ENGINE UNIT REASSEMBLY


  1. INSTALL TIGHT PLUG

    Tech Tips

    If coolant leaks from a tight plug or a plug is corroded, replace it.

    A01BGJ0E03
    Text in Illustration
    *a Front Side *b Intake Side
    *c Rear Side *d Exhaust Side
    *e 1.0 mm (0.0394 in.) - -

    1. Apply adhesive to new tight plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using SST, tap in the tight plug labeled A.

      SST
      09950-60010   ( 09951-00300 )
      09950-70010   ( 09951-07100 )

    3. Using SST, tap in the 8 tight plugs labeled B and D.

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )

    4. Using SST, tap in the tight plugs labeled C.

      SST
      09950-60010   ( 09951-00400 )
      09950-70010   ( 09951-07100 )

  2. INSTALL STUD BOLT

    Tech Tips

    If a stud bolt is deformed or its threads are damaged, replace it.

    A01BE9NE01
    Text in Illustration
    *a Front Side *b Lower Side
    *c Exhaust Side *d 12 mm (0.472 in.)
    *e 85 mm (3.35 in.) *f 37 mm (1.46 in.)
    *g 13 mm (0.512 in.) *h 18 mm (0.709 in.)
    *i 33 mm (1.30 in.) - -

    1. Using an E8 "TORX" socket wrench, install the stud bolts labeled A.

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

    2. Apply adhesive to the hole for the stud bolt labeled B in the cylinder block. Using an E7 "TORX" socket wrench, install the stud bolt labeled B.

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

      Tech Tips

      When reusing a stud bolt, apply adhesive to the bolt before installing it.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using an E7 "TORX" socket wrench, install the stud bolts labeled C.

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

  3. INSTALL STRAIGHT PIN

    Tech Tips

    It is not necessary to remove a straight pin unless it is being replaced.


    1. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

      A01BEFTE05
      Text in Illustration
      *a Height *b Wide
      *c Protrusion Height *d Rear Side
      Standard Straight Pin
      Item Height Width Protrusion
      Pin A 22 mm (0.866 in.) 10 mm (0.394 in.) 13 mm (0.512 in.)
      Pin B 14 mm (0.551 in.) 6.0 mm (0.236 in.) 5.5 mm (0.217 in.)

  4. INSTALL RING PIN

    Tech Tips

    It is not necessary to remove a ring pin unless it is being replaced.


    1. Using a plastic-faced hammer, tap in new ring pins to the cylinder block.

      A01BGCCE05
      Text in Illustration
      *a Front Side *b Lower Side
      *c Upper Side *d Height
      *e Width *f Protrusion
      Standard Ring Pin
      Item Height Width Protrusion
      Pin A 9.0 mm (0.354 in.) 11 mm (0.433 in.) 3.5 to 4.5 mm (0.138 to 0.177 in.)
      Pin B 20 mm (0.787 in.) 14 mm (0.511 in.) 7.0 to 9.0 mm (0.276 to 0.354 in.)
      Pin C 14 mm (0.511 in.) 15 mm (0.591 in.) 7.5 to 9.5 mm (0.295 to 0.374 in.)

  5. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Apply adhesive to the cylinder block water drain cock sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01BBXAE03
      Text in Illustration
      *a Allowable Range
      *b Target Direction
      *c Upper Side
      *d Front

      Install the cylinder block water drain cock sub-assembly as shown in the illustration.

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

      Note


      • Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assembly to the specified torque.

      • Do not loosen the cylinder block water drain cock sub-assembly to adjust it. If an adjustment is necessary, remove the cylinder block water drain cock sub-assembly and reinstall it.

    3. Install the water drain cock plug to the cylinder block water drain cock sub-assembly.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  6. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Using an E7 "TORX" socket wrench, install the 4 No. 1 oil nozzle sub-assemblies.

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

  7. INSTALL CONNECTING ROD SMALL END BUSH


    1. A01BCICE13
      Text in Illustration
      *a Oil Hole

      Align the oil holes of a new bush and the connecting rod.

    2. A01BAS9E05

      Using SST and a press, press in the bush.

      SST
      09222-30010
    3. A01BEJ9

      Using a pin hole grinder, hone the bush to obtain the standard specified clearance Click here between the bush and piston pin.

    4. Check that the piston pin fits at normal room temperature.


      1. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

  8. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. Assemble the piston and connecting rod.


