › Engine Unit › Reassembly

Engine Unit: Reassembly

WARNING: This page is about a different car, the 2008 Toyota Avalon. 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 .
  1. INSTALL TIGHT PLUG 
    NOTE: If water leaks from the tight plug or the plug corrodes, replace it.
    Fig 1: Checking Piston Pin Fitting
    G04996870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply adhesive around the tight plugs.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    2. Using SST, tap in the tight plugs.

      SST 09950-60010 (09951-00340), 09950-70010 (09951-07100) 

      Fig 2: Applying Adhesive Around Tight Plugs
      G04996871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 3: Identifying Tight Plugs Location
      G04996872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL STRAIGHT PIN 
    1. Using a plastic hammer, tap in new straight pins to the cylinder block.

      Standard protrusion 

      PROTRUSION SPECIFICATION

      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.)
      Fig 4: Identifying Straight Pins Dimension In Cylinder Block
      G04996873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL STUD BOLT 
    1. Using E8 and E10 "TORX" sockets wrench, install the stud bolt.

      Torque: A bolt 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      B bolt 

      17 N*m (173 kgf*cm, 13 ft.*lbf) 

      Fig 5: Identifying Stud Bolt Dimension
      G05405151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL SUB-ASSEMBLY OIL NOZZLE NO. 1 
    1. Using a 5 mm hexagon wrench, install the 3 oil nozzles with the bolts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 6: Locating Oil Nozzles
      G04996761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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 end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

      Fig 7: Installing Snap Ring At One End Of Piston Pin Hole
      G04974736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to approximately 80°C (176°F).
      Fig 8: Heating Piston
      G04996877Courtesy 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.

      HINT:

      The piston and pin are a matched set.

      Fig 9: Aligning Front Marks Of Piston And Connecting Rod
      G04974738Courtesy 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 10: Checking Fitting Condition Between Piston And Piston Pin
      G04974647Courtesy 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.

      Fig 11: Installing Snap Ring
      G04974740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL PISTON RING SET 
    1. Install the oil ring expander and 2 side rails by hand.
    2. Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.
      Fig 12: Installing Oil Ring Expander And Side Rails
      G04974741Courtesy 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.
  7. INSTALL CRANKSHAFT 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 13: Positioning Piston Rings
    G04974742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Clean the main journal and the both surfaces of the bearing.
      Fig 14: Identifying Main Journal Bearing Dimension
      G04996839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the upper bearing.
      1. Install the upper bearing to the cylinder block as shown in the illustration.
        NOTE: Do not apply engine oil to the bearing and its contact surface.
        Fig 15: Installing Upper Bearing
        G04996840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the lower bearing.
      1. Install the lower bearing to the bearing cap.
      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 bearing's contact area and underside.
        Fig 16: Installing Lower Bearing To Bearing Cap
        G04974745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL CRANKSHAFT 
    1. Install the crankshaft thrust washer to the cylinder block.
      1. Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
    2. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
      Fig 17: Identifying Oil Grooves
      G04996886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Confirm the front marks 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.

    4. Apply a light coat of engine oil to the threads and under the head of the bearing cap bolts.
    5. Temporarily install the 8 main bearing cap bolts to the inside positions.
      Fig 18: Identifying Front Marks And Numbers Of Main Bearing Caps
      G04996887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert the main bearing cap by 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 19: Checking Clearance Between Main Bearing Cap And Cylinder Block
      G04996843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
    8. Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
      Fig 20: Tapping Bearing Cap
      G04974749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the 8 main bearing cap bolts to the outside positions.

      Bolt length: 105.5 to 107.5 mm (4.15 to 4.23 in.) 

      Fig 21: Identifying Main Bearing Cap Bolts
      G04996890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the crankshaft bearing cap bolts.

      HINT:

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

    11. 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 torque specified, replace it.

