Lexus ES: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL WATER INLET PIPE

(a) Install the water inlet pipe with the 2 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL NO. 2 CYLINDER HEAD GASKET

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3. INSTALL CYLINDER HEAD LH

(a) Place the cylinder head LH onto the cylinder block sub-assembly.

HINT:

The cylinder head set bolts are tightened in 3 progressive steps.

(b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

(c) Step 1:

(1) Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 8 cylinder head set bolts with 8 cylinder head set plate washers in several steps in the order shown in the illustration. Torque: 36 N·m {367 kgf·cm, 27 ft·lbf}

(d) Step 2:

(1) Mark each cylinder head set bolt head with paint as shown in the illustration.

*a	Turn 90°
*b	Paint Mark
	Front of Engine

(2) Tighten the cylinder head set bolts 90° in the order shown in step 1.

(e) Step 3:

(1) Tighten the cylinder head set bolts an additional 90° in the order shown in step 1.

(2) Check that the paint marks are now facing rearward.

(f) Tighten the 2 bolts in the order shown in the illustration. Torque: 30 N·m {306 kgf·cm, 22 ft·lbf} HINT: Perform Inspection After Repair after replacing the cylinder head LH. Click here

4. INSTALL CYLINDER HEAD GASKET

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5. INSTALL CYLINDER HEAD SUB-ASSEMBLY

(a) Place the cylinder head sub-assembly onto the cylinder block sub-assembly.

HINT:

The cylinder head set bolts are tightened in 3 progressive steps.

(b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

(c) Step 1:

(1) Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 8 cylinder head set bolts with 8 cylinder head set plate washers in several steps in the order shown in the illustration. Torque: 36 N·m {367 kgf·cm, 27 ft·lbf}

(d) Step 2:

(1) Mark each cylinder head set bolt head with paint as shown in the illustration.

*a	Turn 90°
*b	Paint Mark
	Front of Engine

(2) Tighten the cylinder head set bolts 90° in the order shown in step 1.

(e) Step 3:

(1) Tighten the cylinder head set bolts an additional 90° in the order shown in step 1.

(2) Check that the paint marks are now facing rearward.

HINT:

Perform Inspection After Repair after replacing the cylinder head sub-assembly.

Click here

6. INSTALL REAR ENGINE OIL SEAL

(a) Place the rear engine oil seal retainer on wooden blocks.

(b) Apply MP grease to the lip of a new rear engine oil seal.

(c) Using SST and a hammer, tap in the rear engine oil seal. SST: 09223-15030 SST: 09950-70010 09951-07100 Oil Seal Protrusion Height: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) NOTICE: Keep the lip free from foreign matter. Do not tap in the rear engine oil seal at an angle.

*1 Rear Engine Oil Seal Retainer *a Oil Seal Protrusion Height

7. INSTALL REAR ENGINE 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 Packing Diameter: 2.0 to 3.0 mm (0.0787 to 0.118 in.) NOTICE: Remove any oil from the contact surfaces. Install the rear engine oil seal retainer within 3 minutes of applying seal packing. Do not start the engine for at least 2 hours after installation.

*a Seal Packing

(b) Install the rear engine oil seal retainer to the cylinder block sub-assembly with the 6 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTICE: Be sure to apply adhesive to the bolts (A) before installing them. Wipe off any seal packing that seeped out from the crankshaft position sensor insert part (B).

8. INSTALL SENSOR WIRE

(a) Install the sensor wire to the cylinder head LH and cylinder block sub-assembly with the 3 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

9. INSTALL VALVE STEM CAP

(a) Install the 24 valve stem caps to the cylinder head sub-assembly and cylinder head LH. NOTICE: Install each part to its original position. Do not drop the valve stem caps into the cylinder head sub-assembly.

10. INSTALL VALVE LASH ADJUSTER ASSEMBLY

(a) Inspect the valve lash adjuster assembly.

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(b) Install the 24 valve lash adjuster assemblies to the cylinder head sub-assembly and cylinder head LH. NOTICE: Install each part to its original position.

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

(a) Apply engine oil to the valve lash adjuster assembly tip and valve stem cap end.