      1. A01BD02E08
        Text in Illustration
        *a Service Hole Cutout Portion

        Using a screwdriver, install a new snap ring at one end of the piston pin hole.

        Tech Tips

        Make sure that the end gap of the snap ring is not aligned with the service hole cutout portion of the piston.

      2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

      3. Coat the piston pin with engine oil.

      4. A01BD0CE04
        Text in Illustration
        *a Front Mark

        Align the front marks of the piston and connecting rod and push in the piston pin with your thumb.

        Tech Tips

        The piston and pin are a matched set.

      5. A01BD02E09
        Text in Illustration
        *a Service Hole Cutout Portion

        Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

        Tech Tips

        Make sure that the end gap of the snap ring is not aligned with the service hole cutout portion of the piston.

      6. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

  9. INSTALL PISTON RING SET


    1. Install the oil ring expander and 2 side rails by hand.

    2. A01BFM4E01
      Text in Illustration
      *1 No. 2 Compression Ring
      *a Code Mark (2N)
      A01BAZL Upward

      Using a piston ring expander, install the 2 compression rings with the code mark as shown in the illustration.

      Tech Tips

      A01BE4EE06

      • The No. 1 compression ring is reversible.

      • Install the No. 2 compression ring with the code mark (2N) facing upward.

    3. A01BATIE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring
      *4 Oil Ring Expander
      *5 No. 1 Compression Ring and Oil Ring
      A01BAZL Front

      Position the piston rings so that the ring ends are as shown in the illustration.

      Note

      Do not align the compression ring ends.

  10. INSTALL CRANKSHAFT BEARING

    Note

    Do not apply engine oil to the contact area or backside of the bearing.

    Tech Tips

    The crankshaft bearing cap bolts are tightened in 2 progressive steps.


    1. Clean the main journal and both surfaces of the bearing.

    2. Install the upper bearing.


      1. A01BENXE04
        Text in Illustration
        *a CORRECT
        *b INCORRECT
        *c Oil Groove

        Install the upper bearing to the cylinder block as shown in the illustration.

        Note


        • Do not apply engine oil to the bearings or their contact surfaces.

        • Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.

    3. A01BFZUE02
      Text in Illustration
      *1 Lower Bearing
      *2 Bearing Cap

      Install the lower bearing.


      1. Install the lower bearing to the bearing cap.

      2. Using a vernier caliper, measure the distance between the bearing cap edge and lower bearing edge.

        Dimension (A - B) or (B - A)
        0.3 mm (0.0118 in.) or less
        Reference (Dimension of (A) or (B))
        Item Specified Condition
        # 1, 5 journal 3.83 mm (0.151 in.)
        # 3 journal 1.74 mm (0.0685 in.)
        # 2, 4 journal 2.75 mm (0.108 in.)

        Note

        Do not apply engine oil to the bearings or their contact surfaces.

    4. With the upper bearing and lower bearing installed, use a plastic-faced hammer to install the bearing caps to the cylinder block.

      Note

      Make sure that the bearing caps are installed in the correct positions and facing in the correct direction.

    5. A01BGJUE04
      Text in Illustration
      *a Misalignment

      Using a vernier caliper, measure the amount of misalignment between the upper bearing and lower bearing as shown in the illustration.

      Standard misalignment
      0.9 mm (0.0354 in.) or less

    6. Remove the bearing cap.

    7. Apply engine oil to the thrust washers.

    8. A01BCXAE03
      Text in Illustration
      *a Oil Groove

      Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil grooves facing outward.

      Note

      Be careful when installing the upper and lower thrust washers as they are similar but cannot be interchanged.

    9. A01BHCFE04
      Text in Illustration
      *a Claw
      *b Oil Groove

      Install the 2 thrust washers to the No. 3 bearing cap with the grooves facing outward.

      Note

      Be careful when installing the upper and lower thrust washers as they are similar but cannot be interchanged. The lower thrust washers have a claw as shown in the illustration.

    10. Apply engine oil to the lower bearing.

  11. INSTALL CRANKSHAFT


    1. Apply engine oil to the upper bearing, and then place the crankshaft on the cylinder block.

    2. A01BB7E

      Install the 5 crankshaft bearing caps to their proper locations.

    3. Install the crankshaft bearing cap bolts.


      1. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

      2. Temporarily install the crankshaft bearing cap bolts.

        Tech Tips

        The main bearing cap bolts are tightened in 2 progressive steps.

      3. A01BI5RE01

        Step 1:

        Uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.

