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Engine Unit: Reassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the new O-ring to the oil drain pipe sub-assembly
    3. Install the oil drain pipe sub-assembly with the bolt.

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

    Fig 1: Locating Oil Drain Pipe Bolt
    G05151290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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 2: Identifying Seal Packing Applying Area
      G04943648Courtesy 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.
      • Do not start the engine for at least 2 hours after installing the oil seal retainer.
      • When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is not damaged.
      • When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is folded correctly.
    2. Install the engine rear oil seal retainer with the 6 bolts.

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

    Fig 3: Locating Engine Rear Oil Seal Retainer Bolts
    G04943634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the new O-ring to the oil strainer sub-assembly.
    3. Install the oil strainer sub-assembly with the 2 bolts

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

    NOTE: Make sure that the O-ring is not twisted or damaged.
    Fig 4: Locating Oil Strainer Bolts
    G04943633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. Install the No. 1 oil pan baffle plate with the 8 bolts

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

    Fig 5: Locating Oil Pan Baffle Plate Bolts
    G05749630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL 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 6: Identifying Seal Diameter
      G05749682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.
    2. Install the oil pan sub-assembly with the 14 bolts and 2 nuts

      Torque: Bolt A 

      35 N*m (357 kgf*cm, 26 ft.*lbf) 

      Bolt B 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Nut 

      35 N*m (357 kgf*cm, 26 ft.*lbf) 

      Fig 7: Locating Oil Pan Bolts And Nuts
      G04943653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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.) 

      Fig 8: Identifying Seal Diameter
      G04943654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.
    2. Install the No 2 oil pan sub-assembly with the 15 bolts and 2 nuts

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

    Fig 9: Locating Oil Pan Bolts And Nuts
    G04943628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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) 

      HINT.

      • Do not tap the ventilation pipe gasket at an angle
      • Do not tap the ventilation pipe gasket excessively
      Fig 10: Installing Ventilation Pipe Gasket
      G04943657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL HEAT EXCHANGER ASSEMBLY 
    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.) 

      NOTE: Remove any oil from the contact surface.
      Fig 11: Identifying Seal Diameter
      G05749687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the heat exchanger assembly with the 11 bolts and 2 nuts.

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

      NOTE:
      • Install the No. 1 heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing the cover.
      Fig 12: Locating Heat Exchanger Assembly Bolts And Nuts
      G05749688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt

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

    Fig 13: Locating Heat Exchanger Bolt
    G05749622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the 2 cylinder block water jacket spacers as shown in the illustration.

      HINT:

      • Face the cutouts away from the center of the engine.
      • Face each "Up" mark as shown in the illustration
      Fig 14: Identifying Cylinder Block Water Jacket Spacers
      G05749690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 2 CYLINDER HEAD GASKET (for Bank 1)  (See INSTALLATION )
  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)  (See INSTALLATION )
  12. INSTALL CYLINDER HEAD GASKET (for Bank 2)  (See INSTALLATION )
  13. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2)  (See INSTALLATION )
  14. INSTALL VALVE ROCKER ARM PIVOT 
    1. Install the 32 valve rocker arm pivots to the cylinder head assembly.

      Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) 

  15. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Apply engine oil to the valve rocker arm pivot and valve adjusting shim
    2. Install the 32 No 1 valve rocker arm sub-assembly on the cylinder heads
    3. Make sure that the 32 No. 1 valve rocker arm sub-assembly are installed as shown in the illustration.
  16. INSTALL NO. 3 CAMSHAFT  (See INSTALLATION )
  17. INSTALL NO. 4 CAMSHAFT  (See INSTALLATION )
  18. INSTALL CAMSHAFT BEARING CAP (for Bank 1)  (See INSTALLATION )
  19. INSTALL CAMSHAFT  (See INSTALLATION )
  20. INSTALL NO. 2 CAMSHAFT  (See INSTALLATION )
  21. INSTALL CAMSHAFT BEARING CAP (for Bank 2)  (See INSTALLATION )
    Fig 15: Identifying Valve Rocker Arm Pivot And Valve Adjusting Shim
    G05749691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Install the crankshaft timing gear key.
      Fig 16: Identifying Crankshaft Timing Gear Key
      G05749692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the crankshaft pulley set bolt, and set the crankshaft timing gear key in the position as shown in the illustration.
    3. Remove the crankshaft pulley set bolt
    Fig 17: Identifying Crankshaft Timing Gear Key
    G05749693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 2) 
    1. Install the No 2 chain tensioner assembly with the 2 bolts

