ENGINE UNIT REASSEMBLY

INSTALL STIFFENING CRANKCASE RING PIN

*1	Protrusion Height
*2	Width
*3	Height

Note:

It is not necessary to remove a ring pin unless it is being replaced.

Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

Standard Ring Pin


Protrusion Height	Height	Width
3.0 mm (0.118 in.)	11 mm (0.433 in.)	8.0 mm (0.315 in.)

Tip:

The amount of protrusion may vary, but 3.0 mm (0.118 in.) is typical.

INSTALL STUD BOLT

Note:

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

*a	23 mm (0.906 in.)
*b	9.0 mm (0.354 in.)

Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

5.0 N*m

51 kgf*cm

44 in.*lbf

*a	21 mm (0.827 in.)
*b	9.0 mm (0.354 in.)
*c	34 mm (1.34 in.)

Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

5.0 N*m

51 kgf*cm

44 in.*lbf

*a	12 mm (0.472 in.)
*b	9.0 mm (0.354 in.)
*c	23 mm (0.906 in.)

Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration.

5.0 N*m

51 kgf*cm

44 in.*lbf

INSTALL STIFFENING CRANKCASE ASSEMBLY

*1	Seal Packing

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


Area	Specified Condition
except Area A	2.0 to 3.0 mm (0.0787 to 0.118 in.)
for Area A	4.5 to 5.5 mm (0.177 to 0.217 in.)

Application Length A

56 mm (2.20 in.)

Note:

Remove any oil from the contact surfaces.
Install the crankcase 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 the stiffening crankcase assembly.

Install the stiffening crankcase with the 11 bolts in the sequence shown in the illustration.

21 N*m

214 kgf*cm

15 ft.*lbf

Bolt Length


Item	Specified Condition
Bolt A	138 mm (5.43 in.)
Bolt B	35 mm (1.38 in.)
Bolt C	70 mm (2.76 in.)

Recheck the torque for bolts 1 and 2.

21 N*m

214 kgf*cm

15 ft.*lbf
Wipe off any excess seal packing with a clean piece of cloth.

INSTALL OIL PUMP ASSEMBLY

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INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

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INSTALL OIL PAN DRAIN PLUG

Install a new gasket and the oil pan drain plug.

37 N*m

377 kgf*cm

27 ft.*lbf

INSTALL ENGINE REAR OIL SEAL

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INSTALL NO. 1 TAPER SCREW PLUG

Clean the No. 1 taper screw plug and plug hole.
Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug. Then install the No. 1 taper screw plug.

Adhesive

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

25 N*m

255 kgf*cm

18 ft.*lbf
Note:
- Install the plug within 3 minutes of applying adhesive.
- Do not start the engine within 1 hour of installing the plug.

INSTALL PCV VALVE SUB-ASSEMBLY

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INSTALL CYLINDER HEAD GASKET

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INSTALL CYLINDER HEAD SUB-ASSEMBLY

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INSTALL VALVE STEM CAP

Apply a light coat of engine oil to the valve stem ends.
Install the 16 valve stem caps to the cylinder head.

Note:
Do not drop the valve stem caps into the cylinder head.

INSTALL VALVE LASH ADJUSTER ASSEMBLY

Inspect each valve lash adjuster before installing it.
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Install the 16 valve lash adjuster assemblies to the cylinder head.

Note:
Install the valve lash adjuster to the same place it was removed from.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

*1	Valve Rocker Arm
*2	Lash Adjuster
*3	Valve Stem
*4	Valve Stem Cap

Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

Make sure that the No. 1 valve rocker arm assemblies are installed as shown in the illustration.

INSTALL CAMSHAFT HOUSING STRAIGHT PIN

*1	Protrusion Height
*2	Height
*3	Width

Note:

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

Using a plastic-faced hammer, tap in a new straight pin to the specified protrusion height.

Standard Straight Pin


Protrusion Height	Height	Width
6.5 to 7.5 mm (0.256 to 0.295 in.)	14 mm (0.551 in.)	6.0 mm (0.236 in.)

INSTALL NO. 1 CAMSHAFT BEARING

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INSTALL OIL CONTROL VALVE FILTER

Check that no foreign matter is on the mesh part of the oil control valve filter.
Install the oil control valve filter.

Note:
Do not touch the mesh when installing the oil control valve filter.

INSTALL NO. 2 CAMSHAFT BEARING

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INSTALL NO. 2 CAMSHAFT

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INSTALL CAMSHAFT

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INSTALL CAMSHAFT BEARING CAP

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INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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INSTALL CRANKSHAFT TIMING GEAR KEY

Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

Tip:
Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Install the sensor plate with the "F" mark facing forward.

INSTALL NO. 2 CHAIN SUB-ASSEMBLY

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INSTALL CRANKSHAFT TIMING SPROCKET

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INSTALL NO. 1 CHAIN VIBRATION DAMPER

Install the No. 1 chain vibration damper with the 2 bolts.

