ENGINE UNIT REASSEMBLY

Info Added 2017-10-06

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE ASSEMBLY

    Note

    It is not necessary to remove ring pins unless they are being replaced.


    1. B0048UFC01
      *a Protrusion Height
      *b 11 mm
      *c 8 mm

      Using a plastic hammer, tap 2 new ring pins into the stiffening crankcase assembly.

      Standard Ring Pin
      Item Protrusion Height Height Width
      Ring pin 4.0 mm (0.157 in.) 8.0 mm (0.315 in.) 11 mm (0.433 in.)
    2. B0048M9N01

      Apply seal packing as shown in the illustration.

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

    3. B0048NRN01

      Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.

      Torque:
      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.)

    4. Recheck the torque for the bolts (1) and (2).

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

    5. Wipe off any excess seal packing with a clean piece of cloth.

  2. INSTALL OIL PUMP ASSEMBLY

    Note

    It is not necessary to remove ring pins unless they are being replaced.


    1. B0048R6C01
      *a Protrusion Height
      *b 11 mm
      *c 8 mm

      Using a plastic hammer, tap 2 new ring pins into the stiffening crankcase assembly.

      Standard Ring Pin
      Item Protrusion Height Height Width
      Ring pin 3.0 mm (0.118 in.) 8.0 mm (0.315 in.) 11 mm (0.433 in.)

    2. Install the oil pump assembly.

      Click here

  3. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Note

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


    1. B0048JLC01
      *a 9 mm (0.354 in.)
      *b 19 mm (0.748 in.)

      Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Remove any remaining seal packing.

      Note


      • Remove any oil from the contact surfaces.

      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the No. 2 oil pan sub-assembly.

      • Keep the contact surfaces of the stiffening crankcase assembly and No. 2 oil pan sub-assembly free of oil.

    3. B0048NAC01
      *a Seal Packing
      *b 6.0 mm
      *c 3.0 to 4.5 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
      Application Specification
      Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing
      (A) - (A) 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.)
      (B) - (B) -
    4. B0048IWC01
      *a Nut

      Install the No. 2 oil pan sub-assembly to the stiffening crankcase assembly with the 10 bolts and 2 nuts.

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

  5. INSTALL OIL PAN DRAIN PLUG


    1. B0048Q9

      Install a new gasket and oil pan drain plug to the No. 2 oil pan sub-assembly.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  6. INSTALL REAR ENGINE OIL SEAL

    Click here

  7. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  8. INSTALL CYLINDER HEAD GASKET

    Click here

  9. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head set bolts are tightened in 3 progressive steps.


    1. Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

    2. Place the cylinder head sub-assembly on the cylinder block sub-assembly.

      Note


      • Remove any oil from the contact surface of the cylinder head sub-assembly.

      • Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the gasket with the bottom of the cylinder head sub-assembly.

    3. Install the 10 cylinder head set plate washers to the 10 cylinder head set bolts.

    4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

    5. Step 1:


      1. B0048NLN02

        Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.

        Torque:
        49 N*m  { 500 kgf*cm, 36 ft.*lbf }

        Note

        Do not drop the cylinder head set plate washers for the cylinder head set bolts into the cylinder head sub-assembly.

    6. B0048N6C02
      *a Paint Mark
      B0048I2 Front of Engine

      Step 2:


      1. Mark each cylinder head set bolt head with paint as shown in the illustration.

      2. Tighten the cylinder head set bolts 90° in the order shown in step 1.

    7. Step 3:


      1. Tighten the cylinder head set bolts another 45° in the order shown in step 1.

    8. Check that the paint marks are now at a 135° angle.

      Note

      Do not add engine oil for at least 2 hours after installing the cylinder head sub-assembly.

    9. B0048L1C02
      *a Before Wiping Off
      *b After Wiping Off

      After tightening the cylinder head set bolts, wipe off any seal packing that seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly.

      Note


      • Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.

      • Be sure to avoid clogging the bolt holes when wiping off the seal packing.

  10. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem ends.

    2. B0048PC

      Install the 16 valve stem caps to the cylinder head sub-assembly.

      Note


      • Install each part to its original location.

      • Do not drop the valve stem caps into the cylinder head sub-assembly.

  11. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the 16 valve lash adjuster assemblies before installing them.

      Click here

    2. B0048VC

      Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

      Install each part to its original location.