        Torque:
        39 N*m  { 398 kgf*cm, 29 ft.*lbf }

        If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.

      4. Mark the front of the bearing cap bolts with paint.

      5. Step 2:

        Tighten the bearing cap bolts 90° in the sequence shown in step 1.

      6. Check that the paint marks are now at a 90° angle to the front.

    4. Check that the crankshaft turns smoothly.

  12. INSPECT CRANKSHAFT THRUST CLEARANCE


    1. A01BFJP

      Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard thrust clearance
      0.02 to 0.22 mm (0.000787 to 0.00866 in.)
      Maximum thrust clearance
      0.30 mm (0.0118 in.)

      If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

      Thrust washer thickness
      2.440 to 2.490 mm (0.0961 to 0.0980 in.)

  13. INSTALL CONNECTING ROD BEARING


    1. A01BAH1E04
      Text in Illustration
      *a Claw

      Align the bearing claw with the groove of the connecting rod or connecting cap.

    2. Install the bearings in the connecting rod and connecting rod cap.

      Note

      Clean the backside of the bearing and the bearing surface of the connecting rod.

  14. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.

    2. A01BATIE01
      Text in Illustration
      *1 No. 1 Compression Ring
      *2 No. 2 Compression Ring
      *3 Oil Ring
      *4 Oil Ring Expander
      *5 No. 1 Compression Ring and Oil Ring
      A01BAZL Front

      Position the piston rings so that the ring ends are as shown in the illustration.

      Note

      Do not align the compression ring ends.

    3. A01BG4GE04
      Text in Illustration
      *a Front
      *b Front Mark

      Using a piston ring compressor, push the numbered piston and connecting rod assembly into the correct cylinder with the front mark of the piston facing forward.

    4. Match the numbered connecting rod cap with the correct connecting rod.

    5. A01BHD1E07
      Text in Illustration
      *a Front Mark

      Check that the front mark of the connecting rod cap is facing forward.

    6. Install the connecting rod cap bolts.

      Tech Tips

      The connecting rod cap bolts are tightened in 2 progressive steps.


      1. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.

      2. A01BG8ZE01

        Step 1:

        Install and alternately tighten the bolts of the connecting rod cap in several steps.

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

      3. Mark the front of each connecting rod cap bolt with paint.

      4. Step 2:

        Tighten the cap bolts 90° as shown.

      5. Check that the paint marks are now at a 90° angle to the front.

    7. Check that the crankshaft turns smoothly.

  15. INSPECT CONNECTING ROD THRUST CLEARANCE


    1. A01BATH

      Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard thrust clearance
      0.15 to 0.35 mm (0.00591 to 0.0138 in.)
      Maximum thrust clearance
      0.40 mm (0.0157 in.)

      If the thrust clearance is more than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

  16. INSTALL INTAKE VALVE GUIDE BUSH


    1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Standard Bush Bore Diameter
      Item Specified Condition
      STD 10.285 to 10.306 mm (0.405 to 0.406 in.)
      O/S 0.05 10.335 to 10.356 mm (0.407 to 0.408 in.)

      If the bush bore diameter of the cylinder head is more than 10.306 mm (0.406 in.), machine the bush bore so that the diameter is between 10.335 and 10.356 mm (0.407 and 0.408 in.).

      If the bush bore diameter of the cylinder head is more than 10.356 mm (0.408 in.), replace the cylinder head.

    2. Select a new valve guide bush.

      New Valve Guide Bush
      Item Specified Condition
      Bush Bore Diameter 10.333 to 10.344 mm (0.4068 to 0.4072 in.) 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
      Bush to be Used STD O/S 0.05

      Tech Tips

      Standard bush length: 43.0 to 44.0 mm (1.69 to 1.73 in.)

    3. Heat the cylinder head to 80 to 100°C (176 to 212°F).

    4. Place the cylinder head on wooden blocks.

    5. A01BGCZE04
      Text in Illustration
      *a Protrusion Height

      Using SST and a hammer, tap in a new valve guide bush to the specified protrusion height.

      SST
      09201-01055
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      9.8 to 10.2 mm (0.386 to 0.402 in.)
    6. A01BCFB

      Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard clearance between the guide bush and valve stem.

      Standard oil clearance
      0.025 to 0.060 mm (0.000984 to 0.00236 in.)