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

    2. While raising the No 2 chain tensioner assembly, insert a 1 0 mm (0 0394 in) pin into the hole to fix it in place
  24. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2) 

    HINT

    The crankshaft timing gear, camshaft timing gear assembly and camshaft timing exhaust gear assembly will be installed with the No 1 chain sub-assembly and No 2 chain sub-assembly connected to the gears

    Fig 18: Installing No 2 Chain Tensioner Assembly (For Bank 2)
    G05749694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 19: Aligning Chain Orange Mark Plates With Camshaft Timing Gear Timing Mark
      G05749695Courtesy 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 20: Aligning Chain Orange Mark Plate With Crankshaft Timing Gear Timing Mark
      G04943370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the No 2 chain's mark plates (yellow) 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
    4. Install the crankshaft timing gear to the crankshaft.
    5. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly
    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 assembly
    7. Remove the pin from the No. 2 chain tensioner assembly
    Fig 21: Aligning Chain's Mark Plates With Timing Marks Of Camshaft Timing Gear Assembly
    G04943371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2) 
    1. Install the No. 1 chain vibration damper with the 2 bolts

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

    Fig 22: Locating Chain Vibration Damper Bolts
    G04943352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2) 
    1. Install the chain tensioner slipper.

      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 23: Identifying Chain Tensioner Slipper
      G05749611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2) 
    1. Move the stopper plate upward to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly
    2. Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the hole of the stopper plate.
      Fig 24: Pushing Plunger Into Chain Tensioner Assembly
      G04943373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the No 1 chain tensioner assembly with the 2 bolts

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

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly.
    Fig 25: Locating Chain Tensioner Bolts
    G04943351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Install the No 3 chain tensioner assembly with the 2 bolts.

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

    2. While raising the No. 3 chain tensioner assembly, insert a 1 0 mm (0 0394 in) pin into the hole to fix it in place
  29. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1) 

    HINT

    The crankshaft timing sprocket, camshaft timing gear assembly and camshaft timing exhaust gear assembly will be installed with the No. 1 chain sub-assembly and No 2 chain sub-assembly connected to the gears

    Fig 26: Inserting Pin Into Hole
    G05749702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 27: Aligning Chain Orange Mark Plates With Camshaft Timing Gear Timing Mark
      G05749703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the No 1 chain's orange mark plate with the crankshaft timing sprocket's timing mark, and attach the chain to the gear as shown in the illustration.
      Fig 28: Aligning Chain Orange Mark Plate With Crankshaft Timing Sprocket Timing Mark
      G04943377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the No 2 chain's mark plates (yellow) 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.
    4. Install the crankshaft timing sprocket to the crankshaft.
    5. Align and attach the knock pin of the No 3 camshaft with the pin hole of the camshaft timing gear assembly
      Fig 29: Aligning Chain Mark Plates With Timing Marks Of Camshaft Timing Gear Assembly
      G05749705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 assembly
      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 3 chain tensioner
  30. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) 
    1. Install the No 1 chain 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 assembly
    Fig 30: Locating Chain Vibration Damper Bolts
    G05749604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1) 
    1. Install the chain tensioner slipper

      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.

      Fig 31: Identifying Chain Tensioner Slipper
      G05749603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) 
    1. Move the stopper plate upward to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly.
    2. Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the hole of the stopper plate.
      Fig 32: Pushing Plunger Into Chain Tensioner Assembly
      G04943373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the No 1 chain tensioner assembly and gasket with the 2 bolts.