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


    1. B0048VJC01
      *1 Valve Lash Adjuster Assembly
      *2 No. 1 Valve Rocker Arm Sub-assembly
      *3 Valve Stem Cap

      Apply engine oil to the tips of the valve lash adjuster assemblies and valve stem caps.

    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note

      Install each part to its original location.

  13. INSTALL RING PIN

    Note

    It is not necessary to remove ring pins unless they are being replaced.


    1. B0048QFC01
      *a Protrusion Height
      *b 20 mm
      *c 13 mm

      Using a plastic hammer, tap 10 new ring pins into the camshaft housing sub-assembly.

      Standard Ring Pin
      Item Protrusion Height Height Width
      Ring pin 3.0 mm (0.118 in.) 13 mm (0.512 in.) 20 mm (0.787 in.)

  14. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean both surfaces of the No. 1 camshaft bearings.

    2. Install the 2 No. 1 camshaft bearings.

    3. B0048LDC01
      *a Vernier Caliper

      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)
      0.7 mm (0.0276 in.) or less

      Note

      Position the No. 1 camshaft bearings to the center of the camshaft bearing cap by measuring dimensions (A) and (B).

  15. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean both surfaces of the No. 2 camshaft bearings.

    2. Install the 2 No. 2 camshaft bearings.

    3. B0048TSC01
      *a Vernier Caliper

      Using a vernier caliper, measure the distance between the camshaft housing sub-assembly 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 housing sub-assembly by measuring dimension (A).

  16. INSTALL OIL CONTROL VALVE FILTER


    1. B0048TE

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

    2. Install the oil control valve filter.

      Note

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

  17. INSTALL NO. 2 CAMSHAFT

    Click here

  18. INSTALL CAMSHAFT

    Tech Tips

    Perform Inspection After Repair after replacing the camshaft.

    Click here


    1. Clean the camshaft journals.

    2. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    3. B0048MJ

      Install the camshaft to the camshaft housing sub-assembly.

  19. INSTALL CAMSHAFT BEARING CAP


    1. B0048RAC02
      *a Knock Pin

      Confirm the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

    2. B0048HQN01

      Tighten the 10 bearing cap bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  20. SET NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. B0048TGC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap
      *a Correct
      *b Incorrect

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

  21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B0048RWC01
      *a Cylinder Head Sub-assembly Upper Side
      *b Seal Packing
      *c 3.5 to 4.0 mm (0.138 to 0.157 in.)

      Apply seal packing 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 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.

    2. B0048L8C01
      B0048I2 Bolt (A)
      B0048S8 Bolt (B)

      Set the camshaft and No. 2 camshaft as shown in the illustration.

    3. Install the camshaft housing sub-assembly with the 17 bolts and tighten them in the order shown in the illustration.

      Torque:
      Bolt (A)
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Bolt (B)
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


      • After installing the camshaft housing sub-assembly, make sure that the cam lobes are positioned as shown in the illustration.

      • If it is necessary to loosen any of the bolts during installation, remove the camshaft housing sub-assembly, clean the installation surfaces, and reapply seal packing.

      • If it is necessary to remove the camshaft housing sub-assembly 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 cylinder head sub-assembly.

  22. INSTALL CAMSHAFT TIMING SPROCKET


    1. B0048PQ

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  23. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. B0048N8C01
      *a Knock Pin
      *b Key Groove

      Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

    2. B0048STC01
      *1 Camshaft Timing Gear Assembly
      *a Camshaft Flange
      *b No Gap

      Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

    3. B0048JF

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
    4. B0048VDC01
      B0048I2 Lock

      Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and locks in the most retarded position.

  24. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. B0048RJ

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

      Tech Tips

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

  25. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B0048L7

      Install the No. 1 crankshaft position sensor plate to the crankshaft with the "F" mark facing forward.

  26. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley set bolt to the crankshaft.

    2. B0048P3C01
      *1 Crankshaft Timing Gear Key

      Set the crankshaft timing gear keys as shown in the illustration.

    3. Turn the oil pump drive shaft so that the flat face is facing upward.

    4. Remove the crankshaft pulley set bolt from the crankshaft.

    5. B0048VHC01
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *a Mark Plate (Yellow)
      *b Timing Mark
      B0048I2 Front of Engine

      Align the mark plates (yellow) with the timing mark of the oil pump drive gear and oil pump drive shaft gear as shown in the illustration.

      Tech Tips

      Make sure the mark plates (yellow) of the No. 2 chain sub-assembly are facing away from the engine assembly.