  17. INSTALL EXHAUST VALVE GUIDE BUSH


    1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Standard Bush Bore Diameter
      Item Specified Condition
      STD 10.285 to 10.306 mm (0.405 to 0.406 in.)
      O/S 0.05 10.335 to 10.356 mm (0.407 to 0.408 in.)

      If the bush bore diameter of the cylinder head is more than 10.306 mm (0.406 in.), machine the bush bore so that the diameter is between 10.335 and 10.356 mm (0.407 and 0.408 in.).

      If the bush bore diameter of the cylinder head is more than 10.356 mm (0.408 in.), replace the cylinder head.

    2. Select a new valve guide bush.

      New Valve Guide Bush
      Item Specified Condition
      Bush Bore Diameter 10.333 to 10.344 mm (0.4068 to 0.4072 in.) 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
      Bush to be Used STD O/S 0.05

      Tech Tips

      Standard bush length: 43.0 to 44.0 mm (1.69 to 1.73 in.)

    3. Heat the cylinder head to 80 to 100°C (176 to 212°F).

    4. Place the cylinder head on wooden blocks.

    5. A01BGPWE04
      Text in Illustration
      *a Protrusion Height

      Using SST and a hammer, tap in a new valve guide bush to the specified protrusion height.

      SST
      09201-01055
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      7.6 to 8.0 mm (0.299 to 0.315 in.)
    6. A01BG5R

      Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard clearance between the guide bush and valve stem.

      Standard oil clearance
      0.030 to 0.065 mm (0.00118 to 0.00256 in.)

  18. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove a ring pin unless it is being replaced.

    A01BHSHE07

    1. Remove the ring pins.

    2. Using a plastic-faced hammer, tap in a new ring pin until the pin stops.

      Standard Ring Pin
      Item Height Width Protrusion Height
      Ring pin 7 mm (0.276 in.) 10 mm (0.394 in.) 2.5 to 3.8 mm (0.0984 to 0.150 in.)
      Text in Illustration
      *a Height
      *b Width
      *c Protrusion Height

  19. INSTALL STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.

    A01BCBXE08
    Text in Illustration
    *a Cylinder Head Upper Side *b Intake Side
    *c Front Side *d Exhaust Side
    *e 21 mm (0.827 in.) *f 34 mm (1.34 in.)
    *g 9.0 mm (0.354 in.) *h 24 mm (0.945 in.)
    *i 45 mm (1.77 in.) *j 13 mm (0.512 in.)
    *k 20 mm (0.787 in.) *l 35 mm (1.38 in.)

    1. Using E6, E7 and E8 "TORX" socket wrenches, install the stud bolts.

      Torque:
      for stud bolt A
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }
      for stud bolt B and C
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  20. INSTALL NO. 1 HEAD STRAIGHT SCREW PLUG

    Note

    If coolant leaks from a No. 1 head straight screw plug or a plug is corroded, replace it.


    1. Using a 10 mm hexagon wrench, install 3 new gaskets and the No. 1 head straight screw plugs.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  21. INSTALL NO. 2 HEAD STRAIGHT SCREW PLUG

    Note

    If coolant leaks from the No. 2 head straight screw plug or the plug is corroded, replace it.


    1. Using a 19 mm hexagon wrench, install a new gasket and the No. 2 head straight screw plug.

      Torque:
      90 N*m  { 918 kgf*cm, 66 ft.*lbf }

  22. INSTALL OIL CONTROL VALVE FILTER


    1. Check that no foreign matter is on the mesh part of the filter.

      If foreign objects are present, clean the part thoroughly.

    2. Using an 8 mm hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  23. INSTALL VALVE SPRING SEAT


    1. Install the 16 valve spring seats to the cylinder head.

  24. INSTALL VALVE STEM OIL SEAL


    1. A01BB1GE06
      Text in Illustration
      *a Intake Side
      *b Exhaust Side
      *c Gray
      *d Black

      Apply a light coat of engine oil to new oil seals.

      Note

      Pay attention when installing the intake and exhaust oil seals. Installing an intake oil seal to the exhaust side or installing an exhaust oil seal to the intake side can cause installation problems later.

      Tech Tips

      The intake valve oil seals are gray and the exhaust valve oil seals are black.

    2. A01BEZ6E02
      Text in Illustration
      *1 Valve Stem Oil Seal

      Using SST, push in the 16 oil seals to install them.

      SST
      09201-41020

      Note

      Failure to use SST will cause the seal to be damaged or improperly seated.