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

    Fig 33: Locating Chain Tensioner Bolts
    G04943344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. 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 camshaft timing gear assembly with a new bolt

        Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf) 

        Fig 34: Tightening Camshaft Timing Gear Assembly (For Bank 1)
        G05749710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using a wrench to hold the hexagonal portion of the No 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt

        Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 

        Fig 35: Tightening Camshaft Timing Exhaust Gear Assembly (For Bank 1)
        G05749711Courtesy 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 camshaft timing gear assembly with a new bolt

        Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf) 

        Fig 36: Tightening Camshaft Timing Gear Assembly (For Bank 2)
        G05749712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.

        Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 

  34. INSPECT 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 37: Tightening Camshaft Timing Exhaust Gear Assembly (For Bank 2)
      G05749713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the crankshaft pulley bolt
    Fig 38: Aligning Timing Marks On Crankshaft Timing Gear And Camshaft Timing Gears
    G05749600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSPECT VALVE CLEARANCE  (See VALVE CLEARANCE )
  36. ADJUST VALVE CLEARANCE  (See ADJUSTMENT )
  37. INSTALL OIL REFLECTOR PLATE LH (for Bank 1) 
    1. Install the oil reflector plate LH with the 2 bolts

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

    Fig 39: Locating Oil Reflector Plate LH Bolts (For Bank 1)
    G05749618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL OIL REFLECTOR PLATE RH (for Bank 2) 
    1. Install the oil reflector plate RH with the 2 bolts

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

  39. INSTALL INLET WATER PIPE  (See INSTALLATION )
  40. INSTALL SCAVENGING PUMP ASSEMBLY  (See INSTALLATION )
  41. INSTALL NO. 3 OIL PIPE  (See INSTALLATION )
  42. INSTALL NO. 2 OIL PIPE  (See INSTALLATION )
  43. INSTALL NO. 1 OIL PIPE  (See INSTALLATION )
  44. INSTALL WATER PUMP ASSEMBLY 
    Fig 40: Locating Oil Reflector Plate RH Bolts (For Bank 1)
    G05749619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the water pump assembly and new water pump gasket with the 5 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

  45. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY  (See INSTALLATION )
  46. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL  (See INSTALLATION )
    Fig 41: Locating Water Pump Assembly Bolts
    G05749598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL OIL CONTROL VALVE FILTER 
    1. for Bank 1
      1. Install the oil control valve filter to the cylinder head cover spacer LH.
      2. Install a new gasket and the cylinder head cover spacer LH with the 2 bolts

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

      Fig 42: Locating Oil Control Valve Filter Bolts (For Bank 1)
      G05749595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Bank 2.
      1. Install the oil control valve filter to the cylinder head cover spacer
      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 Oil Control Valve Filter Bolts (For Bank 2)
      G05749596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL SPARK PLUG TUBE GASKET 
    1. Install the 8 new spark plug tube gaskets to each cylinder head sub-assembly
      NOTE:
      • Install the gaskets in the correct direction.
      • Push in each gasket until its bottom surface contacts the cylinder head.
      Fig 44: Identifying Spark Plug Tube Gaskets
      G05749720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 1) 
    1. Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.
    2. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH
      NOTE: Remove any oil from the contact surface.
      Fig 45: Locating Oil Hole Gaskets And O-Rings
      G05749591Courtesy 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 

      Fig 46: Locating Seal Packing Applying Area
      G05749722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly 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 the cylinder head cover sub-assembly.
    4. Install the cylinder head cover sub-assembly LH with 3 new seal washers and the 16 bolts.

      Torque: Bolt A 

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

      Except bolt A 

      12 N*m (122 kgf*cm, 9 ft.*lbf) 

    5. Install a new fuel pump spacer gasket
    Fig 47: Locating Cylinder Head Cover Seal Washers And Bolts
    G05749723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) 
    1. Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps
    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly
      NOTE: Remove any oil from the contact surface.
      Fig 48: Locating Oil Hole Gaskets And O-Rings
      G05749593Courtesy 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 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly 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 the cylinder head cover sub-assembly.
      Fig 49: Locating Seal Packing Applying Area
      G05749725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the cylinder head cover sub-assembly with 3 new seal washers and the 16 bolts.

