ENGINE UNIT(w/o DPF) REASSEMBLY

PROCEDURE


  1. INSTALL OIL PAN SUB-ASSEMBLY

    A01VL64E10
    *1 φ 2.0 to 3.0
    *2 Min. 7.0
    *3 Min. 3.0
    *4 (mm)

    1. Apply a continuous bead of seal packing to the oil pan as illustrated.

      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


      • Remove any oil from the contact surface.

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

    2. A01VEEPE03

      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)

  2. INSTALL ENGINE REAR OIL SEAL


    1. A01VL9IE01

      Apply MP grease to a new oil seal lip.

      Note

      Keep the lip free of foreign matter.

    2. Using SST and a hammer, tap in the new oil seal until its surface is flush with the cylinder block edge.

      SST
      09223-15030
      09950-70010   ( 09951-07100 )
      Oil seal tap in depth
      -1.0 to 0 mm (-0.0394 to 0 in.)

      Note


      • Tap the oil seal from the vertical position.

      • Wipe any extra grease off the crankshaft.

  3. INSTALL ENGINE OIL LEVEL SENSOR

    A01VGBM

    1. Install the engine oil level sensor with the 4 bolts.

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

  4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01VFNIE02
      Text in Illustration
      *1 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 as illustrated.

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

      Note


      • Remove any oil from the contact surface.

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

    2. Temporarily tighten the No. 2 oil pan with the 10 bolts and 2 nuts.

    3. A01VLJ9E02

      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 }

    4. Install a new oil pan drain plug gasket and oil pan drain plug.

      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 installation surface.

    2. A01VLW3

      Install a new oil filter bracket gasket to the oil pan.

    3. A01VL03

      Install the oil filter bracket 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 installation surface.

    2. A01VE61

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

    3. A01VM1SE01
      Text in Illustration
      *1 Nut and Plate Washer

      Install the oil cooler 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

    A01VFY9E01

    1. Using SST, tighten the oil filter cap.

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

  9. INSTALL CYLINDER BLOCK WATER JACKET SPACER

    A01VM5G

    1. Install the cylinder block water jacket spacer to cylinder block.

  10. INSTALL CYLINDER HEAD GASKET

    Click here

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in multiple steps.


    1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

    2. A01VIEOE08
      Text in Illustration
      A01VE7C Engine Front
      *a Paint Mark
      *b 90°

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

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

    3. Mark the front of the cylinder head bolts with paint.

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

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

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


    1. A01VFXM

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

    2. Install the 8 valve rocker arms.

  13. INSTALL CAMSHAFT

    Click here

  14. INSTALL CHAIN DAMPER SPRING

    A01VDL9

    1. Install the chain damper spring to the chain tensioner plate.

  15. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

    A01VGQLE07

    1. Align the crankshaft key with the TDC mark on the cylinder block.

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

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

    3. A01VITSE06
      Text in Illustration
      *1 Timing Mark
      *2 Mark Link
      *3 Oil Pump Drive Gear
      *4 Oil Pump Drive Shaft Gear

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

    4. A01VKSB

      Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears.

    5. A01VJY4

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

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    6. A01VDYTE05
      Text in Illustration
      *1 Tensioner Plate
      *2 Damper Spring
      *3 Pin
      *4 Pivot Hole

      Install the chain tensioner plate with the 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 spring should contact the side of the oil pan so that tension is applied to the chain.

    7. A01VFC2E06
      Text in Illustration
      *1 Timing Mark
      *2 Mark Link
      *3 TDC Mark
      *4 Key

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

  16. INSTALL CHAIN SUB-ASSEMBLY


    1. A01VGIJE08
      Text in Illustration
      *1 Straight Pin

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

    2. A01VISTE09
      Text in Illustration
      *1 TDC Mark
      *2 Key
      *a Turn

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

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

      A01VIR6E01
      Text in Illustration
      *1 Timing Mark
      *2 Orange Mark Plate
      *3 Yellow Mark Plate

    4. Install the chain, camshaft timing sprocket and crankshaft sprocket together onto the engine.

    5. A01VJSBE01

      Using SST, fix the camshaft timing sprocket, and install the camshaft timing sprocket with the 3 bolts.

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

  17. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01VEGV

      Using an 8 mm socket hexagon wrench, install the No. 1 chain vibration damper with the 2 bolts.

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

  18. INSTALL CHAIN TENSIONER SLIPPER


    1. A01VL57

      Install the chain tensioner slipper onto the cylinder block.

  19. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01VG3RE04
      Text in Illustration
      *a 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. A01VDIE

      Install the chain tensioner 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 chain tensioner.

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

      A01VK86E01
      Text in Illustration
      *1 Timing Mark
      *2 Orange Mark Plate
      *3 Yellow Mark Plate

  20. INSTALL WATER INLET HOUSING

    A01VICB

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

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

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

  21. INSTALL TIMING CHAIN COVER OIL SEAL

    A01VIONE01

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

      SST
      09223-22010
      Oil seal tap in depth
      -0.6 to 0 mm (-0.0236 to 0 in.)

      Note

      Tap the oil seal in from a vertical position.

    2. Apply MP grease to the new oil seal lip.

      Note

      Keep the lip free of foreign matter.

  22. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Apply seal packing to the engine body and oil pump as shown in the illustration below.

      A01VG8VE10
      Text in Illustration
      *1 Seal Width (Toyota Genuine Seal Packing Black, Three Bond 1207B) *2 Seal Width (Toyota Genuine Seal Packing 1282B, Three Bond 1282B)
      *a Width *b Height

      Note


      • Remove any oil from the contact surface.

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

      Seal packing
      Water pump: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Other: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

    2. Install the timing chain cover with the 20 bolts and 2 nuts, in the order shown in the illustration.

      A01VIUKE06
      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.

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

  23. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  24. INSTALL NO. 2 TIMING CHAIN COVER

    A01VE40

    1. Install the No. 2 timing chain cover with the washer plate and bolt.

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

  25. INSTALL ENGINE MOUNTING BRACKET RH

    A01VJ28E01

    1. Temporarily tighten the engine mounting bracket with the 4 bolts.

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

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

  26. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    A01VG4ME12
    Text in Illustration
    *1 Adhesive

    1. Apply adhesive to 2 or 3 threads of the oil pressure switch assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01VEKTE01
      Text in Illustration
      *1 24 mm Deep Socket Wrench

      Using a 24 mm deep socket wrench, install the oil pressure switch assembly.

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

  27. INSTALL WATER INLET


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

    2. A01VJ8B

      Install the water inlet with the 3 bolts.

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

  28. INSTALL WATER OUTLET SUB-ASSEMBLY

    A01VFZZ

    1. Install a new water outlet gasket to the cylinder head.

    2. Install the water outlet with the 2 bolts and 2 nuts.

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

  29. INSTALL WATER TEMPERATURE SENSOR


    1. Install a new gasket to the water temperature sensor.

    2. A01VDKTE07

      Using SST, install the water temperature sensor.

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

  30. CHECK VALVE CLEARANCE

    Click here

  31. ADJUST VALVE CLEARANCE

    Click here

  32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install a new cylinder head cover gasket onto the cylinder head cover.

    2. A01VHEB

      Apply seal packing to the 4 locations shown in the illustration, and then install the cylinder head cover.

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

      Note


      • Remove any oil from the contact surface.

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

    3. A01VJ2BE05

      Temporarily tighten the cylinder head cover with the 12 bolts.

    4. Fully tighten the 12 bolts, in the order shown in the illustration.

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

  33. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap gasket onto the oil filler cap.

    2. Install the oil filler cap onto the cylinder head cover.