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ENGINE UNIT REASSEMBLY

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PROCEDURE


  1. Click here

    INSTALL STIFFENING CRANKCASE RING PIN

    Note:

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


    1. B004HI8C02
      *a Protrusion Height

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

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

    INSTALL STUD BOLT

    Note:

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


    1. B004HW2C02
      *a 16 mm (0.63 in.)
      *b 9 mm (0.354 in.)
      *c 27 mm (1.06 in.)

      Using an E6 "TORX" socket wrench, install the 3 stud bolts to the cylinder head cover sub-assembly.

      5.0 N*m 51 kgf*cm 44 in.*lbf

    2. When reusing the stud bolt:


      1. B004IDFC05
        *a 20 mm (0.787 in.)
        *b 35 mm (1.38 in.)
        *c 13 mm (0.512 in.)

        Apply adhesive 1324 to the threaded portion (camshaft housing sub-assembly side) of the stud bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using an E8 "TORX" socket wrench, install the stud bolt to the camshaft housing sub-assembly.

      6.5 N*m 66 kgf*cm 58 in.*lbf
    4. B004NNYC03
      *a Front Side *b Bottom Side
      *c 20 mm (0.787 in.) *d 13 mm (0.512 in.)
      *e 35 mm (1.38 in.) *f 8.5 mm (0.335 in.)
      *g 8.0 mm (0.315 in.) *h 18 mm (0.709 in.)

      Using E5 and E8 "TORX" socket wrenches, install the 3 stud bolts to the stiffening crankcase assembly.

      Stud Bolt (A)
      9.5 N*m 97 kgf*cm 84 in.*lbf
      Stud Bolt (B)
      4.0 N*m 41 kgf*cm 35 in.*lbf
    5. B004KM7C03
      *a 46 mm (1.81 in.)
      *b 19 mm (0.748 in.)
      *c 67 mm (2.64 in.)

      Using an E10 "TORX" socket wrench, install the stud bolt to the cylinder block sub-assembly.

      8.5 N*m 87 kgf*cm 75 in.*lbf
  3. Click here

    INSTALL ENGINE BALANCER ASSEMBLY


    1. B004IQ2C17
      *a Alignment Mark

      Check that the alignment marks of the balance shaft damper cover and No. 1 balance shaft driven gear are aligned.

      If the alignment marks are not aligned, realign them.


      1. B004ICYC18
        *a No. 1 Balance Shaft Driven Gear
        *b Balance Shaft Damper Cover
        *c Alignment Mark

        Using a wrench, securely hold the No. 2 balance shaft.

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

    2. B004K1EN11

      Install the engine balancer assembly to the stiffening crankcase assembly with the 3 bolts in the order shown in the illustration.

      24 N*m 245 kgf*cm 18 ft.*lbf
  4. Click here

    INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. B004LVQC03
      *1 Crankshaft Pulley Key

      Rotate the crankshaft clockwise so that the crankshaft pulley key is at the position 270° from the bottom as shown in the illustration.

    2. B004K3JC05
      *a Seal Packing
      *b 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *c 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *d 28 mm (1.10 in.)
      B0071FR Stiffening Crankcase Assembly
      B007066 Cylinder Block Sub-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 Packing 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
      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 add engine oil for at least 2 hours after the installation.

    3. B004LROC13
      *a Cutout

      Check that the rear cutouts are as shown in the illustration.

    4. Clean the bolts and bolt holes.

    5. B004IOPC12
      *a Adhesive

      Apply adhesive to 3 or more threads at the tips of the bolts (A).

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. B004M17C01
      *a Bolt Type

      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.)
      Tip:

      Apply adhesive to the bolts (A) before installation.

    7. B004M17C02
      *a Tightening Order

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

      Bolt (A)
      24 N*m 245 kgf*cm 18 ft.*lbf
      Except Bolt (A)
      43 N*m 438 kgf*cm 32 ft.*lbf
  5. Click here

    INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. B004LJVN06

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

      10 N*m 102 kgf*cm 7 ft.*lbf
  6. Click here

    INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. B004IW2C02
      *a Protrusion

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

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

      9.0 N*m 92 kgf*cm 80 in.*lbf
  7. Click here

    INSTALL OIL PAN SUB-ASSEMBLY


    1. B004M3OC05
      *a 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 Packing Diameter
      2.5 to 3.5 mm (0.0984 to 0.138 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 10 minutes of applying seal packing.

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

    2. B004KLAC07
      *a Nut

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

      10 N*m 102 kgf*cm 7 ft.*lbf
      Tip:

      Bolt (A) and nut (A) are tightened twice.

  8. Click here

    INSTALL OIL PAN DRAIN PLUG


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

      40 N*m 408 kgf*cm 30 ft.*lbf
  9. Click here

    INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  10. Click here

    INSTALL REAR ENGINE OIL SEAL

    Click here

  11. Click here

    INSTALL CYLINDER BLOCK WATER JACKET SPACER


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

  12. Click here

    INSTALL CYLINDER HEAD GASKET

    Click here

  13. Click here

    INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  14. Click here

    INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note:

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.


    1. B004KY3C03
      *a Protrusion Height

      Using a plastic hammer, tap in 10 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.)
  15. Click here

    INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    Note:

    It is not necessary to remove the camshaft housing straight pins unless they are being replaced.


