ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE RING PIN

    Note

    It is not necessary to remove the stiffening crankcase ring pin unless it is being replaced.


    1. A01W4GME03
      Text in Illustration
      *a Protrusion Height

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

      Standard protrusion height
      4.3 to 5.3 mm (0.169 to 0.209 in.)

  2. INSTALL ENGINE BALANCER ASSEMBLY


    1. A01W08XE11
      Text in Illustration
      *a Alignment Mark

      Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

      If the alignment marks are not aligned, align them.


      1. A01W1RIE11
        Text in Illustration
        *1 Driven Gear
        *2 Damper Cover
        *a Alignment Mark

        Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the shaft in place.

      2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.

    2. A01VZMVE01

      Install the engine balancer assembly to the stiffening crankcase assembly with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  3. INSTALL STIFFENING CRANKCASE STUD BOLT

    Note

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


    1. Using an E5 and E8 "TORX" socket wrench, install the stiffening crankcase stud bolts.

      A01VZE3E03
      Torque:
      for Stud Bolt A
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      for Stud Bolt B
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      Text in Illustration
      *a Front Side *b Lower Side

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01VZYTE06
      Text in Illustration
      *1 Crankshaft Pulley Key

      Rotate the crankshaft clockwise so that the crankshaft pulley key is at the position 90° from the bottom as shown in the illustration.

    2. A01W4NEE03
      *1 2.5 to 3.5 mm
      *2 7.0 to 9.0 mm

      Apply seal packing in a continuous line as shown in the illustration.

      Text in Illustration
      B001NZR Stiffening Crankcase Assembly
      A01W46C cylinder block sub-assembly
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Dimension
      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick
      Application Length A
      28 mm (1.10 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

      • Do not apply oil for at least 2 hours after the installation.

    3. A01W0Q3E03
      Text in Illustration
      *a Cutout

      Check that the rear cutout parts are as shown in the illustration.

    4. Clean the bolts and their installation holes.

    5. A01VZAYE03
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 3 or more threads of the ends of the bolts A.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01W3ZFE02

      Temporarily install the stiffening crankcase assembly with the 11 bolts.

      Bolt Length
      Item Length
      Bolt A 65 mm (2.56 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 125 mm (4.92 in.)
      Bolt D 165 mm (6.50 in.)

      Tech Tips

      Apply adhesive to the bolts A before installation.

    7. A01W42BE05

      Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase assembly.

      Torque:
      for Bolt A
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      except Bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  5. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01W0NGE05

      Install the No. 1 oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  6. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to a new gasket.

    2. A01W41BE04
      Text in Illustration
      *a Protrusion

      Align the protrusion of the gasket with the cutout of the oil strainer sub-assembly, and install the gasket to the oil strainer sub-assembly.

    3. Install the oil strainer sub-assembly with the 3 bolts in several steps, in the sequence shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  7. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01W3GVE02
      *1 2.5 to 3.5 mm

      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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      • Do not apply oil for at least 2 hours after the installation.

    2. A01W4IQE02
      Text in Illustration
      *1 Nut

      Install the oil pan sub-assembly with the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      The bolt A and the nut A are tightened twice.

  8. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and the oil pan drain plug to the oil pan sub-assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  9. INSTALL OIL FILTER BRACKET CLIP


    1. Install the oil filter bracket clip to the stiffening crankcase assembly.

  10. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  11. INSTALL REAR ENGINE OIL SEAL

    Click here

  12. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01W0OH

      Install the cylinder block water jacket spacer to the cylinder block sub-assembly.

  13. INSTALL CYLINDER HEAD GASKET

    Click here

  14. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  15. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  16. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.


    1. A01W51LE03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, tap in 10 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  17. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    Note

    It is not necessary to remove the camshaft housing straight pin unless it is being replaced.


    1. A01W2U9E03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, tap in 2 new camshaft housing straight pins to the camshaft housing sub-assembly.

      Standard protrusion height
      5.0 to 7.0 mm (0.197 to 0.276 in.)

