ENGINE UNIT REASSEMBLY


  1. INSTALL REAR CRANKSHAFT OIL SEAL


    1. A01DSR2E01

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

      SST
      09223-15030
      09950-70010   ( 09951-07100 )

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

  2. INSTALL REAR CRANKSHAFT OIL SEAL RETAINER


    1. Install a new gasket and the retainer with the 4 bolts.

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

  3. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A01DQCSE02

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

      SST
      09214-60010

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

  4. INSTALL TIMING BELT CASE SUB-ASSEMBLY


    1. Place a new gasket on the cylinder block.

    2. Install the timing belt case with the 5 bolts.

      Torque:
      23 N*m  { 230 kgf*cm, 17 ft.*lbf }

  5. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

      Torque:
      for nut
      21 N*m  { 210 kgf*cm, 17 ft.*lbf }
      for bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  6. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old packing (FIPG) material and do not drop any oil on the contact surfaces of the oil pan and cylinder block.


      • Using a gasket scraper, remove all the old packing (FIPG) material from the installation surface.

      • Thoroughly clean all components to remove all the loose material.

      • Using a non-residue solvent, clean both of the sealing surfaces.

        Note

        Do not use a solvent which will affect the painted surfaces.

    2. A01DQDXE01
      Text in Illustration
      *1 Seal Packing
      *a Timing Belt Case Contact Portion
      *b Rear Oil Seal Retainer Contact Portion

      Apply seal packing to the oil pan as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Application Specification
      Item Seal Packing Diameter Seal Packing Application Length
      Dashed line 7.0 mm (0.276 in.) 128 mm (5.04 in.)
      Continuous line 5.0 mm (0.197 in.) -

      Tech Tips


      • Do not apply an excessive amount to the surface, especially near the oil passages.

      • Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

    3. Install the oil pan with the 16 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several steps.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  7. INSTALL CRANKSHAFT TIMING PULLEY


    1. A01DOSXE04
      Text in Illustration
      *a Inside

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

    2. Using SST and a hammer, tap in the timing pulley with the flange side facing inward.

      SST
      09223-46011

  8. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. A01DNHUE05

      Install the No. 1 belt idler with the 3 bolts.

      Torque:
      for bolt A
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      for bolt B, C
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips

      A01DMBME03

      • The bolt lengths for bolt A, B and C as follows.

      • Bolt C is combined with the No. 1 timing belt idler.

      Standard Bolt
      Item Length
      A 76.5 mm (3.01 in.)
      B 42.9 mm (1.69 in.)
      C 41.3 mm (1.63 in.)

  9. INSTALL WATER PUMP ASSEMBLY


    1. Install a new gasket, the water pump and tension spring bracket with the 6 bolts.

      Torque:
      23 N*m  { 236 kgf*cm, 17 ft.*lbf }

  10. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY


    1. Install the spacer and No. 2 timing belt idler with the bolt.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

    2. Check that the No. 2 timing belt idler moves smoothly.

  11. INSTALL CYLINDER HEAD GASKET


    1. Check the piston protrusion for each cylinder.


      1. A01DMBXE02
        Text in Illustration
        *a Measuring Tip
        *b Protrusion

        Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.

      2. A01DTCDE04
        Text in Illustration
        *a Measuring Point
        A01DQPB Front

        Measure the protrusion of each cylinder at 2 places as shown in the illustration, making a total of 8 measurements.

      3. For the piston protrusion value of each cylinder, use the average of the 2 measurements of that cylinder.

        Standard protrusion
        0.68 to 0.98 mm (0.0268 to 0.0386 in.)

        After installing the piston and connecting rod assembly, if the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    2. A01DM2RE04
      Text in Illustration
      *1 Cutout Mark
      A01DQPB Front

      Select a new cylinder head gasket.

      Tech Tips

      There are 3 sizes of new cylinder head gaskets, marked "B", "D" or "F" accordingly.

      New Cylinder Head Gasket Thickness
      Item Specified Condition
      Mark B 1.40 to 1.50 mm (0.0551 to 0.0591 in.)
      Mark D 1.50 to 1.60 mm (0.0591 to 0.0630 in.)
      Mark F 1.60 to 1.70 mm (0.0630 to 0.0669 in.)

      1. Select the largest piston protrusion value from the measurements made, then select a new appropriate gasket according to the table below.

        Gasket Size
        Piston Protrusion Gasket Size
        0.68 to 0.78 mm (0.0268 to 0.0307 in.) Use B
        0.78 to 0.88 mm (0.0307 to 0.0346 in.) Use D
        0.88 to 0.98 mm (0.0346 to 0.0385 in.) Use F
    3. A01DOGSE01

      Install the selected cylinder head gasket to the cylinder block.

      Note

      Make sure that the gasket is installed facing the proper direction.

      Be careful of the installation direction.

  12. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    • If any bolt is broken or deformed, replace it.


    1. A01DPVB

      Using the crankshaft pulley bolt, turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

      Text in Illustration
      A01DQPB Turn

    2. Place the cylinder head on the cylinder block.

      Note


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

      • Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

    3. Install the plate washers to the cylinder head bolts.

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

    5. Step 1:


      1. A01DS00E01

        Install and uniformly tighten the 18 cylinder head bolts, in several steps, in the sequence shown in the illustrations.

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

        Tech Tips

        Each bolt length is indicated below.

        Standard Bolt
        Item Length
        Bolt A 107 mm (4.21 in.)
        Bolt B 127 mm (5.00 in.)

        If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder set head bolt.

    6. Step 2:


      1. Mark the front side of each cylinder head bolt head with paint.

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

    7. Step 3:


      1. Tighten the cylinder head 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.

  13. INSTALL CAMSHAFT


    1. A01DOGME05
      Text in Illustration
      *1 Timing Mark
      *2 Protrusion

      Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration.

    2. Install the camshaft.


      1. Place the camshaft on the cylinder head with the key groove facing upward.

      2. A01DNW1E01

        Install the 5 bearing caps in their proper locations.

      3. A01DQREE03

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

      4. Install and uniformly tighten the 10 bearing cap bolts in several steps in the sequence shown in the illustration.

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

  14. INSTALL CAMSHAFT OIL SEAL


    1. A01DPEWE02

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

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

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

  15. INSTALL CAMSHAFT OIL SEAL RETAINER


    1. Install a new gasket and the retainer with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG material).

    2. A01DOCTE05
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the cylinder head as shown in the illustration.

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

    3. Install the gasket to the cylinder head cover.

    4. Install the cylinder head cover with the 9 bolts and nut. Uniformly tighten the bolts and nut in several steps.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  17. INSTALL NO. 2 TIMING BELT COVER


    1. Install the timing belt cover with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  18. INSTALL CAMSHAFT TIMING PULLEY


    1. Install the woodruff key to the key groove of the camshaft.

    2. A01DPMJ

      Align the timing mark on the camshaft timing pulley with the timing mark on the No. 2 timing belt cover and temporarily install the pulley with the bolt.

    3. A01DOGWE01

      Using SST, tighten the bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

  19. 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:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the crankshaft position sensor connector.