  25. INSTALL INTAKE VALVE


    1. A01BBT0E05
      Text in Illustration
      *a 30 mm (1.18 in.) or more

      Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

    2. Install the valve, compression spring and spring retainer to the cylinder head.

      Note

      Install the same parts in the same combination to the original locations.

    3. A01BANCE01

      Using SST and wooden blocks, compress the spring and install the 2 retainer locks.

      SST
      09202-70020   ( 09202-00010 )

    4. Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

      Note

      Do not damage the valve stem tip.

  26. INSTALL EXHAUST VALVE


    1. A01BHD0E05
      Text in Illustration
      *a 30 mm (1.18 in.) or more

      Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.

    2. Install the valve, compression spring and spring retainer to the cylinder head.

      Note

      Install the same parts in the same combination to the original locations.

    3. A01BHPME01

      Using SST and wooden blocks, compress the spring and install the 2 retainer locks.

      SST
      09202-70020   ( 09202-00010 )

    4. Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

      Note

      Do not damage the valve stem tip.

  27. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Install 2 new gaskets and 2 straight screw plugs to the oil filter bracket sub-assembly.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

    2. Install 2 new O-rings, gasket and oil filter bracket with the union bolt and nut.

      Torque:
      for union bolt
      69 N*m  { 699 kgf*cm, 51 ft.*lbf }
      for nut
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Apply a light coat of engine oil to the new O-rings.

  28. INSTALL OIL FILTER ELEMENT


    1. Clean the inside of the oil filter cap, its threads and its O-ring groove.

    2. A01BH5JE01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

      Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

      Note


      • Be sure to install the O-ring in the proper location, otherwise oil may leak.

      • Do not twist the O-ring.

    3. Set a new oil filter element in the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

    6. A01BD1NE01
      Text in Illustration
      *1 Oil Filter Cap
      *2 O-Ring
      *3 Oil Filter Bracket
      *a No Gap

      Using SST, tighten the oil filter cap.

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

  29. INSTALL REAR CRANKSHAFT OIL SEAL


    1. A01BFQKE03
      Text in Illustration
      *a Wooden Block

      Place the rear engine oil seal retainer on wooden blocks.

    2. Using SST, tap in a new rear crankshaft oil seal until its surface is flush with the rear engine oil seal retainer edge.

      SST
      09223-15030
      09950-70010   ( 09951-07150 )

      Note

      Do not tap the rear crankshaft oil seal at an angle.

    3. Apply a light coat of MP grease to the lip of a new oil seal.

      Note


      • Do not allow foreign matter to contact the lip of the rear crankshaft oil seal.

      • Do not allow MP grease to contact the dust seal.

  30. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. A01BHGHE05
      Text in Illustration
      *a Seal Packing

      Apply seal packing in a continuous bead as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal width
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the crankcase within 3 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installing.

    2. Install the rear engine oil seal retainer with the 6 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  31. INSTALL CYLINDER HEAD GASKET


    1. A01BF1SE07
      Text in Illustration
      *a Lot No.
      A01BAZL Front

      Place a new cylinder head gasket on the cylinder block surface with the lot No. stamp facing upward.

      Note

      Make sure that the cylinder head gasket is installed so that it is facing in the correct direction.

  32. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head set bolts are tightened in 3 successive steps.


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

      Note


      • Make sure that no oil is on the mounting surface of the cylinder head sub-assembly.

      • Place the cylinder head sub-assembly on the cylinder block gently so as not to damage the gasket with the bottom part of the head.

    2. Install the plate washers to the cylinder head set bolts.

    3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

    4. A01BBAVE05

      Step 1:

      Using several steps, install and uniformly tighten the 10 cylinder head set bolts with plate washers in the sequence shown in the illustration.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    5. Mark the front of each cylinder head set bolt head with paint.

    6. Step 2:

      Tighten the cylinder head set bolts 90° in the sequence shown in step 1.

    7. Step 3:

      Tighten the cylinder head set bolts another 90° in the sequence shown in step 1.

    8. Check that the paint marks are now at a 180° angle to the front.

  33. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET


    1. Mount the No. 2 camshaft in a vise and install the camshaft timing gear or sprocket to the No. 2 camshaft with the bolt.

      Torque:
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

      Note

      Do not damage the No. 2 camshaft in the vise.

  34. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01BCSDE02
      Text in Illustration
      *1 Straight Pin
      *2 Pin Hole

      Align the pin hole and straight pin and install the camshaft timing gear assembly to the camshaft.