        Fig 22: Tightening Main Bearing Cap Bolts
        G04996846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Step 2
      1. Mark the front of the bearing cap bolts with paint.
      2. Tighten the bearing cap bolts another 90° in the order above.
      3. Check that the painted mark is now at a 90° angle to the front.
    13. Check that the crankshaft turns smoothly.
    14. Check the crankshaft thrust clearance.
      Fig 23: Identifying Front Mark Of Bearing Cap Bolts With Paint
      G04996892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Install 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) 

      HINT:

      • Bolt (A) length: 45 mm (1.77 in.)
      • Except bolt (A) length: 30 mm (1.18 in.)
    16. Check that the crankshaft turns smoothly.
    17. Check the crankshaft thrust clearance.
      Fig 24: Identifying Bearing Cap Bolts Tightening Sequence
      G04996848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. 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 each connecting rod bearing's edge.

      Dimension (A-B): 0.7 mm (0.0276 in.) or less 

      NOTE: Do not apply engine oil to the bearing's contact area and underside.
  10. 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 25: Measuring Distance Between Connecting Rod's And Bearing Cap's Edges
      G04996894Courtesy 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 26: Positioning Piston Rings
      G04974742Courtesy 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.
    4. Match the numbered connecting rod cap with the connecting rod.
      Fig 27: Pushing Piston And Connecting Rod Assembly Into Cylinder
      G04974756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check that the front mark of the connecting rod cap is facing forward.
    6. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
    7. Install the connecting cap bolts.

      HINT:

      The connecting cap bolts are tightened in 2 progressive steps.

      Fig 28: Checking Front Mark Of Connecting Rod Cap
      G04974757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. 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 29: Tightening Connecting Rod Cap Bolts
        G04974758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Step 2
      1. Mark the front side of each connecting cap bolt with paint.
      2. Tighten the cap bolts another 90° as shown in the illustration.
      3. Check the painted mark is now at a 90° angle to the front.
    10. Check that the crankshaft turns smoothly.
    11. Check the connecting rod thrust clearance.
      Fig 30: Marking Front Side Of Connecting Cap Bolt With Paint
      G04996899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL RING PIN 
    1. Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.

      Specified protrusion height: 2.5 to 3.5 mm (0.098 to 0.138 in.) 

      Fig 31: Tapping Ring Pins
      G04974766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL WITH HEAD STRAIGHT SCREW PLUG NO. 1 
    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 32: Removing Screw Plugs And Gaskets
      G04974635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL WITH HEAD STRAIGHT SCREW PLUG NO. 2 
    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) 

  14. INSTALL STUD BOLT 
    NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
    1. Using E6 and E8 "TORX" socket wrenches, install the stud bolts.

      Torque: A and B bolts 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      C bolt 

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

      Fig 33: Locating Screw Plugs
      G04974636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 34: Identifying Straight Pins Installing Location
      G04996903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL STRAIGHT PIN 
    1. Using a plastic hammer, tap in 4 new straight pins as shown in the illustration.

      Specified protrusion height: 17.5 to 19.5 mm (0.689 to 0.768 in.) 

      Fig 35: Tapping Straight Pins
      G04974770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL VALVE SPRING SEAT 
    1. Install the valve spring seats to the cylinder head.
  17. 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 white and the exhaust valve oil seals are black.

      Fig 36: Identifying Valve Oil Seals
      G04996905Courtesy 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 37: Pushing Oil Seals
      G04996906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL INTAKE VALVE 
    1. Apply a plenty 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 38: Identifying Valve Stem Tip Area Dimension
      G04996907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.

      SST 09202-70020 (09202-00010) 

      Fig 39: Compressing Compression Spring
      G04974631Courtesy 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 40: Tapping Valve Stem Tip
      G04974778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL EXHAUST VALVE 
    1. Apply a plenty 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 Valve Stem Tip Area Dimension
      G04996910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.

      SST 09202-70020 (09202-00010) 

      Fig 42: Compressing Compression Spring
      G04974632Courtesy 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.
  20. INSTALL VALVE STEM CAP 
    1. Apply a light coat of engine oil to the valve stem caps.
    2. Install the valve stem caps to the cylinder head.
      Fig 43: Tapping Valve Stem Tip
      G04974775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL ENGINE REAR OIL SEAL RETAINER 
    1. Apply seal packing in a continuous bead 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 crankcase within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
        Fig 44: Applying Seal Packing In Continuous Bead
        G05405190Courtesy 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 45: Identifying Oil Seal Retainer With Bolts
      G04974781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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 water by-pass hose No. 1.
      Fig 46: Locating Water Outlet Pipe Bolts
      G04974630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL CYLINDER HEAD SUB-ASSEMBLY 
    1. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
      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: Ensure that no oil is on the mounting surface of the cylinder head.

