Repair Procedure: Reassembly

Reassemble the engine.

1. Install the camshaft bearing cap (for bank 1).

A. Apply engine oil to the camshaft journals, camshaft housing, and bearing caps.

B. Install the camshaft and No. 2 camshaft to the camshaft housing RH.





C. Note the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.





D. Temporarily tighten the 8 bolts in the order shown.

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

2. Install the camshaft housing sub-assembly RH.





A. Make sure that the valve rocker arm is installed as shown.





B. Apply seal packing in a continuous line as shown.

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

Seal diameter:
3.5 - 4.5 mm (0.138 - 0.177 in.)

NOTE

^ Remove any oil from the contact surface.

^ Install the camshaft housing sub-assembly RH within 3 minutes.

^ Do NOT start the engine for at LEAST 2 hours after installing.





C. Install the camshaft housing RH and tighten the 12 bolts in the order shown.

Torque: 28 N*m (286 kgf*cm, 21 ft*lbf)

NOTE

^ When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

^ If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.

^ If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does NOT enter any oil passages.





D. Tighten the 8 bolts in the order shown.

Torque: 16 N*m (163 kgf*cm, 12 ft*lbf)

3. Install the camshaft bearing cap (for bank 2).

A. Apply engine oil to the camshaft journals, camshaft housing, and bearing caps.

B. Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing LH.

C. Note the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.

D. Temporarily tighten the 8 bolts in the order shown.

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

4. Install the camshaft housing sub-assembly LH.





A. Make sure that the valve rocker arm is installed as shown.





B.10Apply seal packing in a continuous line as shown.

Seal packing:

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

Seal diameter:

3.5 - 4.5 mm (0.138 - 0.177 in.)

NOTE

^ Remove any oil from the contact surface.

^ Install the camshaft housing sub-assembly RH within 3 minutes.

^ Do NOT start the engine for at LEAST 2 hours after installing.





C. Install the camshaft housing LH and tighten the 13 bolts in the order shown.

Torque: 28 N*m (286 kgf*cm, 21 ft*lbf)

NOTE

^ When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.

^ If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.

^ If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does NOT enter any oil passages.





D. Tighten the 8 bolts in the order shown.

Torque: 16 N*m (163 kgf*cm, 12 ft*lbf)

5. Install the No. 2 chain tensioner assembly.

A. Install the No. 2 chain tensioner with the bolt.

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





B. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) diameter into the hole to hold it.

6. Install the camshaft timing gears and No. 2 chain (for bank 1).





A. Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown.

B. Apply a light coat of engine oil to the bolt threads and bolt seating surface.

C. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear.

D. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed.





E. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

Torque: 100 N*m (1,020 kgf*cm, 74 ft*lbf)

F. Remove the pin from the chain tensioner.

7. Install the No. 3 chain tensioner assembly.

A. Install the No. 3 chain tensioner with the bolt.

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





B. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 in.) diameter into the hole to hold it.

8. Install the camshaft timing gears and No. 2 chain (for bank 2).





A. Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown.

B. Apply a light coat of engine oil to the bolt threads and bolt seating surface.

C. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear.

D. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed.





E. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

Torque: 100 N*m (1,020 kgf*cm, 74 ft*lbf)

F. Remove the pin from the chain tensioner.

9. Install the chain sub-assembly.

A. Align the mark plate and timing marks as shown and install the chain.

HINT

The camshaft mark plate is orange.





B. Do NOT pass the chain over the crankshaft at this time.





C. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.

NOTE

When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

D. Align the mark plate and timing mark as shown and install the chain onto the crankshaft timing sprocket.

HINT

The crankshaft mark plate is yellow.

E. Temporarily tighten the pulley set bolt.





F. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

10. Install the chain tensioner slipper.

11. Install the No. 1 chain tensioner assembly.





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 N*m (102 kgf*cm, 7 ft*lbf)





D. Remove the hexagon wrench of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC/compression.

E. Remove the pulley set bolt.





12. Install the timing chain case oil seal. Using the SST, tap in a NEW oil seal until its surface is flush with the timing gear case edge. SST P/N: 09223-22010, 09506-35010

NOTE

^ Keep the lip free of foreign matter.

^ Do NOT tap on the oil seal at an angle.

^ Make sure that the oil seal edge does NOT stick out of the timing chain case.





13. Install the water pump assembly. Install a NEW gasket and the water pump with the 8 bolts.

Torque: 9.1 N*m (93 kgf*cm, 81 in*lbf)

NOTE

Be sure to replace the bolts indicated by "A" with NEW ones or reuse them after applying Toyota Genuine Adhesive 1344, Three Bond 1344, or equivalent.





14. Install the timing chain cover sub-assembly.

A. Apply seal packing in a continuous line to the engine unit as shown below.

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

Seal diameter:
3.0 mm (0.118 in.)

NOTE

^ Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by "C" in Figure 77.

^ When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

^ Install the chain cover within 3 minutes.

^ Do NOT start the engine for at LEAST 2 hours after installing.





B. Apply seal packing in a continuous line to the timing chain cover as shown below.

NOTE

^ When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

^ Install the chain cover 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.





Apply seal packing as shown.





C. Install a NEW gasket.





D. Align the oil pump's drive rotor spline and the crankshaft as shown. Install the spline and chain cover to the crankshaft.





E. Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

NOTE

Make sure that there is NO oil on the bolt threads.

F. Fully tighten the bolts in this order: Area 1 and Area 2.

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

G. Fully tighten the bolts in this order: Area 3.

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

HINT

Tighten the bolts and nuts in the order as shown in Figure 81.

