ENGINE UNIT REASSEMBLY


  1. INSTALL RING PIN

    Note

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


    1. A01I532E03
      Text in Illustration
      *a Protrusion Height

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

      Standard protrusion height
      4.3 to 5.3 mm (0.169 to 0.209 in.)

  2. INSTALL ENGINE BALANCER ASSEMBLY


    1. A01I5FVE07
      Text in Illustration
      *1 Driven Gear
      *2 Damper Cover
      *a Alignment Mark

      Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

      If the alignment marks are not aligned, realign them.


      1. A01I2XVE07
        Text in Illustration
        *1 Driven Gear
        *2 Damper Cover
        *a Alignment Mark

        Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the shaft in place.

      2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.

    2. A01I49XE01

      Install the engine balancer assembly to the stiffening crankcase with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  3. INSTALL STUD BOLT

    Note

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


    1. Using an E5 and E8 "TORX" socket wrench, install the 3 stud bolts.

      A01I3Q1E06
      Text in Illustration
      *a Front Side *b Lower Side
      Torque:
      for Stud Bolt A
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      for Stud Bolt B
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01I2TSE02
      Text in Illustration
      *1 Key

      Rotate the crankshaft clockwise so that the crankshaft key is at the position 90° from the bottom as shown in the illustration.

    2. A01I3NUE01

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

      Text in Illustration
      A01I43D Stiffening Crankcase
      A01I46G Cylinder Block
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Dimension
      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick
      Application Length A
      28 mm (1.10 in.)

      Note


      • Remove any oil from the contact surface.

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

      • Do not apply oil for at least 2 hours after the installation.

    3. A01I4FAE03
      Text in Illustration
      *a Cutout

      Check that the rear cutout parts are as shown in the illustration.

    4. Clean the bolts and their installation holes.

    5. A01I58AE03
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 3 or more threads of the ends of bolts A.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01I5NTE01

      Temporarily install the stiffening crankcase with the 11 bolts.

      Bolt Length
      Item Length
      Bolt A 65 mm (2.56 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 125 mm (4.92 in.)
      Bolt D 165 mm (6.50 in.)

      Tech Tips

      Apply adhesive to bolts A before installation.

    7. A01I5NTE02

      Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase

      Torque:
      for Bolt A
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      except Bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  5. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01I4QHE01

      Install the No. 1 oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.

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

  6. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to a new gasket.

    2. A01I2Y0E03
      Text in Illustration
      *a Protrusion

      Align the protrusion of the gasket with the cutout of the oil strainer, and install the gasket to the oil strainer sub-assembly.

    3. Install the oil strainer sub-assembly with the 3 bolts in several steps, in the sequence shown in the illustration.

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

  7. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01I3GVE01

      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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      • Do not apply oil for at least 2 hours after the installation.

    2. A01I3SQE05
      Text in Illustration
      *1 Nut

      Install the oil pan with the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

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

      Tech Tips

      Bolt A and nut A are tightened twice.

  8. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and oil pan drain plug to the oil pan sub-assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  9. INSTALL OIL FILTER CAP ASSEMBLY


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

    2. A01I4YWE01
      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 assembly.

      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 into the oil filter cap assembly.

    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 assembly.

      Note

      Make sure that the O-ring does not get caught between the parts.

    6. A01I2CQE01
      Text in Illustration
      *1 Oil Filter Cap Assembly
      *2 O-ring
      *3 Oil Filter Bracket
      *a No Gap

      Using SST, tighten the oil filter cap assembly.

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

      Note

      After tightening the oil filter cap assembly, make sure that there is no gap and that the O-ring is not protruding.

    7. A01I3OBE01
      Text in Illustration
      *1 O-ring

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

      Note

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap assembly.

    8. Install the oil filter drain plug.

      Torque:
      13 N*m  { 127 kgf*cm, 10 ft.*lbf }

      Note

      Be careful that the O-ring does not get caught between any surrounding parts.

  10. INSTALL REAR ENGINE OIL SEAL


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

      Note


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

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

    2. A01I537E01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the edges of the cylinder block and crankcase.

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

      Note


      • Keep the lip of the oil seal free from foreign matter.

      • Do not tap in the oil seal at an angle.

  11. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01I4GY

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

  12. INSTALL CYLINDER HEAD GASKET


    1. A01I3QXE01
      Text in Illustration
      *1 Cylinder Head Gasket
      *2 Cylinder Block Sub-assembly
      *a Lot No.
      *b 3.0 mm or more
      *c 20 mm or more
      A01I3Q9 Seal Packing
      A01I679 Front

      Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

    2. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Dimension
      3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) or thicker

      Tech Tips

      Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block sub-assembly.

