ENGINE UNIT(w/ Glow Plug Controller) REASSEMBLY
PROCEDURE
INSTALL OIL PAN SUB-ASSEMBLY
Remove any old packing material from the contact surface.
Apply seal packing to the oil pan sub-assembly in a continuous line as shown in the illustration.
*a
Seal Packing
*b
Straight Pin Hole
Standard Seal Packing Diameter
Area
Bead Size
mm (in.)
A - A
2.0 to 3.0
(0.0787 to 0.118)
B - B
Width: 7.0 (0.276) or more
Height: 3.0 (0.118) or more
Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Note:If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.
When applying seal packing, make sure that it does not enter the 2 straight pin holes.
Install the oil pan sub-assembly within 3 minutes, and tighten the bolts within 10 minutes of applying the seal packing.
-
Install and uniformly tighten the 12 bolts in several steps in the order shown in the illustration.
21 N*m
214 kgf*cm
15 ft.*lbf
Bolt Length
Bolt
Length
(A)
35 mm (1.38 in.)
(B)
143.7 mm (5.66 in.)
(C)
119 mm (4.69 in.)
Note:Wipe away any seal packing that is protruding from the front surface of the cylinder block sub-assembly before the seal packing hardens.
INSTALL ENGINE REAR OIL SEAL
INSTALL ENGINE OIL LEVEL SENSOR
-
Temporarily tighten the engine oil level sensor to the oil pan sub-assembly with the 5 bolts.
Fully tighten the 4 bolts (A) first, and then the bolt (B).
11 N*m
112 kgf*cm
8 ft.*lbf
-
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
Remove any old packing material from the contact surface.
-
*a
Seal Packing
Apply seal packing (diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.)) to the No. 2 oil pan sub-assembly in a continuous line as shown in the illustration.
Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Note:Remove any oil from the contact surfaces.
Install the No. 2 oil pan sub-assembly within 3 minutes, and tighten the bolts and nuts within 10 minutes of applying the seal packing.
Do not start the engine for at least 2 hours after installing the No. 2 oil pan sub-assembly.
Temporarily tighten the No. 2 oil pan sub-assembly to the oil pan sub-assembly with the 10 bolts and 2 nuts.
-
Fully tighten the 10 bolts and 2 nuts as shown in the illustration.
9.0 N*m
92 kgf*cm
80 in.*lbf
Install a new oil pan drain plug gasket and oil pan drain plug.
38 N*m
387 kgf*cm
28 ft.*lbf
INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
Check and clean the oil filter bracket sub-assembly installation surface.
-
Install a new oil filter bracket gasket to the oil pan sub-assembly.
-
Install the oil filter bracket sub-assembly to the oil pan sub-assembly with the 2 bolts.
21 N*m
214 kgf*cm
15 ft.*lbf
INSTALL OIL COOLER ASSEMBLY
Check and clean the oil cooler assembly installation surface.
-
Install 2 new O-rings and a new gasket to the oil filter bracket sub-assembly.
-
*a
Nut and Plate Washer
Install the oil cooler assembly to the oil filter bracket sub-assembly with the 2 bolts, 2 nuts and 2 plate washers.
21 N*m
214 kgf*cm
15 ft.*lbf
INSTALL OIL FILTER ELEMENT
INSTALL CYLINDER BLOCK WATER JACKET SPACER
-
Install the cylinder block water jacket spacer to the cylinder block sub-assembly.
-
INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY
Place the cylinder head sub-assembly on the cylinder block sub-assembly.
Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
-
*a
Paint Mark
*b
90°
Engine Front
Using several steps, install and uniformly tighten the 10 cylinder head set bolts and 10 plate washers in the order shown in the illustration. (*1)
50 N*m
510 kgf*cm
37 ft.*lbf
Mark the front of the 10 cylinder head set bolts with paint.
Using the same order as step (*1), tighten the 10 cylinder head set bolts an additional 90°.
Repeat the step above 2 more times as shown in the illustration.
Check that each paint mark is now 270° from the front.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
-
Apply engine oil to the valve stem end caps, No. 1 valve rocker arm sub-assembly pivot top surfaces and No. 1 valve rocker arm sub-assembly roller portions.
Install the 8 No. 1 valve rocker arm sub-assemblies to the cylinder head sub-assembly.
-
INSTALL CAMSHAFT
INSTALL CHAIN DAMPER SPRING
-
Install the chain damper spring to the chain tensioner plate.
-
INSTALL NO. 2 CHAIN SUB-ASSEMBLY
-
*a
TDC Mark
*b
Key
*c
Oil Pump Shaft
*d
Flat side faces left
Align the key with the TDC mark on the cylinder block sub-assembly.
Rotate the oil pump shaft so that the flat side faces left when viewing the cylinder block sub-assembly from the front.
-
*1
Oil Pump Drive Gear
*2
Oil Pump Drive Shaft Gear
*a
Timing Mark
*b
Orange Mark Plate
Align the orange mark plates with the timing mark of each gear as shown in the illustration.