(b) Install the 24 No. 1 valve rocker arm sub-assemblies as shown in the illustration. NOTICE: Install each part to its original position.

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap

12. INSTALL STRAIGHT PIN (for Bank 2)

HINT:

It is not necessary to remove the straight pin unless it is being replaced.

(a) Using a plastic hammer, tap in a new straight pin to the camshaft housing sub-assembly LH. Standard Protrusion Height: 7.7 to 8.3 mm (0.303 to 0.327 in.)

*a Protrusion Height

13. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN (for Bank 2)

HINT:

It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.

(a) Using a plastic hammer, tap 10 new camshaft bearing cap setting ring pins into the camshaft housing sub-assembly LH. Standard Protrusion Height: 2.7 to 3.3 mm (0.106 to 0.130 in.)

*a Protrusion Height

14. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

(a) Apply a light coat of engine oil to the No. 3 camshaft sub-assembly journals and camshaft housing sub-assembly LH.

(b) Install the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH.

HINT:

Perform Inspection After Repair after replacing the No. 3 camshaft sub-assembly.

Click here

15. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY

(a) Apply a light coat of engine oil to the No. 4 camshaft sub-assembly journals and camshaft housing sub-assembly LH.

(b) Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH.

HINT:

Perform Inspection After Repair after replacing the No. 4 camshaft sub-assembly.

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16. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

(a) Install the 2 oil control valve filters to the 2 camshaft bearing caps.

(b) Apply engine oil to the 5 camshaft bearing caps.

(c) Install the 5 camshaft bearing caps to the camshaft housing sub-assembly LH.

(d) Temporarily install and tighten the 8 bolts in the order shown in the illustration. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

17. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 3 chain tensioner assembly to the camshaft housing sub-assembly LH with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

*a	Pin
*b	Plunger
	Push

(b) While pushing down the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure it.

18. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.

*a Timing Mark *b Mark Plate

(b) Align the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly with the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

NOTICE:

Be careful not to damage the contact surface of the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly.

HINT:

Perform Inspection After Repair after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly.

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19. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)

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20. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)

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21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap

(b) Apply seal packing as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal Packing Application Specification: Area Seal Packing Diameter Continuous Line Area 3.0 to 4.0 mm (0.118 to 0.157 in.) Dashed Line Area 4.0 to 4.5 mm (0.157 to 0.177 in.) NOTICE: Remove any oil from the contact surface. Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes of applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation.

*a Continuous Line Area *b Dashed Line Area *c 3.0 to 4.0 mm *d Separated by 4.0 to 6.0 mm (0.157 to 0.236 in.)

(c) Install the camshaft housing sub-assembly LH and tighten the 15 bolts in the order shown in the illustration.

*a	Straight Pin	*b	Intake Side
*c	Exhaust Side	-	-
	Bolt (A)		Bolt (B)

Torque:

28 N·m {286 kgf·cm, 21 ft·lbf}

Bolt Length:

Item	Length
Bolt (A)	68 mm (2.68 in.)
Bolt (B)	48 mm (1.89 in.)

(d) Tighten the 8 bolts in the order shown in the illustration. Torque: 16 N·m {163 kgf·cm, 12 ft·lbf}

(e) Remove any protruding seal packing black.

NOTICE:

Be careful not to drop seal packing black into the cylinder head LH.

22. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)

(a) Using a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

*a	Hold
	Turn

NOTICE:

Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.

23. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)

(a) Using a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

NOTICE:

Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.

*a	Hold
	Turn

(b) Remove the pin from the No. 3 chain tensioner assembly.

24. INSTALL STRAIGHT PIN (for Bank 1)

HINT:

It is not necessary to remove the straight pin unless it is being replaced.

(a) Using a plastic hammer, tap in a new straight pin to the camshaft housing sub-assembly. Standard Protrusion Height: 7.7 to 8.3 mm (0.303 to 0.327 in.)

*a Protrusion Height

25. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN (for Bank 1)

HINT:

It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.

