3UR-FE Engine unit - Reassembly

1. INSTALL STUD BOLT

2. INSTALL RING PIN

3. INSTALL REAR CRANKSHAFT OIL SEAL

4. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY

5. INSTALL ENGINE REAR OIL SEAL RETAINER

6. INSTALL OIL STRAINER SUB-ASSEMBLY

7. INSTALL NO. 1 OIL PAN BAFFLE PLATE

8. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

10. INSTALL NO. 1 HEAT EXCHANGER COVER

11. INSTALL VENTILATION PIPE GASKET

12. INSTALL CYLINDER BLOCK WATER JACKET SPACER

13. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

14. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

15. INSTALL VALVE STEM CAP

16. INSTALL VALVE LASH ADJUSTER ASSEMBLY

17. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

18. INSTALL CAMSHAFT BEARING CAP RH

19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

20. INSTALL CAMSHAFT BEARING CAP LH

21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

22. INSTALL CRANKSHAFT TIMING GEAR KEY

23. SET NO. 1 CYLINDER TO TDC/COMPRESSION

24. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

25. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH

26. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH

27. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

28. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH

29. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

30. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH

31. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH

33. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH

34. TIGHTEN CAMSHAFT TIMING GEAR

35. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

36. INSTALL WATER INLET PIPE

37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

38. INSTALL WATER PUMP ASSEMBLY

39. INSTALL FRONT CRANKSHAFT OIL SEAL

40. INSTALL CRANKSHAFT TIMING GEAR KEY

41. INSTALL CRANKSHAFT PULLEY

42. INSTALL SPARK PLUG TUBE GASKET

43. INSTALL OIL CONTROL VALVE FILTER

44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

46. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

47. INSTALL WATER PUMP PULLEY

48. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY

49. INSTALL CRANKSHAFT POSITION SENSOR

50. INSTALL CRANK POSITION SENSOR PROTECTOR

51. INSTALL CAMSHAFT POSITION SENSOR

52. INSTALL VVT SENSOR

53. INSTALL SPARK PLUG

54. INSTALL OIL FILLER CAP HOUSING

55. INSTALL OIL FILLER CAP SUB-ASSEMBLY

56. INSTALL OIL FILTER BRACKET

57. INSTALL NO. 1 OIL COOLER BRACKET

58. INSTALL OIL FILTER ELEMENT

59. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

1. INSTALL STUD BOLT

NOTICE:

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

1. Install the timing chain cover stud bolt.

   1. Using an E10 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque:

      20 N*m{ 204 kgf*cm , 15 ft.*lbf }

2. Install the oil pan stud bolt.

   1. Using an E6 and E7 "TORX" socket wrench, install the 3 stud bolts as shown in the illustration.

      Torque:

      for stud bolt A:

      5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

      for stud bolt B:

      9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

2. INSTALL RING PIN

NOTICE:

It is not necessary to remove the ring pin unless it is being replaced.

1. Using a plastic-faced hammer, tap in new ring pins to the timing chain cover.

   Standard Protrusion:

   Item	Ring Pin Diameter	Specified Condition
   Ring pin A	13 mm (0.512 in.)	7.5 to 8.5 mm (0.295 to 0.335 in.)
   Ring pin B	11 mm (0.433 in.)	3.6 to 4.6 mm (0.142 to 0.181 in.)

   Text in Illustration

   *a	7.5 to 8.5 mm
   *b	3.6 to 4.6 mm

3. INSTALL REAR CRANKSHAFT OIL SEAL

1. 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)

   Standard depth:

   0 to 1.0 mm (0 to 0.0394 in.)

   NOTICE:

   1. Keep the lip free from foreign matter.
   2. Do not tap on the oil seal at an angle.

4. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY

1. Apply a light coat of engine oil to a new O-ring.

2. Install the O-ring to the drain pipe.

3. Install the oil drain pipe with the bolt.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

5. 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

   Standard Seal diameter:

   2.0 to 3.0 mm (0.0787 to 0.118 in.)