      Torque: Bolt A 

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

      Except bolt A 

      12 N*m (122 kgf*cm, 9 ft.*lbf) 

    5. Install a new fuel pump spacer gasket
    Fig 50: Locating Cylinder Head Cover Seal Washers And Bolts
    G05749726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL NO. 1 V-BANK COVER BRACKET (for Bank 1) 
    1. Install the No. 1 V-bank cover bracket to the cylinder head cover sub-assembly LH

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

    Fig 51: Locating V-Bank Cover Bracket (For Bank 1)
    G05749588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL NO. 1 V-BANK COVER BRACKET (for Bank 2) 
    1. Install the No. 1 V-bank cover bracket to the cylinder head cover sub-assembly RH.

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

  53. INSTALL CRANKSHAFT PULLEY  (See INSTALLATION )
    Fig 52: Locating V-Bank Cover Bracket (For Bank 2)
    G05749589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL OIL FILTER BRACKET 
    1. Install 2 new gaskets and the filter bracket with the 2 bolts and 2 nuts.

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

      Fig 53: Locating Oil Filter Bracket Bolts And Nuts
      G05749587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil filter bracket stay with the 2 bolts.

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

    Fig 54: Locating Oil Filter Bracket Stay Bolts
    G05750436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL OIL COOLER ASSEMBLY 
    1. Temporarily install the oil cooler assembly with the bolt.
    2. Install the union bolt to the oil cooler assembly with a new gasket.
    3. Tighten the bolt and union bolt.
      Fig 55: Locating Oil Cooler Assembly Union Bolt
      G05749585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Union bolt 

      59 N*m (602 kgf*cm, 43 ft.*lbf) 

  56. INSTALL OIL FILTER ELEMENT 
    1. Clean the inside of the oil filter cap, the threads and O-ring groove
    2. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap
    3. Set a new oil filter element in the oil filter cap.
    4. Remove any dirt or foreign matter from the installation surface of the oil filter bracket.
    5. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
      Fig 56: Identifying Oil Filter Element And O-Ring
      G05749584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST, tighten the oil filter cap

      SST 09228-06501 

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      NOTE:
      • Make sure that the oil filter is installed securely as shown in the illustration.
      • Be careful that the O-ring does not get caught between the parts.
      Fig 57: Tightening Oil Filter Cap
      G05749733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the cylinder block water drain cock sub-assembly

      Adhesive: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 58: Applying Adhesive To Threads Of Cylinder Block Water Drain Cock
      G04943675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cylinder block water drain cock sub-assembly as shown in the illustration.

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

      NOTE:
      • Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening to the specified torque.
      • Do not loosen the cylinder block water drain cock sub-assembly to adjust them. If an adjustment is necessary, remove the cylinder block water drain cock sub-assembly and reinstall them.
    3. Install the cylinder block water drain cock plugs to the cylinder block water drain cock sub-assembly.

      Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf) 

      Fig 59: Identifying Cylinder Block Water Drain Cock Rotating Angle
      G05749735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL FRONT WATER BY-PASS JOINT 
    1. Install the front water by-pass joint and 2 new gaskets with the 4 nuts.

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

    Fig 60: Locating Front Water By-Pass Joint Nuts
    G05749582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (for Bank 1) 
    1. Turn the camshaft timing gear assembly intermediate shaft index slot in the counterclockwise direction by hand, to set it to the maximum retard angle position.

      HINT

      • When a camshaft lobe opens a valve, the intermediate shaft becomes difficult to turn
      • The position where the intermediate shaft stops is the maximum retard angle
      Fig 61: Turning Camshaft Timing Gear Assembly Intermediate Shaft Index Slot In Counterclockwise Direction
      G05751879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new O-ring to the timing chain cover.
      Fig 62: Locating Timing Chain Cover O-Ring
      G05751873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the joint of the camshaft timing control motor assembly LH and the keyway of the camshaft timing gear assembly, and install the camshaft timing control motor assembly LH with the 3 bolts