(a) Using a plastic hammer, tap 10 new camshaft bearing cap setting ring pins into the camshaft housing sub-assembly. Standard Protrusion Height: 2.7 to 3.3 mm (0.106 to 0.130 in.)

*a Protrusion Height

26. INSTALL CAMSHAFT

(a) Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.

(b) Install the camshaft to the camshaft housing sub-assembly.

HINT:

Perform Inspection After Repair after replacing the camshaft.

Click here

27. INSTALL NO. 2 CAMSHAFT

(a) Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.

(b) Install the No. 2 camshaft to the camshaft housing sub-assembly.

HINT:

Perform Inspection After Repair after replacing the No. 2 camshaft.

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28. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

(a) Install the 2 oil control valve filters to the 2 camshaft bearing caps.

(b) Apply engine oil to the 5 camshaft bearing caps.

(c) Install the 5 camshaft bearing caps to the camshaft housing sub-assembly.

(d) Install the fuel pump lifter housing to the camshaft housing sub-assembly.

(e) Temporarily install and tighten the 9 bolts in the order shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt Length:

Item	Length
Bolt (A)	40 mm (1.57 in.)
Bolt (B)	58 mm (2.28 in.)

	Bolt (A)
	Bolt (B)

29. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 2 chain tensioner assembly to the camshaft housing sub-assembly with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

*a	Pin
*b	Plunger
	Push

(b) While pushing up the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure it.

30. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.

*a Timing Mark *b Mark Plate

(b) Align the straight pins of the camshaft and No. 2 camshaft with the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly. Temporarily install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

NOTICE:

Be careful not to damage the contact surface of the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the straight pins of the camshaft and No. 2 camshaft.

HINT:

Perform Inspection After Repair after replacing the camshaft timing gear assembly or camshaft timing exhaust gear assembly.

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31. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)

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32. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)

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33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

(a) Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap

(b) Apply seal packing as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal Packing Diameter: 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTICE: Remove any oil from the contact surface. Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing. Do not add engine oil for at least 2 hours after installation. Do not start the engine for at least 2 hours after installation.

*a Seal Packing *b 3.0 to 4.0 mm *c Separated by 4.0 to 6.0 mm (0.157 to 0.236 in.)

(c) Install the camshaft housing sub-assembly and tighten the 15 bolts in the order shown in the illustration.

*a	Straight Pin	*b	Intake Side
*c	Exhaust Side	*d	45°
	Bolt (A)		Bolt (B)

Torque:

28 N·m {286 kgf·cm, 21 ft·lbf}

Bolt Length:

Item	Length
Bolt (A)	68 mm (2.68 in.)
Bolt (B)	48 mm (1.89 in.)

(d) Tighten the 9 bolts in the order shown in the illustration. Torque: 16 N·m {163 kgf·cm, 12 ft·lbf}

(e) Remove any protruding seal packing black.

NOTICE:

Be careful not to drop seal packing black into the cylinder head sub-assembly.

34. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)

(a) Using a wrench to hold the hexagonal portion of camshaft, tighten the camshaft timing gear bolt of the camshaft timing gear assembly.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

NOTICE:

Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.

*a	Hold
	Turn

35. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)

(a) Using a wrench to hold the hexagonal portion of No. 2 camshaft, tighten the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

NOTICE:

Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.

*a	Hold
	Turn

(b) Remove the pin from the No. 2 chain tensioner assembly.

36. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Install the 2 crankshaft timing gear keys to the crankshaft.

37. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the crankshaft timing sprocket to the crankshaft.

38. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 No. 2 chain vibration dampers to the cylinder head LH and cylinder head sub-assembly.

39. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper to the cylinder head LH and cylinder block sub-assembly with the 2 bolts. Torque: 22.5 N·m {229 kgf·cm, 17 ft·lbf}

40. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

*a	Knock Pin
	Light coat of engine oil

(b) Temporarily install the No. 1 idle gear shaft and idle sprocket assembly with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the pin hole of the cylinder block sub-assembly.

NOTICE:

Make sure to install the No. 1 idle gear shaft installation in the correct direction.

HINT:

Check that there is no foreign matter on the No. 1 idle gear shaft or No. 2 idle gear shaft.

