Reassembly
1UR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL OIL PAN STUD BOLT
NOTICE:
If a stud bolt is deformed or the threads are damaged, replace it.
(a) for 2WD:
Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) for AWD:
Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
2. INSTALL NO. 1 VENTILATION CONNECTOR
(a) Install the No. 1 ventilation connector as shown in the illustration.
Acceptable angle (A):
-5 to 5°
Tap-in depth (B):
0.2 to 3.2 mm (0.008 to 0.126 in.)
NOTICE:
After the installation of the ventilation connector, do not rotate it.
HINT
Connect the No. 1 ventilation connector so that its flat surface faces the rear part of the engine.
3. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the O-ring to the drain pipe.
(c) Install the oil drain pipe with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL ENGINE REAR 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
Standard seal diameter:
2.0 to 3.0 mm (0.079 to 0.118 in.)
Application position from inside edge of retainer:
3.5 mm (0.138 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
* When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.
* When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.
(b) Install the oil seal retainer with the 6 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL OIL STRAINER SUB-ASSEMBLY (for 2WD)
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the O-ring to the oil strainer.
(c) Install the oil strainer with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
Make sure the O-ring is not twisted or damaged.
6. INSTALL NO. 2 OIL PAN BAFFLE PLATE (for AWD)
(a) Install the baffle plate with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
7. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) for 2WD:
Install the baffle plate with the 8 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for AWD:
Install the baffle plate with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
8. INSTALL OIL PAN SUB-ASSEMBLY (for 2WD)
(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:
3.0 to 4.0 mm (0.118 to 0.157 in.)
Application position from inside edge of oil pan:
6.0 mm (0.236 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
(b) Install the oil pan with the 14 bolts and 2 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for bolt A
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf) for bolt B
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf) for nut
NOTICE:
Do not start the engine for at least 2 hours after installing.
9. INSTALL OIL PAN PROTECTOR (for 2WD)
(a) Install the protector with the 2 nuts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
HINT
Install the oil pan protector with its protrusion facing the bottom of the engine.
10. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) for 2WD:
(1) 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:
3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(2) Install the oil pan with the 15 bolts and 2 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for AWD:
(1) 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:
3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
(2) Install the oil pan with the 13 bolts and 2 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
Do not start the engine for at least 2 hours after installing.
11. INSTALL VENTILATION PIPE GASKET
(a) Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.
SST : 09950-60010
09951-00360
SST : 09950-70010
09951-07100
NOTICE:
* Do not tap the gasket at an angle.
* Do not tap the gasket excessively.
12. INSTALL NO. 1 HEAT EXCHANGER COVER
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
(b) Install the heat exchanger cover with the 11 bolts and 2 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
Do not start the engine for at least 2 hours after installing.
(c) Install the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
13. INSTALL OIL RETURN PIPE GASKET
(a) Install a new oil return pipe gasket.
14. INSTALL CYLINDER BLOCK WATER JACKET SPACER
(a) Install the 2 water jacket spacers as shown in the illustration.
HINT
* Face the cutouts (indicated by arrows in illustration) away from the engine.
* Face the "UP" mark as shown in the illustration.
15. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1) Installation
16. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2) Installation
17. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the 32 valve stem caps to the cylinder head.
18. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Be sure to inspect the valve lash adjuster before installing it Engine Unit.
(b) Install the 32 valve lash adjusters to the cylinder head.
NOTICE:
Install the lash adjuster at the same place it was removed from.
19. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.
(b) Make sure that the 32 valve rocker arms are installed as shown in the illustration.
20. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation
21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1) Installation
22. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation
23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2) Installation
24. INSTALL CRANKSHAFT TIMING GEAR KEY
(a) Install the 2 timing gear keys.
25. SET NO. 1 CYLINDER TO TDC / COMPRESSION Installation
26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Installation
27. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2) Installation
28. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2) Installation
29. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2) Installation
30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2) Installation
31. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Installation
32. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1) Installation
33. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1) Installation
34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) Installation
35. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) Installation
36. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY Installation
37. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION Installation
38. INSTALL WATER INLET PIPE Installation
39. INSTALL WATER PUMP ASSEMBLY Installation
40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
41. INSTALL OIL CONTROL VALVE FILTER
(a) for Bank 1:
(1) Install the valve filter in the cylinder head.
(2) Install a new gasket and the cylinder head cover spacer with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for Bank 2:
(1) Install the valve filter in the cylinder head.
(2) Install a new gasket and the cylinder head cover spacer with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3, No. 7).
(b) Install a new gasket to the cylinder head cover.
NOTICE:
Remove any oil from the contact surface.
(c) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head 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 the installation.
(d) Install the cylinder head cover with 2 new seal washers and the 15 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for bolt A
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) for except bolt A
(e) Install a new fuel pump spacer gasket.
43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 1, No. 3, No. 6).
(b) Install a new gasket to the cylinder head cover.
NOTICE:
Remove any oil from the contact surface.
(c) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head 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 the installation.
(d) Install the cylinder head cover with 2 new seal washers and the 15 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for bolt A
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) except bolt A
(e) Install a new fuel pump spacer gasket.
44. INSTALL SPARK PLUG TUBE GASKET
(a) Perform a visual inspection on the spark plug tube gasket.
OK:
(b) Install the 8 plug tube gaskets to the cylinder head covers.
45. INSTALL TIMING CHAIN CASE OIL SEAL Replacement
46. INSTALL CRANKSHAFT PULLEY Installation
47. INSTALL FRONT WATER BY-PASS JOINT
(a) Install the 2 new gaskets and water by-pass joint with the 4 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
48. INSTALL OIL FILTER BRACKET (for 2WD) Installation
49. INSTALL OIL FILTER BRACKET (for AWD) Installation
50. INSTALL OIL FILTER ELEMENT (for 2WD) Replacement
51. INSTALL OIL FILTER ELEMENT (for AWD) Replacement
52. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the drain cock.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the water drain cocks as shown in the illustration.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTICE:
* Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
* Do not loosen the drain cocks to adjust them. If an adjustment is necessary, remove the drain cocks and reinstall them.
(c) Install the water drain cock plugs to the water drain cocks.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
53. INSTALL CAMSHAFT TIMING CONTROL MOTOR LH Installation
54. INSTALL CAMSHAFT TIMING CONTROL MOTOR RH Installation
55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) for Bank 1:
(1) Apply a light coat of engine oil to a new O-ring.
(2) Install the O-ring to the oil control valve.
(3) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for Bank 2:
(1) Apply a light coat of engine oil to a new O-ring.
(2) Install the O-ring to the oil control valve.
(3) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
56. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
57. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the camshaft position sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
58. INSTALL VVT SENSOR
(a) for Bank 1:
(1) Install the 2 VVT sensors with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for Bank 2:
(1) Install the 2 VVT sensors with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
59. INSTALL SPARK PLUG Installation
60. INSTALL OIL FILLER CAP HOUSING
(a) Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing.
(b) Install the cap housing with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
61. INSTALL OIL FILLER CAP SUB-ASSEMBLY