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

      Fig 63: Locating Camshaft Timing Control Motor Assembly LH Bolts
      G05749580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that [L] is printed on the label of the camshaft timing control motor assembly LH.
      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor assembly LH (the surface that contacts the timing chain cover sub-assembly).
      • When installing the camshaft timing control motor assembly LH, do not use excessive force.
      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor assembly LH.
      • Install the camshaft timing control motor assembly LH with the arrow facing upward, as shown in the illustration.
      • Do not drop the camshaft timing control motor assembly LH. If dropped, replace it.
      • Do not disassemble the camshaft timing control motor assembly LH. If disassembled, replace it.
  60. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (for Bank 2) 
    1. Turn the camshaft timing gear assembly intermediate shaft index slot in the counterclockwise direction by hand, to set it to the maximum retard angle position.

      HINT.

      • When a camshaft lobe opens a valve, the intermediate shaft becomes difficult to turn.
      • The position where the intermediate shaft stops is the maximum retard angle
      Fig 64: Turning Camshaft Timing Gear Assembly Intermediate Shaft Index Slot In Counterclockwise Direction
      G05751884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new O-ring to the timing chain cover
      Fig 65: Locating Timing Chain Cover O-Ring
      G05751877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the joint of the camshaft timing control motor assembly RH and the keyway of the camshaft timing gear assembly, and install the camshaft timing control motor assembly RH with the 3 bolts

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

      Fig 66: Locating Camshaft Timing Control Motor Assembly RH Bolts
      G05749581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that [R] is printed on the label of the camshaft timing control motor assembly RH.
      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor assembly RH (the surface that contacts the timing chain cover sub-assembly).
      • When installing the camshaft timing control motor assembly RH, do not use excessive force.
      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor assembly RH.
      • Install the camshaft timing control motor assembly RH with the arrow facing upward, as shown in the illustration.
      • Do not drop the camshaft timing control motor assembly RH. If dropped, replace it.
      • Do not disassemble the camshaft timing control motor assembly RH. If disassembled, replace it.
  61. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the camshaft timing oil control valve assembly LH
    3. Install the camshaft timing oil control valve assembly LH with the bolt

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

    Fig 67: Locating Camshaft Timing Oil Control Valve Assembly LH Bolt
    G05749743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH 
    1. Apply a light coat of engine oil to a new O-ring
    2. Install the O-ring to the camshaft timing oil control valve assembly RH
    3. Install the camshaft timing oil control valve assembly RH with the bolt

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

  63. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.
    2. Install the crankshaft position sensor with the bolt

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

    Fig 68: Locating Camshaft Timing Oil Control Valve Assembly RH Bolt
    G05749744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL CAMSHAFT POSITION SENSOR 
    1. Apply a light coat of engine oil to the O-ring on each camshaft position sensor
      Fig 69: Locating Crankshaft Position Sensor Bolt
      G05749576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the camshaft position sensor with the bolt

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

  65. INSTALL VVT SENSOR 
    1. for Bank 1
      1. Apply a light coat of engine oil to the O-ring on each VVT sensor
        Fig 70: Locating Camshaft Position Sensor Bolt
        G05749575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the 2 VVT sensors 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 the O-ring on the VVT sensor.
        Fig 71: Locating VVT Sensors Bolts (For Bank 1)
        G05749574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the 2 VVT sensors with the 2 bolts.

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

  66. INSTALL SPARK PLUG  (See INSTALLATION )
    Fig 72: Locating VVT Sensors Bolts (For Bank 2)
    G05749573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. INSTALL OIL FILLER CAP HOUSING 
    1. Align the protrusion of a new oil filler cap gasket with the cutout of the oil filler cap housing, and install the oil filler cap gasket to the oil filler cap housing
      Fig 73: Identifying Oil Filler Cap Gasket
      G04943683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil filler cap housing with the 2 bolts.

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

  68. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install a new oil filler cap gasket to the oil filler cap
    2. Install the oil filler cap sub-assembly to the oil filler cap housing.
    Fig 74: Locating Oil Filler Cap Housing Bolts
    G05749572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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