(c) Using a 10 mm hexagon socket wrench, tighten the No. 2 idle gear shaft.

Torque:

60 N·m {612 kgf·cm, 44 ft·lbf}

HINT:

After installing the idle sprocket assembly, check that the idle sprocket assembly turns smoothly.

41. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly. HINT: The camshaft mark plates are yellow.

*a Mark Plate *b Timing Mark

(b) Temporarily place the chain sub-assembly on the crankshaft as shown in the illustration.

(c) Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain sub-assembly between the banks.

*a	Chain Plate
*b	When the idle sprocket assembly is reused
*c	Mark
*d	Align
	Turn

NOTICE:

When reusing the idle sprocket assembly, align the chain plate with the mark where the mark plate had been in order to tighten the chain sub-assembly between the banks.

(d) Align the mark plate and timing marks as shown in the illustration and install the chain sub-assembly around the crankshaft timing sprocket. HINT: The crankshaft mark plate is pink.

*a Mark Plate *b Timing Mark

(e) Temporarily tighten the crankshaft pulley set bolt to the crankshaft.

(f) Turn the crankshaft clockwise to set it to the center line of the block bore (for Bank 1) (TDC /compression).

*a Center Line *b Key Groove

42. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper to the cylinder block sub-assembly.

43. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

*a Stopper Plate *b Plunger

(b) Turn the stopper plate counterclockwise to set the lock, and insert a 1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate.

(c) Install the No. 1 chain tensioner assembly with the 2 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Remove the 1.0 mm (0.0394 in.) diameter pin from the No. 1 chain tensioner assembly.

44. INSPECT VALVE TIMING

(a) Check the camshaft timing marks.

(b) Check that each camshaft timing mark is positioned as shown in the illustration.

*a

Timing Mark

*b

Viewpoint

HINT:

For the camshaft or No. 3 camshaft sub-assembly:

Be sure to check the mark (A) at the point where the marks (B), (C) and (D) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

(c) If the valve timing is misaligned, reinstall the chain sub-assembly.

(d) Remove the crankshaft pulley set bolt from the crankshaft.

45. INSTALL ENGINE WATER PUMP ASSEMBLY

(a) Install a new water pump gasket and the engine water pump assembly with the 7 bolts. Torque: 11 N·m {112 kgf·cm, 8 ft·lbf}

46. INSTALL TIMING CHAIN COVER ASSEMBLY

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47. INSTALL TIMING CHAIN CASE OIL SEAL

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48. INSTALL TIMING CHAIN COVER PLATE

(a) Install a new timing chain cover gasket and the timing chain cover plate to the timing chain cover assembly with the 4 bolts. Torque: 11 N·m {112 kgf·cm, 8 ft·lbf}

49. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate to the crankshaft bearing cap set bolt.

(b) Temporarily tighten the 2 bolts (A).

(c) Fully tighten the 8 bolts order shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

50. INSTALL OIL FILTER BRACKET CLIP

(a) Install the oil filter bracket clip to the oil pan sub-assembly.

51. INSTALL OIL PAN SUB-ASSEMBLY

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using an E8 and E6 "TORX" socket wrench, install the 4 stud bolts to the oil pan sub-assembly and cylinder block sub-assembly.

*a	Cylinder Block Sub-assembly Side	*b	Oil Pan Sub-assembly Side
*c	20 mm (0.787 in.)	*d	13 mm (0.512 in.)
*e	35 mm (1.38 in.)	*f	16 mm (0.630 in.)
*g	9 mm (0.354 in.)	*h	27 mm (1.06 in.)

Torque:

Stud bolt (A) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Stud bolt (B) :

4.0 N·m {41 kgf·cm, 35 in·lbf}

(b) Install the oil pan sub-assembly.

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52. INSTALL ENGINE OIL LEVEL SENSOR

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53. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Apply a light coat of engine oil to a new oil strainer gasket.

(b) Align the protrusion of the oil strainer gasket with the cutout of the oil strainer sub-assembly, and install the oil strainer gasket to the oil strainer sub-assembly.

