Click here

ENGINE UNIT REASSEMBLY

Click here
Click here Click here

PROCEDURE


  1. Table 1. *1 φ 2.0 to 3.0 *2 Min. 7.0 *3 Min. 3.0 *4 (mm)
    Click here

    INSTALL OIL PAN SUB-ASSEMBLY


    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 15 minutes of applying the seal packing.

    2. A01VEEPE04

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

    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.

      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. Click here

    INSTALL ENGINE OIL LEVEL SENSOR (w/ DPF)


    1. Temporarily tighten the oil level sensor with the 5 bolts.

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

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

    INSTALL ENGINE OIL LEVEL SENSOR (w/o DPF)


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

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

    INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01VFNIE02

      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.

      Table 2. Text in Illustration
      *1 Seal Packing
      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. A01VLJ9E03

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

      9.0 N*m 92 kgf*cm 80 in.*lbf

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

      38 N*m 387 kgf*cm 28 ft.*lbf
  6. Click here

    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.

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

    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. A01VM1S

      Install the oil cooler assembly with the 2 bolts and 2 nuts.

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

    INSTALL OIL FILTER ELEMENT

    Click here

  9. Click here

    INSTALL OIL FILTER CAP ASSEMBLY WITH ELEMENT


    1. Using SST, tighten the oil filter cap.

      09228-06501
      25 N*m 255 kgf*cm 18 ft.*lbf
  10. Click here

    INSTALL CYLINDER BLOCK WATER JACKET SPACER


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

  11. Click here

    INSTALL CYLINDER HEAD GASKET

    Click here

  12. Click here

    INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tip:

    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

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

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

  13. Click here

    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.

  14. Click here

    INSTALL CAMSHAFT

    Click here

  15. Click here

    INSTALL CHAIN DAMPER SPRING


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

  16. Click here

    INSTALL NO. 2 CHAIN SUB-ASSEMBLY


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

      Table 4. 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. A01VITSE07

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

      Table 5. Text in Illustration
      *1 Timing Mark
      *2 Mark Link
      *3 Oil Pump Drive Gear
      *4 Oil Pump Drive Shaft Gear
    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.

      30 N*m 306 kgf*cm 22 ft.*lbf
    6. A01VDYTE06

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

      Table 6. Text in Illustration
      *1 Tensioner Plate
      *2 Damper Spring
      *3 Pin
      *4 Pivot Hole
      Tip:

      • 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. A01VFC2E07

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

      Table 7. Text in Illustration
      *1 Timing Mark
      *2 Mark Link
      *3 TDC Mark
      *4 Key
  17. Click here

    INSTALL CHAIN SUB-ASSEMBLY


    1. A01VGIJE06

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

      Table 8. Text in Illustration
      *1 Straight Pin
    2. A01VISTE10

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

      Table 9. Text in Illustration
      *1 TDC Mark
      *2 Key
      *a Turn
    3. A01VIR6E01

      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.

      Table 10. 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.

      09960-10010 09962-01000 09963-01000
      20 N*m 204 kgf*cm 15 ft.*lbf
  18. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01VEGV

      Using an 8 mm socket hexagon wrench, install the chain vibration damper with the 2 bolts.

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

    INSTALL CHAIN TENSIONER SLIPPER


    1. A01VL57

      Install the chain tensioner slipper onto the cylinder block.

  20. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01VG3RE04

      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.

      Table 11. Text in Illustration
      *a Push
    2. A01VDIE

      Install the chain tensioner with the 2 bolts.

      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. A01VK86E01

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

      Table 12. Text in Illustration
      *1 Timing Mark
      *2 Orange Mark Plate
      *3 Yellow Mark Plate
  21. Click here

    INSTALL WATER INLET HOUSING


    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.

      9.1 N*m 93 kgf*cm 81 in.*lbf
  22. Click here

    INSTALL OIL CHECK VALVE SUB-ASSEMBLY (w/ DPF)


    1. Using a 6 mm hexagon wrench, install the oil check valve sub-assembly with the bolt.

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

    INSTALL TIMING CHAIN COVER OIL SEAL


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

      09223-22010
      Oil seal tap in depth
      -1.0 to 0 mm (-0.0394 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.

  24. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/ DPF)


    1. Install the new oil pump gasket.

    2. A01VEZME03

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

      Table 13. 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 15 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
    3. A01VJR1E02

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

      Table 14. Text in Illustration
      *a Nut - -
      Bolt A, B, Nut
      21 N*m 214 kgf*cm 15 ft.*lbf
      Bolt C
      40 N*m 408 kgf*cm 30 ft.*lbf
      Bolt Length
      Bolt

      Length

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

  25. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/o DPF)


    1. A01VG8VE10

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

      Table 15. 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 15 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. A01VIUKE07

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

      Table 16. Text in Illustration
      *a Nut - -
      Bolt A, B, Nut
      21 N*m 214 kgf*cm 15 ft.*lbf
      Bolt C
      40 N*m 408 kgf*cm 30 ft.*lbf
      Bolt Length
      Bolt

      Length

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

  26. Click here

    INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  27. Click here

    INSTALL NO. 2 TIMING CHAIN COVER (w/ DPF)


    1. Install the No. 2 timing chain cover with the harness bracket and bolt.

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

    INSTALL NO. 2 TIMING CHAIN COVER (w/o DPF)


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

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

    INSTALL ENGINE MOUNTING BRACKET RH


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

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

      55 N*m 561 kgf*cm 41 ft.*lbf
  30. Click here

    INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (w/ DPF)


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

      Table 17. Text in Illustration
      *1 Adhesive
      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01VEKTE01

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

      Table 18. Text in Illustration
      *1 27 mm Deep Socket Wrench
      15 N*m 153 kgf*cm 11 ft.*lbf
  31. Click here

    INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY (w/o DPF)


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

      Table 19. Text in Illustration
      *1 Adhesive
      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01VEKTE01

      Using a 27 mm deep socket wrench, install the oil pressure switch assembly.

      Table 20. Text in Illustration
      *1 27 mm Deep Socket Wrench
      15 N*m 153 kgf*cm 11 ft.*lbf
  32. Click here

    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.

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

    INSTALL WATER OUTLET SUB-ASSEMBLY


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

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

      11 N*m 112 kgf*cm 8 ft.*lbf
  34. Click here

    INSTALL WATER TEMPERATURE SENSOR


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

    2. A01VDKTE06

      Using SST, install the water temperature sensor.

      09817-33190
      20 N*m 204 kgf*cm 15 ft.*lbf
  35. Click here

    CHECK VALVE CLEARANCE

    Click here

  36. Click here

    ADJUST VALVE CLEARANCE

    Click here

  37. Click here

    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.

      Table 21. 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 15 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.

      11 N*m 112 kgf*cm 8 ft.*lbf
  38. Click here

    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.