    2. Lightly press the gear against the camshaft and turn the gear. Push further at the position where the pin enters the groove.

      Note

      Be sure not to turn the camshaft timing gear assembly in the retard direction (the right angle).

    3. Check that there is no gap between the camshaft timing gear and the flange of the camshaft.

      Note


      • Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

      • Be sure not to remove the other 3 bolts. If removing the bolts, exchange the camshaft timing gear assembly.

    4. With the camshaft timing gear assembly fixed in place, install the flange bolt.

      Torque:
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

    5. Check that the camshaft timing gear assembly can move in the retard direction (the right angle), and is locked at the most retarded position.

  35. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect each valve lash adjuster assembly before installing it Click here.

    2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

      Install each valve lash adjuster assembly to the same place it was removed from.

  36. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem ends.

    2. Install the 16 valve stem caps to the cylinder head sub-assembly.

      Note

      Do not drop the valve stem caps into the cylinder head sub-assembly.

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


    1. Apply clean engine oil to the valve lash adjuster assembly tips and valve stem cap surfaces.

    2. A01BGIOE01
      Text in Illustration
      *1 Valve Stem Cap
      *2 Valve Rocker Arm
      *3 Valve Lash Adjuster
      *a CORRECT
      *b INCORRECT

      Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note

      Install the valve stem cap, valve lash adjuster assembly and No. 1 valve rocker arm sub-assembly to the same places they were removed from.

  38. INSTALL CAMSHAFT


    1. A01BGADE01

      Apply clean engine oil to the camshaft cams and cylinder head journals.

    2. Position the camshaft and No. 2 camshaft as shown in the illustration.

  39. INSTALL CAMSHAFT BEARING CAP


    1. A01BCGT

      Temporarily install the No. 1 camshaft bearing cap.

    2. Confirm the location for each No. 2 camshaft bearing cap and install each one to the proper location.

    3. A01BC5XE02
      Text in Illustration
      *1 O-Ring

      Install a new O-ring to the No. 1 camshaft bearing cap.

    4. Temporarily install the oil delivery pipe.

    5. A01BCRRE04

      Install the 21 bolts and tighten them in the order shown in the illustration.

      Torque:
      for bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      except bolt A
      16 N*m  { 158 kgf*cm, 11 ft.*lbf }

  40. INSTALL OIL JET


    1. Install a new gasket and oil jet with the bolt.

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

  41. INSTALL CRANKSHAFT PULLEY SET KEY


    1. Install the 2 crankshaft pulley set keys to the crankshaft.

  42. INSTALL CRANK POSITION SENSOR ROTOR


    1. A01BAS3E06
      Text in Illustration
      *1 Crankshaft Pulley Set Key
      *a Front Mark
      *b Key Groove

      Install the crankshaft position sensor rotor with the front mark facing forward.

  43. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. Install the No. 1 chain vibration damper with the 2 bolts.

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

  44. INSTALL CHAIN SUB-ASSEMBLY


    1. A01BGXWE09
      Text in Illustration
      *1 Key
      *a Timing Mark
      *b Mark Plate (Yellow)
      *c Mark Plate (Orange)

      As shown in the illustration, install the chain sub-assembly to the camshaft timing gear or sprocket and camshaft timing gear assembly with the mark plates aligned with the timing marks on the camshaft timing gear or sprocket and camshaft timing gear assembly.

      Tech Tips


      • The camshaft mark plate is yellow.

      • The crankshaft mark plate is orange.

    2. A01BDT5E01

      Use a rope to secure the chain sub-assembly of the crankshaft timing sprocket. Tie the rope near the crankshaft timing sprocket.

      Note

      After the chain tensioner has been installed, the rope must be removed.

      Tech Tips

      The rope is used to prevent the chain sub-assembly from jumping a tooth.

  45. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  46. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01BBLJE15
      Text in Illustration
      *1 Plunger
      *a Stopper Plate
      *b Hexagon Wrench

      Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

    3. Install a new gasket and the No. 1 chain tensioner assembly with the bolt and nut.

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

  47. INSTALL TIMING CHAIN GUIDE


    1. Install a new O-ring and the timing chain guide with the 2 bolts.

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

  48. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. Apply MP grease to the lip of a new timing chain case oil seal.

      Note


      • Do not allow foreign matter to contact the lip of the timing chain case oil seal.

      • Do not allow MP grease to contact the dust seal.