-
Install the oil pump drive gear and oil pump drive shaft gear to the crankshaft and oil pump shaft with the No. 2 chain sub-assembly wrapped on the oil pump drive gear and oil pump drive shaft gear.
-
Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
30 N*m
306 kgf*cm
22 ft.*lbf
-
*1
Chain Tensioner Plate
*2
Chain Damper Spring
*a
Pin
*b
Pivot Hole
Install the chain tensioner plate with the chain damper spring to the pin.
Note:Push the chain tensioner plate so that the area around the pivot hole reaches the base of the pin.
The end of the chain damper spring should contact the side of the oil pan sub-assembly so that tension is applied to the No. 2 chain sub-assembly.
-
*a
Timing Mark
*b
Orange Mark Plate
*c
TDC Mark
*d
Key
Check that the orange mark plates and timing marks are in the positions shown in the illustration.
-
INSTALL CHAIN SUB-ASSEMBLY
-
*a
Straight Pin
Turn the camshaft to set the straight pin in the position shown in the illustration.
-
*a
TDC Mark
*b
Key
Turn
Turn the crankshaft to set the key in the position shown in the illustration.
-
*a
Timing Mark
*b
Pink Mark Plate
*c
Yellow Mark Plate
Align the 2 yellow mark plates with the timing mark on the camshaft timing sprocket, and the pink mark plate with the timing mark on the crankshaft timing sprocket.
Install the camshaft timing sprocket and crankshaft timing sprocket to the camshaft and crankshaft with the chain sub-assembly wrapped on the camshaft timing sprocket and crankshaft timing sprocket.
-
Using SST, fix the camshaft timing sprocket, and install the camshaft timing sprocket and sensor plate to the camshaft with the 3 bolts.
09960-10010
09962-01000
09963-01000
20 N*m
204 kgf*cm
15 ft.*lbf
Note:Check that the contact surfaces of the No. 2 crank angle sensor plate and camshaft timing sprocket are securely contacting, and then tighten the bolt.
-
INSTALL NO. 1 CHAIN VIBRATION DAMPER
-
Using an 8 mm socket hexagon wrench, install the chain vibration damper to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.
21 N*m
214 kgf*cm
15 ft.*lbf
-
INSTALL CHAIN TENSIONER SLIPPER
-
Install the chain tensioner slipper to the cylinder head sub-assembly.
-
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
-
*a
Plunger
*b
Groove
*c
Hole
Push
Push in the plunger until the groove is aligned with the hole, and then insert a 1.1 mm (0.0433 in.) diameter bar.
-
Install the No. 1 chain tensioner assembly with the 2 bolts.
21 N*m
214 kgf*cm
15 ft.*lbf
Remove the 1.1 mm (0.0433 in.) diameter bar from the No. 1 chain tensioner assembly.
-
*a
Timing Mark
*b
Pink Mark Plate
*c
Yellow Mark Plate
Check that the mark plates and timing marks are in the positions shown in the illustration.
-
INSTALL WATER INLET HOUSING
-
Install a new No. 2 water inlet housing gasket to the water inlet housing.
-
Install the water inlet housing to the timing chain cover sub-assembly with the 3 bolts.
9.0 N*m
92 kgf*cm
80 in.*lbf
Note:Do not reuse the water inlet housing if it has been dropped.
-
INSTALL OIL CHECK VALVE SUB-ASSEMBLY
-
Using a 5 mm hexagon wrench, install the oil check valve sub-assembly to the timing chain cover sub-assembly with the bolt.
9.0 N*m
92 kgf*cm
80 in.*lbf
-
INSTALL TIMING CHAIN COVER OIL SEAL
-
*a
-0.6 to 0 mm (-0.0236 to 0 in.)
Using SST and a hammer, tap in a new timing chain cover oil seal until its surface is flush with the timing chain cover sub-assembly edge.
09223-22010
Timing Chain Cover Oil Seal Tap in Depth
-0.6 to 0 mm (-0.0236 to 0 in.)
Note:Keep the timing chain cover oil seal lip free from foreign matter.
Do not tap in the timing chain cover oil seal at an angle.
Apply MP grease to the timing chain cover oil seal lip.
Note:Keep the lip free of foreign matter.
-
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
-
Install a new oil pump gasket to the oil pan sub-assembly.
Remove any old packing material from the contact surface.
Apply seal packing to the engine body and timing chain cover sub-assembly as shown in the illustration below.
*a
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
*b
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
*c
27 mm (1.06 in.)
*d
24 mm (0.945 in.)
*e
26 mm (1.02 in.)
-
-
Seal Packing
Engine water pump assembly part: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Other part: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Note:Remove any oil from the contact surfaces.
Install the timing chain cover assembly within 3 minutes, and tighten the bolts within 10 minutes of applying the seal packing.
Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.
Tip:Areas A - A, B - B and C - C are the joints between the cylinder block sub-assembly and cylinder head sub-assembly, and the cylinder block sub-assembly and oil pan sub-assembly.
Application Specification
Area
Seal Packing Diameter
Seal Packing Dimension
Seal Packing Application Length
Continuous Line Area Except A - A, B - B, C - C and D
3.5 to 4.5 mm (0.138 to 0.177 in.)
