Part 1

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

REASSEMBLY

1. INSTALL REAR CRANKSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-78010
(b) Apply MP grease to the oil seal lip.
2. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.

(b) Apply seal packing in a continuous line as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE: Parts must be assembled within 3 minutes of application. Otherwise the seal packing must be removed and reapplied.

Standard seal diameter: 2 to 3 mm (0.00315 to 0.00472 in.)
(c) Install the oil seal retainer with the 5 bolts and 2 nuts.
Torque:
for nut 9.0 N*m (92 kgf*cm, 80 in.*lbf)
for bolt 10 N*m (102 kgf*cm, 7 ft.*lbf)

3. INSTALL KNOCK SENSOR
(a) Install the 2 knock sensors with the 2 bolts as shown in the illustration.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Connect the 2 knock sensor connectors.

4. INSTALL NO. 1 WATER OUTLET PIPE
(a) Install the water outlet pipe with the 3 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
5. INSTALL CYLINDER HEAD GASKET (for Bank 1)
6. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH (for Bank 1)
(a) Place the cylinder head on the cylinder head gasket.

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

(b) Install the 8 cylinder head bolts and plate washers.

HINT:
^ The cylinder head bolts are tightened in 3 progressive steps.
^ If any cylinder head bolt is broken or deformed, replace it.

(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.

(c) Step 1:
(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

(d) Step 2:
(1) Mark the cylinder head bolt heads with paint as shown in the illustration.
(2) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
(e) Step 3:
(1) Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.
(f) Check that the painted marks are now facing rearward.

(g) Seal packing will seep out from the engine's front side. Thoroughly wipe off seeped out seal packing.
7. INSTALL NO. 2 CYLINDER HEAD GASKET (for Bank 2)
8. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH (for Bank 2)
(a) Place the cylinder head on the cylinder head gasket.

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

(b) Install the 8 cylinder head bolts and plate washers.

HINT:
^ The cylinder head bolts are tightened in 3 progressive steps.
^ If any cylinder head bolt is broken or deformed, replace it.

(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.

(g) Install the 2 bolts in the order shown in the illustration.
(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(2) Install the 2 cylinder head bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

(h) Seal packing will seep out from the engine's front side. Thoroughly wipe off seeped out seal packing.

9. INSTALL NO. 1 CAMSHAFT BEARING
(a) Align the bearing claw with the claw groove of the bearing cap, and push in the No. 1 camshaft bearing.

NOTICE:
^ Install the bearing while aligning it with the oil hole in the bearing cap.
^ Clean the backside of the bearing and the contact surface of the bearing cap and prevent oil from adhering to them.

10. INSTALL NO. 2 CAMSHAFT BEARING
(a) Install the No. 2 camshaft bearing to the cylinder head.

NOTICE: Clean the backside of the bearing and the bearing surface of the cylinder head and prevent oil from adhering to them.

11. INSTALL CAMSHAFTS

NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Set the crankshaft position.
(1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position.

NOTICE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when the camshaft is installed, causing damage. Always set the crankshaft at the correct angle.

(b) for Bank 1: Apply new engine oil to the thrust portion and journal of the camshafts.

(c) Install the camshaft.
(1) Place the 2 camshafts onto the cylinder head with the cam lobes of the No. 1 cylinder facing each direction as shown in the illustration.

(2) Install the 8 bearing caps in their proper locations.
(3) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(4) Uniformly install the 16 bolts in several steps in the order shown in the illustration.
Torque:
for 10 mm head 9.0 N*m (92 kgf*cm, 80 in.*lbf)
for 12 mm head 24 N*m (245 kgf*cm, 18 ft.*lbf)

(5) Using a wrench, turn the camshafts clockwise until the camshaft knock pin is at a position 90° to the cylinder head.

(d) for Bank 2: Install the camshafts.
(1) Place the 2 camshafts onto the cylinder head with the cam lobes of the No. 2 cylinder facing as shown in the illustration.

(2) Install the 8 bearing caps in their proper locations.
(3) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

12. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 1)
(a) While pushing in the tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it.

(b) Install the No. 2 chain tensioner with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

13. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
(a) Align the mark links (yellow) of the No. 2 chain with the timing marks (1-dot mark) of the camshaft timing gear and sprocket as shown in the illustration.

(b) Align the timing marks on the camshaft timing gear and sprocket with the timing marks on the bearing caps, and install the camshaft timing gear and sprocket with the No. 2 chain to the camshafts.
(c) Temporarily install the camshaft timing gear bolt and camshaft timing sprocket bolt.

NOTICE: Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it.

(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(e) Remove the pin from the No. 2 chain tensioner.

14. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (for Bank 2)
(a) While pushing in the tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it.

(b) Install the No. 3 chain tensioner with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

15. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
(a) Align the mark links (yellow) of the No. 2 chain with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gear and sprocket as shown in the illustration.

(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(e) Remove the pin from the No. 3 chain tensioner.

16. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)

17. INSTALL CRANKSHAFT TIMING GEAR
(a) Align the timing gear set key with the key groove of the timing gear.
(b) Install the timing gear onto the crankshaft with the gear facing inward as shown in the illustration.
18. INSTALL CHAIN TENSIONER SLIPPER

19. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of [diameter]3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

20. INSTALL NO. 1 CHAIN
(a) Set the No. 1 cylinder to TDC / compression.
(1) Align the timing marks of the camshaft timing gears and sprockets with the timing marks of the bearing caps.

(2) Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

(b) Align the mark link (yellow) with the timing mark of the crankshaft timing gear.

21. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the 2 No. 2 chain vibration dampers.
22. INSTALL NO. 1 IDLE GEAR SHAFT
(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

(b) Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

NOTICE: Be careful of the idle gear direction.

(c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)
(d) Remove the bar from the chain tensioner.

23. INSTALL FRONT CRANKSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09226-10010
(b) Apply MP grease to the oil seal lip.

24. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 8 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)