Engine Unit: Reassembly

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HINT

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side

INSTALL TIMING CHAIN COVER STRAIGHT PIN
1. Install the timing chain cover straight pin.
  1. Using a plastic-faced hammer, tap in new straight pins to the timing chain cover
    Standard protrusion: 5.5 to 6.5 mm (0.217 to 0.256 in.)
    
    Fig 1: Identifying Timing Chain Cover Straight Pin Protrusion
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TIMING CHAIN COVER STUD BOLT
1. Install the timing chain cover stud bolt.
  1. Using an E8 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
    
    Fig 2: Identifying Timing Chain Cover Stud Bolt Dimensions
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN STUD BOLT
1. Install the oil pan stud bolt
  1. Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
    Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf)
    
    Fig 3: Identifying Oil Pan Stud Bolt Dimensions
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  NOTE:
  - Keep the lip free from foreign matter.
  - Do not tap on the oil seal at an angle.
    
    Fig 4: Installing Rear Crankshaft Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  Fig 5: Locating Oil Drain Pipe Bolt
  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 (0.0787 to 0.118 in.)
  
  Application position from inside edge of retainer:
  
  3.5 mm (0.138 in.)
  
  Fig 6: Identifying Seal Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil seal retainer within 3 minutes and tighten the bolts and nuts 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)
  NOTE:
  - Do not start the engine for at least 2 hours after installing.
  - When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.
  - When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.
    
    Fig 7: Locating Engine Rear Oil Seal Retainer Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: 21 N.m (214 kgf/cm, 15 ft.lbf)
  
  NOTE: Make sure the O-ring is not twisted or damaged.
INSTALL ENGINE OIL LEVEL SENSOR (See INSPECTION )

Fig 8: Locating Oil Strainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 OIL PAN BAFFLE PLATE
1. Install the baffle plate with the 4 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 9: Locating No 2 Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 OIL PAN BAFFLE PLATE
Install the baffle plate with the 4 bolts.

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

Fig 10: Locating No 1 Oil Pan Baffle Plate Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.)
  
  Application position from inside edge of oil pan:
  
  6.0 mm (0.236 in.)
  
  Fig 11: Identifying Seal Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
2. Install the oil pan with the 14 bolts and 2 nuts
  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)
  
  NOTE: Do not start the engine for at least 2 hours after installing.
  
  Fig 12: Locating No 1 Oil Pan Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
    
    Fig 13: Identifying Seal Diameter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil pan with the 13 bolts and 2 nuts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  NOTE: Do not start the engine for at least 2 hours after installing.
  
  Fig 14: Locating No 2 Oil Pan Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  NOTE:
  - Do not tap the gasket at an angle.
  - Do not tap the gasket excessively.
    
    Fig 15: Installing Ventilation Pipe Gasket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 1 HEAT EXCHANGER COVER

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.)
NOTE:
- Remove any oil from the contact surface.
- Install the heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
  
  Fig 16: Identifying Seal Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Torque: for bolt A and B

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

for bolt C

10 N.m (102 kgf/cm, 7 ft.lbf)

for nut

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

BOLT LENGTH

BOLT LENGTH AND THREAD DIAMETER SPECIFICATION

Item	Length	Thread diameter
Bolt A	70 mm (2.76 in.)	8 mm (0 315 in.)
Bolt B	20 mm (0 787 in.)	8 mm (0.315 in.)
Bolt C	16 mm (0 630 in)	6 mm (0 236 in.)

Fig 17: Locating Heat Exchanger Cover Bolts And Nuts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSTALL CYLINDER BLOCK WATER JACKET SPACER
1. Install the 2 water jacket spacers as shown in the illustration.
  HINT.
  - Face the cutouts (indicated by the arrows in the illustration) away from the engine
  - Face the "UP" mark as shown in the illustration.
INSTALL CYLINDER HEAD SUB-ASSEMBLY LH (See INSTALLATION )

Fig 18: Identifying Cylinder Block Water Jacket Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD SUB-ASSEMBLY RH (See INSTALLATION )
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem caps.
2. Install the 32 valve stem caps to the cylinder head.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
1. Be sure to inspect the valve lash adjuster before installing it (see INSPECTION ).
2. Install the 32 valve lash adjusters to the cylinder head
  NOTE: Install the lash adjuster to the same place it was removed from.
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.
INSTALL CAMSHAFT BEARING CAP LH (See INSTALLATION )
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH (See INSTALLATION )
INSTALL CAMSHAFT BEARING CAP RH (See INSTALLATION )
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH (See INSTALLATION )

Fig 19: Identifying Valve Rocker Arm, Valve Lash Adjuster And Valve Stem Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING GEAR KEY
1. Install the timing gear key.
  HINT:
  
  The other timing gear key will be installed at a later step.
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.
  NOTE: When the crankshaft or a camshaft is rotated excessively, the valves and pistons may interfere with each other.
  