H. Fully tighten the bolts in this order: Area 4.

Torque:
Bolt A:
43 N*m (438 kgf*cm, 32 ft*lbf)

Torque:
Except Bolt A:
21 N*m (214 kgf*cm, 15 ft*lbf)

HINT

Tighten the bolts and nuts in the order as shown in Figure 81.

I. Install a NEW gasket and the chain cover plate with the 4 bolts.

Torque: 9.1 N*m (93 kgf*cm, 81 in*lbf)

15. Install the water inlet housing.





A. Install 2 NEW O-rings.

HINT

Apply a small amount of water or soapy water to O-ring "A" shown before installing it.





B. Install the water inlet with the 2 bolts and nut.

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

NOTE

Be careful that the O-ring does NOT get caught between the parts.





16. Install the front engine mounting bracket No. 1 LH.

Install the engine mounting bracket with the 6 bolts.

Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)

NOTE

^ Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.

^ Do NOT start the engine for at LEAST 2 hours after installation.

17. Install the oil pan sub-assembly.





A. Install 2 NEW O-rings.

B. Apply seal packing in a continuous line as shown.

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

Seal diameter:
3.0 mm (0.118 in.)

NOTE

^ 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.





C. Install the oil pan with the 16 bolts and 2 nuts.

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

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





18. Install the oil strainer sub-assembly.

Install a NEW gasket and the oil strainer with the bolt and 2 nuts.

Torque: 10 N*m (41 kgf*cm, 7 ft*lbf)





19. Install the No. 2 oil pan sub-assembly.

A. Apply seal packing in a continuous line as shown.

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

Seal diameter:
3.0 4.0 mm (0.118 0.156 in.)

NOTE

^ Remove any oil from the contact surface.

^ Install the oil pan No. 2 within 3 minutes after applying seal packing.

^ Do NOT start the engine for at LEAST 2 hours after installing.





B. Install the oil pan with the 16 bolts and 2 nuts.

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

20. Install the cylinder head cover sub-assembly (for bank 1).





A. Apply seal packing as shown.

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

NOTE

^ 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 installing.





B. Install 3 NEW gaskets as shown.

C. Install a NEW gasket to the head cover.





D. Install a head cover with the 12 bolts and a NEW washer.

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

Torque:
Except Bolt A:
10 N*m (102 kgf*cm, 7 ft*lbf)

HINT

Reconfirm the tightening torque of bolt 1.

21. Install the cylinder head cover sub-assembly (for bank 2).





A. Apply seal packing as shown.

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

NOTE

^ 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 installing.





B. Install 3 NEW gaskets as shown.

C. Install a NEW gasket to the head cover.





D. Install the head cover with the 12 bolts and a NEW washer.

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

Torque:
Except Bolt A:
10 N*m (102 kgf*cm, 7 ft*lbf)

HINT

Reconfirm the tightening torque of bolts 1 and 10.

22. Install the crankshaft pulley.

A. Align the pulley set key with the key groove of the pulley, and slide on the pulley.





B. Using the SST, install the pulley bolt.

SST P/N: 09213-70011 (09213-70020), 09330-00021

Torque: 250 N*m (2550 kgf*cm, 184 ft*lbf)

23. Install the oil filter element.





A. Clean the inside of the oil filter cap, the threads, and O-ring groove.

GB. Apply a light coat of engine oil to a NEW O-ring and install it to the oil filter cap (P/N 90301-79006).

C. Set a NEW oil filter element to the oil filter cap.

D. Remove dirt or foreign matter from the installation surface of the engine.

E. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.

NOTE

^ Be careful that the O-ring does NOT get caught between the parts.

^ The O-ring must NOT be twisted on the groove.





F. Using the SST, tighten the oil filter cap.

SST P/N: 09228-06501

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

NOTE

Make sure that the oil filter is installed securely as shown.





G. Apply a light coat of engine oil to a NEW O-ring and install it to the oil filter cap (P/N 96723-35028).

NOTE

Remove all dirt and foreign matter from the installation surface.

H. Install the oil filter drain plug to the oil filter cap.

Torque: 13 N*m (130 kgf*cm, 9 ft*lbf)

NOTE

Make sure that the O-ring does NOT get caught between the parts.

24. Install the No. 1 oil pipe.

A. Make sure that there is NO foreign matter on the mesh of the oil control valve filter LH.

NOTE

Do NOT touch the mesh when installing the oil control valve filter.





B. Install the oil control valve filter LH to the oil pipe union. Install NEW gaskets and temporarily install the oil pipe (on the head cover side).

C. Install a NEW gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

D. Tighten the oil pipe union (on the head cover side).

Torque: 65 N*m (663 kgf*cm, 48 ft*lbf)

E. Tighten the oil pipe union (on the cylinder head side).

Torque: 65 N*m (663 kgf*cm, 48 ft*lbf)

NOTE

If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

25. Install the oil pipe.

A. Make sure that there is NO foreign matter on the mesh of the oil control valve filter RH.

NOTE

Do NOT touch the mesh when installing the oil control valve filter.





B. Install the oil control valve filter RH to the oil pipe union. Install NEW gaskets and temporarily install the oil pipe (on the head cover side).

C. Install a NEW gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

D. Install bolt "A" to the cylinder head.

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

E. Tighten the oil pipe union (on the head cover side).

Torque: 65 N*m (663 kgf*cm, 48 ft*lbf)

F. Tighten the oil pipe union (on the cylinder head side).

Torque: 65 N*m (663 kgf*cm, 48 ft*lbf)

NOTE
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

26. Reinstall the engine assembly.

Refer to TIS, 2007 model year ES 350 Repair Manual, Engine/Hybrid System - Engine Mechanical - "2GR-FE Engine Mechanical: Engine Assembly: Installation".