ENGINE UNIT REASSEMBLY
CAUTION / NOTICE / HINT
Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly or engine coolant temperature sensor.
PROCEDURE
INSTALL RING PIN
Note:It is not necessary to remove a ring pin unless it is being replaced.
-
*a
Protrusion Height
Install 2 new ring pins to the stiffening crankcase assembly.
Standard protrusion
3 mm (0.118 in.)
Tip:Standard protrusion may vary, but 3 mm is typical.
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INSTALL STUD BOLT
Note:If a stud bolt is deformed or the threads are damaged, replace it.
for Stiffening crankcase assembly:
-
Using an E5 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
5.0 N*m
51 kgf*cm
44 in.*lbf
-
for Water inlet housing:
-
Using an E5 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
5.0 N*m
51 kgf*cm
44 in.*lbf
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INSTALL STIFFENING CRANKCASE ASSEMBLY
-
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
Continuous Line
2.0 to 3.0 mm (0.0787 to 0.118 in.)
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 stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.
-
Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.
21 N*m
214 kgf*cm
16 ft.*lbf
Bolt Length
Item
Length
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
16 ft.*lbf
Wipe off any excess seal packing with a clean piece of cloth.
-
INSTALL REAR ENGINE OIL SEAL
INSTALL OIL PUMP ASSEMBLY
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
INSTALL OIL PAN DRAIN PLUG
-
Install a new gasket and the oil pan drain plug.
37 N*m
377 kgf*cm
27 ft.*lbf
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INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)
INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY
INSTALL VALVE LASH ADJUSTER ASSEMBLY
Note:Keep the valve lash adjuster assembly free of dirt and foreign matter.
Only use clean engine oil.
Place the valve lash adjuster assembly into a container filled with engine oil.
-
*a
Correct
*b
Incorrect
*c
Taper Part
*d
Low Pressure Chamber
*e
High Pressure Chamber
*f
Plunger
*g
Check Ball
Insert the SST tip into the valve lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
09276-75010
Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.
Check the movement of the plunger and bleed it.
OK
Plunger moves up and down.
Note:When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.
After bleeding, remove SST. Then, try to press the plunger quickly and firmly with a finger.
OK
Plunger is very difficult to move.
If the result is not as specified, replace the valve lash adjuster assembly.
Install the valve lash adjuster assemblies.
Note:Install each valve lash adjuster assembly to the same place it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
Apply engine oil to each valve lash adjuster assembly tip and valve stem cap end.
-
*1
Valve Rocker Arm
*2
Valve Lash Adjuster
*3
Valve Stem
*4
Valve Stem Cap
Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.
INSTALL NO. 1 CAMSHAFT BEARING
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
Clean both surfaces of the 2 No. 2 camshaft bearings.
Note:Do not apply engine oil to the No. 2 camshaft bearings or the contact surfaces.
Install the 2 No. 2 camshaft bearings to the camshaft housing sub-assembly.
-
*1
Vernier Caliper
Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the No. 2 camshaft bearing edge.
Dimension (A)
1.05 to 1.75 mm (0.0413 to 0.0689 in.)
Note:Position the No. 2 camshaft bearings to the center of the camshaft bearing cap by measuring dimension A.
INSTALL NO. 2 CAMSHAFT
Clean the camshaft journals.
Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
-
Install the No. 2 camshaft to the camshaft housing sub-assembly.
INSTALL CAMSHAFT
Clean the camshaft journals.
Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.
-
Install the camshaft to the camshaft housing sub-assembly.
INSTALL CAMSHAFT BEARING CAP
Apply engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
-
*1
Straight Pin
*2
Camshaft
*3
No. 2 Camshaft
Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
Tip:Make sure that the straight pin of each camshaft is positioned as shown in the illustration.
-
Tighten the 10 bolts in the order shown in the illustration.
16 N*m
163 kgf*cm
12 ft.*lbf
INSTALL NO. 1 TAPER SCREW PLUG
-
Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).
25 N*m
255 kgf*cm
18 ft.*lbf
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Note:Install the No. 1 taper screw plug within 3 minutes of applying adhesive.
Do not start the engine within 1 hour after installing the No. 1 taper screw plug.
Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (B).
43 N*m
438 kgf*cm
32 ft.*lbf
Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Note:Install the No. 1 taper screw plug within 3 minutes of applying adhesive.
Do not start the engine within 1 hour after installing the No. 1 taper screw plug.