  Fig 20: Identifying Crankshaft Timing Gear Key
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the crankshaft pulley bolt.
  
  Fig 21: Identifying Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
2. While raising up the No. 2 chain tensioner, insert a pin of Ø 1.0 mm (0.0394 in.) into the hole to fix it in place.
  
  Fig 22: Installing No 2 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH
1. Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.
  
  Fig 23: Aligning Chain's Orange Mark Plates With Camshaft Timing Gear's Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration
  
  Fig 24: Aligning Chain's Orange Mark Plate With Crankshaft Timing Gear's Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the No. 2 chain's 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.
  HINT.
  
  The crankshaft timing sprocket RH and camshaft 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
  
  Fig 25: Aligning Chain's Yellow Mark Plates With Timing Marks Of Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 a new bolt, with a 12 mm socket hexagon wrench.
9. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, temporarily install the bolt.
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)
INSTALL NO. 1 CHAIN TENSIONER SUPPER 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.

Fig 26: Locating Vibration Damper Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
  
  Fig 27: Pushing Plunger Deep Into Tensioner
  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)
4. Remove the hexagon wrench from the chain tensioner.
  
  Fig 28: Locating Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
2. While pushing down the No. 2 chain tensioner, insert a pin of Ø 1.0 mm (0.0394 in.) into the hole to fix it in place.
  
  Fig 29: Installing No 3 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH
1. Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration
  
  Fig 30: Aligning Chain's Orange Mark Plates With Camshaft Timing Gear's Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration
  
  Fig 31: Aligning Chain's Orange Mark Plate With Crankshaft Timing Gear's Timing Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the No. 2 chain's 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.
  HINT:
  
  The crankshaft timing sprocket LH and camshaft exhaust gear will be installed with the No 1 and No. 2 chains connected to the gears
  
  Fig 32: Aligning Chain's Yellow Mark Plates With Timing Marks Of Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  NOTE: Because the gears' timing mark positions 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. 2 chain tensioner.
8. Using a wrench to hold the hexagonal portion of the No. 3 camshaft, temporarily install a new bolt, with a 12 mm socket hexagon wrench
9. Using a wrench to hold the hexagonal portion of the No 4 camshaft, temporarily install the bolt
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 then install the chain tensioner slipper.
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
2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
  
  Fig 33: Pushing Plunger Deep Into Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new gasket and the chain tensioner with the 2 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 34: Locating Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 35: Locating Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY
1. for Bank 1:
  1. Using a wrench, hold the hexagonal portion of the No. 3 camshaft.
  2. Using a 12 mm socket hexagon wrench, tighten the bolt of the camshaft timing gear.
    Torque: 79 N.m (806 kgf/cm, 58 ft.lbf)
    
    Fig 36: Tightening Camshaft Timing Gear Assembly (For Bank 1)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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)
    
    Fig 37: Tightening Camshaft Timing Gear Bolt (For Bank 1)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2-
  1. Using a wrench, hold the hexagonal portion of the No 1 camshaft.
  2. Using a 12 mm socket hexagon wrench, tighten the bolt of the camshaft timing gear.
    Torque: 79 N.m (806 kgf/cm, 58 ft.lbf)
    
    Fig 38: Tightening Camshaft Timing Gear Bolt (For Bank 2)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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)
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 gear and camshaft timing gears are as shown in the illustration.
  
  Fig 39: Tightening Camshaft Timing Gear (For Bank 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the crankshaft pulley bolt.
  
  Fig 40: Identifying Timing Marks On Crankshaft Timing Gear And Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER INLET PIPE (See INSTALLATION )
INSTALL WATER PUMP (See INSTALLATION )
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See INSTALLATION )
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 to a depth between 0 to 1.0 mm (0 to 0.0394 in.) from the timing chain cover edge.
  SST 09223-22010,09506-35010
  NOTE:
  - Keep the lip free from foreign matter.
  - Do not tap the oil seal at an angle.
    
    Fig 41: Installing Front Crankshaft Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING GEAR KEY
1. Install the crankshaft timing gear key to the crankshaft.
  
  Fig 42: Identifying Crankshaft Timing Gear Key
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL CONTROL VALVE FILTER
1. for LH:
  1. Install the valve filter to the cylinder head.
  2. Install a new gasket and the cylinder head cover spacer with the 2 bolts.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
    
    Fig 43: Locating Cylinder Head Cover Spacer Bolts (For LH)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for RH:
  1. Install the valve filter to the cylinder head.
  2. Install a new gasket and the cylinder head cover spacer with the 2 bolts.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
    
    Fig 44: Locating Cylinder Head Cover Spacer Bolts (For RH)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3 and No. 7).
2. Install a new gasket to the cylinder head cover.
  NOTE: Remove any oil from the contact surface.
  
