ENGINE UNIT REASSEMBLY


  1. INSTALL OIL CHECK VALVE SUB-ASSEMBLY


    1. Install a new gasket and the oil check valve with the bolt.

      Torque:
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

  2. INSTALL REAR ENGINE OIL SEAL


    1. A01CI3TE01

      Using SST and a hammer, tap in a new rear engine oil seal until it is 4 mm (0.157 in.) below the upper edge of the flywheel housing.

      SST
      09223-78010

      Note


      • Be careful not to tap the oil seal at an angle.

      • Keep the gap between the rear oil seal retainer edge and the oil seal free of foreign matter.

    2. Apply MP grease to the oil seal lip.

  3. INSTALL FLYWHEEL HOUSING


    1. A01CHBOE02
      Text in Illustration
      *1 Seal Packing

      Remove any oil or packing material from the contact surfaces.

    2. Apply a continuous bead of seal packing (diameter: 1.5 to 2.5 mm (0.0591 to 0.0984 in.)) as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

      • Install the flywheel housing within 3 minutes of applying the seal packing.

      • Do not expose the seal packing to engine oil for at least 2 hours after installing the flywheel housing.

    3. Install the flywheel housing with the 14 bolts.

      Torque:
      132 N*m  { 1350 kgf*cm, 98 ft.*lbf, for bolt (M14) }
      29 N*m  { 290 kgf*cm, 21 ft.*lbf, for bolt (M8) }

  4. INSTALL FLYWHEEL RING GEAR


    1. A01CIHYE03
      Text in Illustration
      *1 Chamfer
      *2 Ring Gear
      *3 Flywheel
      *a 0.25 mm or less

      Using a torch, heat the ring gear evenly to approximately 200°C (392°F).

      Note

      Be careful not to overheat the ring gear.

    2. Using a brass bar, strike the ring gear onto the flywheel with its chamfered gear teeth facing the block.

      Standard clearance
      0.25 mm (0.00984 in.) or less

      CAUTION:

      After installing the ring gear, allow it to cool before handling.

  5. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Insert the flywheel slowly until it contacts the collar knock in order to prevent impact with the guide bar. Adjust the position, then insert it completely.

      Note

      The flywheel is heavy. When installing the flywheel, be careful not to drop it.

    2. Apply clean engine oil to the threads of the flywheel bolts and the flywheel bolt seats.

    3. Insert a screwdriver through the inspection hole of the flywheel housing into the ring gear of the flywheel to keep it from turning together with the crankshaft.

    4. Tighten the flywheel bolts in several steps in the order shown in the illustration.

      Torque:
      190 N*m  { 1938 kgf*cm, 140 ft.*lbf }
    5. A01CICA

      Using a dial indicator, measure the runout of the flywheel.

      Maximum runout
      0.15 mm (0.00591 in.)

      If the runout is greater than the maximum, resurface the flywheel surface.

    6. Temporarily install the 4 bolts in the positions of the cylinder block shown in the illustration to prevent the cables from sliding toward the center of the block.

    7. Attach the 2 cables to the cylinder block.

      Tech Tips

      The cables must be attached outside the installed bolts.

    8. Using a chain block and an engine sling device, install the cylinder block to the engine stand.

    9. Remove the 4 bolts from the cylinder block.

  6. INSTALL FRONT END PLATE


    1. Install the front end plate and a new gasket with the 4 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

    2. Using a cutter, cut the gasket so that it is flush with the lower surface of the cylinder block.

  7. INSTALL OIL PUMP ASSEMBLY


    1. A01CJ0PE01
      Text in Illustration
      *1 Engine Oil

      Apply engine oil to the oil pump case of the cylinder block.

      Note

      If engine oil is not applied, an oil suction malfunction will occur when starting the engine. The malfunction will cause seizure or abnormal wear to the engine.

    2. Install a new gasket and the oil pump with the 7 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

    3. Check that the oil pump rotates smoothly by hand after installation.

  8. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A01CI08E03
      Text in Illustration
      *a No. 1, No. 4 Cylinder
      *b Alignment Mark

      Turn the crankshaft clockwise, and align the alignment mark on the flywheel with the alignment mark between the 2 numbers on the edge of the flywheel housing to set the No. 1 cylinder to TDC.

    2. Align the set key on the crankshaft with the key groove of the crankshaft timing gear.

    3. Using a hammer, tap in the crankshaft timing gear.

  9. INSTALL NO. 1 IDLE GEAR SUB-ASSEMBLY


    1. A01CHKIE02
      Text in Illustration
      *1 Oil Hole

      Install the idle gear and idle gear thrust plate to the idle gear shaft.

    2. A01CHC3E02
      Text in Illustration
      *a Alignment Mark

      With the idle gear shaft oil hole facing down, match the alignment marks for each gear, and insert the shaft into the cylinder block.

      Note

      If the oil hole is not facing down, it will cause oil burning or abnormal engine wear.