   Application position from inside edge of retainer:

   3.5 mm (0.138 in.)

   Text in Illustration

   *a	2.0 to 3.0 mm

   NOTICE:

   1. Remove any oil from the contact surface.
   2. Install the oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

2. Install the oil seal retainer with the 6 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

   NOTICE:

   1. Do not start the engine for at least 2 hours after installing.
   2. When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.
   3. When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.

6. INSTALL OIL STRAINER SUB-ASSEMBLY

1. Apply a light coat of engine oil to a new O-ring.

2. Install the O-ring to the oil strainer.

3. Install the oil strainer with the 2 bolts.

   Torque:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

   NOTICE:

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

7. INSTALL NO. 1 OIL PAN BAFFLE PLATE

1. Install the baffle plate with the 7 bolts.

   Torque:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

8. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

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

   Standard seal diameter:

   3.0 to 4.0 mm (0.118 to 0.157 in.)

   Text in Illustration

   *a	3.0 to 4.0 mm

   NOTICE:

   1. Remove any oil from the contact surface.
   2. Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

2. Install the oil pan with the 14 bolts and 2 nuts.

   Torque:

   for bolt A:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

   for bolt B:

   35 N*m{ 357 kgf*cm , 26 ft.*lbf }

   for nut:

   35 N*m{ 357 kgf*cm , 26 ft.*lbf }

   Text in Illustration

   	Bolt
   	Nut

   NOTICE:

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

   Standard Bolt:

   Item	Length	Thread Diameter
   Bolt A	92 mm (3.62 in.)	6 mm (0.236 in.)
   Bolt B	30 mm (1.18 in.)	10 mm (0.394 in.)

9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

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

   Standard seal diameter:

   3.0 to 4.0 mm (0.118 to 0.157 in.)

   Text in Illustration

   *a	3.0 to 4.0 mm

   NOTICE:

   1. Remove any oil from the contact surface.
   2. Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

2. Install the oil pan with the 14 bolts and 2 nuts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

   Text in Illustration

   	Bolt
   	Nut

   NOTICE:

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

10. INSTALL NO. 1 HEAT EXCHANGER COVER

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

   Seal packing:

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

   Standard seal diameter:

   3.0 to 4.0 mm (0.118 to 0.157 in.)

   Text in Illustration

   *a	3.0 to 4.0 mm

   NOTICE:

   1. Remove any oil from the contact surface.
   2. Install the heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

2. Install the heat exchanger cover with the 12 bolts and 2 nuts.

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

   Text in Illustration

   	Bolt
   	Nut

   NOTICE:

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

   Standard Bolt:

   Item	Length	Thread Diameter
   Bolt A	20 mm (0.787 in.)	8 mm (0.315 in.)
   Bolt B	70 mm (2.76 in.)	8 mm (0.315 in.)
   Bolt C	16 mm (0.630 in.)	6 mm (0.236 in.)

11. INSTALL VENTILATION PIPE GASKET

1. Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.

   SST

   09950-60010 (09951-00360) 09950-70010 (09951-07100)

   NOTICE:

   1. Do not tap the gasket at an angle.
   2. Do not tap the gasket excessively.

12. INSTALL CYLINDER BLOCK WATER JACKET SPACER

1. Install the 2 water jacket spacers as shown in the illustration.

   Text in Illustration

   *a

   UP Mark

   HINT:

   1. Face the cutouts indicated by the arrows in illustration away from the engine.
   2. Face the "UP" mark as shown in the illustration.

13. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

1. Clean the cylinder block with solvent.

2. Set the piston of the No. 1 cylinder to slightly ATDC.

3. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

   Text in Illustration

   *1	Lot No.
   *a	Front

   NOTICE:

   1. Be careful of the installation direction.
   2. Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.

4. Place the cylinder head on the cylinder block.

   NOTICE:

   1. Ensure that no oil is on the mounting surface of the cylinder head.
   2. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

   HINT:

   The cylinder head bolts are tightened in 3 progressive steps.

5. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

6. Step 1:

   1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.

      Torque:

      36 N*m{ 367 kgf*cm , 27 ft.*lbf }

7. Step 2:

   1. Mark the front side of each cylinder head bolt head with paint.

   2. Tighten the cylinder head bolts another 90°.

8. Step 3:

   1. Tighten the cylinder head bolts an additional 90°.

   2. Check that the paint marks are now at a 180° angle to the front.

9. Install and uniformly tighten the 2 bolts in the sequence shown in the illustration.

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

14. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

1. Clean the cylinder block with solvent.

2. Set the piston of the No. 1 cylinder to slightly ATDC.

3. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

   Text in Illustration

   *1	Lot No.
   *a	Front

   NOTICE:

   1. Be careful of the installation direction.
   2. Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.

4. Place the cylinder head on the cylinder block.

   NOTICE:

   1. Ensure that no oil is on the mounting surface of the cylinder head.
   2. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

   HINT:

   The cylinder head bolts are tightened in 3 progressive steps.

5. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

6. Step 1:

   HINT:

   The cylinder head bolts are tightened in 3 progressive steps.

   1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.

      Torque:

      36 N*m{ 367 kgf*cm , 27 ft.*lbf }

7. Step 2:

   1. Mark the front side of each cylinder head bolt head with paint.

   2. Tighten the cylinder head bolts another 90°.

8. Step 3:

   1. Tighten the cylinder head bolts an additional 90°.

   2. Check that the paint marks are now at a 180° angle to the front.

9. Install and uniformly tighten the 2 bolts in the sequence shown in the illustration.

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

15. INSTALL VALVE STEM CAP

1. Apply a light coat of engine oil to the valve stem caps.

2. Install the 32 valve stem caps to the cylinder heads.

16. INSTALL VALVE LASH ADJUSTER ASSEMBLY

1. Inspect the valve lash adjuster before installing it.

2. Install the 32 valve lash adjusters to the cylinder heads.

   NOTICE:

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

17. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

1. Apply engine oil to the lash adjuster tips and valve stem cap ends.

2. Install the 32 valve rocker arms as shown in the illustration.

   Text in Illustration

   *1	Valve Rocker Arm
   *2	Valve Stem Cap
   *3	Valve Lash Adjuster

18. INSTALL CAMSHAFT BEARING CAP RH

1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

2. Install the No. 1 and No. 2 camshafts to the camshaft housing.

3. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

4. Temporarily install the 10 bolts in the order shown in the illustration.

19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

1. Make sure that the valve rocker arms are installed as shown in the illustration.

   Text in Illustration

   *1	Valve Rocker Arm
   *2	Valve Stem Cap
   *3	Valve Lash Adjuster
   *a	INCORRECT
   *b	CORRECT

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

   Standard seal diameter:

   3.5 to 4.0 mm (0.138 to 0.157 in.)

   Text in Illustration

   *a	3.5 to 4.0 mm

   NOTICE:

   1. Remove any oil from the contact surface.
   2. Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

3. Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

   Torque:

   for bolt A:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

   except bolt A:

   30 N*m{ 306 kgf*cm , 22 ft.*lbf }

   Text in Illustration

   *1	EX
   *2	IN
   *3	Knock Pin

   NOTICE:

   1. Do not start the engine for at least 2 hours after the installation.
   2. Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

4. Tighten the 10 bolts in the order shown in the illustration.

   Torque:

   16 N*m{ 163 kgf*cm , 12 ft.*lbf }

   NOTICE:

   Thoroughly wipe clean any seal packing.

20. INSTALL CAMSHAFT BEARING CAP LH

1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

2. Install the No. 3 and No. 4 camshafts to the camshaft housing.

3. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

4. Temporarily install the 10 bolts in the order shown in the illustration.

21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

1. Make sure that the valve rocker arms are installed as shown in the illustration.

   Text in Illustration

   *1	Valve Rocker Arm
   *2	Valve Stem Cap
   *3	Valve Lash Adjuster
   *a	INCORRECT
   *b	CORRECT

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

   Standard seal diameter:

   3.5 to 4.0 mm (0.138 to 0.157 in.)