      HINT:

      The cylinder head bolts are tightened in 3 progressive steps.

      Fig 47: Placing Cylinder Head Gasket On Cylinder Block Surface With Lot No. Stamp Upward
      G04974783Courtesy 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 48: Identifying Cylinder Head Bolts Tightening Sequence
        G04974784Courtesy 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 by an additional 90°.
      2. Check that the painted mark is now facing rearward.
        Fig 49: Marking Cylinder Head Bolt Head With Paint
        G04996918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
      Fig 50: Identifying Seal Packing Seepage
      G04996919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL CYLINDER HEAD LH 
    1. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.
      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: Ensure that no oil is on the mounting surface of the cylinder head.
      Fig 51: Placing Cylinder Head Gasket On Cylinder Block Surface With Lot No. Stamp Upward
      G04974786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 and in the sequence shown in the illustration.

        Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

        Fig 52: Identifying Cylinder Head Bolts With Plate Washers Tightening Sequence
        G04974787Courtesy 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 by an additional 90°.
      2. Check that the painted mark is now facing rearward.
        Fig 53: Marking Cylinder Head Bolt Head With Paint
        G04996918Courtesy 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) 

      NOTE: Only use the specifications stated above when tightening the bolts 1 and 2 shown in the illustration.
      Fig 54: Identifying Tightening Sequence Of Bolts
      G04974789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
  25. INSTALL VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the lash adjuster free from dirt and foreign objects.
    • Only use clean engine oil.
      Fig 55: Identifying Seal Packing Seepage
      G04996919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the lash adjuster into a container full of engine oil.
    2. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.

      SST 09276-75010 

    3. Squeeze 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 high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.
    5. After bleeding the air, remove SST. Then quickly and firmly press the plunger 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 at the same place it was removed from.
      Fig 56: Inserting SST's Tip Into Lash Adjuster's Plunger
      G04996762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the lash adjuster tips and valve stem cap ends.
    2. Make sure that the valve rocker arms are installed as shown in the illustration.
      Fig 57: Identifying Valve Rocker Arm Sub-Assembly
      G04974791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL CAMSHAFT BEARING CAP RH 
    1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
    2. Install the camshaft and camshaft No. 2 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 58: Identifying Marks And Numbers On Camshaft Bearing Caps
      G04974792Courtesy 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 59: Identifying Camshaft Bolts Tightening Sequence
      G04974793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    1. Apply seal packing in a continuous bead 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 and tighten the bolts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
        Fig 60: Applying Seal Packing In Continuous Bead
        G04974795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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: Make sure that the knock pins of the camshafts are positioned as shown in the illustration before installing the camshaft housing RH.
      Fig 61: Identifying Camshaft Bolts Tightening Sequence
      G04974796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the 8 bolts in the order shown in the illustration.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

      NOTE: Thoroughly wipe clean any seal packing.
      Fig 62: Identifying Camshaft Bolts Tightening Sequence
      G04974797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install 3 new gaskets.
      Fig 63: Locating Camshaft Bearing Cap Gaskets
      G04974585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL CAMSHAFT BEARING CAP 
    1. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
    2. Install the camshaft No. 3 and camshaft No. 4 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 64: Identifying Marks And Numbers On Camshaft Bearing Caps
      G04996933Courtesy 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 65: Identifying Camshaft Bolts Tightening Sequence
      G04974799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 
    1. Apply seal packing in a continuous bead 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 and tighten the bolts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
        Fig 66: Applying Seal Packing In Continuous Bead
        G04974801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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: Make sure that the knock pins of the camshafts are positioned as shown in the illustration before installing the camshaft housing LH.
      Fig 67: Identifying Camshaft Housing Bolts Tightening Sequence
      G04974802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the 8 bolts in the order shown in the illustration.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

      NOTE: Thoroughly wipe clean any seal packing.
      Fig 68: Identifying Camshaft Bolts Tightening Sequence
      G04996937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install 3 new gaskets.
      Fig 69: Locating Camshaft Bearing Cap Bolts
      G04974587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Install the chain tensioner No. 2 with the bolt.