    6. With the No. 2 chain sub-assembly placed around the oil pump drive gear and oil pump drive shaft gear, install the oil pump drive gear to the crankshaft and temporarily install the oil pump drive shaft gear to the oil pump drive shaft.

    7. Temporarily install the oil pump drive shaft gear nut.

    8. B0048KBC01
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring

      Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

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

    9. Temporarily install the crankshaft pulley to the crankshaft with the crankshaft pulley set bolt.

    10. B0048MLN01

      Using SST, hold the crankshaft pulley and tighten the oil pump drive shaft gear nut.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    11. Remove SST, the crankshaft pulley set bolt and crankshaft pulley.

  27. INSTALL CRANKSHAFT TIMING SPROCKET


    1. B0048VX

      Install the crankshaft timing sprocket to the crankshaft.

  28. SET NO. 1 CYLINDER TO TDC (COMPRESSION)


    1. Temporarily install the crankshaft pulley set bolt to the crankshaft.

    2. B0048MUC01
      *1 Crankshaft Timing Gear Key

      Turn the crankshaft clockwise until the crankshaft timing gear key is facing upward.

    3. B0048P4C01
      *a Timing Mark
      *b Timing Mark (Rectangle)
      *c Mark (Circle)

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

      Tech Tips

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

    4. Remove the crankshaft pulley set bolt from the crankshaft.

  29. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  30. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. B0048TR

      Install the No. 2 chain vibration damper to the camshaft housing sub-assembly with the 2 bolts.

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

  31. INSTALL CHAIN TENSIONER SLIPPER


    1. B0048QX

      Install the chain tensioner slipper to the cylinder block sub-assembly.

  32. INSTALL OIL FILTER BRACKET WITH HEAD STRAIGHT SCREW PLUG


    1. B0048KX

      Using a 10 mm hexagon socket wrench, install 2 new gaskets and the 2 oil filter bracket with head straight screw plugs to the oil filter bracket.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Note

    If the stud bolts are deformed or the threads are damaged, replace them.


    1. Type A:


      1. B0048VNC01
        *a 21 mm (0.827 in.)
        *b 9 mm (0.354 in.)
        *c 34 mm (1.34 in.)

        Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. B0048NV

      Install the 2 stud bolts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Remove any remaining seal packing.

    4. B0048HI

      Install a new gasket to the engine water pump assembly.

      Tech Tips

      Be sure to clean the contact surfaces.

    5. B0048OP

      Install the engine water pump assembly to the timing chain cover sub-assembly with the 3 bolts.

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

    6. Clean the contact surfaces of the timing chain cover sub-assembly, camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.

      B0048P0C01
      *a Cylinder Head Sub-assembly and Cylinder Block Sub-assembly Side *b Timing Chain Cover Sub-assembly Side
      B0048NZ Clean and degrease - -
    7. B0048KR

      Install 3 new O-rings to the cylinder head sub-assembly and cylinder block sub-assembly.

    8. B0048K4

      Apply seal packing to the engine unit as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Packing Diameter
      5.0 mm (0.197 in.)

      Note

      Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

    9. Apply seal packing to the timing chain cover sub-assembly in a continuous line as shown in the illustration.

      B0048JHC02
      *a 2.5 mm *b 5.0 mm
      *c 7.5 mm *d 2.5 to 3.5 mm
      *e 4.5 to 5.5 mm *f 7.0 to 8.0 mm
      Seal Packing
      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Application Specification
      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -
      (A) - (A) 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      (B) - (B) 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Opposite edge of seal packing

      5.0 mm (0.197 in.)

      		 - -
      (C) - (C) 7.0 to 8.0 mm (0.276 to 0.315 in.)

      Opposite edge of seal packing

      7.5 mm (0.295 in.)

      		 - -
      (F) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.5 mm (0.610 in.) 50.4 mm (1.98 in.)
      (G) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 143.1 mm (5.63 in.)
      (H) 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 153.4 mm (6.04 in.)
      (I) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 16.0 mm (0.630 in.) 385.8 mm (1.27 ft.)
      (J) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      (K) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 121.9 mm (4.80 in.)
      (L) 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 147.2 mm (5.80 in.)
      (M) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.1 mm (0.201 in.) 173.0 mm (6.81 in.)
      (N) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 385.8 mm (1.27 ft.)
      (O) 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -

      Note

      Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

    10. Clean the bolts and their installation holes.

    11. B0048LNC55
      *a Adhesive

      Apply adhesive to 5 and a half threads or more of the end of the 2 bolts (E).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    12. B0048V4C03
      *1 Seal Washer

      Temporarily install the timing chain cover sub-assembly with the 18 bolts and a new seal washer.