   Text in Illustration

   *a	3.5 to 4.0 mm

   NOTICE:

   1. Remove any oil from the contact surface.
   2. Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

3. Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

   Torque:

   for bolt A:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

   except bolt A:

   30 N*m{ 306 kgf*cm , 22 ft.*lbf }

   Text in Illustration

   *1	IN
   *2	EX
   *3	Knock Pin

   NOTICE:

   1. Do not start the engine for at least 2 hours after the installation.
   2. Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

4. Tighten the 10 bolts in the order shown in the illustration.

   Torque:

   16 N*m{ 163 kgf*cm , 12 ft.*lbf }

   NOTICE:

   Thoroughly wipe clean any seal packing.

22. INSTALL CRANKSHAFT TIMING GEAR KEY

1. Install the timing gear key.

   HINT:

   The other timing gear key will be installed at a later step.

23. SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

2. Rotate the crankshaft so that the timing gear key is as shown in the illustration. Then using a wrench, rotate each camshaft so that the timing marks are as shown in the illustration.

   NOTICE:

   When the crankshaft or a camshaft is rotated excessively, the valves and pistons may interfere with each other.

3. Remove the crankshaft pulley bolt.

   

   Text in Illustration

   *1	IN	*2	EX
   *3	Knock Pin	*4	Key
   *a	Toward Ceiling	-	-

24. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

1. Install the chain tensioner with the 2 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

   Text in Illustration

   *1	Plunger
   *2	Pin
   *a	Push

2. While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

25. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH

1. Align the No. 1 chain orange mark plate with the camshaft timing gear timing mark, and attach the chain to the gear as shown in the illustration.

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

2. Align the No. 1 chain orange mark plate with the crankshaft timing sprocket timing mark, and attach the chain to the gear as shown in the illustration.

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

3. Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

   HINT:

   The crankshaft timing sprocket RH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.

4. Install the crankshaft timing sprocket RH to the crankshaft.

5. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

6. Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.

7. Remove the pin from the No. 2 chain tensioner.

8. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, temporarily install the bolt.

9. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, temporarily install the bolt.

26. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH

1. Install the vibration damper with the 2 bolts.

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

27. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

HINT:

If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.

28. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH

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

   Text in Illustration

   *1	Stopper Plate
   *2	Plunger

2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

3. Install the chain tensioner with the 2 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

4. Remove the hexagon wrench from the chain tensioner.

29. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

1. Install the chain tensioner with the 2 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

   Text in Illustration

   *1	Plunger
   *2	Pin
   *a	Push

2. While pushing down the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

30. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH

1. Align the No. 1 chain orange mark plate with the camshaft timing gear timing mark, and attach the chain to the gear as shown in the illustration.

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

2. Align the No. 1 chain orange mark plate with the crankshaft timing sprocket timing mark, and attach the chain to the gear as shown in the illustration.

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

3. Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

   HINT:

   The crankshaft timing sprocket LH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.

4. Install the crankshaft timing sprocket LH to the crankshaft.

5. Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear.

6. Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear.

   NOTICE:

   Because the timing mark positions of the gears may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

7. Remove the pin from the No. 3 chain tensioner.

8. Using a wrench to hold the hexagonal portion of the No. 3 camshaft, temporarily install the bolt.

9. Using a wrench to hold the hexagonal portion of the No. 4 camshaft, temporarily install the bolt.

31. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

HINT:

If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and install the chain tensioner slipper.

