Reassembly

1UR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL NO. 1 VENTILATION CONNECTOR

(a) Install the No. 1 ventilation connector as shown in the illustration.

Acceptable angle (A):

-5° to 5°

Tap-in depth (B):

0.2 to 3.2 mm (0.008 to 0.126 in.)

NOTICE:
After the installation of the ventilation connector, do not rotate it.

HINT
Connect the No. 1 ventilation connector so that its flat surface faces the rear part of the engine.

2. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY

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

(b) Install the new O-ring to the oil drain pipe sub-assembly.

(c) Install the oil drain pipe sub-assembly with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

3. INSTALL ENGINE REAR OIL SEAL RETAINER

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

Seal packing:

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

Seal diameter:

2.0 to 3.0 mm (0.079 to 0.118 in.)

Application position from inside edge of retainer:

3.5 mm (0.138 in.)

NOTICE:
* 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.
(b) Install the engine rear oil seal retainer with the 6 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

4. INSTALL OIL STRAINER SUB-ASSEMBLY

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

(b) Install the new O-ring to the oil strainer sub-assembly.

(c) Install the oil strainer sub-assembly with the 2 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

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

5. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate with the 8 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

6. INSTALL OIL PAN SUB-ASSEMBLY

(a) 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 0.156 in.)

Application position from inside edge of oil pan:

6.0 mm (0.236 in.)

NOTICE:
* 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.
(b) Install the oil pan sub-assembly with the 14 bolts and 2 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for bolt A)

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf for bolt B)

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf for nut)

7. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) 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 0.156 in.)

NOTICE:
* 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.
(b) Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

8. INSTALL VENTILATION PIPE GASKET

(a) 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

SST : 09950-70010

09951-07100

HINT
* Do not tap the ventilation pipe gasket at an angle.
* Do not tap the ventilation pipe gasket excessively.
9. INSTALL NO. 1 HEAT EXCHANGER COVER

(a) 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 0.156 in.)

NOTICE:
Remove any oil from the contact surface.

(b) Install the No. 1 heat exchanger cover with the 11 bolts and 2 nuts the cover.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

NOTICE:
* 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.
10. INSTALL OIL RETURN PIPE GASKET

(a) Install a new oil return pipe gasket.

11. INSTALL CYLINDER BLOCK WATER JACKET SPACER

(a) Install the 2 cylinder block water jacket spacers as shown in the illustration.

HINT
* Face the cutouts (indicated by the arrows in the illustration) in the opposite direction to the engine.
* Face each "Up" mark as shown in the illustration.
12. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1) Installation

13. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2) Installation

14. INSTALL VALVE STEM CAP

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

(b) Install the 32 valve stem caps to the cylinder head.

15. INSTALL VALVE LASH ADJUSTER ASSEMBLY

(a) Inspect the valve lash adjuster before installing it Engine Unit.

(b) Install the 32 valve lash adjusters to the cylinder head.

NOTICE:
Install the lash adjusters to their original positions they were removed from.

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

(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.

(b) Make sure that the 32 valve rocker arms are installed as shown in the illustration.

17. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation

18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2) Installation

19. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation

20. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1) Installation

21. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Install the 2 crankshaft timing gear keys.

22. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the chain tensioner with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.

23. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)

(a) 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.

(b) 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.

(c) Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot mark) 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.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

25. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)

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.

26. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

(c) Install the chain tensioner with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(d) Remove the hexagon wrench from the chain tensioner.

27. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the chain tensioner with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) While pushing down the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.

28. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)

(a) 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.

(b) 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.

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

(d) Install the crankshaft timing gear to the crankshaft.

(e) Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly.

(f) 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.

NOTICE:
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.

(g) Remove the pin from the No. 2 chain tensioner.

29. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)

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.

30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

(c) Install the chain tensioner and gasket with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

31. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)

(a) Install the vibration damper with the 2 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(b) Remove the hexagon wrench from the No. 1 chain tensioner.

32. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY

(a) 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 Nm (806 kgf-cm, 58 ft-lbf)

(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 Nm (1020 kgf-cm, 74 ft-lbf)

(b) 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 Nm (806 kgf-cm, 58 ft-lbf)

(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 Nm (1020 kgf-cm, 74 ft-lbf)

33. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily install the crankshaft pulley bolt.

(b) 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.

(c) Remove the crankshaft pulley bolt.

34. INSTALL WATER INLET PIPE [1][2]Installation

35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY [1][2]Installation

36. INSTALL WATER PUMP Installation

37. INSTALL OIL CONTROL VALVE FILTER

(a) for Bank 1:

(1) Install the oil control valve filter in the cylinder head.

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) for Bank 2:

(1) Install the oil control valve filter in the cylinder head.

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

38. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3, No. 7).

(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

NOTICE:
Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.

Seal packing:

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

NOTICE:
* 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.
(d) Install the cylinder head cover sub-assembly with 2 new seal washers and the 15 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf for bolt A)

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf for bolts except A)

(e) Install a new fuel pump spacer gasket.

39. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps. (No. 1, No. 3, No. 6).

(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

NOTICE:
Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf for bolt A)

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf for bolts except A)

(e) Install a new fuel pump spacer gasket.

40. INSTALL SPARK PLUG TUBE GASKET

(a) Perform a visual inspection on the spark plug tube gasket.

Standard:

(b) Install the 8 spark plug tube gaskets to the cylinder head cover sub-assembly.

41. INSTALL CRANKSHAFT PULLEY Installation

42. INSTALL FRONT WATER BY-PASS JOINT

(a) Install the front water by-pass joint and 2 new gaskets with the 4 nuts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

43. INSTALL OIL FILTER BRACKET

(a) Install 2 new gaskets and the filter bracket with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

44. INSTALL OIL FILTER ELEMENT Replacement

45. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the drain cock.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the drain cocks as shown in the illustration.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

NOTICE:
* Do not rotate the water drain cocks more than 1 revolution (360°) after tightening the water drain cocks to the specified torque.
* Do not loosen the water drain cocks to adjust them. If an adjustment is necessary, remove the cylinder block water drain cocks and reinstall them.
(c) Install the cylinder block water drain cock plugs to the water drain cocks.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

46. INSTALL CAMSHAFT TIMING CONTROL MOTOR (for Bank 1) Installation

47. INSTALL CAMSHAFT TIMING CONTROL MOTOR (for Bank 2) Installation

48. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) for Bank 1:

(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.

(3) Install the camshaft timing oil control valve assembly with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) for Bank 2:

(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.

(3) Install the camshaft timing oil control valve assembly with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

49. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the crankshaft position sensor with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

50. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the camshaft position sensor with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

51. INSTALL VVT SENSOR

(a) for Bank 1:

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) for Bank 2:

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

52. INSTALL SPARK PLUG Installation

53. INSTALL OIL FILLER CAP HOUSING

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

(b) Install the oil filler cap housing with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

54. INSTALL OIL FILLER CAP SUB-ASSEMBLY