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

    2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it.
      Fig 70: Locating Chain Tensioner No. 2 With Bolt
      G04996939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for RH BANK) 
    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 small amount 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 71: Aligning Mark Plate With Timing Marks Of Camshaft Timing Gears
      G04996940Courtesy 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 No. 2.
      Fig 72: Holding Hexagonal Portion Of Camshaft
      G04996723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Install the chain tensioner No. 3 with the bolt.

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

    2. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it.
      Fig 73: Locating Chain Tensioner No. 3 With Bolt
      G04996942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for LH BANK) 
    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 small amount 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 74: Aligning Mark Plate With Timing Marks Of Camshaft Timing Gears
      G04996943Courtesy 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 No. 2.
      Fig 75: Holding Hexagonal Portion Of Camshaft
      G04996731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL NO. 1 CHAIN VIBRATION DAMPER 
    1. Install the chain vibration damper No. 1 with the 2 bolts.

      Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf) 

  36. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
    1. Install the 2 chain vibration damper.
      Fig 76: Locating Chain Vibration Dampers
      G04974611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL CRANKSHAFT TIMING GEAR 
    1. Install the timing gear set keys and timing gear as shown in the illustration.
  38. INSTALL IDLE SPROCKET ASSEMBLY 
    1. Apply a light coat of engine oil to the rotating surface of the idle gear shaft No. 1.
      Fig 77: Identifying Crankshaft Timing Gear
      G04996721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the idle gear shaft No. 1 and idle sprocket with the idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block.
      NOTE: Be careful of the idle gear direction.
    3. Using a 10 mm hexagon wrench, tighten the idle gear shaft No. 2.

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

      Fig 78: Tightening Idle Gear Shaft No. 2
      G04974812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL CHAIN SUB-ASSEMBLY 
    1. Align the mark plate and timing marks as shown in the illustration and install the chain.

      HINT:

      The camshaft mark plate is orange.

      Fig 79: Aligning Mark Plate And Timing Marks
      G04974813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Do not pass the chain over the crankshaft, just put it on it.
      Fig 80: Passing Chain Over Crankshaft
      G04974608Courtesy 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 plates with the marks on the sprocket in order to tighten the chain between the banks.
      Fig 81: Turning Camshaft Timing Gear Assembly On RH Bank Counterclockwise
      G04974815Courtesy 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 crankshaft mark plate is yellow.

    5. Temporarily tighten the pulley set bolt.
      Fig 82: Aligning Mark Plate And Timing Marks
      G04996951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
  40. INSTALL CHAIN TENSIONER SLIPPER 
    1. Install the chain tensioner slipper.
      Fig 83: Identifying Sensor Plate And Timing Mark
      G04996952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. 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 84: Pushing Plunger Deep Into Tensioner
      G04974818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the chain tensioner No. 1 with the 2 bolts.

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

      Fig 85: Locating Chain Tensioner No. 1 With Bolts
      G04974606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the lock pin of the chain tensioner assembly No. 1. Check that each timing mark is aligned with the crankshaft at the TDC / compression.
    5. Remove the pulley set bolt.
      Fig 86: Aligning Timing Mark With Crankshaft At TDC / Compression
      G04974820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. 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 B with new ones or reuse them after applying adhesive 1344.
      Fig 87: Locating Water Pump Bolts
      G04996956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Install a new gasket and the chain cover plate with the 4 bolts.

      Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf) 

    2. Apply seal packing in a continuous bead to the engine unit as shown in the following illustration.
      Fig 88: Applying Seal Packing In Continuous Bead To Engine Unit
      G04974823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Seal width: 3.0 mm or more (0.118 in.) 