32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH

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

   Text in Illustration

   *1	Stopper Plate
   *2	Plunger

2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

3. Install a new gasket and the chain tensioner with the 2 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

33. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH

1. Install the vibration damper with the 2 bolts.

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

2. Remove the hexagon wrench from the No. 1 chain tensioner.

34. TIGHTEN CAMSHAFT TIMING GEAR

1. for Bank 1:

   1. Using a wrench, hold the hexagonal portion of the No. 3 camshaft.

      

      Text in Illustration

      *a	Hold
      	Turn

   2. Tighten the bolt of the camshaft timing gear.

      Torque:

      100 N*m{ 1020 kgf*cm , 74 ft.*lbf }

   3. Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the bolt of the camshaft timing exhaust gear.

      

      Torque:

      100 N*m{ 1020 kgf*cm , 74 ft.*lbf }

      Text in Illustration

      *a	Hold
      	Turn

2. for Bank 2:

   1. Using a wrench, hold the hexagonal portion of the No. 1 camshaft.

      

      Text in Illustration

      *a	Hold
      	Turn

   2. Tighten the bolt of the camshaft timing gear.

      Torque:

      100 N*m{ 1020 kgf*cm , 74 ft.*lbf }

   3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt of the camshaft timing exhaust gear.

      

      Torque:

      100 N*m{ 1020 kgf*cm , 74 ft.*lbf }

      Text in Illustration

      *a	Hold
      	Turn

35. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

3. Remove the crankshaft pulley bolt.

   

   Text in Illustration

   *1	Timing Mark	*2	Timing Mark Position
   *3	Knock Pin Position	*4	Key
   *a	Toward Ceiling	*b	Approximately 2°
   *c	Approximately 45°	*d	Approximately 16°
   *e	Approximately 18°	*f	Approximately 32°

36. INSTALL WATER INLET PIPE

1. Apply soapy water to 2 new O-rings and install them to the inlet pipe.

2. Install the inlet pipe to the No. 1 heat exchanger cover.

37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

1. Apply a light coat of engine oil to a new oil pump gasket.

2. Install the oil pump gasket.

3. Apply a light coat of engine oil to a new O-ring.

4. Install the O-ring.

5. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

   

   Text in Illustration

   *1	Continuous line area	*2	Dashed line area
   *3	Diagonal line area	-	-

   Seal packing:

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

   1. 

      Apply Seal Packing as Follows:

      Area	Seal Packing Diameter	Application Position from Inside Edge of Cover
      Continuous Line Area	3.0 to 4.0 mm (0.118 to 0.157 in.)	2.5 mm (0.0984 in.)
      Dashed Line Area	6.4 mm (0.252 in.) or more, or within OK area shown in illustration	7.0 mm (0.276 in.)
      Diagonal Line Area	3.0 to 4.0 mm (0.118 to 0.157 in.)	5.5 mm (0.217 in.)

      Text in Illustration

      *1	Seal Packing Thickness mm (in.)
      *2	Seal Packing Width mm (in.)
      *3	Seal Packing Thickness
      *4	Seal Packing Width
      *5	OK Area

   NOTICE:

   1. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   2. Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

7. Temporarily install the timing chain cover with the 28 bolts and nut.

   Standard Bolt:

   Item	Length	Thread Diameter
   Bolt A	25 mm (0.984 in.)	8 mm (0.315 in.)
   Bolt B	55 mm (2.17 in.)	8 mm (0.315 in.)
   Bolt C	70 mm (2.76 in.)	8 mm (0.315 in.)
   Bolt D	35 mm (1.38 in.)	10 mm (0.394 in.)
   Bolt E	55 mm (2.17 in.)	10 mm (0.394 in.)
   Bolt F	80 mm (3.15 in.)	10 mm (0.394 in.)

   Text in Illustration

   *1

   Nut

   NOTICE:

   Make sure that there is no oil on the bolt threads.

8. Tighten the 3 bolts in several steps in the sequence shown in the illustration.

   Torque:

   47 N*m{ 479 kgf*cm , 35 ft.*lbf }

9. Temporarily install the fluid coupling bracket with the 4 bolts.

   Standard Bolt:

   Item	Length	Thread Diameter
   Bolt A	70 mm (2.76 in.)	8 mm (0.315 in.)
   Bolt B	80 mm (3.15 in.)	10 mm (0.394 in.)

10. Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

11. Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.

    Torque:

    47 N*m{ 479 kgf*cm , 35 ft.*lbf }

12. Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.

    Torque:

    23 N*m{ 235 kgf*cm , 17 ft.*lbf }

    NOTICE:

    1. Do not start the engine for at least 2 hours after installing.
    2. After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

       

38. INSTALL WATER PUMP ASSEMBLY

1. Install a new gasket and the water pump with the 8 bolts shown in the illustration.

   Torque:

   for bolt A:

   47 N*m{ 479 kgf*cm , 35 ft.*lbf }

   for bolt B:

   23 N*m{ 235 kgf*cm , 17 ft.*lbf }

   for bolt C:

   20 N*m{ 204 kgf*cm , 15 ft.*lbf }

   Standard Bolt:

   Item	Length	Thread Diameter
   Bolt A	80 mm (3.15 in.)	10 mm (0.394 in.)
   Bolt B	70 mm (2.76 in.)	8 mm (0.315 in.)
   Bolt C	25 mm (0.984 in.)	8 mm (0.315 in.)

39. INSTALL FRONT CRANKSHAFT OIL SEAL

1. Apply MP grease to the lip of a new oil seal.

2. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.

   SST

   09226-10010

40. INSTALL CRANKSHAFT TIMING GEAR KEY

1. Install the crankshaft timing gear key.

41. 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 set bolt.

   SST

   09213-70011 09330-00021

   Torque:

   300 N*m{ 3059 kgf*cm , 221 ft.*lbf }

   Text in Illustration

   *a	Hold
   	Turn

42. INSTALL SPARK PLUG TUBE GASKET

1. Using a cutter knife, cut off the seal part of the removed gasket.

   Text in Illustration

   Area to cut off

2. Using the removed gasket and a hammer, tap in a new gasket until it stops.

   Text in Illustration

   *1	Removed Gasket
   *2	New Gasket

   HINT:

   If the removed gasket does not fit on the new one, correct the removed one with pliers.

3. Apply a light coat of MP grease to the lip of the gasket.

4. Return the 4 ventilation baffle plate claws to the original positions.

43. INSTALL OIL CONTROL VALVE FILTER

1. LH:

   1. Install the filter in the cylinder head.

      Text in Illustration

      *1	Cylinder Head Cover Spacer
      *2	Gasket
      *3	Filter

   2. Install a new gasket and the cylinder head cover spacer with the 3 bolts.

      Torque:

      10 N*m{ 102 kgf*cm , 7 ft.*lbf }

2. RH:

   1. Install the filter in the cylinder head.

      Text in Illustration

      *1	Cylinder Head Cover Spacer
      *2	Gasket
      *3	Filter

   2. Install a new gasket and the cylinder head cover spacer with the 3 bolts.

      Torque:

      10 N*m{ 102 kgf*cm , 7 ft.*lbf }

44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

1. Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).

2. Install a new gasket to the cylinder head cover.

   NOTICE:

   Remove any oil from the contact surface.

3. Apply seal packing as shown in the illustration.

   Seal packing:

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

   Text in Illustration

   Seal Packing

   NOTICE:

   1. Remove any oil from the contact surface.
   2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

4. Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

   Torque:

   for bolt A:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

   except bolt A:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

   NOTICE:

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

5. Install the noise filter to the cylinder head cover with the bolt.

   Torque:

   7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

1. Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).

2. Install a new gasket to the cylinder head cover.

   NOTICE:

   Remove any oil from the contact surface.