  Fig 45: Locating Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing 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.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    
    Fig 46: Locating Seal Packing Applying Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the cylinder head cover and 2 new seal washers with the 15 bolts in the order shown in the illustration
  Torque: for bolt A
  
  21 N.m (214 kgf/cm, 12 ft.lbf)
  
  except bolt A
  
  12 N.m (122 kgf/cm, 9 ft.lbf)
  
  NOTE: Do not start the engine for at least 2 hours after the installation.
  
  Fig 47: Locating Tightening Sequence Of Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the fuel pump spacer gasket
  NOTE: After pressing in the fuel pump spacer gasket, make sure the gasket protrudes 1 mm (0.0394 in) or less from the cylinder head cover.
6. Install the fuel pump spacer.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
1. Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No 1, No. 3 and No. 6).
2. Install a new gasket to the cylinder head cover
  NOTE: Remove any oil from the contact surface.
  
  Fig 48: Locating Camshaft Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing 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.)
  NOTE:
  - Remove any oil from the contact surface.
  - Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    
    Fig 49: Locating Seal Packing Applying Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the cylinder head cover and 2 new seal washers with the 15 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)
  
  NOTE: Do not start the engine for at least 2 hours after the installation.
  
  Fig 50: Locating Tightening Sequence Of Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the fuel pump spacer gasket.
  NOTE: After pressing in the fuel pump spacer gasket, make sure the gasket protrudes 1 mm (0.0394 in) or less from the cylinder head cover.
6. Install the fuel pump spacer.

INSTALL SPARK PLUG TUBE GASKET

Visual check the spark plug tube gasket.

INSPECTION AREA AND SPECIFIED CONDITION

Inspection Area	Specified Condition
Upper surface	No scratches or deformation
Outer lip	No scratches or deformation
Inner lip	No scratches

If the result is not as specified, replace the spark plug tube gasket.

Fig 51: Identifying Fuel Pump Spacer Gasket

Install the 8 plug tube gaskets to the cylinder head covers.
NOTE: After pressing in the spark plug tube gasket, make sure the gasket protrudes 1 mm (0.0394 in) or less from the cylinder head cover.

INSTALL CRANKSHAFT PULLEY (See INSTALLATION )

Fig 52: Locating Plug Tube Gaskets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT WATER BY-PASS JOINT
1. Install the 2 new gaskets and water by-pass joint with the 4 nuts.
  Torque: 21 N.m (214 kgf/cm, 15 ft.lbf)
INSTALL WATER PUMP PULLEY (See INSTALLATION )
INSTALL OIL FILTER BRACKET (See INSTALLATION )
INSTALL OIL FILTER ELEMENT (See REPLACEMENT )

Fig 53: Locating Water By-Pass Joint Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the wire harness clamp bracket with the bolt.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL CAMSHAFT TIMING CONTROL MOTOR RH (See INSTALLATION )
INSTALL CAMSHAFT TIMING CONTROL MOTOR LH (See INSTALLATION )

Fig 54: Locating Wire Harness Clamp Bracket Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive to 2 or 3 threads of the drain cock.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  Fig 55: Applying Adhesive To Threads Of Drain Cock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water drain cocks as shown in the illustration.
  Torque: 30 N.m (306 kgf/cm, 22 ft.lbf)
  NOTE:
  - Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.
  - Do not loosen the drain cocks to adjust them. If an adjustment is necessary, remove the drain cocks and reinstall them.
3. Install the water drain cock plugs to the water drain cocks.
  Torque: 13 N.m (133 kgf/cm, 10 ft.lbf)
  
  Fig 56: Locating Water Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. For Bank 1
  1. Apply a light coat of engine oil to a new O-ring.
  2. Install the O-ring to the oil control valve.
  3. Install the oil control valve with the bolt.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
    
    Fig 57: Locating Camshaft Timing Oil Control Valve Bolt (For Bank 1)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. For Bank 2:
  1. Apply a light coat of engine oil to a new O-ring.
  2. Install the O-ring to the oil control valve.
  3. Install the oil control valve with the bolt.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
    
    Fig 58: Locating Camshaft Timing Oil Control Valve Bolt (For Bank 2)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the crankshaft position sensor with the bolt.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 59: Locating Crankshaft Position Sensor With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT POSITION SENSOR
1. Install the camshaft position sensor with the bolt.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 60: Locating Camshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VVT SENSOR
1. for Bank 1:
  Install the 2 VVT sensors with the 2 bolts.
  
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 61: Locating VVT Sensor Bolts (For Bank 1)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2
  Install the 2 VVT sensors with the 2 bolts.
  
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL SPARK PLUG (See INSTALLATION )

Fig 62: Locating VVT Sensor Bolts (For Bank 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 63: Identifying Oil Filler Cap Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cap housing with the 2 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL OIL FILLER CAP SUB-ASSEMBLY