    1. B004N8VC02
      *a Protrusion Height

      Using a plastic hammer, tap in 2 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.)
  16. Click here

    INSTALL NO. 1 CAMSHAFT BEARING


    1. B004K74C12
      *a 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.

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)
  17. Click here

    INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. B004HMHC20
      *a Vernier Caliper

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

    3. 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.)
  18. Click here

    INSTALL OIL CONTROL VALVE FILTER


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

  19. Click here

    INSTALL NO. 2 CAMSHAFT

    Click here

  20. Click here

    INSTALL CAMSHAFT

    Click here

  21. Click here

    INSTALL CAMSHAFT BEARING CAP

    Click here

  22. Click here

    INSTALL VALVE STEM CAP

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  23. Click here

    INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

  24. Click here

    INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  25. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  26. Click here

    INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  27. Click here

    INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  28. Click here

    INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the crankshaft timing sprocket to the crankshaft.

  29. Click here

    ADD ENGINE OIL

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  30. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  31. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  32. Click here

    INSTALL CHAIN SUB-ASSEMBLY

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  33. Click here

    INSTALL CHAIN TENSIONER SLIPPER

    Click here

  34. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  35. Click here

    INSTALL TIMING CHAIN GUIDE

    Click here

  36. Click here

    CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  37. Click here

    INSTALL TIMING CHAIN COVER PLATE

    Click here

  38. Click here

    INSTALL OIL PUMP RELIEF VALVE PLUG


    1. Using a 14 mm hexagon wrench, install a new gasket and the oil pump relief valve plug.

      37.5 N*m 382 kgf*cm 28 ft.*lbf
  39. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  40. Click here

    INSTALL ENGINE MOUNTING BRACKET RH

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  41. Click here

    INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  42. Click here

    INSTALL SPARK PLUG TUBE GASKET


    1. Install 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.

  43. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B004HTEC02
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *a Gasket

      Apply a light coat of engine oil to 2 new camshaft bearing cap oil hole gaskets and a new gasket.

    2. Install the 2 camshaft bearing cap oil hole gaskets to the No. 1 camshaft bearing cap.

    3. Install the gasket to the No. 2 camshaft bearing cap.

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

      Note:

      Remove any oil from the contact surfaces.

    5. B004HREC01
      *1 Timing Chain Cover Sub-assembly
      *2 Camshaft Housing Sub-assembly
      *a Application Width: 5.0 mm (0.197 in.)
      *b Seal Packing Diameter: 3.0 to 6.0 mm
      B006Z38 Seal Packing

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application Width
      10.0 mm (0.394 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.

    6. B004LHNC06
      *a Pin (A)
      *b Pin (B)
      *c Seal Washer

      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.

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

      12 N*m 122 kgf*cm 9 ft.*lbf
      Note:

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

  44. Click here

    INSTALL CRANKSHAFT PULLEY

    Click here

  45. Click here

    INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  46. Click here

    INSTALL WATER INLET HOUSING

    Note:

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


    1. w/o Oil Cooler:


      1. B004LUHC01
        *a 34 mm (1.34 in.) *b 21 mm (0.827 in.)
        *c 9.0 mm (0.354 in.) *d 27 mm (1.06 in.)
        *e 16 mm (0.630 in.) - -

        Using an E6 "TORX" socket wrench, install the 4 stud bolts to the water inlet housing.

        4.4 N*m 45 kgf*cm 39 in.*lbf

    2. w/ Oil Cooler:


      1. B004LJ9C01
        *a 21 mm (0.827 in.) *b 9.0 mm (0.354 in.)
        *c 34 mm (1.34 in.) *d 16 mm (0.630 in.)
        *e 27 mm (1.06 in.) - -

        Using an E6 "TORX" socket wrench, install the 5 stud bolts to the water inlet housing.

        Stud Bolt (A), (B)
        4.4 N*m 45 kgf*cm 39 in.*lbf
        Stud Bolt (C)
        4.0 N*m 41 kgf*cm 35 in.*lbf

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

    4. Install the water inlet housing to the cylinder block sub-assembly with the 4 bolts and nut.

      43 N*m 438 kgf*cm 32 ft.*lbf
  47. Click here

    INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  48. Click here

    INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
  49. Click here

    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


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

      21 N*m 214 kgf*cm 15 ft.*lbf
  50. Click here

    INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)

    Click here

  51. Click here

    INSTALL THERMOSTAT

    Click here

  52. Click here

    INSTALL WATER INLET

    Click here

  53. Click here

    INSTALL NO. 1 WATER BY-PASS PIPE


    1. B004KECN01

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

      10 N*m 102 kgf*cm 7 ft.*lbf
      Note:

      Temporarily tighten the bolt (A), fully tighten the 2 nuts (B), and then fully tighten the bolt (A).

  54. Click here

    INSTALL SEPARATOR CASE


    1. B004L9T

      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.

      10 N*m 102 kgf*cm 7 ft.*lbf
  55. Click here

    INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. B004K66C05
      *a 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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Note:

      • Remove any oil from the contact surfaces.

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

    2. B004JTBN04

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

      21 N*m 214 kgf*cm 15 ft.*lbf
      Tip:

      The bolts (A) are tightened twice.

  56. Click here

    INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  57. Click here

    INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  58. Click here

    INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  59. Click here

    INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

    Click here

  60. Click here

    INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

    Click here

  61. Click here

    INSTALL OIL FILLER CAP GASKET


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

  62. Click here

    INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

  63. Click here

    INSTALL SPARK PLUG

    Click here

  64. Click here

    INSTALL ENGINE COVER JOINT


    1. B004L27

      Install the 3 engine cover joints.

      10 N*m 102 kgf*cm 7 ft.*lbf