ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A004889

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

  2. INSTALL CYLINDER HEAD GASKET

    Click here

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  4. INSTALL VALVE LIFTER


    1. A004AXM

      Apply engine oil to the circumference of the 12 valve lifters.

    2. Install the 12 valve lifters to the cylinder head sub-assembly.

      Note

      Check that the valve lifters turn smoothly after installing them.

  5. INSTALL ENGINE REAR OIL SEAL


    1. A0048VS

      Apply engine oil to the lip of a new engine rear oil seal.

      Text in Illustration
      A0048UM Apply Engine Oil
    2. A004ADYE02
      Text in Illustration
      *a Wooden Block

      Using SST and wooden blocks, tap in the engine rear oil seal to the rear engine oil seal retainer.

      SST
      09223-15020
      09950-70010   ( 09951-07200 )
      Standard depth
      -0.5 to 1.0 mm (-0.0197 to 0.0394 in.)

      Note


      • Keep the lip free from foreign matter.

      • Do not tap in the engine rear oil seal at an angle.

  6. INSTALL STUD BOLT


    1. A004AVK

      Using an E6 "TORX" socket wrench, install the stud bolt to the rear engine oil seal retainer.

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

  7. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. Clean and degrease the rear engine oil seal retainer and cylinder block sub-assembly.

    2. A0049JCE01
      Text in Illustration
      *a Seal Packing (3.0 to 4.0 mm (0.118 to 0.157 in.))

      Apply a continuous bead of seal packing to the rear engine oil seal retainer as shown in the illustration.

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

      Note


      • Install the rear engine oil seal retainer 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 installation.

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

    3. A0049NV

      Install the rear engine oil seal retainer to the cylinder block sub-assembly with the 4 bolts.

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

  8. INSTALL CAMSHAFT


    1. A004BD0E04

      Before installing the camshaft, set the No. 1 piston to TDC/exhaust, and then turn the crankshaft approximately 90° clockwise so that a lifted valve and piston do not touch each other when the camshaft and No. 2 camshaft are installed.

    2. A004AWEE03
      Text in Illustration
      *a Apply Engine Oil

      Apply engine oil to the contact areas of the cams and journals of the camshaft and No. 2 camshaft.

    3. A004B8X

      Install the camshaft to the cylinder head sub-assembly.

    4. A0048S0E02
      Text in Illustration
      *1 Camshaft
      *a No. 1 Cylinder
      *b No. 3 Cylinder

      Set the camshaft as shown in the illustration.

  9. INSTALL NO. 2 CAMSHAFT


    1. A0049JE

      Install the No. 2 camshaft to the cylinder head sub-assembly.

    2. A0048QHE02
      Text in Illustration
      *1 No. 2 Camshaft
      *a No. 1 Cylinder
      *b No. 2 Cylinder

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

  10. INSTALL CAMSHAFT BEARING CAP


    1. A0049LME02
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap

      Set the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps.

      Note


      • Install the camshaft bearing caps with the front marks facing the front of the engine.

      • Install the bolts to the correct positions by referring to the numbers inscribed on the bolts and the following table.

      Installation Position of No. 2 Bearing Cap
      Installation Position Inscribed No.
      Intake No. 1 Cylinder I2
      Intake No. 2 Cylinder I3
      Intake No. 3 Cylinder I4
      Exhaust No. 1 Cylinder E2
      Exhaust No. 2 Cylinder E3
      Exhaust No. 3 Cylinder E4
    2. A004BH0E02

      Install the 15 bolts in the order shown in the illustration.

      Torque:
      No. 1 Camshaft Bearing Cap
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      No. 2 Camshaft Bearing Cap
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  11. INSTALL CAMSHAFT TIMING GEAR


    1. A0047T2

      Fit the camshaft timing gear and No. 2 camshaft together by aligning the straight pin hole and straight pin.

    2. A004AC5E01
      Text in Illustration
      *a Hold

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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  12. INSTALL CAMSHAFT TIMING SPROCKET ASSEMBLY


    1. A004BCV

      Apply engine oil to the camshaft timing sprocket assembly installation portion of the camshaft.