    2. Temporarily install the timing chain case oil seal to the timing chain or belt cover sub-assembly.

    3. Place the timing chain or belt cover sub-assembly on the wooden blocks.

    4. A01BAXTE02
      Text in Illustration
      *a Wooden Block

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

      SST
      09223-75010
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  49. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. Install a new gasket and the engine water pump assembly with the 8 bolts.

      Torque:
      8.9 N*m  { 91 kgf*cm, 79 in.*lbf }

  50. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01BCSVE01
      Text in Illustration
      *1 Timing Chain Cover O-ring
      *2 Water Pump O-ring
      *3 Oil Pump O-ring

      Install 3 new O-rings to the timing chain or belt cover sub-assembly as shown in the illustration.

    2. Apply adhesive to the timing chain cover plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using a 10 mm socket hexagon wrench, install the timing chain cover plug.

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }

    4. Apply seal packing in a continuous bead to the timing chain or belt cover sub-assembly as shown in the following illustration.

      A01BHCUE01
      Text in Illustration
      *1 Cylinder Head *2 Cylinder Block
      *3 Seal Packing - -
      *a Seal Packing Thickness *b Seal Packing Width
      *c Protrusion - -
      Application Specification
      Area Seal Packing Diameter Distance from Edge of Cover to Center of Seal Packing Seal Packing Application Length Protrusion from Cylinder Head

      A - A

      (Dashed line)

      		 2.5 to 4.0 mm (0.0984 to 0.157 in.) 2.0 mm (0.0787 in.) - -

      B - B

      (Continuous line)

      		 10 to 14 mm (0.394 to 0.551 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick 6.0 mm (0.236 in.) 40 mm (1.57 in.) from top of bolt hole -

      C - C

      (Continuous line)

      		 10 to 14 mm (0.394 to 0.551 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick 6.0 mm (0.236 in.) 49 mm (1.93 in.) from top of bolt hole -

      D - D

      (Continuous line)

      		 9.0 to 13 mm (0.354 to 0.512 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick - 13 mm (0.512 in.) from top of bolt hole -

      E - E

      (Continuous line)

      		 9.0 to 13 mm (0.354 to 0.512 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick - 13 mm (0.512 in.) from top of bolt hole -

      I - I

      (Continuous line)

      		 8.0 mm (0.315 in.) - 56.5 mm (2.22 in.) from bottom of cylinder head 5.0 to 6.0 mm (0.0197 to 0.236 in.)
      J 10 mm (0.394 in.) - 20 mm (0.787 in.) -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after the installation.

    5. A01BDOPE02
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft Timing Gear

      Align the drive rotor spline of the oil pump and the crankshaft timing gear as shown in the illustration.

    6. Install the timing chain or belt cover sub-assembly.


      1. Loosely install the timing chain or belt cover sub-assembly with the 16 bolts and nut but do not tighten the bolts and nuts yet.

        A01BA7UE01
        Text in Illustration
        *1 Nut - -
        *a Area 1 *b Area 2
        *c Area 3 *d Area 4

      2. Excluding the bolts labeled A and F, tighten the bolts and nuts in this order: Area 1, Area 3, Area 2.

        Torque:
        for bolt C
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }
        for bolt A, D and nut
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }
        Bolt Length
        Item Length Thread Diameter
        Bolt A 75 mm (2.95 in.) 10 mm (0.394 in.)
        Bolt B 75 mm (2.95 in.) 8 mm (0.315 in.)
        Bolt C 90 mm (3.54 in.) 8 mm (0.315 in.)
        Bolt D 95 mm (3.74 in.) 8 mm (0.315 in.)
        Bolt E 35 mm (1.38 in.) 8 mm (0.315 in.)
        Bolt F 75 mm (2.95 in.) 10 mm (0.394 in.)

      3. Tighten the bolts labeled B in this order: Area 2 and Area 3.

        Torque:
        60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      4. Tighten the bolts labeled F.

        Torque:
        46 N*m  { 469 kgf*cm, 34 ft.*lbf }

      5. Tighten the bolts labeled E in area 4.

        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      6. A01BCNX

        Remove the seal packing from the 2 bolt holes for the No. 1 compressor mounting bracket.

        Note

        Do not use any cleaners to remove the seal packing.

  51. INSTALL OIL PAN SUB-ASSEMBLY

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. Install the stud bolt.


      1. Using an E5 "TORX" socket wrench, install the stud bolts labeled A for the oil pan sub-assembly as shown in the illustration.