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INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
-
*1
Valve Rocker Arm
*2
Lash Adjuster
*3
Valve Stem
*4
Valve Stem Cap
Make sure that the valve rocker arm is installed as shown in the illustration.
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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
Continuous line
3.5 to 4.5 mm (0.138 to 0.177 in.)
A
8.0 mm (0.315 in.)
B
7.0 mm (0.276 in.)
Application Length A and B
15 mm (0.591 in.)
Note:Remove any oil from the contact surfaces.
Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installation.
-
Set the camshaft and No. 2 camshaft as shown in the illustration.
Install the camshaft housing sub-assembly and tighten the 17 bolts in the order shown in the illustration.
27 N*m
275 kgf*cm
20 ft.*lbf
Note:After installing the camshaft housing sub-assembly, make sure that the cam lobes are positioned as shown in the illustration.
If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly, clean the installation surfaces, and reapply seal packing.
If the camshaft housing sub-assembly 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.
After installing the camshaft housing sub-assembly, wipe off any seal packing that seeped out from between the camshaft housing sub-assembly and the cylinder head sub-assembly.
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INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
Check that the straight pin is installed on the No. 2 camshaft.
-
*a
Straight Pin
*b
Key Groove
Put the camshaft timing exhaust gear assembly and No. 2 camshaft together by aligning the key groove and straight pin.
Lightly press the camshaft timing exhaust gear assembly against the No. 2 camshaft, and turn the camshaft timing exhaust gear assembly. Push further at the position where the pin enters the groove.
Note:Be sure not to turn the camshaft timing exhaust gear assembly in the retard direction (clockwise).
Check that there is no clearance between the gear and the No. 2 camshaft flange.
-
Tighten the flange bolt while holding the hexagonal portion of the No. 2 camshaft.
54 N*m
551 kgf*cm
40 ft.*lbf
Check the lock of the camshaft timing exhaust gear assembly.
Make sure that the camshaft timing exhaust gear assembly is locked.
Tip:Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
Check that the straight pin is installed on the camshaft.
-
*a
Straight Pin
*b
Key Groove
Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
Note:Do not forcibly push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.
-
*a
Straight Pin
*b
Key Groove
Turn the camshaft timing gear assembly as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
Note:Do not turn the camshaft timing gear assembly assembly in the retard direction (clockwise).
-
*1
Camshaft Timing Gear Assembly
*a
Clearance
*b
No clearance
*c
Flange
Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.
-
Tighten the flange bolt while holding the hexagonal portion of the camshaft.
54 N*m
551 kgf*cm
40 ft.*lbf
-
*a
Lock
Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and is locked in the most retarded position.
Tip:Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.
INSTALL CRANKSHAFT TIMING GEAR KEY
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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.
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INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
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Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.
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INSTALL NO. 2 CHAIN SUB-ASSEMBLY
INSTALL CRANKSHAFT TIMING SPROCKET
INSTALL NO. 1 CHAIN VIBRATION DAMPER
-
Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.
21 N*m
214 kgf*cm
15 ft.*lbf
-
INSTALL CHAIN SUB-ASSEMBLY
Check that the No. 1 cylinder is at TDC/compression.
Temporarily tighten the crankshaft pulley bolt.
-
*1
Timing Gear Key
Turn the crankshaft counterclockwise to position the timing gear key to the top.
Remove the crankshaft pulley bolt.
-
*a
Timing Mark
Check that the timing marks on each camshaft timing gear assembly are aligned as shown in the illustration.
-
*a
Place the Chain Sub-assembly on the Sprocket
*b
Pass the Chain Sub-assembly through the Damper
*c
Mark Plate (Orange)
*d
Timing Mark
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 pass the chain sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
Pass the chain sub-assembly through the No. 1 vibration damper.
-
Place the chain sub-assembly 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 assembly counterclockwise to align the mark plates (orange) and timing mark.
Tip:Be sure to position the mark plates at the front of the engine.
The mark plates on the camshaft side are colored orange.
*a
Turn
*b
Tension the Chain Sub-assembly
*c
Mark Plate (Orange)
*d
Timing Mark
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.
Tip:To tension the chain sub-assembly, slowly turn the camshaft timing gear assembly clockwise to prevent the chain sub-assembly from being misaligned.
-
*a
Timing Mark
*b
Mark Plate (Yellow)
Align the mark plates (yellow) and timing marks and install the chain sub-assembly to the crankshaft timing gear.
Tip:The mark plates on the crankshaft side are colored yellow.
Recheck each timing mark at TDC/compression.