3. Apply seal packing as shown in the illustration.

   Seal packing:

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

   Text in Illustration

   Seal Packing

   NOTICE:

   1. Remove any oil from the contact surface.
   2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

4. Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

   Torque:

   for bolt A:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

   except bolt A:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

   NOTICE:

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

46. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

1. Install the idler pulley with the bolt.

   Torque:

   43 N*m{ 438 kgf*cm , 32 ft.*lbf }

47. INSTALL WATER PUMP PULLEY

1. Temporarily install the pulley with the 4 bolts.

2. Using SST, hold the pulley and tighten the 4 bolts.

   SST

   09960-10010 (09962-01000,09963-01000)

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

48. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY

1. for Bank 1:

   1. Apply a light coat of engine oil to 2 new O-rings.

   2. Install the 2 O-rings to the 2 oil control valves.

   3. Install the 2 oil control valves with the 2 bolts.

      Torque:

      10 N*m{ 102 kgf*cm , 7 ft.*lbf }

2. for Bank 2:

   1. Apply a light coat of engine oil to 2 new O-rings.

   2. Install the 2 O-rings to the 2 oil control valves.

   3. Install the 2 oil control valves with the 2 bolts.

      Torque:

      10 N*m{ 102 kgf*cm , 7 ft.*lbf }

49. INSTALL CRANKSHAFT POSITION SENSOR

1. Install the crankshaft position sensor with the bolt.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

50. INSTALL CRANK POSITION SENSOR PROTECTOR

1. Install the sensor protector with the 2 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

51. INSTALL CAMSHAFT POSITION SENSOR

1. Install the camshaft position sensor with the bolt.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

52. INSTALL VVT SENSOR

1. for Bank 1:

   1. Install the 2 VVT sensors with the 2 bolts.

      Torque:

      10 N*m{ 102 kgf*cm , 7 ft.*lbf }

2. for Bank 2:

   1. Install the 2 VVT sensors with the 2 bolts.

      Torque:

      10 N*m{ 102 kgf*cm , 7 ft.*lbf }

53. INSTALL SPARK PLUG

1. Using a 16 mm plug wrench, install the 8 spark plugs.

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

54. INSTALL OIL FILLER CAP HOUSING

1. Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing.

2. Install the cap housing with the 2 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

55. INSTALL OIL FILLER CAP SUB-ASSEMBLY

56. INSTALL OIL FILTER BRACKET

1. Apply a light coat of engine oil to 2 new O-rings.

2. Install the 2 O-rings to the timing chain cover.

3. Install the oil filter bracket with the 2 nuts and 2 bolts.

   Torque:

   35 N*m{ 357 kgf*cm , 26 ft.*lbf }

57. INSTALL NO. 1 OIL COOLER BRACKET

1. Connect the ground wire to the cylinder block.

2. Install the oil cooler bracket with the 2 nuts.

   Torque:

   21 N*m{ 214 kgf*cm , 15 ft.*lbf }

58. INSTALL OIL FILTER ELEMENT

1. Clean the inside of the oil filter cap, its threads and its 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 any dirt or foreign matter from the installation surface of the engine.

5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

   NOTICE:

   Do not remove the oil filter bracket clip.

6. Using SST, tighten the oil filter cap.

   SST

   09228-06501

   Torque:

   25 N*m{ 255 kgf*cm , 18 ft.*lbf }

   Text in Illustration

   *1	Oil Filter Bracket Clip

   NOTICE:

   1. When tightening the oil filter cap, do not remove the oil filter bracket clip.
   2. Make sure that the oil filter is installed securely as shown in the illustration.
   3. Be careful that the O-ring does not get caught between any surrounding parts.

7. Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

   Text in Illustration

   *1

   O-Ring

   NOTICE:

   Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

8. Install the oil filter drain plug.

   Torque:

   13 N*m{ 127 kgf*cm , 9 ft.*lbf }

   NOTICE:

   Be careful that the O-ring does not get caught between any surrounding parts.

9. Install the No. 2 engine under cover seal with the 2 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

59. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

1. Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.

   Adhesive:

   Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

   NOTICE:

   

   Do not allow adhesive to contact the oil hole.

   Text in Illustration

   *1

   Oil Hole

2. Install the oil pressure sender gauge.

   Torque:

   15 N*m{ 153 kgf*cm , 11 ft.*lbf }

   NOTICE:

   Do not start the engine within 1 hour after installation.

3. Connect the sender gauge connector.