Part 2

ENGINE UNIT

COMPONENTS (Part 1) (for Bank 1):

COMPONENTS (Part 2) (for Bank 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4) (for 2WD):

COMPONENTS (Part 5) (for 4WD):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8) (for Bank 1):

COMPONENTS (Part 9) (for Bank 2):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

REASSEMBLY Continued

12. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.

13. INSTALL VALVE STEM OIL SEAL

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

NOTICE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

HINT: The intake valve oil seals are gray and the exhaust valve oil seals are black.

(b) Using SST, push in the oil seals.
SST 09201-41020

NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated.

14. INSTALL INTAKE VALVE

(a) Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to original locations.

(d) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the retainer.

15. INSTALL EXHAUST VALVE

(a) Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to their original locations.

(d) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the retainer.

16. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the valve stem caps to the cylinder head.

17. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY
(a) Install the water outlet pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

18. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to slightly before TDC.

(b) Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter: 2.5 to 3.0 mm (0.098 to 0.118 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head gasket within 3 minutes after applying the seal packing.
^ Do not apply engine oil within 2 hours of installation.

(c) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

NOTICE:
^ Be careful of the installation direction.
^ Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder head.

(d) Place the cylinder head on the cylinder block.

NOTICE: Ensure that no oil is on the mounting surface of the cylinder head.

HINT: The cylinder head bolts are tightened in 3 progressive steps.

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

(f) 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)

(g) 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.
(h) Step 3:
(1) Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.
(2) Check that the painted marks are now facing rearward.

For Engine Front Side:

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

19. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to slightly before TDC.

(b) Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter: 2.5 to 3.0 mm (0.098 to 0.118 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head gasket within 3 minutes after applying the seal packing.
^ Do not apply engine oil within 2 hours of installation.

(i) Install the 2 bolts in the order shown in the illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

For Engine Front Side:

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

20. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Be sure to inspect the valve lash adjuster before installing it.
(b) Install the lash adjusters.

NOTICE: Install each lash adjuster to the same place it was removed from.

21. INSTALL NO. 1 VALVE ROCKER ARM SUBASSEMBLY
(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.

(b) Install the valve rocker arms.

NOTICE: Make sure that the valve rocker arms are installed as shown in the illustration.

22. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the camshaft and No. 2 camshaft to the camshaft housing.

(c) Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper position and direction.

(d) Uniformly install the 9 bolts in several steps in the order shown in the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

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

(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: 3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the camshaft housing 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 the installation.

(b) Uniformly install the camshaft housing, and install the 14 bolts in several steps in the order shown in the illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)

NOTICE: Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

(c) Uniformly install the 9 bolts in several steps in the order shown in the illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)

NOTICE: Thoroughly wipe clean any seal packing.

(d) Install 3 new gaskets.

24. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing.
(c) Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper position and direction.

(d) Uniformly install the 8 bolts in several steps in the order shown in the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

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

(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: 5.0 to 5.5 mm (0.197 to 0.217 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the camshaft housing 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 the installation.

(b) Uniformly install the camshaft housing and tighten the 13 bolts in several steps in the order shown in the illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)

NOTICE: Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

(c) Uniformly install the 8 bolts in several steps in the order shown in the illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)

NOTICE: Thoroughly wipe clean any seal packing.

(d) Install 3 new gaskets.

26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the 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 diameter 1.0 mm (0.039 in.) into the hole to fix it in place.

27. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) Align the mark plates (yellow) of the No. 2 chain with the timing marks (1 dot mark) of the camshaft timing gears as shown in the illustration.
(b) Apply a small amount 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. Install the camshaft timing gear and camshaft timing exhaust gear with the No. 2 chain installed.

(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.

28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the 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 diameter 1.0 mm (0.039 in.) into the hole to fix it in place.

29. INSTALL 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 in the illustration.
(b) Apply a small amount 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. Install the camshaft timing gear and camshaft timing exhaust gear with the No. 2 chain installed.

(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.