    3. Tighten the bolt.

      Torque:
      137 N*m  { 1400 kgf*cm, 100 ft.*lbf }

  10. INSTALL CAMSHAFT


    1. A01CJ0HE08
      Text in Illustration
      *a Alignment Mark

      Apply engine oil to the camshaft journal and bearing.

    2. Match the alignment marks of the camshaft timing gear, and oil pump gear and install the camshaft.

  11. INSTALL NO. 2 IDLE GEAR SHAFT


    1. A01CISXE02
      Text in Illustration
      *1 Oil Hole

      Install the lock plate to the end plate with the 3 bolts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

    2. Install a new O-ring to the idle gear shaft.

    3. With the idle gear shaft oil hole facing down, install the gear shaft to the lock plate with the 2 bolts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

      Note

      If the oil hole is not facing down, it will cause oil burning or abnormal engine wear.

  12. INSTALL NO. 2 IDLE GEAR SUB-ASSEMBLY


    1. A01CGQBE04
      Text in Illustration
      *a Alignment Mark

      Match the alignment marks of the No. 1 and No. 2 idle gears, and install the No. 2 idle gear.

  13. INSTALL NO. 2 IDLE GEAR THRUST PLATE


    1. Install the thrust plate with the 2 bolts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

  14. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL


    1. A01CJGPE01

      Using SST and a hammer, tap in a new oil seal to the timing gear case so that the oil seal is flush with the timing gear edge.

      SST
      09223-78010

      Note


      • Be careful not to tap the oil seal at an angle.

      • Keep the gap between the gear case edge and the oil seal free of foreign matter.

    2. Apply MP grease to the oil seal lip.

  15. INSTALL TIMING GEAR CASE


    1. A01CJHKE04
      Text in Illustration
      *1 Seal Packing

      Remove any oil or packing material from the contact surfaces.

    2. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.118 to 0.157 in.)) as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

      • Install the timing gear case within 3 minutes of applying the seal packing.

      • Do not expose the seal packing to engine oil for at least 2 hours after installing the timing gear case.

    3. Install the timing gear case with the 15 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  16. INSTALL CRANKSHAFT PULLEY


    1. Install the pulley and spacer to the crankshaft.

      Tech Tips

      Align the pulley set key with the key groove of the pulley.

    2. Step 1


      1. Using a 46 mm socket wrench, tighten the nut.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

        Tech Tips

        Insert a screwdriver through the inspection hole of the flywheel housing into the ring gear of the flywheel to keep it from turning together with the crankshaft.

    3. Step 2


      1. A01CHGIE01
        Text in Illustration
        *1 Paint Mark
        A01CHW8 RH

        Mark the RH of each crankshaft pulley bolt head with paint.

      2. Further tighten the bolts 90° as shown in the illustration.

      3. Check that the paint mark are now at a 90° angle to the RH.

  17. INSTALL OIL SEPARATOR ASSEMBLY


    1. Install 2 new O-rings to the timing gear case.

    2. Install the oil separator with the 5 bolts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

  18. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new O-ring to the cylinder block.

    2. Install the oil strainer sub-assembly with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  19. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01CI6QE01
      Text in Illustration
      *1 Seal Packing

      Remove any oil or packing material from the contact surfaces.

    2. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.118 to 0.157 in.)) as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan within 3 minutes of applying the seal packing.

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

    3. Install the oil pan with the 26 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  20. INSTALL FLYWHEEL HOUSING STAY RH


    1. Install the stay with the 4 bolts.

      Torque:
      132 N*m  { 1350 kgf*cm, 97 ft.*lbf, for bolt (M14) }
      97 N*m  { 990 kgf*cm, 72 ft.*lbf, for bolt (M12) }

  21. INSTALL FLYWHEEL HOUSING STAY LH


    1. Install the stay with the 4 bolts.

      Torque:
      132 N*m  { 1350 kgf*cm, 97 ft.*lbf, for bolt (M14) }
      97 N*m  { 990 kgf*cm, 72 ft.*lbf, for bolt (M12) }

  22. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the bracket with the 4 bolts.

      Torque:
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

  23. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the bracket with the 4 bolts.

      Torque:
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

  24. INSTALL VALVE LIFTER

    Note

    Be sure to install the removed valve lifter to their original position.

  25. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. A01CHO9

      Install a new cylinder head gasket.

      Note

      Always install a new cylinder head gasket. Clean the surface of the cylinder head and cylinder block.

    2. Install the cylinder head over the straight pins on the cylinder block.

    3. A01CHHQE02

      Uniformly install and tighten the cylinder head bolts (1 to 18) in several steps in the order shown in the illustration.

      Torque:
      60 N*m  { 610 kgf*cm, 44 ft.*lbf }

      Tech Tips

      Since the cylinder head bolts are unique to this engine, do not substitute them with ordinary bolts.