*a
Timing Mark
*b
Mark Plate (Orange)
*c
Mark Plate (Yellow)
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INSTALL CHAIN TENSIONER SLIPPER
-
Install the chain tensioner slipper to the cylinder block sub-assembly.
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INSTALL NO. 2 CHAIN VIBRATION DAMPER
-
Install the No. 2 chain vibration damper with the 2 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
-
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 water inlet housing with the 3 bolts.
21 N*m
214 kgf*cm
15 ft.*lbf
-
INSTALL TIMING CHAIN COVER OIL SEAL
-
Using SST, tap in a new timing chain cover oil seal until its surface is flush with the timing gear case edge.
09223-22010
Apply a light coat of MP grease to the lip of the timing chain cover oil seal.
Note:Keep the lip free of foreign matter.
Do not tap in the timing chain cover oil seal at an angle.
Make sure that the timing chain cover oil seal edge does not stick out of the timing chain cover sub-assembly.
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INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
INSTALL CRANKSHAFT PULLEY
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
-
*a
Correct
*b
Incorrect
*c
Push
*d
Raise
*e
Cam
*f
Hook
*g
Pin
Release the ratchet pawl, then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.
Note:Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.
-
Install a new gasket, the bracket and No. 1 chain tensioner assembly with the 2 nuts.
12 N*m
122 kgf*cm
9 ft.*lbf
Note:If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, engage the hook again.
-
*a
Turn
*b
Disconnect
*c
Hook
*d
Pin
Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.
-
*a
Turn
*b
Push
*c
Plunger
Turn the crankshaft clockwise, then check that the plunger is extended.
-
INSTALL OIL FILTER CAP ASSEMBLY
INSTALL SPARK PLUG TUBE GASKET
-
*a
Plug Tube Gasket without Sealing Part
*b
New Plug Tube Gasket
*c
Claw
Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.
Note:Keep the lip free of foreign matter.
Do not tap in the oil seal at an angle.
Tip:If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.
Return the claws of the ventilation baffle plate to their original positions.
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INSTALL CYLINDER HEAD COVER GASKET
-
Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
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
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 of applying seal packing.
Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly.
-
Install the cylinder head cover sub-assembly to the camshaft housing sub-assembly with a new seal washer and the 13 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
-
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
-
*a
Adhesive
Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Note:Install the oil pressure switch within 3 minutes of applying adhesive.
Do not start the engine within 1 hour after installation.
-
Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.
15 N*m
153 kgf*cm
11 ft.*lbf
-
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
-
Install a new gasket to the engine coolant temperature sensor.
Install the engine coolant temperature sensor.
20 N*m
204 kgf*cm
15 ft.*lbf
Tip:Perform "Inspection After Repair" after replacing the engine coolant temperature sensor.
-
INSTALL KNOCK CONTROL SENSOR
-
Install the knock control sensor with the bolt.
21 N*m
214 kgf*cm
15 ft.*lbf
Note:Make sure that the knock control sensor is in the correct position.
-
INSTALL CRANKSHAFT POSITION SENSOR
-
*1
O-ring
Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.
-
Install the crankshaft position sensor with the bolt.
10 N*m
102 kgf*cm
7 ft.*lbf
-
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
-
*1
O-ring
Apply a light coat of engine oil to 2 new O-rings and install them to the camshaft timing oil control valve assemblies.
-
*1
Bracket
Install the 2 camshaft timing oil control valves and bracket to the cylinder head cover sub-assembly with the 2 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
Note:Do not allow foreign matter to contact the oil seal face of the camshaft oil control valve assembly (surface that contacts cylinder head cover sub-assembly).
Be careful that the O-ring is not cracked or moved out of place when installing the camshaft oil control valve assembly.
-
INSTALL CAMSHAFT POSITION SENSOR
-
*1
O-ring
Apply a light coat of engine oil to the O-ring of the camshaft position sensor.
-
Install the 2 camshaft position sensors to the cylinder head cover sub-assembly with the 2 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
Note:Make sure that the O-rings are not cracked or jammed when installing the camshaft position sensors.
-
INSTALL SPARK PLUG
INSTALL ENGINE COVER JOINT
-
Install the 2 engine cover joints to the cylinder head cover sub-assembly.
10 N*m
102 kgf*cm
7 ft.*lbf
-
INSTALL OIL FILLER CAP GASKET
-
Install the oil filler cap gasket to the oil filler cap sub-assembly.
-
INSTALL OIL FILLER CAP SUB-ASSEMBLY
-
Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
-