*a Protrusion *b Cutout

(c) Install the oil strainer sub-assembly to the timing chain cover assembly with the 2 nuts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

54. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using an E6 "TORX" socket wrench, install the 2 stud bolts to the oil pan sub-assembly as shown in the illustration. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

*a 9 mm (0.354 in.) *b 19 mm (0.748 in.)

(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 Seal Packing Diameter: 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTICE: Remove any oil from the contact surfaces. Install the No. 2 oil pan sub-assembly within 3 minutes of applying seal packing. Do not start the engine for at least 2 hours after installation.

*a Seal Packing

(c) Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts as shown in the illustration. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

*a Nut

55. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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56. INSTALL OIL FILTER CAP ASSEMBLY

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57. INSTALL OIL PAN DRAIN PLUG

(a) Install a new oil pan drain plug gasket and the oil pan drain plug to the No. 2 oil pan sub-assembly. Torque: 40 N·m {408 kgf·cm, 30 ft·lbf}

58. INSTALL SPARK PLUG TUBE GASKET

(a) Install 6 new spark plug tube gaskets to the cylinder head cover sub-assembly and cylinder head cover sub-assembly LH.

59. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Install 3 new No. 2 cylinder head cover gaskets to the cylinder head cover sub-assembly LH. NOTICE: Make sure that there is no oil or foreign matter inside the groove of the camshaft housing sub-assembly LH or on the contact surfaces of the cylinder head cover sub-assembly LH and timing chain cover assembly. Clean if necessary.

(b) Install a new camshaft bearing cap oil hole gasket LH to the camshaft bearing cap.

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

*1	Timing Chain Cover Assembly	*2	Camshaft Housing Sub-assembly LH
*a	Seal Packing (Diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.))	*b	Seal Packing (Diameter 5.0 to 7.0 mm (0.197 to 0.276 in.))
*c	Mark	*d	5.0 to 10 mm (0.197 to 0.394 in.)
*e	Thickness: 1.0 to 3.0 mm (0.0394 to 0.118 in.)	-	-
	Seal Packing	-	-

Seal Packing:

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

Seal Packing Application Specification:

Area	Seal Packing Diameter
(A)	Thickness: 5 to 10 mm (0.197 to 0.394 in.) Width: 2 to 3 mm (0.0787 to 0.118 in.)
(B)	Thickness: 1 to 3 mm (0.0394 to 0.118 in.) Width: 5 to 7 mm (0.197 to 0.276 in.)

(d) Apply a light coat of engine oil to the 2 O-rings of the 2 VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2).

NOTICE:

If reusing the 2 VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2), be sure to inspect them before installation.

(e) Clean the 4 bolt holes and bolts shown in the illustration.

(f) Apply adhesive to 2 to 3 threads at the end of each bolt that was cleaned in the previous step. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

*a Adhesive

(g) Install the cylinder head cover sub-assembly LH with the 16 bolts and 2 VVT sensors (for Exhaust Side of Bank 2 and for Intake Side of Bank 2) in the order shown in the illustration.

*a	Bolt with VVT Sensor
	Bolt (A)
	Bolt (B)

Torque:

Bolt (A) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt (B) :

7.3 N·m {74 kgf·cm, 65 in·lbf}

HINT:

After tightening all bolts, check the tightening torque of the bolts (1) and (18). Retighten them if necessary.

(h) 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}

60. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Install 3 new cylinder head cover gaskets to the cylinder head cover sub-assembly. NOTICE: Make sure that there is no oil or foreign matter inside the groove of the camshaft housing sub-assembly or on the contact surfaces of the cylinder head cover sub-assembly and timing chain cover assembly. Clean if necessary.

(b) Install a new camshaft bearing cap oil hole gasket to the camshaft bearing cap.

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

*1	Timing Chain Cover Assembly	*2	Camshaft Housing Sub-assembly
*a	Seal Packing (Diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.))	*b	Seal Packing (Diameter 5.0 to 7.0 mm (0.197 to 0.276 in.))
*c	Mark	*d	5.0 to 10 mm (0.197 to 0.394 in.)
*e	Thickness: 1.0 to 3.0 mm (0.0394 to 0.118 in.)	-	-
	Seal Packing	-	-

Seal Packing:

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

(d) Apply a light coat of engine oil to the 2 O-rings of the 2 VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1).