      NOTE:
      • Be sure to clean and degrease the contact surfaces, especially the areas indicated by C in the illustration.
      • When the contact surfaces are wet, degrease with cleaning agent and wipe off with an oil-free cloth before applying seal packing.
      • Install the crankcase 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 installation.
    3. Apply seal packing in a continuous bead to the timing chain cover as shown in the following illustration.
      Fig 89: Applying Seal Packing In Continuous Bead To Timing Chain Cover
      G05000297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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, degrease with cleaning agent and wipe off with an oil-free cloth before applying seal packing.
      • Install the crankcase 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 installation.

      HINT:

      Apply seal packing referring to the table and illustration below.

      SEAL PACKING DIAMETER SPECIFICATION

      Area Seal Packing Diameter Application Position from Inside Seal Line
      Dashed line area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.)
      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.)
      Diagonal line area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.)
    4. Install a new gasket.
      Fig 90: Identifying Gasket
      G05000298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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 91: Aligning Oil Pump's Drive Rotor Spline And Crankshaft
      G04996960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Loosely install the timing chain cover with the 23 bolts and 2 nuts, but do not tighten the bolts and 2 nuts yet.
      Fig 92: Locating Timing Chain Cover With Bolts And Nuts
      G04974827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that there is no oil on the bolt threads.

      HINT:

      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.)
    7. Fully tighten the bolts in this order: Area 1 and Area 2.

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

    8. Fully tighten the bolts and nuts in this order: Area 3.

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

    9. Fully tighten the bolts in this order: Area 4.

      Torque: Bolt A 

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

      Bolts except A 

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

  44. INSTALL WATER INLET HOUSING 
    1. Install 2 new O-rings.
    2. Apply soapy water to the O-ring.
      Fig 93: Locating O-Rings
      G04974581Courtesy 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 94: Locating Water Inlet Housing Bolts And Nuts
      G04996695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply adhesive around the drain cock.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    5. Install the water drain cock to the water inlet housing.

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

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

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

    7. Install a new gasket to the thermostat.
      Fig 95: Applying Adhesive Around Drain Cock
      G04996964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. 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 position.

      Fig 96: Aligning Thermostat Jiggle Valve With Upper Stud Bolt
      G04996965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the water inlet with the 2 nuts.

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

      Fig 97: Locating Water Inlet Housing Nuts
      G04974579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 LH 
    1. Install the engine mounting bracket front No. 1 LH 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.
        Fig 98: Locating Engine Mounting Bracket Front No. 1 Bolts
        G04974578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not start the engine for at least 2 hours after installation.
  46. INSTALL OIL PAN BAFFLE PLATE NO.1 
    1. Install the oil pan baffle plate with the 7 bolts.

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

      Fig 99: Locating Oil Pan Baffle Plate Bolts
      G04974594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Install the stud bolt.
      1. Using an E8 "TORX" socket wrench, install the stud bolts as shown in the illustration.

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

        Fig 100: Locating Oil Pan Baffle Plate Bolts
        G04974594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Fig 101: Locating Stud Bolt
        G04996970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing in a continuous bead 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 crankcase within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
        Fig 102: Applying Seal Packing In Continuous Bead
        G04974837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install 2 new O-rings.
      Fig 103: Locating O-Rings
      G04974593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the oil pan with the 16 bolts and 2 nuts.

      Torque: Bolt A 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Bolts except A 

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

      Fig 104: Locating Oil Pan With Bolts And Nuts
      G04974838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Install the stud bolt.
      1. Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

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

        Fig 105: Locating Stud Bolts
        G04996974Courtesy 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 106: Locating Oil Strainer Sub-Assembly Bolts And Nuts
      G04974590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL OIL PAN SUB-ASSEMBLY NO. 2 
    1. Apply seal packing in a continuous bead 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 crankcase within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
        Fig 107: Applying Seal Packing In Continuous Bead
        G04996976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the stud bolt.
      1. Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

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

        Fig 108: Identifying Stud Bolt Dimension
        G04996977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil pan No. 2 with the 16 bolts and 2 nuts.