  18. INSTALL CAMSHAFT HOUSING STUD BOLT

    Note

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


    1. A01W00PE09
      *1 20 mm (0.787 in.)
      *2 35 mm (1.38 in.)
      *3 13 mm (0.512 in.)

      Using an E8 "TORX" socket wrench, install the camshaft housing stud bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  19. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01W3KJE02
      Text in Illustration
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

    2. Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.

    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  20. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

    3. A01W57XE08
      Text in Illustration
      *1 Vernier Caliper

      Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  21. INSTALL OIL CONTROL VALVE FILTER


    1. A01W4GF

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  22. INSTALL CAMSHAFT

    Click here

  23. INSTALL CAMSHAFT BEARING CAP

    Click here

  24. INSTALL VALVE STEM CAP

    Click here

  25. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

  26. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  28. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  29. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  30. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01W4DC

      Install the crankshaft timing sprocket to the crankshaft.

  31. ADD ENGINE OIL

    Click here

  32. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  33. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  34. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  35. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  36. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  37. INSTALL TIMING CHAIN GUIDE

    Click here

  38. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  39. INSTALL TIMING CHAIN COVER PLATE


    1. A01W54J

      Install a new gasket and the timing chain cover plate with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  40. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. A01W3NP

      Using a 14 mm hexagon wrench, install a new gasket and the timing chain cover tight plug.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  41. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  42. INSTALL ENGINE MOUNTING BRACKET RH

    Click here

  43. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  44. INSTALL SPARK PLUG TUBE GASKET


    1. A01W27Y

      Tap in 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

      Note

      After pressing in the spark plug tube gasket, make sure the gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover sub-assembly.

  45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01W1LV

      Apply a light coat of engine oil to 3 new camshaft bearing cap oil hole gaskets.

    2. Install the 3 camshaft bearing cap oil hole gaskets.

    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

      Note

      Remove any oil from the contact surface.

    4. A01W0FQE10
      Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover Sub-assembly
      *3 Camshaft Housing Sub-assembly

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application width A
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    5. A01VZIYE04

      Align the cylinder head cover sub-assembly with the pin A. Then align the cylinder head cover sub-assembly with the pin B and install the cylinder head cover sub-assembly.

    6. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      Do not apply oil for at least 2 hours after the installation.

  46. INSTALL CRANKSHAFT PULLEY


    1. A01W1ZAE01
      Text in Illustration
      *a Hold
      *b Turn

      Align the crankshaft pulley key with the key groove of the crankshaft pulley.

    2. Using SST, hold the crankshaft pulley and install the pulley bolt.

      SST
      09213-54015
      09330-00021
      Torque:
      260 N*m  { 2651 kgf*cm, 192 ft.*lbf }

      Tech Tips

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

  47. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  48. INSTALL WATER INLET HOUSING


    1. A01W2CH

      Install a new gasket and the water inlet housing with the 4 bolts and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  49. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  50. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01W4E3

      Install the V-ribbed belt tensioner assembly with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  51. INSTALL THERMOSTAT

    Click here

  52. INSTALL WATER INLET

    Click here

  53. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A01W0V8

      Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  54. INSTALL SEPARATOR CASE


    1. A01W0G5

      Apply a light coat of engine oil to a new gasket.

    2. Install the gasket to the separator case.

    3. Install the separator case to the ventilation case sub-assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  55. INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. A01VZ96E01
      *1 2.5 to 3.5 mm

      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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the ventilation case sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01W4BBE04

      Install the ventilation case sub-assembly, and install the 8 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      The bolt A is tightened twice.

  56. INSTALL VENTILATION VALVE SUB-ASSEMBLY

    Click here

  57. INSTALL CAMSHAFT POSITION SENSOR

    Click here

  58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  59. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install a new gasket to the oil filler cap sub-assembly.

    2. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  60. INSTALL SPARK PLUG

    Click here

  61. INSTALL ENGINE COVER JOINT


    1. A01W22L

      Install the 3 engine cover joints.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }