ENGINE UNIT(w/ DPF) REASSEMBLY

PROCEDURE


  1. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old packing material from the contact surface.

    2. Apply a continuous bead of seal packing to the oil pan sub-assembly as shown in the illustration.

      A01VHXDE02
      Text in Illustration
      *a Seal Packing *b Straight Pin Hole
      Standard Seal Diameter
      Area

      Bead Size

      mm (in.)
      A - A

      2.0 to 3.0

      (0.079 to 0.118)
      B - B

      Min. Width: 7.0 (0.2756)

      Min. Height: 3.0 (0.1181)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • When applying seal packing, make sure that it does not protrude into the 2 straight pin holes.

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

    3. A01VLTLE02

      Using several steps, temporarily tighten the 12 bolts in the order shown in the illustration, and then tighten the bolts to the specified torque.

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

      Length

      mm (in.)
      A 35 (1.378)
      B 143.7 (5.657)
      C 119 (4.685)

      Note

      Wipe away any seal packing that is protruding from the front surface of the cylinder block sub-assembly before the seal packing hardens.

  2. INSTALL ENGINE REAR OIL SEAL

    Click here

  3. INSTALL ENGINE OIL LEVEL SENSOR


    1. A01VDWSE02

      Temporarily tighten the engine oil level sensor to the oil pan sub-assembly with the 5 bolts.

    2. Fully tighten the bolts A first, and then tighten bolt B.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any old packing material from the contact surface.

    2. A01VM4PE01
      Text in Illustration
      *a Seal Packing

      Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.098 to 0.138 in.)) to the No. 2 oil pan sub-assembly as shown in the illustration.

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

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

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

    3. A01VKC2E02

      Temporarily tighten the No. 2 oil pan sub-assembly to the oil pan sub-assembly with the 10 bolts and 2 nuts.

    4. Fully tighten the 10 bolts and 2 nuts, in the order shown in the illustration.

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

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

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  5. SET OIL FILTER BRACKET SUB-ASSEMBLY


    1. Check and clean the oil filter bracket sub-assembly installation surface.

    2. A01VKYZ

      Install a new oil filter bracket gasket to the oil pan sub-assembly.

    3. A01VHP9

      Install the oil filter bracket sub-assembly to the oil pan sub-assembly with the 2 bolts.

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

  6. INSTALL OIL COOLER ASSEMBLY


    1. Check and clean the oil cooler assembly installation surface.

    2. A01VELU

      Install 2 new oil cooler O-rings and a new oil cooler gasket to the oil filter bracket sub-assembly.

    3. A01VLCAE01
      Text in Illustration
      *1 Nut and Plate Washer

      Install the oil cooler assembly to the oil filter bracket sub-assembly with the 2 bolts, 2 nuts and 2 plate washers.

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

  7. INSTALL OIL FILTER ELEMENT

    Click here

  8. INSTALL OIL FILTER CAP ASSEMBLY WITH ELEMENT


    1. A01VJTSE01

      Using SST, tighten the oil filter cap assembly with element to the oil filter bracket sub-assembly.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  9. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01VEDO

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

      Note

      Check that the top of the cylinder block water jacket spacer is settled below the top surface of the cylinder block sub-assembly.

  10. INSTALL CYLINDER HEAD GASKET

    Click here

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head set bolts are tightened in multiple steps.


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

    2. Apply a light coat of engine oil to the threads of the cylinder head set bolts and area beneath the cylinder head set bolt heads that come in contact with the cylinder head set plate washers.

    3. A01VG94E02
      Text in Illustration
      A01VE7C Engine Front
      *a Paint Mark
      *b 90°

      Using several passes, uniformly install and tighten the 10 cylinder head set bolts and 10 new cylinder head set plate washers in the order shown in the illustration. (*1)

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    4. Mark the front of the cylinder head set bolts with paint.

    5. Using the same sequence as step (*1), retighten the cylinder head set bolts by an additional 90° and repeat it 2 more times.

    6. Check that each paint mark is now 270° from the front.

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


    1. Apply engine oil to the valve stem caps, valve rocker arm pivot top surfaces and valve rocker arm roller portions.

    2. A01VFXM

      Install the 8 No. 1 valve rocker arm sub-assemblies to the cylinder head sub-assembly.

  13. INSTALL CAMSHAFT

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  14. INSTALL CHAIN DAMPER SPRING


    1. A01VDL9

      Install the chain damper spring to the chain tensioner plate.

  15. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. A01VG41E02
      Text in Illustration
      *1 Key
      *2 Oil Pump Shaft
      *a TDC Mark
      *b Flat faces left

      Align the crankshaft key with the TDC mark on the cylinder block sub-assembly.

    2. Rotate the oil pump shaft so that the flat faces left when viewing the cylinder block sub-assembly from the front.

    3. A01VGNZE02
      Text in Illustration
      *1 Mark Link
      *2 Oil Pump Drive Gear
      *3 Oil Pump Drive Shaft Gear
      *a Timing Mark

      Align the orange mark links with the timing marks of each gear as shown in the illustration.

    4. A01VITJ

      Install the oil pump drive gear and oil pump drive shaft gear onto the crankshaft and oil pump shaft with the No. 2 chain sub-assembly wrapped on the oil pump drive gear and oil pump drive shaft gear.

    5. A01VEHF

      Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole on the oil pump drive shaft gear to lock the oil pump drive shaft gear in position, and then tighten the nut.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    6. A01VH4OE01
      Text in Illustration
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring
      *3 Pin
      *4 Pivot Hole

      Install the chain tensioner plate with chain damper spring to the pin.

      Tech Tips


      • Push the chain tensioner plate so that the area around the pivot hole reaches the base of the pin.

      • The end of the chain damper spring should contact the side of the oil pan sub-assembly so that tension is applied to the chain.

    7. A01VE3DE02
      Text in Illustration
      *1 Mark Link
      *2 Key
      *a Timing Mark
      *b TDC Mark

      Check that the mark plate and timing mark are in the positions shown in the illustration.

  16. INSTALL CHAIN SUB-ASSEMBLY


    1. A01VGIJE06
      Text in Illustration
      *1 Straight Pin

      Turn the camshaft to set the straight pin in the position shown in the illustration.

    2. A01VLCQE01
      Text in Illustration
      *1 Key
      *a TDC Mark
      A01VL3H Turn

      Turn the crankshaft to set the key in the position shown in the illustration.

    3. A01VJFQE02
      Text in Illustration
      *1 Yellow Mark Plate
      *2 Pink Mark Plate
      *a Timing Mark

      Align the chain's 2 yellow mark plates with the timing mark on the camshaft timing sprocket, and pink mark plate with the timing mark on the crankshaft timing sprocket.

    4. Install the camshaft timing sprocket and crankshaft timing sprocket onto the camshaft and crankshaft with the chain sub-assembly wrapped on the camshaft timing sprocket and crankshaft timing sprocket.

    5. A01VE41E01

      Using SST, fix the camshaft timing sprocket, and install the camshaft timing sprocket and No. 2 crank angle sensor plate to the camshaft with the 3 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Check that the contact surfaces of the No. 2 crank angle sensor plate and camshaft timing sprocket are securely contacting, and then tighten the bolt.

  17. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01VKJ7

      Using an 8 mm socket hexagon wrench, install the No. 1 chain vibration damper to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.

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

  18. INSTALL CHAIN TENSIONER SLIPPER


    1. A01VI8L

      Install the chain tensioner slipper onto the cylinder head sub-assembly.

  19. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01VG3RE05
      Text in Illustration
      *1 Plunger
      *2 Groove
      *3 Hole
      A01VL3H Push

      Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.

    2. A01VJ48

      Install the No. 1 chain tensioner assembly to the cylinder block sub-assembly with the 2 bolts.

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

    3. Remove the 1.1 mm (0.043 in.) diameter bar from the No. 1 chain tensioner assembly.

    4. A01VHYJE02
      Text in Illustration
      *1 Yellow Mark Plate
      *2 Pink Mark Plate
      *a Timing Mark

      Check that the mark plate and timing mark are in the positions shown in the illustration.

  20. INSTALL WATER INLET HOUSING


    1. A01VFH0

      Install a new No. 2 water inlet housing gasket to the water inlet housing.

    2. A01VJAX

      Install the water inlet housing to the timing chain cover assembly with the 3 bolts.

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

      Note

      Do not reuse a water inlet housing that has been dropped.

  21. INSTALL OIL CHECK VALVE SUB-ASSEMBLY


    1. A01VE4Y

      Using a 5 mm socket hexagon wrench, install the oil check valve sub-assembly to the timing chain cover assembly with the bolt.

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

  22. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A01VK25E01

      Using SST and a hammer, tap in a new timing chain cover oil seal until its surface is flush with the timing chain cover assembly edge.

      SST
      09223-22010
      Timing chain cover oil seal tap in depth
      -0.6 to 0 mm (-0.0236 to 0 in.)

      Note


      • Keep the timing chain cover oil seal lip free from foreign matter.

      • Do not tap the timing chain cover oil seal at an angle.

    2. Apply MP grease to the timing chain cover oil seal lip.

      Note

      Keep the lip free of foreign matter.

  23. INSTALL TIMING CHAIN COVER ASSEMBLY


    1. A01VLBB

      Install a new oil pump gasket to the oil pan sub-assembly.

    2. Remove any old packing material from the contact surface.

    3. Apply seal packing to the engine body and timing chain cover assembly as shown in the illustration below.

      A01VDNBE02
      Text in Illustration
      *a Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent *b Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Seal packing
      Water pump part: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Other part: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

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

      Tech Tips

      Areas A-A, B-B and C-C are the joints between the cylinder block sub-assembly and cylinder head sub-assembly, and the cylinder block sub-assembly and oil pan sub-assembly.

      Application Specification
      Area Seal Packing Diameter Seal Packing Dimension Seal Packing Application Length
      Continuous Line Area Except A-A, B-B, C-C and D 3.5 to 4.5 mm (0.138 to 0.177 in.) - -
      Dashed Line Area 3.5 to 4.5 mm (0.138 to 0.177 in.) - -
      A-A -

      Width: 15 mm (0.591 in.)