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

      Fig 109: Locating Oil Pan No. 2 With Bolts And Nuts
      G04974588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. 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 110: Locating Drain Plug And Gasket
      G04974564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    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 crankcase within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
        Fig 111: Locating Gasket To Head Cover
        G04974845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the gasket to the head cover.
    3. Install the head cover with the 12 bolts.

      Torque: Bolt A 

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

      Bolts except A 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT:

      Make sure the tightening torque of bolt 1.

      Fig 112: Identifying Head Cover Bolts Tightening Sequence
      G04974847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    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 crankcase within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    2. Install the gasket to the head cover.
      Fig 113: Locating Gasket To Head Cover
      G04974848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the head cover with the 14 bolts.

      Torque: Bolt A 

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

      Bolts except A 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT:

      Make sure the tightening torque of bolts 1 and 10.

      Fig 114: Locating Head Cover With Bolts Tightening Sequence
      G04996983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL WATER OUTLET 
    1. Install 2 new gaskets and a new O-ring.
    2. Apply soapy water to the O-ring.
      Fig 115: Locating Gaskets And O-Ring
      G04974583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the water outlet with the 2 bolts and 4 nuts.

      Torque: Bolts 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Nuts 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 116: Locating Water Outlet Bolts And Nuts
      G04996697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. 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 117: Installing Pulley Bolt
      G04996986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL OIL FILTER ELEMENT 
    1. Clean the inside of the oil filter cap, the threads and O-ring groove.
    2. Apply a small amount 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 and inside of the engine.
      Fig 118: Identifying Oil Filter Element And O-Ring
      G04996690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply a small amount 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, install 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 119: Installing Oil Filter Cap
      G04974855Courtesy 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 (130 kgf*cm, 9 ft.*lbf) 

      NOTE: Make sure that the O-ring does not get caught between the parts.
      Fig 120: Installing Oil Filter Drain Plug To Oil Filter Cap
      G04996989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. 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 121: Applying Adhesive Around Drain Cocks
      G04943675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cylinder block 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 with the specified torque.
      • Do not loosen the drain cocks after setting correctly.
    3. Install the water drain cock plug to the water drain cocks.

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

      Fig 122: Identifying Drain Cocks Rotating Angle
      G04996991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL OIL PIPE NO. 1 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
    2. Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install oil pipe No. 1 (on the head cover side) with the oil pipe union.
    3. Install a new gasket and temporarily install oil pipe No. 1 (on the cylinder head side) with the oil pipe union.
      NOTE: Remove any oil from the contract surface.
      Fig 123: Locating Oil Pipe Unions And Oil Pipe No. 1
      G04996684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the oil pipe union (on the head cover side).

      Torque: 65 N*m (662 kgf*cm, 48 ft.*lbf) 

    5. Tighten the oil check valve bolt (on the cylinder head side).

      Torque: 65 N*m (662 kgf*cm, 48 ft.*lbf) 

  58. INSTALL OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
    2. Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the head cover side) with the oil pipe union.
      NOTE: Remove any oil from the contact surface.
    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.
      NOTE: Remove any oil from the contact surface.
      Fig 124: Identifying Oil Pipe
      G04996993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 (662 kgf*cm, 48 ft.*lbf) 

    6. Tighten the oil pipe union (on the cylinder head side).

      Torque: 65 N*m (662 kgf*cm, 48 ft.*lbf) 

  59. INSTALL CRANK POSITION SENSOR 
    1. Install the crankshaft position sensor with the bolt.

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

      Fig 125: Locating Crankshaft Position Sensor With Bolt
      G04974861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Install the 4 camshaft timing oil control valves with the 4 bolts.

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

      Fig 126: Locating Camshaft Timing Oil Control Valves Bolts
      G04974567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL CAMSHAFT POSITION SENSOR 
    1. Install the 4 camshaft position sensors with the 4 bolts.

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

      Fig 127: Locating Camshaft Position Sensors Bolts
      G04974566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. 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 sub-assembly.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

  63. INSTALL SPARK PLUG 
    1. Install the 6 spark plugs.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Fig 128: Locating Ventilation Valve Sub-Assembly
      G04974565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filter cap sub-assembly.
About FixVault