      Text in Illustration
      A0049LZ Apply Engine Oil
    2. A00472N

      Fit the camshaft timing sprocket assembly and camshaft together by aligning the straight pin hole and straight pin.

      Note


      • After insertion, gently rotate the camshaft timing sprocket assembly and check that the straight pin is securely inserted.

      • Because the tip of the camshaft straight pin may damage the seal surface of the camshaft timing sprocket assembly resulting in an improper seal, do not press forcefully on the camshaft timing sprocket assembly.

    3. A0049U2E01
      Text in Illustration
      *a Hold

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the bolt to install the camshaft timing sprocket assembly to the camshaft.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  13. INSTALL CRANKSHAFT STRAIGHT PIN


    1. A004BG9

      Install the crankshaft straight pin into the crankshaft groove.

  14. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A0048SKE01
      Text in Illustration
      *a Groove

      Align the groove of the crankshaft timing gear or sprocket with the straight pin of the crankshaft and install the crankshaft timing gear or sprocket to the crankshaft.

  15. INSTALL TIMING CHAIN GUIDE


    1. A00480Z

      Install the timing chain guide to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.

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

  16. INSTALL CHAIN SUB-ASSEMBLY


    1. A0047HTE02
      Text in Illustration
      *a Mark Plate (Yellow)
      *b Timing Mark

      Align the mark plate (yellow) with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly as shown in the illustration.

    2. A0046YME10
      Text in Illustration
      *a Camshaft Timing Sprocket Assembly Side
      *b Camshaft Timing Gear Side
      *c Timing Mark
      *d Mark Plate (Orange)

      Align the 2 mark plates (orange) with the timing marks of the camshaft timing sprocket assembly and camshaft timing gear, and install the chain sub-assembly as shown in the illustration.

  17. INSTALL TIMING CHAIN TENSION ARM


    1. A0049NB

      Install the timing chain tension arm to the cylinder block sub-assembly with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A004923E01
      Text in Illustration
      *a Turn

      Using a wrench, slightly turn the hexagonal portion of the camshaft assembly (intake side) counterclockwise so that there is some slack in the chain sub-assembly on the No. 1 chain tensioner assembly side.

    2. A004AZ6

      Install a new chain tensioner gasket to the No. 1 chain tensioner assembly.

    3. A0049FGE02
      Text in Illustration
      *a Temporarily Tighten
      *b 3 mm Hexagon Wrench

      Install the No. 1 chain tensioner assembly with the chain tensioner gasket to the cylinder block sub-assembly with the 2 bolts in the order shown in the illustration.

      Torque:
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

    4. Remove the 3 mm hexagon wrench, turn the crankshaft 2 complete revolutions and adjust the chain tension.

    5. A004BAPE02
      Text in Illustration
      *a Timing Mark

      Make sure that the timing mark of the camshaft timing gear is at the top with the chain sub-assembly tensioned (set No. 1 piston to TDC/ exhaust).

  19. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  20. INSTALL TIMING GEAR COVER TIGHT PLUG

    Click here

  21. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  22. INSTALL CRANKSHAFT PULLEY

    Click here

  23. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  24. INSTALL THERMOSTAT

    Click here

  25. INSTALL WATER INLET

    Click here

  26. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A0048KI

      Install a new oil strainer gasket to the oil strainer sub-assembly.

    2. A004A6Z

      Install the oil strainer sub-assembly to the timing chain cover sub-assembly with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  27. INSTALL STRAIGHT PIN

    Tech Tips

    Perform this procedure only when replacement of the straight pin is necessary.


    1. A004B0FE03
      Text in Illustration
      *a Upper Side
      *b Protrusion Height

      Using a plastic hammer, tap in 2 new straight pins to the specified protrusion height.

      Standard protrusion height
      3.0 to 5.0 mm (0.118 to 0.197 in.)