NOTICE:

If reusing the 2 VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1), be sure to inspect them before installation.

(e) Clean the 2 bolts and 2 bolt holes of the VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1).

(f) Apply adhesive to 2 or 3 threads at the end of the 2 bolts of the VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1). Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

*a Adhesive

(g) Install the cylinder head cover sub-assembly with the 15 bolts and 2 VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1) in the order shown in the illustration. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} NOTICE: If a VVT sensor (for Exhaust Side of Bank 1 or for Intake Side of Bank 1) has been struck or dropped, replace it. Make sure that the 2 O-rings are not cracked or moved out of place when installing the 2 VVT sensors (for Exhaust Side of Bank 1 and for Intake Side of Bank 1). HINT: After tightening all bolts, check the tightening torque of the bolts (1) and (17). Retighten them if necessary.

*a Bolt with VVT Sensor

(h) Type A (1) Install the No. 1 engine cover sub-assembly to the cylinder head cover sub-assembly with the 2 clips.

(i) Type B (1) Install the No. 1 engine cover sub-assembly to the cylinder head cover sub-assembly with the clip.

61. INSTALL WATER OUTLET

(a) Install 2 new No. 2 water inlet housing gaskets to the water outlet.

(b) w/ Stud Bolt:

	Bolt
	Bolt or Nut

(1) Install the water outlet to the cylinder head sub-assembly and cylinder head LH with the 4 bolts and 2 nuts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) w/o Stud Bolt:

(1) Install the water outlet to the cylinder head sub-assembly and cylinder head LH with the 6 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

62. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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63. INSTALL CRANKSHAFT POSITION SENSOR

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64. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR

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65. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

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66. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

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67. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

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68. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

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69. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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70. INSTALL WATER BY-PASS HOSE

(a) Install the water by-pass hose to the water inlet pipe and water inlet with thermostat sub-assembly and slide the 2 clips to secure it.

71. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using an E8 "TORX" socket wrench, install the 2 stud bolts to the front No. 1 engine mounting bracket LH. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

*a 14 mm (0.551 in.) *b 13 mm (0.512 in.) *c 29 mm (1.14 in.)

(b) Install the front No. 1 engine mounting bracket LH to the timing chain cover assembly with the 7 bolts in the order shown in the illustration. Torque: 54 N·m {551 kgf·cm, 40 ft·lbf} NOTICE: Make sure that there is no oil on the threads of the bolts. Bolt Length: Item Length Bolt (A) 115 mm (4.53 in.) Bolt (B) 85 mm (3.35 in.) Bolt (C) 40 mm (1.57 in.)

72. INSTALL CRANKSHAFT PULLEY

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73. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to the cylinder block water drain cock sub-assembly. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTICE: Install the cylinder block water drain cock sub-assembly within 3 minutes of applying adhesive.

*a Adhesive

(b) Install the cylinder block water drain cock sub-assembly to the cylinder block sub-assembly as shown in the illustration. Torque: 25 N·m {255 kgf·cm, 18 ft·lbf} NOTICE: Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening it to the specified torque. Do not loosen the cylinder block water drain cock sub-assembly after setting it to the correct position.

*a 20° *b 12°

(c) Install the cylinder block water drain cock plug to the cylinder block water drain cock sub-assembly.

Torque:

12.7 N·m {130 kgf·cm, 9 ft·lbf}

74. INSTALL TAPER SCREW PLUG (w/ Taper Screw Plug)

(a) Apply adhesive to the taper screw plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTICE: Install the taper screw plug within 3 minutes of applying adhesive.

*a Adhesive

(b) Install the taper screw plug to the cylinder block sub-assembly. Torque: 25 N·m {255 kgf·cm, 18 ft·lbf}

75. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

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76. INSTALL SPARK PLUG

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77. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install a new oil filler cap gasket to the oil filler cap sub-assembly.

(b) Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly LH.

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