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head gasket within 3 minutes and tighten the cylinder head bolts within 15 minutes after applying seal packing.

    3. Place the cylinder head gasket on the cylinder block sub-assembly surface with the Lot No. stamp facing upward.

      Note

      Pay attention to the installation direction.

  13. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

    The cylinder head bolts are tightened in 4 progressive steps.


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

      Note


      • Ensure that no oil is on the contact surface of the cylinder head sub-assembly.

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

    2. Install the 10 plate washers to the cylinder head bolts.

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

    4. Step 1:


      1. A01I2FCE02

        Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

        Note

        Do not drop the plate washers for the cylinder head bolts into the cylinder head sub-assembly.

    5. Step 2:


      1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    6. Step 3:


      1. A01I5JOE02
        Text in Illustration
        *a Paint Mark
        A01I3Q9 Front

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

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

    7. Step 4:


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

      2. Check that the paint marks are now facing rearward.

        Note


        • Do not add engine oil for at least 2 hours after installation.

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

        • After installation, if the seal packing has seeped out, wipe it off.

        Tech Tips

        Perform "Inspection After Repair" after replacing the cylinder head sub-assembly Click here.

  14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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


    1. A01I410E03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, tap in 10 camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  15. INSTALL STRAIGHT PIN

    Note

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


    1. A01I5HIE03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, tap in 2 straight pins to the camshaft housing sub-assembly.

      Standard protrusion height
      5.0 to 7.0 mm (0.197 to 0.276 in.)

  16. INSTALL STUD BOLT

    Note

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


    1. When reusing the stud bolt.


      1. Apply adhesive to threads of the stud bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01I535E01

      Using an E8 "TORX" socket wrench, install the camshaft housing stud bolt.

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

  17. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

    2. A01I391E02
      Text in Illustration
      *1 Vernier Caliper

      Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.

    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Standard dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  18. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. A01I4PVE04
      Text in Illustration
      *1 Vernier Caliper

      Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

    3. Using a vernier caliper, measure the distance between the camshaft housing edge and the No. 2 camshaft bearing edge.

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  19. INSTALL OIL CONTROL VALVE FILTER


    1. A01I5W9

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  20. INSTALL CAMSHAFT


    1. Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journal, camshaft housing sub-assembly and camshaft bearing caps.

    3. Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft Click here.

  21. INSTALL CAMSHAFT BEARING CAP


    1. A01I3C7E02

      Confirm the marks and numbers on the 3 No. 3 camshaft bearing caps, No. 2 camshaft bearing cap, No. 1 camshaft bearing cap and place them in their proper positions and directions.

    2. A01I67HE04

      Install the 11 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      Make sure that the camshaft and No. 2 camshaft rotate smoothly after installing the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and No. 3 camshaft bearing caps.

  22. 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.

  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the valve lash adjuster assemblies before installing them Click here.

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

      Note

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

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


    1. A01I3HXE06
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

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

  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01I34FE03
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Incorrect
      *b Correct

      Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

    2. A01I3OUE01
      Text in Illustration
      *a Dashed Line
      *b Groove

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

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Apply Seal Packing as Follows
      Area Seal Packing Diameter Application Position
      Continuous Line 3.0 to 4.0 mm (0.118 to 0.157 in.) Distance from edge of camshaft housing sub-assembly to center of seal packing: 3.5 to 4.0 mm (0.138 to 0.157 in.)
      Dashed Line Distance from outside edge of groove to center of seal packing: 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

    3. A01I3RWE02
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°
      *b Approximately 2°

      Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.

    4. A01I2ZGE04

      Install the camshaft housing sub-assembly, and then install the 20 bolts in the order shown in the illustration.

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

      Note


      • Do not add engine oil for at least 2 hours after installation.

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

      • After installation, if the seal packing has seeped out, wipe it off.

  26. INSTALL CAMSHAFT TIMING SPROCKET


    1. A01I4XOE02
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing sprocket with the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

  27. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01I3W6E08
      Text in Illustration
      *a Knock Pin Hole
      *b Alignment Mark

      Check the camshaft timing gear assembly position.

      If the camshaft timing gear assembly is not set to the advanced position, release the lock pin and reset the camshaft timing gear assembly. (Refer to the "Set Camshaft Timing Gear Assembly" procedure.)

    2. A01I37LE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    3. A01I5YTE19
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Clearance
      *d Camshaft Flange
      *e No Clearance

      Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

    4. A01I3TDE02
      Text in Illustration
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly Click here.

  28. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01I4XV

      Install the crankshaft timing sprocket to the crankshaft.

  29. ADD ENGINE OIL


    1. A01I4SO

      Add 50 cc (3.1 cu. in.) of engine oil into the oil hole shown in the illustration.