  28. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0048TSE01
      Text in Illustration
      *a Hole

      Install the No. 2 oil pan sub-assembly to the oil pan sub-assembly with the 2 bolts.

      Note

      Make sure that the gasket around the hole of the No. 2 oil pan sub-assembly is not displaced of protruding.

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

  29. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A004BF0

      Temporarily install the No. 1 oil pan baffle plate to the No. 2 oil pan sub-assembly with the 4 bolts.

    2. A00486FE01
      Text in Illustration
      *a Temporarily Tighten

      Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A004B2G

      Fully tighten the 3 bolts.

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

  30. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing remaining on the sealing surfaces before applying seal packing.

    2. Clean the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly, and confirm that there is no oil, moisture or other foreign matter on the surfaces.

    3. A004A3TE02
      Text in Illustration
      *a Continuous Line Area (3.0 to 4.0 mm (0.118 to 0.157 in.))
      *b Contact surfaces of the rear engine oil seal retainer and cylinder block sub-assembly (5.0 to 6.0 mm (0.197 to 0.236 in.))
      *c Contact surfaces of the timing chain cover sub-assembly and cylinder block sub-assembly (5.0 to 6.0 mm (0.197 to 0.236 in.))
      *d 39.5 mm (1.56 in.)
      *e 25.5 mm (1.00 in.)

      Apply seal packing to the oil pan sub-assembly as shown in the illustration.

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

      Note


      • Apply seal packing to the contact surfaces between the timing chain cover sub-assembly and cylinder block sub-assembly, and between the rear engine oil seal retainer and cylinder block sub-assembly.

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

      • Do not expose the seal to engine oil for at least 2 hours after installation.

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

    4. A00494UE01

      Temporarily install the oil pan sub-assembly to the cylinder block sub-assembly and timing chain cover sub-assembly with the 6 bolts.

    5. Fully tighten the 6 bolts in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    6. A004BGDE02
      Text in Illustration
      *a Nut

      Install the 7 bolts and 2 nuts.

      Torque:
      Bolt A
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Bolt B, Nut
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  31. INSTALL OIL PAN DRAIN PLUG


    1. A0046YU

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

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }

  32. INSTALL GROMMET


    1. A0049EF

      Install the 2 grommets to the cylinder head cover sub-assembly.

  33. INSTALL VENTILATION SYSTEM GROMMET


    1. A004BHU

      Install the ventilation system grommet to the cylinder head cover sub-assembly.

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


    1. A0049RP

      Install the PCV valve (ventilation valve sub-assembly) to the ventilation system grommet.

  35. INSTALL CYLINDER HEAD COVER GASKET


    1. A0047NHE02
      Text in Illustration
      *a Boss

      Install a new cylinder head cover gasket into the groove of the cylinder head cover sub-assembly and to the center bosses.

      Note

      Insert the cylinder head cover gasket securely into the bosses.

  36. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Clean the cylinder head cover sub-assembly, cylinder head sub-assembly and timing chain cover sub-assembly.

    2. A004A3RE01
      Text in Illustration
      *a Seal Packing
      *b Diameter

      Apply a continuous bead of seal packing to the contact surface between the cylinder head sub-assembly and timing chain cover sub-assembly as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


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

      • Do not expose the seal to engine oil for at least 2 hours after installation.

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

    3. A004ABNE02

      Temporarily install the cylinder head cover sub-assembly to the cylinder head sub-assembly and timing chain cover sub-assembly with the 16 bolts.

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

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

  37. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A0048D8

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

    2. A0049FF

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

  38. INSTALL OIL CONTROL VALVE FILTER


    1. A0049ZJE01
      Text in Illustration
      *1 Oil Control Valve Filter
      *2 Cylinder Head Screw Plug Gasket
      *3 Head Taper Screw Plug

      Install the oil control valve filter to the head taper screw plug.

    2. Using an 8 mm hexagon socket wrench, install a new cylinder head screw plug gasket and head taper screw plug with the oil control valve filter to the cylinder head sub-assembly.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  39. INSTALL KNOCK SENSOR


    1. A0049CYE04
      Text in Illustration
      *a Top

      Install the knock sensor to the cylinder block sub-assembly with the bolt so that the knock sensor installation position is as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note


      • If the knock sensor has been struck or dropped, replace it.

