Part 2

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(continued)
25. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

(b) Install a new O-ring to the cylinder head for bank 2 shown in the illustration.

(c) Apply seal packing 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.)
(d) Apply seal packing in a continuous line to the timing chain cover as shown in the illustration.

Seal packing:
for water related part: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
for oil related part: 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.)

HINT: Water related part is "B" shown in the illustration.

NOTICE:
^ Install the timing chain cover within 3 minutes after applying seal packing. After installing it, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
^ Do not apply seal packing to "A" shown in the illustration.

(e) Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.

(f) Install the timing chain cover with the 24 bolts labeled A and B, and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)

NOTICE:
^ Make sure not to wrap the No. 1 chain and slipper over the timing chain cover seal line.
^ After installing the timing chain cover, install the water pump within 15 minutes.

Bolt length:

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

26. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

(b) Using an E6 "TORX" wrench, install the 4 stud bolts.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

Bolt length:

(d) 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 to 4 mm (0.118 to 0.157 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

(e) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
for bolt A, B and nut 21 N*m (214 kgf*cm, 15 ft.*lbf)
for bolt C 10 N*m (102 kgf*cm, 7 ft.*lbf)

Bolt length:

27. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
28. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
29. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug and a new gasket.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)

30. INSTALL CRANKSHAFT PULLEY
(a) Using SST, install the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 250 N*m (2549 kgf*cm, 184 ft.*lbf)
31. SET NO. 1 CYLINDER TO TDC/COMPRESSION
32. INSPECT VALVE CLEARANCE
33. ADJUST VALVE CLEARANCE
34. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

(b) Apply seal packing as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter: 2 to 3 mm (0.0787 to 0.118 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the head cover within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after the installation.

(c) Install a new gasket to the cylinder head cover.
(d) Install the seal washers to the bolts.

(e) Temporarily install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf)
for bolt B and nut 9.0 N*m (92 kgf*cm, 80 in.*lbf)
35. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

36. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive to the threads of the ventilation valve.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the ventilation valve to the cylinder head cover.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
37. INSPECT SPARK PLUG
38. INSTALL SPARK PLUG

39. INSTALL OIL FILLER CAP HOUSING
(a) Install a new gasket and the oil filter cap housing with the 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
40. INSTALL OIL FILLER CAP SUB-ASSEMBLY

41. INSTALL OIL CONTROL VALVE FILTER
(a) Install 2 new gaskets to 2 new unions.
(b) Insert new filters to the unions.
(c) Apply adhesive to 2 or 3 threads of the unions.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(d) Install the unions to each cylinder head.
Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf)

42. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

43. INSTALL VVT SENSOR
(a) Apply a light coat of engine oil to the O-ring of each VVT sensor.
(b) Install the 2 VVT sensors with the 2 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

44. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring of the camshaft timing oil control valve and install the O-ring.

(b) Install the camshaft timing oil control valve with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

NOTICE: Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.

45. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the drain cocks end.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the drain cock.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)

NOTICE:
^ Install the drain cock within 3 minutes after applying adhesive.
^ Do not expose the drain cock to coolant within 1 hour after installing.

(c) Rotate the drain cock clockwise as shown in the illustration.

NOTICE:
^ Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock with the specified torque.
^ Do not loosen the drain cock after setting it correctly.

46. INSTALL REAR WATER BY-PASS JOINT
(a) Apply soapy water to a new O-ring, and install it to the water outlet pipe. Then set 2 new gaskets to the water ports LH and RH.

(b) Install the rear water by-pass joint with the 2 bolts and 4 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

47. INSTALL WATER INLET HOUSING
(a) Apply soapy water to a new O-ring, install it to the water outlet pipe.
(b) Install a new O-ring to the water pump.
(c) Install a new gasket to the water pump.

(d) Install the water inlet with the 5 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
48. CONNECT NO. 3 WATER BY-PASS HOSE
49. CONNECT NO. 2 WATER BY-PASS HOSE
50. CONNECT NO. 1 WATER BY-PASS HOSE
51. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
(a) Set a new O-ring to the timing chain cover.

(b) Install the oil filter bracket with the 3 bolts and 2 nuts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
52. INSTALL OIL COOLER ASSEMBLY
(a) Clean the oil cooler contact surface of the oil filter bracket with the cooler mounting.
(b) Apply a light coat of engine oil to a new O-ring, and install it into the oil cooler.
(c) Apply a light coat of engine oil to the threads of the oil cooler union bolt.

(d) Align the protrusion of the oil filter bracket with the cutout of the oil cooler.
Torque: 68 N*m (693 kgf*cm, 50 ft.*lbf)
(e) Install the oil cooler and plate washer with the union bolt.

53. CONNECT OIL COOLER HOSE
54. CONNECT NO. 2 OIL COOLER HOSE
55. INSTALL OIL FILTER SUB-ASSEMBLY