      Height: 4.5 mm (0.177 in.)

      		 27 mm (1.06 in.)
      B-B -

      Width: 7.0 mm (0.276 in.)

      Height: 3.5 mm (0.138 in.)

      		 24 mm (0.945 in.)
      C-C -

      Width: 7.0 mm (0.276 in.)

      Height: 3.5 mm (0.138 in.)

      		 26 mm (1.02 in.)
      D 3.0 to 4.0 mm (0.118 to 0.157 in.): Double Line Area - 45.1 mm (1.78 in.)
      E-E 3.5 to 4.5 mm (0.138 to 0.177 in.) - -

    4. Install the timing chain cover assembly to the cylinder head sub-assembly, cylinder block sub-assembly and oil pan sub-assembly with the 20 bolts and 2 nuts, in the order shown in the illustration.

      A01VEGJE02
      Text in Illustration
      *a Nut - -
      Torque:
      Bolt A, B, Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Bolt C
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt Length
      Bolt

      Length

      mm (in.)
      A 25 (0.984)
      B 40 (1.575)
      C 41 (1.614)

      Note


      • Make sure that the chain does not come into contact with the seal packing when installing the timing chain cover assembly.

      • Install the engine mounting bracket RH and engine water pump assembly within 10 minutes of installing the timing chain cover assembly.

    5. A01VGIO

      Apply a light coat of engine oil to the O-ring of the oil pressure switching valve assembly.

      Note

      If reusing the oil pressure switching valve assembly, be sure to inspect the O-ring.

    6. A01VJ20

      Install the oil pressure switching valve assembly to the timing chain cover assembly with the bolt.

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

      Note


      • If a component has been dropped or subjected to a strong impact, replace the oil pressure switching valve assembly.

      • Make sure that the O-ring is not damaged or does not jump out of position during installation.

  24. INSTALL CAMSHAFT POSITION SENSOR


    1. A01VHIB

      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. A01VG21

      Install the camshaft position sensor to the timing chain cover assembly with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note


      • If a component has been dropped or subjected to a strong impact, replace the camshaft position sensor.

      • Make sure that the O-ring is not damaged or does not jump out of position during installation.

  25. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  26. INSTALL NO. 2 TIMING CHAIN COVER


    1. A01VEAH

      Install the No. 2 timing chain cover to the timing chain cover assembly.

    2. Install the manifold temperature sensor bracket to the timing chain cover assembly with the bolt.

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

  27. INSTALL ENGINE MOUNTING BRACKET RH


    1. A01VDODE02

      Temporarily tighten the engine mounting bracket to the timing chain cover assembly with the 4 bolts.

      Bolt Length
      Bolt

      Length

      mm (in.)
      A 55 (2.165)
      B 70 (2.756)

    2. Fully tighten the 4 bolts, in the order shown in the illustration.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  28. CHECK VALVE CLEARANCE

    Click here

  29. ADJUST VALVE CLEARANCE

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  30. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01VGTV

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

      Note


      • Remove any oil from the contact surfaces.

      • Check that the cylinder head cover gasket is securely installed into the groove of the cylinder head cover sub-assembly.

    2. Remove any old packing material from the contact surface.

    3. A01VJW8

      Apply seal packing to the 6 locations shown in the illustration.

      Text in Illustration
      A01VL3H Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.

      • Install the cylinder head cover sub-assembly within 3 minutes, and tighten the bolts within 10 minutes of applying the seal packing.

    4. A01VHKZE02

      Temporarily install the cylinder head cover sub-assembly to the cylinder head sub-assembly with the 11 bolts and nut.

    5. Temporarily tighten the bolt A.

    6. Fully tighten the 11 bolts and nut, in the order shown in the illustration.

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

  31. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A01VKGC

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

    2. A01VI3S

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

  32. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A01VJHXE01
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads of the oil pressure sender gauge assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

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

    2. A01VEHAE02
      Text in Illustration
      *1 27 mm Deep Socket Wrench

      Using a 27 mm deep socket wrench, install the oil pressure sender gauge assembly to the oil pan sub-assembly.

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

      Note

      If a component has been dropped or subject to a strong impact, replace the oil pressure sender gauge assembly.

  33. INSTALL WATER INLET


    1. A01VFA8

      Install a new No. 1 water inlet housing gasket to the water inlet.

    2. A01VL3F

      Install the water inlet to the water inlet housing with the 3 bolts.

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

      Note

      Do not reuse a water inlet that has been dropped.

  34. INSTALL WATER OUTLET SUB-ASSEMBLY


    1. A01VDWP

      Install a new water outlet gasket to the cylinder head sub-assembly.

    2. A01VJCO

      Install the water outlet sub-assembly to the cylinder head sub-assembly with the 3 bolts and 2 nuts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  35. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A01VGC4

      Install a new gasket to the engine coolant temperature sensor.

    2. A01VJSME01

      Using SST, install the engine coolant temperature sensor to the water outlet sub-assembly.

      SST
      09817-33190
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      If a component has been dropped or subjected to a strong impact, replace the engine coolant temperature sensor.