      • Make sure that the knock sensor is in the correct position.

  40. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A004AL1E02
      Text in Illustration
      *a Adhesive

      Clean and degrease the threads of the engine oil pressure switch assembly and threaded hole of the cylinder block sub-assembly.

    2. 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

      To prevent contamination by foreign matter, install immediately after applying adhesive.

    3. A004AXP

      Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly to the cylinder block sub-assembly.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note


      • If the engine oil pressure switch assembly has been struck or dropped, replace it.

      • Do not start the engine for at least 1 hour after installation.

  41. INSTALL CRANKSHAFT POSITION SENSOR


    1. A004971

      Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

      Note

      If reusing the crankshaft position sensor, be sure to inspect the O-ring.

    2. A0047MN

      Install the crankshaft position sensor to the timing chain cover sub-assembly with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note


      • If the crankshaft position sensor has been struck or dropped, replace it.

      • Make sure that the O-ring is not cracked or does not move out of place during installation.

  42. INSTALL CAM TIMING OIL CONTROL VALVE O-RING


    1. A0049O8

      Apply a light coat of engine oil to a new cam timing oil control valve O-ring and install it to the camshaft timing oil control valve assembly.

  43. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A00483X

      Install the camshaft timing oil control valve assembly to the cylinder head sub-assembly with the bolt.

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

      Note


      • If the camshaft timing oil control valve assembly has been struck or dropped, replace it.

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (connecting surface with the cylinder head sub-assembly).

      • Make sure that the cam timing oil control valve O-ring is not cracked or does not move out of place during installation.

  44. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A0049SRE01
      Text in Illustration
      *a Fulcrum Length of 19 mm Union Nut Wrench
      *b Fulcrum Length of Torque Wrench

      Using a 19 mm union nut wrench, install the engine coolant temperature sensor and a new gasket to the cylinder head sub-assembly.

      Torque:
      Specified tightening torque
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Note

      If the engine coolant temperature sensor has been struck or dropped, replace it.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a 19 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 17 N*m (173 kgf*cm, 13 ft.*lbf).

  45. INSTALL CAMSHAFT POSITION SENSOR


    1. A00485S

      Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

      Note

      If reusing the camshaft position sensor, be sure to inspect the O-ring.

    2. A004715

      Install the camshaft position sensor to the cylinder head sub-assembly with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note


      • If the camshaft position sensor has been struck or dropped, replace it.

      • Make sure that the O-ring is not cracked or does not move out of place during installation.

  46. INSTALL SPARK PLUG

    Click here

  47. INSTALL OIL LEVEL DIPSTICK GUIDE O-RING


    1. A004826

      Apply a light coat of engine oil to the oil level dipstick guide O-ring.

    2. Install the oil level dipstick guide O-ring to the oil level dipstick guide.

  48. INSTALL OIL LEVEL DIPSTICK GUIDE


    1. A004A3E

      Install the oil level dipstick guide to the cylinder head sub-assembly and oil pan sub-assembly with the bolt.

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

  49. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY


    1. A004B3M

      Install the oil level dipstick sub-assembly to the oil level dipstick guide.

  50. INSTALL WATER BY-PASS PIPE


    1. A0047CWE03
      Text in Illustration
      *a Folded Tab

      Install 2 new water by-pass pipe gaskets to the water by-pass pipe as shown in the illustration.

      Note

      Install the water by-pass pipe gasket with its folded tab towards the water by-pass pipe.

      Tech Tips

      Apply water to the water by-pass pipe before installing the water by-pass gaskets to the water by-pass pipe.

    2. A004B9HE03
      Text in Illustration
      *a Temporarily Tighten

      Install the water by-pass pipe to the cylinder head sub-assembly, cylinder block sub-assembly and timing chain cover sub-assembly with the 3 bolts in the order shown in the illustration.

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