ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A00595GE19
    *1 Width
    *2 Protrusion Height
    *3 Height

    Note

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


    1. Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

      Standard Ring Pin
      Item Protrusion Height Height Width
      Ring pin 3.0 mm (0.118 in.) 11 mm (0.433 in.) 8 mm (0.315 in.)
  2. INSTALL STIFFENING CRANKCASE STUD BOLT

    A005915E03
    *1 8.5 mm (0.335 in.)
    *2 8.0 mm (0.315 in.)
    *3 18 mm (0.709 in.)

    Note

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


    1. Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
  3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A0052XBE16
      *1 2.0 to 3.0 mm
      *2 4.5 to 5.5 mm

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three bond 1207B or equivalent
      Standard Seal Diameter
      Area Specified Condition
      Continuous Line 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      A 4.5 to 5.5 mm (0.177 to 0.217 in.)
      Application Length A
      56 mm (2.20 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.

    2. A0053QXE08

      Install the stiffening crankcase with the 11 bolts in the sequence shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Specified Condition
      Bolt A 138 mm (5.43 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 70 mm (2.76 in.)
    3. Recheck the torque for bolts 1 and 2.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. Wipe off any excess seal packing with a clean piece of cloth.

  4. INSTALL OIL PUMP ASSEMBLY

    Click here

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  6. INSTALL OIL PAN DRAIN PLUG


    1. A0057YP

      Install a new gasket and the drain plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  7. INSTALL ENGINE REAR OIL SEAL

    Click here

  8. INSTALL NO. 1 TAPER SCREW PLUG


    1. A0054E3E01

      Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note


      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the plug.

    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (B).

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the plug.

  9. INSTALL VENTILATION VALVE SUB-ASSEMBLY

    Click here

  10. INSTALL CYLINDER HEAD GASKET

    Click here

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  12. 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.

      Note

      Do not drop the valve stem caps into the cylinder head.

  13. INSTALL VALVE LASH ADJUSTER ASSEMBLY


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

    2. Install the 16 valve lash adjusters to the cylinder head.

      Note

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

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


    1. A0052SVE34
      Text in Illustration
      *1 Lash Adjuster
      *2 Valve Rocker Arm
      *3 Valve Stem
      *4 Valve Stem Cap

      Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

    2. Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A0059LME06
    *1 Protrusion Height
    *2 Height
    *3 Width

    Note

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


    1. Using a plastic-faced hammer, tap in a new straight pin to the specified protrusion height.

      Standard Ring Pin
      Item Protrusion Height Height Width
      Straight pin 6.5 to 7.5 mm (0.256 to 0.295 in.) 14 mm (0.551 in.) 6.0 mm (0.236 in.)
  16. INSTALL CAMSHAFT HOUSING STUD BOLT

    Note

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

    A0052UKE08
    *1 12 mm (0.472 in.)
    *2 18 mm (0.709 in.)
    *3 48.5 mm (1.91 in.)

    1. Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
  17. INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY


    1. A0058SFE02
      Text in Illustration
      *1 Protrusion

      Install a new O-ring to the continuously variable valve lift controller.

      Note


      • Align the protrusion of the O-ring with the protrusion of the continuously variable valve lift controller.

      • Make sure that the O-ring is not protruding from the groove in the continuously variable valve lift controller.

    2. A0055WM

      Install the control actuator clip to the control actuator connector.

      Tech Tips

      When the continuously variable valve lift controller is new, a control actuator connector is attached to it. Remove the control actuator connector before performing these procedures.

      Note

      Be sure to insert the protrusions of the control actuator clip into the holes in the control actuator connector.

    3. A0057WI

      Install the valve lift control actuator connector to the valve rocker shaft.

      Tech Tips

      There are two types of valve lift control actuator connectors. One type is installed by rotating the connector, and the other type can be installed without being rotated.

    4. Insert the continuously variable valve lift controller into the camshaft housing.

    5. A0055NR

      Install the continuously variable valve lift controller to the camshaft housing with the bolt.

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

      Note

      Do not let the O-ring become jammed between parts.

    6. A0056FL

      Using a screwdriver, slide the control actuator clip from the control actuator connector.

    7. Slide only the upper part of the control actuator clip as the straight pin may fall if the control actuator clip is completely removed.