21 N*m

214 kgf*cm

15 ft.*lbf

INSTALL NO. 2 CHAIN VIBRATION DAMPER

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SET NO. 1 CYLINDER TO TDC/COMPRESSION

Temporarily install the crankshaft pulley bolt.

*1	Timing Gear Key

Turn the crankshaft counterclockwise to position the timing gear key at the top.

*1	Timing Mark

Check that the timing marks on the camshaft timing gear and camshaft timing exhaust gear assembly are aligned as shown in the illustration.

Remove the crankshaft pulley bolt.

INSTALL CHAIN SUB-ASSEMBLY

*1	Mark Plate (Orange)
*2	Timing Mark
*a	Place the Chain on the Sprocket
*b	Pass the Chain through the Damper

Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain sub-assembly.

Tip:

Be sure to position the mark plate at the front of the engine.
The mark plate on the camshaft side is colored orange.
Do not engage the chain with the sprocket of the camshaft timing gear. Only place it on the camshaft timing gear.
Pass the chain through the No. 1 vibration damper.

Place the chain on the crankshaft without passing it around the shaft.

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plates (orange) and timing mark, and then install the chain sub-assembly.

*1	Mark Plate (Orange)	*2	Timing Mark
*a	Apply Tension to the Chain	*b	Turn

Tip:

To apply tension to the chain, slowly turn the camshaft timing gear assembly and camshaft timing exhaust gear assembly clockwise to prevent the chain sub-assembly from being misaligned.

*1	Timing Mark
*2	Mark Plate (Yellow)

Align the mark plate (yellow) and timing marks and install the chain sub-assembly to the crankshaft timing sprocket.

INSTALL CHAIN TENSIONER SLIPPER

CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

Check each timing mark with the No. 1 cylinder at TDC/compression.

*1	Timing Mark	*2	Mark Plate (Orange)
*3	Mark Plate (Yellow)	-	-

INSTALL NO. 1 GENERATOR BRACKET

Install the No. 1 generator bracket with the 4 bolts.

24 N*m

245 kgf*cm

18 ft.*lbf

INSTALL WATER INLET HOUSING

Install a new gasket and the water inlet housing with the 3 bolts.

21 N*m

214 kgf*cm

15 ft.*lbf

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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INSTALL TIMING CHAIN COVER OIL SEAL

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INSTALL ENGINE MOUNTING BRACKET STUD BOLT

Note:

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

Install the stud bolt.

10 N*m

102 kgf*cm

7 ft.*lbf

INSTALL CRANKSHAFT PULLEY

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INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

*1	Cam
*2	Hook
*3	Pin
*a	CORRECT
*b	INCORRECT
*c	Push
*d	Raise

Release the ratchet pawl. Then fully push in the plunger and attach the hook to the pin so that the plunger is in the position shown in the illustration.

Note:

Make sure that the cam engages with the first tooth of the plunger to allow the hook to pass over the pin.

Install a new gasket, the bracket and the No. 1 chain tensioner with the 2 nuts.

12 N*m

122 kgf*cm

9 ft.*lbf

Note:
If the hook becomes detached from the plunger while the chain tensioner is being installed, attach the hook again.

*1	Pin
*2	Hook
*a	Release
*b	Turn

Turn the crankshaft counterclockwise slightly and check that the hook is released.

*1	Plunger
*a	Plunger Extended
*b	Turn

Turn the crankshaft clockwise and check that the plunger is extended.

INSTALL OIL FILTER CAP ASSEMBLY

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INSTALL SPARK PLUG TUBE GASKET

*a	Before Cutting
*b	After Cutting
	Area to be Cut Off

Using a cutter knife, cut off the seal part of the removed spark plug tube gasket.

*1	Spark Plug Tube Gasket without Sealing Part
*2	New Plug Plug Tube Gasket
*3	Claw

Using a hammer and the removed spark plug tube gasket which has had the sealing part cut off, uniformly tap in a new spark plug tube gasket all the way.

Note:

Keep the lip free of foreign matter.
Do not tap in the spark plug tube gasket at an angle.

Tip:

If a spark plug tube gasket that will be used to install a new spark plug tube gasket is deformed and cannot be positioned on a new spark plug tube gasket, correct the deformation using pliers.

Return the claws of the ventilation baffle plate to their original positions.

INSTALL CYLINDER HEAD COVER GASKET

Install a new cylinder head cover gasket to the cylinder head cover.

Note:
Remove any oil from the contact surfaces.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Install 3 new gaskets to the camshaft bearing cap.
Apply seal packing as shown in the illustration.

Seal packing

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

Standard diameter

4.0 mm (0.157 in.)
Note:
- Remove any oil from the contact surfaces.
- Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Install the cylinder head cover with a new seal washer and the 13 bolts.

10 N*m

102 kgf*cm

7 ft.*lbf

Note:
Do not start the engine for at least 2 hours after the installation.