      2. Using an E8 "TORX" socket wrench, install the stud bolts labeled B for the oil strainer sub-assembly as shown in the illustration.

        A01BDXOE07
        Text in Illustration
        *1

        Stud Bolt A

        (Oil Strainer)

        		 *2

        Stud Bolt B

        (Oil Pan)
        *a 20.0 mm (0.787 in.) *b 13.0 mm (0.512 in.)
        *c 8.0 mm (0.315 in.) *d 35.0 mm (1.38 in.)
        *e 18.0 mm (0.709 in.) *f 8.5 mm (0.335 in.)
        Torque:
        for stud bolt A
        7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
        for stud bolt B
        3.0 N*m  { 31 kgf*cm, 27 in.*lbf }
    2. A01BD08E06
      Text in Illustration
      *a 8.0 mm (0.315 in.)
      *b 6.5 mm (0.256 in.)
      *c Seal Packing
      *d Seal Width

      Apply seal packing in a continuous bead as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal width
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installing.

    3. Install a new O-ring to the timing chain cover sub-assembly.

    4. A01BAP2E03
      Text in Illustration
      *1 Nut

      Temporarily install the oil pan sub-assembly with the 16 bolts and 2 nuts.

      Bolt Length
      Item Length
      Bolt A 20 mm (0.787 in.)
      Bolt B 40 mm (1.57 in.)

    5. Uniformly tighten the 16 bolts and 2 nuts in the sequence shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  52. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts to the oil pan sub-assembly.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  53. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01BF9LE04
      Text in Illustration
      *a 6.0 mm (0.236 in.)
      *b Seal Packing
      *c Seal Width

      Apply seal packing in a continuous bead as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installing.

    2. A01BA53E02

      Temporarily install the No. 2 oil pan sub-assembly with the 18 bolts and 2 nuts.

    3. Uniformly tighten the 18 bolts and 2 nuts in the sequence shown in the illustration.

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

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

      Torque:
      38 N*m  { 382 kgf*cm, 28 ft.*lbf }

  54. INSTALL CRANKSHAFT PULLEY


    1. Align the key groove of the pulley with the pulley set key and slide on the crankshaft pulley.

    2. A01BHWLE01

      Using SST, install a new crankshaft pulley bolt.

      Torque:
      260 N*m  { 2650 kgf*cm, 192 ft.*lbf }
      SST
      09213-54015   ( 91651-60855 )
      09330-00021

      Note

      Do not reuse the crankshaft pulley bolt.

  55. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install a new cylinder head cover gasket and new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly.

    2. A01BBP5E04
      Text in Illustration
      *a Seal Packing

      Apply seal packing as shown in the illustration.

      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 sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installing.

    3. Temporarily install the cylinder head cover sub-assembly with the 19 bolts and 2 nuts.

    4. A01BCT5E03
      Text in Illustration
      *1 Nut

      Tighten the bolts (A) shown in the illustration.

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

    5. Tighten the bolts (B) shown in the illustration.

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

      Tech Tips

      Make sure the tightening torque of bolts (A).

  56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. Apply a light coat of engine oil to the O-ring of the camshaft timing oil control valve assembly.

    2. Install the camshaft timing oil control valve assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • When reusing the camshaft timing oil control valve assembly, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the camshaft timing oil control valve assembly.

    3. Connect the camshaft timing oil control valve connector.

  57. INSTALL CRANKSHAFT POSITION SENSOR


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

    2. Install the crankshaft position sensor with the bolt.

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

      Note


      • When reusing the crankshaft position sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the crankshaft position sensor.

    3. Connect the crankshaft position sensor connector and attach the 2 wire harness clamps.

  58. INSTALL CAMSHAFT POSITION SENSOR


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

    2. Install the camshaft position sensor with the bolt.

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

      Note


      • When reusing the camshaft position sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the camshaft position sensor.

    3. Connect the camshaft position sensor connector.

  59. INSTALL PCV VALVE SUB-ASSEMBLY


    1. A01BEBLE01
      Text in Illustration
      *1 O-Ring

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

    2. Install the PCV valve sub-assembly.

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

      Tech Tips

      When reusing the PCV valve sub-assembly, inspect the O-ring.

      If the O-ring has scratches or cuts, replace the PCV valve sub-assembly.

    3. Connect the PCV hose to the PCV valve sub-assembly, and slide the clamp to secure the hose.

  60. INSTALL OIL FILLER CAP SUB-ASSEMBLY