    8. Using a screwdriver, lightly pry the control actuator connector and align the hole in the control actuator connector with the hole in the continuously variable valve lift controller.

      A00544WE01
      Text in Illustration
      *1 Rocker Shaft
      *2 Clip
      *3 Straight Pin Hole
      *4 Connector
      *5 Controller Shaft

      Note


      • Do not forcefully pry the control actuator connector.

      • Do not damage the camshaft housing or camshaft bearing cap.

    9. A0059CQ

      Insert the straight pin into the control actuator connector.

      Note

      Do not use a tool to insert the straight pin. Insert the straight pin by hand.

      Tech Tips

      If the straight pin is difficult to insert, insert the straight pin while lightly prying the control actuator connector.

    10. Using a screwdriver, install the control actuator clip to the control actuator connector.

      Note

      Insert the protrusion of the control actuator clip into the hole in the control actuator connector.

  18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  19. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  20. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  21. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A0054TU

      Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

      Tech Tips

      Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

  22. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A0053RN

      Install the crankshaft position sensor plate with the "F" mark facing forward.

  23. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  24. INSTALL CRANKSHAFT TIMING SPROCKET

    Click here

  25. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  26. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  27. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  28. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  29. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  30. INSTALL NO. 1 GENERATOR BRACKET


    1. A0054TS

      Install the generator bracket with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
  31. INSTALL WATER INLET HOUSING STUD BOLT

    A0053OGE12
    *1 15 mm (0.591 in.)
    *2 34 mm (1.34 in.)
    *3 12 mm (0.472 in.)

    Note

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


    1. Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
  32. INSTALL WATER INLET HOUSING


    1. A0058JJ

      Install a new gasket and the water inlet housing with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  34. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  35. INSTALL ENGINE MOUNTING BRACKET STUD BOLT

    Note

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

    A00550Q

    1. Install the stud bolt.

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

    Click here

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  38. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  39. INSTALL SPARK PLUG TUBE GASKET


    1. A0054X7E05
      Text in Illustration
      *1 Part to Cut Off

      Using a cutter knife, cut off the seal part of the removed gasket.

    2. A0057RGE04
      Text in Illustration
      *1 Plug Tube Gasket without Sealing Part
      *2 New Plug Tube Gasket
      *3 Claw

      Using a hammer and a plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.

      Tech Tips

      If a plug tube gasket that will be used to install a new gasket is deformed and cannot be positioned on a new gasket, correct the deformation using pliers.

      Note


      • Keep the lip free of foreign matter.

      • Do not tap in the plug tube gasket at an angle.

    3. Return the claws of the ventilation baffle plate to their original positions.

  40. INSTALL CYLINDER HEAD COVER GASKET


    1. A0052V0

      Install a new cylinder head cover gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surfaces.

  41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A005723

      Install 3 new gaskets to the camshaft bearing cap.

    2. A0054DA

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard diameter
      4.0 mm (0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    3. A0053C4

      Install the cylinder head cover with a new seal washer and the 13 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  42. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  43. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A0055NPE01

      Using SST, install a new gasket engine coolant temperature sensor.

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


    1. A0057RTE04

      Install the knock sensor with the bolt.

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

      Note

      Make sure that the knock sensor is in the correct position.

  45. INSTALL CRANKSHAFT POSITION SENSOR


    1. A0055EJE04
      Text in Illustration
      *1 O-Ring

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

    2. A005605

      Install the crankshaft position sensor with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  46. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A0054D1E15
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of engine oil to 2 new O-rings and install them to the camshaft timing oil control valves.

    2. A0052GEE05
      Text in Illustration
      *1 Bracket

      Install the 2 camshaft timing oil control valves and bracket with the 2 bolts.

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

      Note


      • Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover).

      • Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

  47. INSTALL CAMSHAFT POSITION SENSOR


    1. A0056JDE33
      Text in Illustration
      *1 O-Ring

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

    2. A0058H9

      Install the 2 camshaft position sensors with the 2 bolts.

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

      Note

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

  48. INSTALL SPARK PLUG

    Click here

  49. INSTALL ENGINE COVER JOINT


    1. A0055YO

      Install the 2 engine cover joints.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  50. INSTALL OIL FILLER CAP GASKET


    1. A0056SD

      Install the gasket to the oil filler cap.

  51. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A0054LY

      Install the oil filler cap.