      Note


      • Oil must be added if the valve lash adjuster assemblies were removed.

      • Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.

  30. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01I5F9E02

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

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

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01I3YJE02

      Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.

    3. A01I4XKE02
      Text in Illustration
      *a Timing Mark
      *b Approximately 7°
      *c Approximately 32°

      Check that the timing marks of the camshaft timing gear assembly and camshaft timing sprocket are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  32. INSTALL CHAIN SUB-ASSEMBLY


    1. Place the chain sub-assembly onto the camshaft timing gear assembly, camshaft timing sprocket and crankshaft timing sprocket.

      Tech Tips


      • Make sure the mark plate of the chain sub-assembly faces away from the engine.

      • It is not necessary to install the chain sub-assembly to the teeth of the camshaft timing gear assembly, camshaft timing sprocket and crankshaft timing sprocket.

    2. A01I55DE02
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Align the mark plate (yellow or gold) of the chain sub-assembly with the timing mark of the camshaft timing sprocket and install the chain sub-assembly to the camshaft timing sprocket.

    3. A01I5SIE08
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Align the mark plate (pink or gold) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.

    4. A01I28H

      Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.

    5. A01I2XEE02
      Text in Illustration
      *a Mark Plate
      *b Timing Mark

      Using a wrench, hold the hexagonal portion of the camshaft, rotate the camshaft counterclockwise, align the timing mark of the camshaft timing gear assembly with the mark plate (yellow or gold) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    6. A01I37F

      Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.

      Note

      Make sure the chain sub-assembly is secure.

  33. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

    2. Remove the pin from the stopper plate.

  35. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  36. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01I4P3E07
      Text in Illustration
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.

    3. Check that the timing marks on the camshaft timing gear assembly and camshaft timing sprocket are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    4. Remove the crankshaft pulley bolt.

  37. INSTALL TIMING CHAIN COVER PLATE


    1. A01I4DD

      Install a new gasket and the timing chain cover plate with the 4 bolts.

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

  38. INSTALL OIL PUMP RELIEF VALVE PLUG


    1. A01I4W8

      Using a 14 mm hexagon wrench, install a new gasket and the oil pump relief valve plug.

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

  39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01I3DE

      Apply a light coat of engine oil to 3 new gaskets.

    2. Install the 3 gaskets to the stiffening crankcase assembly.

    3. A01I3Z8E02
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft Timing Sprocket

      Align the drive rotor spline and the crankshaft timing sprocket as shown in the illustration.

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

      A01I2AWE08
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Apply Seal Packing as Follows
      Area Seal Packing Diameter (Round) Distance from Edge of Cover to Center of Seal Packing Seal Packing Application Length
      Seal Pacing Dimension (Flat)
      Dashed Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) -
      -
      A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) -
      -
      B - B 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 28 mm (1.10 in.)
      7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick
      C - C 7.0 mm (0.276 in.) 5.0 mm (0.197 in.) 25 mm (0.984 in.)
      13.0 mm (0.512 in.) or more wide and 3.0 mm (0.118 in.) or more thick
      D - D 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 26 mm (1.02 in.)
      7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick
      E 2.5 to 3.5 mm (0.0984 to 0.138 in.) 3.0 mm (0.118 in.) -
      -

      Note


      • When there is oil on the contact surfaces, clean the surfaces with non-residue solvent before applying seal packing.

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

      • After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

      • Do not add oil for at least 2 hours after the installation.

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

    5. Temporarily install the timing chain cover sub-assembly with the 17 bolts and 2 nuts.

      A01I5FCE01
      Text in Illustration
      *1 Nut - -
      Bolt Length
      Item Length Thread Diameter
      Bolt A 30 mm (1.18 in.) 8 mm (0.315 in.)
      Bolt B 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt C 45 mm (1.77 in.) 8 mm (0.315 in.)

      Note

      Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

    6. Tighten the 17 bolts and 2 nuts in several steps, in the order shown in the illustration.

      Torque:
      for bolt A, C, and Nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  40. INSTALL ENGINE MOUNTING BRACKET RH


    1. A01I3HKE01

      Install the engine mounting bracket RH with the 5 bolts in the order shown in the illustration.

      Torque:
      for bolt 1, 2 and 3
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      for bolt 4 and 5
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

      After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

  41. INSTALL TIMING CHAIN COVER OIL SEAL


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

      Note


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

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

    2. A01I50SE01

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

      SST
      09223-22010

      Note


      • Keep the lip of the oil seal free from foreign matter.

      • Do not tap in the oil seal at an angle.