-
-
Dashed Line Area
3.5 to 4.5 mm (0.138 to 0.177 in.)
-
-
A - A
-
Width: 15 mm (0.591 in.) Height: 4.5 mm (0.177 in.)
27 mm (1.06 in.)
B - B
-
Width: 7.0 mm (0.276 in.) Height: 3.5 mm (0.138 in.)
24 mm (0.945 in.)
C - C
-
Width: 7.0 mm (0.276 in.) Height: 3.5 mm (0.138 in.)
26 mm (1.02 in.)
D
3.0 to 4.0 mm (0.118 to 0.157 in.): Double Line Area
-
45.1 mm (1.78 in.)
E - E
3.5 to 4.5 mm (0.138 to 0.177 in.)
-
-
Install the timing chain cover sub-assembly to the cylinder head sub-assembly, cylinder block sub-assembly and oil pan sub-assembly with the 20 bolts and 2 nuts, in the order shown in the illustration.
*a
Torque
*b
Tightening Order
*c
Nut
-
-
Bolt (A), (B), Nut
18 N*m
184 kgf*cm
13 ft.*lbf
Bolt (C)
31 N*m
316 kgf*cm
23 ft.*lbf
Bolt Length
Bolt
Length
(A)
25 mm (0.984 in.)
(B), (C)
40 mm (1.57 in.)
Note:Make sure that the chain sub-assembly does not come into contact with the seal packing when installing the timing chain cover sub-assembly.
Install the engine mounting bracket RH and engine water pump assembly within 10 minutes of installing the timing chain cover sub-assembly.
-
Apply a light coat of engine oil to the O-ring of the oil pressure switching valve assembly.
Note:If reusing the oil pressure switching valve assembly, be sure to inspect the O-ring.
-
Install the oil pressure switching valve assembly to the timing chain cover sub-assembly with the bolt.
9.0 N*m
92 kgf*cm
80 in.*lbf
Note:If a component has been dropped or subjected to a strong impact, replace the oil pressure switching valve assembly.
Make sure that the O-ring is not damaged or does not jump out of position during installation.
-
INSTALL CAMSHAFT POSITION SENSOR
-
Apply a light coat of engine oil to the O-ring of the camshaft position sensor.
Note:If reusing the camshaft position sensor, be sure to inspect the O-ring.
Install the camshaft position sensor to the timing chain cover sub-assembly with the bolt.
7.0 N*m
71 kgf*cm
62 in.*lbf
Note:If a component has been dropped or subjected to a strong impact, replace the camshaft position sensor.
Make sure that the O-ring is not damaged or does not jump out of position during installation.
-
INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
INSTALL NO. 2 TIMING CHAIN COVER
-
Install the No. 2 timing chain cover to the timing chain cover assembly.
Install the manifold temperature sensor bracket to the timing chain cover sub-assembly with the bolt.
9.0 N*m
92 kgf*cm
80 in.*lbf
-
INSTALL ENGINE MOUNTING BRACKET RH
-
Temporarily tighten the engine mounting bracket RH to the timing chain cover sub-assembly with the 4 bolts.
Bolt Length
Bolt
Length
(A)
55 mm (2.17 in.)
(B)
70 mm (2.76 in.)
Fully tighten the 4 bolts in the order shown in the illustration.
55 N*m
561 kgf*cm
41 ft.*lbf
-
CHECK VALVE CLEARANCE
ADJUST VALVE CLEARANCE
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
-
Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
Note:Remove any oil from the contact surface.
Check that the cylinder head cover gasket is securely installed into the groove of the cylinder head cover sub-assembly.
Remove any old packing material from the contact surface.
-
Seal Packing
Apply seal packing to the 6 locations shown in the illustration.
Seal Packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Note:If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.
Install the cylinder head cover sub-assembly within 3 minutes, and tighten the bolts within 10 minutes of applying the seal packing.
-
Temporarily install the cylinder head cover sub-assembly to the cylinder head sub-assembly with the 11 bolts and nut.
Temporarily tighten the bolt (A).
Fully tighten the 11 bolts and nut, in the order shown in the illustration.
10 N*m
102 kgf*cm
7 ft.*lbf
-
INSTALL OIL FILLER CAP SUB-ASSEMBLY
-
Install the oil filler cap gasket to the oil filler cap sub-assembly.
-
Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
-
INSTALL OIL PRESSURE SENDER GAGE ASSEMBLY
INSTALL WATER INLET
-
Install a new No. 1 water inlet housing gasket to the water inlet.
-
Install the water inlet to the water inlet housing with the 3 bolts.
9.0 N*m
92 kgf*cm
80 in.*lbf
Note:Do not reuse the water inlet if it has been dropped.
-
INSTALL WATER OUTLET SUB-ASSEMBLY
-
Install a new water outlet gasket to the cylinder head sub-assembly.
-
Install the water outlet sub-assembly to the cylinder head sub-assembly with the 3 bolts and 2 nuts.
11 N*m
112 kgf*cm
8 ft.*lbf
-
INSTALL ENGINE COOLANT TEMPERATURE SENSOR