    4. A01CJC1E03
      Text in Illustration
      *1 Paint
      A01CHIJ Front

      Mark the front side of each cylinder head bolt with paint as shown in the illustration.

    5. Retighten the cylinder head bolts 90° in the same order as step (c).

    6. Perform step (e) again.

    7. Check that each painted mark is now at a 180° angle to the front.

    8. A01CHHQE02

      Uniformly install and tighten the cylinder head bolts (19 to 22) in several steps in the order shown in the illustration.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

  26. INSTALL VALVE BRIDGE

    Note

    Be sure to install the removed valve bridges to their original locations.

  27. INSTALL VALVE PUSH ROD

    Note

    Be sure to install the removed push rods to their original locations.

  28. INSTALL NO. 1 VALVE ROCKER SHAFT SUB-ASSEMBLY


    1. Lubricate the rocker arm shaft and bush.

      Note

      Confirm that the oil hole of the No. 1 valve rocker support aligns with the shaft oil hole. Improper installation will result in burning of the valve.

    2. Install the No. 1 and No. 2 valve rocker arms, No. 1 and No. 2 valve rocker supports, and the rocker arm bushes to the No. 1 valve rocker shaft.

      A01CIABE03
      Text in Illustration
      *1 No. 1 Valve Rocker Arm *2 Valve Rocker Arm Bush
      *3 No. 2 Valve Rocker Arm *4 No. 1 Valve Rocker Support
      *5 No. 2 Valve Rocker Support *6 No. 1 Valve Rocker Shaft
      *a Cylinder Head Cover Side *b Cylinder Head Side
      A01CHW8 Front - -

      Note

      When installing, face the hole on the cylinder head side of the No. 1 valve rocker shaft as shown in the illustration.

    3. A01CGKLE02

      Apply engine oil to the rocker arm and push rod.

    4. Install the rocker shaft to the cylinder head.

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

      Torque:
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

      Note

      Be careful that each push rod does not interfere with the adjusting screw.

  29. ADJUST VALVE CLEARANCE


    1. A01CICKE07
      Text in Illustration
      *a TDC of No. 1 and No. 4 Cylinder
      *b TDC of No. 2 and No. 3 Cylinder
      *c Alignment Mark

      Flywheel housing side:

      Turn the crankshaft clockwise to align the alignment mark on the flywheel with the alignment mark between the 2 numbers on the edge on the flywheel housing.

    2. A01CH8ZE06
      Text in Illustration
      *1 Pointer
      *a TDC of No. 1 and No. 4 Cylinder
      *b TDC of No. 2 and No. 3 Cylinder
      *c Timing Mark

      Crankshaft pulley side:

      Turn the crankshaft clockwise to align the alignment mark on the crankshaft pulley with the pointer on the timing gear case.

      Tech Tips

      If not, turn the crankshaft 1 revolution (360°) to align the timing mark with the pointer.

    3. A01CHWVE05
      Text in Illustration
      *1 Adjusting Screw
      *2 Feeler Gauge
      *3 Lock Nut

      With the No. 1 piston positioned at TDC on the compression stroke, adjust each valve clearance using a feeler gauge.

      Standard Valve Clearance (Cold)
      Intake 0.30 mm (0.0118 in.)
      Exhaust 0.45 mm (0.0177 in.)

      Tech Tips

      The feeler gauge should move with a very slight pull.

    4. Loosen the lock nut on the valve rocker arm and loosen the adjusting screw.

    5. Insert a 0.30 mm (0.0118 in.) feeler gauge for the intake or a 0.45 mm (0.0177 in.) feeler gauge for the exhaust between the adjusting screw on the valve rocker arm and the valve bridge.

    6. Turn the adjusting screw on the valve rocker arm until the feeler gauge slides with a very slight drag, and lock the adjusting screw with the lock nut.

      Torque:
      29 N*m  { 300 kgf*cm, 21 ft.*lbf }

    7. Recheck the clearance.

    8. Adjust the other valves.


      1. Turn the crankshaft 1 revolution (360°) clockwise.

      2. Adjust the valve clearance for each cylinder in the firing order.

        Firing order
        1 - 3 - 4 - 2
        (The cylinder number is counted from the timing gear side)

  30. INSTALL CYLINDER HEAD COVER GASKET


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

  31. INSTALL CYLINDER HEAD COVER CUSHION


    1. Install the 2 cylinder head cover spacers and 2 cylinder head cover cushions onto the cylinder head cover sub-assembly.

  32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  33. INSTALL CYLINDER HEAD COVER STAY


    1. Install the 2 cylinder head cover stays onto the No. 2 cylinder head cover sub-assembly.

  34. INSTALL CYLINDER HEAD COVER CUSHION RUBBER


    1. Install the cylinder head cover cushion rubber onto the No. 2 cylinder head cover.

  35. INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install the No. 2 cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  36. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly onto the No. 2 cylinder head cover sub-assembly.