  42. INSTALL SPARK PLUG TUBE GASKET


    1. A01I3MLE01
      Text in Illustration
      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly

      Tap in the 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

      Note


      • Do not allow foreign matter to contact the lip of the spark plug tube gasket.

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

  43. INSTALL STUD BOLT

    Note

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


    1. A01I2FUE01

      Using an E6 "TORX" socket wrench, install the 3 stud bolts.

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

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01I4QT

      Apply a light coat of engine oil to 2 new gaskets.

    2. Install the 2 gaskets to the camshaft bearing caps.

    3. Install a new gasket to the cylinder head cover sub-assembly.

      Note

      Remove any oil from the contact surface.

    4. A01I52AE01
      Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover
      *3 Camshaft Housing

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application width A
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes after applying seal packing.

    5. A01I423E01

      Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover sub-assembly.

    6. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

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

      Note

      Do not apply oil for at least 2 hours after the installation.

  45. INSTALL CRANKSHAFT PULLEY


    1. A01I5VWE15
      Text in Illustration
      *a Hold
      *b Turn

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

    2. Using SST, hold the crankshaft pulley and install the pulley bolt.

      SST
      09213-54015
      09330-00021
      Torque:
      260 N*m  { 2651 kgf*cm, 192 ft.*lbf }

      Tech Tips

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

  46. INSTALL CRANKSHAFT POSITION SENSOR


    1. Clean and degrease the threads of the bolt for the crankshaft position sensor.

    2. A01I493E07
      Text in Illustration
      *1 O-ring

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

    3. A01I4BXE06
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

    4. Install the sensor with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

      Make sure that the O-ring is not cracked or does not jump out of position during installation.

    5. Connect the sensor connector.

  47. INSTALL SEPARATOR CASE


    1. A01I5A7

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

    2. Install the gasket to the separator case.

    3. Install the separator case with the 2 bolts.

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

  48. INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. A01I4MGE01

      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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01I4FWE02

      Install the ventilation case sub-assembly, and install the 8 bolts and 2 nuts in the order shown in the illustration.

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

      Note

      Do not apply oil for at least 2 hours after the installation.

      Tech Tips

      Bolt A is tightened twice.

  49. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly.

      Adhesive
      Toyota genuine adhesive 1324, three bond 1324 or equivalent

    2. Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly.

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

    3. Install the No. 2 ventilation hose.

  50. INSTALL CAMSHAFT POSITION SENSOR


    1. Clean and degrease the threads of the bolt for the camshaft position sensor.

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

      Note

      Make sure that the O-ring is not cracked or does not jump out of position during installation.

    3. A01I4BXE06
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

    4. Install the sensor with the bolt.

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

    5. Connect the sensor connector.

  51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01I48AE06
      Text in Illustration
      *1 New O-ring

      Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve.

    2. Install the oil control valve with the bolt.

      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.

    3. Connect the oil control valve connector.

  52. INSTALL OIL FILLER CAP GASKET


    1. Install a new oil filler cap gasket to the oil filler cap sub-assembly.

  53. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  54. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01I3F7E15
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      TOYOTA Genuine Adhesive 1344, Three Bond 1344 or equivalent.

      Note

      Do not let adhesive adhere to the oil hole.

    2. Using a 24 mm deep socket wrench, install the oil pressure switch.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note

      Do not start the engine within 1 hour of installation.

    3. Connect the connector.

  55. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Install a new gasket to the engine coolant temperature sensor.

    2. Using a 19 mm ball joint lock nut wrench, install the engine coolant temperature sensor.

      Torque:
      Specified tightening torque
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a ball joint lock nut wrench (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 155 mm (6.1 in.)):

        10 N*m (102 kgf*cm, 7 ft.*lbf)

      • Perform "Inspection After Repair" after replacing the engine coolant temperature sensor Click here.

    3. Connect the engine coolant temperature sensor connector.

    4. Install the wire harness with the 2 bolts.

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

    5. Connect the ventilation hose to the cylinder head cover.

  56. INSTALL KNOCK CONTROL SENSOR


    1. A01I4DPE04
      Text in Illustration
      *a Front of Engine
      *b Up
      *c 7°
      *d 10°

      Install the sensor with the bolt so that the sensor is angled as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      The acceptable installation angle of the sensor is between 7° upward and 10° downward from the horizontal position.

      Tech Tips

      Perform "Inspection After Repair" after replacing the knock control sensor Click here

    2. Connect the sensor connector.

  57. INSTALL SPARK PLUG


    1. Using a spark plug wrench, install the 4 spark plugs.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the spark plug Click here.

  58. INSTALL ENGINE COVER JOINT


    1. A01I4VQ

      Install the 3 engine cover joints.

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