      Bolt Length
      Item Length
      Bolt (A), (E) 35 mm (1.38 in.)
      Bolt (B), (D) 55 mm (2.17 in.)
      Bolt (C) 40 mm (1.57 in.)

      Note

      Make sure that there is no oil on the threads of the bolts.

    13. Temporarily install the engine mounting bracket RH to the timing chain cover sub-assembly with the 3 bolts.

      Bolt Length
      Item Length
      Bolt 80 mm (3.15 in.)

      Note

      Make sure that there is no oil on the threads of the bolts.

    14. Install 2 new oil filter bracket O-rings to the timing chain cover sub-assembly.

    15. Temporarily install the oil filter bracket to the timing chain cover sub-assembly with the 4 bolts.

      Bolt Length
      Item Length
      Bolt 35 mm (1.38 in.)

      Note

      Make sure that there is no oil on the threads of the bolts.

    16. Fully tighten the 25 bolts in the order shown in the illustration.

      B0048OXC01
      *a Torque *b Bolt Tightening Order
      Torque:
      Bolt (A), (D), (E)
      25.5 N*m  { 260 kgf*cm, 19 ft.*lbf }
      Bolt (B), (F)
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      Bolt (C)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • Tighten the bolts within 10 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

  34. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  35. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

    Click here

  36. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  37. INSTALL KNOCK SENSOR

    Click here

  38. INSTALL NO. 1 TAPER SCREW PLUG


    1. B0048RFC02
      *a 5.0 mm (0.197 in.)
      *b 11 mm (0.433 in.)
      *c 18 mm (0.709 in.)
      *d 8.0 mm (0.315 in.)
      *e 12.5 mm (0.492 in.)
      *f 22 mm (0.866 in.)

      Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).

      Torque:
      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 for at least 1 hour after installing the No. 1 taper screw plug.

    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (B).

      Torque:
      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 for at least 1 hour after installing the No. 1 taper screw plug.

  39. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  40. INSTALL CRANKSHAFT PULLEY

    Click here

  41. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0048PKC02
      *a Cam
      *b Hook
      *c Plunger
      *d Pin
      *e Correct
      *f Incorrect
      *g Push
      *h Raise

      Raise the cam, then fully push in the plunger and engage the hook with 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.

    2. B0048NE

      Install a new gasket, the bracket and No. 1 chain tensioner assembly to the timing chain cover sub-assembly with the 2 nuts.

      Torque:
      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, set the hook again.

    3. B0048ODC01
      *a Hook
      *b Release

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

    4. B0048M7C01
      *a Plunger
      *b Plunger is extended

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

  42. INSTALL OIL FILTER BRACKET CLIP


    1. B0048K3

      Install the oil filter bracket clip to the oil filter bracket.

  43. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  44. INSTALL SPARK PLUG TUBE GASKET


    1. B0048L9

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

  45. INSTALL CYLINDER HEAD COVER GASKET


    1. B0048HSC01
      *1 Cylinder Head Cover Sub-assembly
      *2 Cylinder Head Cover Gasket

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

      Note


      • Remove any oil from the contact surfaces.

      • Misalignment between the center of the cylinder head cover sub-assembly rib and the center of the cylinder head gasket tab should be 4.0 mm (0.157 in.) or less.

  46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0048QP

      Install 2 new gaskets as shown in the illustration.

    2. B0048SX

      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 of applying seal packing.

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

    3. B0048QC

      Install the cylinder head cover sub-assembly with the 16 bolts.

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

      Note

      Misalignment between the contact surfaces of the timing chain cover sub-assembly and camshaft housing sub-assembly and the center of the cylinder head cover gasket tab should be 4.0 mm (0.157 in.) or less.

      B0048HZC01
      *1 Timing Chain Cover Sub-assembly
      *2 Camshaft Housing Sub-assembly
      *3 Cylinder Head Cover Gasket
      *a Projection

  47. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  48. INSTALL CAMSHAFT POSITION SENSOR

    Click here

  49. INSTALL SPARK PLUG

    Click here

  50. INSTALL OIL FILLER CAP GASKET


    1. B0048VK

      Install the oil filler cap gasket to the oil filler cap sub-assembly.

  51. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. B0048I6

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