ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL REAR CRANKSHAFT OIL SEAL


    1. B001FHCE01

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

      SST
      09518-36030
      09950-70010   ( 09951-07100 )

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

  2. INSTALL SUPPLY PUMP OIL SEAL


    1. B001E6PE03

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

      SST
      09223-15020
      09502-12010
      09950-70010   ( 09951-07100 )

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

  3. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. B001H68E02

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

      SST
      09214-76011

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

  4. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. Remove any old seal packing (FIPG material) from the oil pan and cylinder block.

    2. B001GGUE01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the places shown in the illustration.

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

      Note

      After applying seal packing, install the rear engine oil seal retainer within 3 minutes and tighten the bolts within 15 minutes.

    3. B001DDDE02

      Install the retainer with the 5 bolts. Alternately tighten the 5 bolts in several passes.

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

  5. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR


    1. B001DFW

      Mount the balanceshaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balanceshaft.

    2. Align the balanceshaft knock pin with the knock pin hole. Then install the balanceshaft thrust washer and balanceshaft driven gear.

    3. Install the bolt.

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

  6. INSTALL NO. 2 BALANCESHAFT SUB-ASSEMBLY


    1. B001CH2

      Install the balanceshaft with the 2 bolts.

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

  7. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR


    1. B001EVS

      Mount the balanceshaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balanceshaft.

    2. Align the balanceshaft knock pin with the knock pin hole. Then install the balanceshaft thrust washer and balanceshaft driven gear.

    3. Install the bolt.

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

  8. INSTALL NO. 1 BALANCESHAFT SUB-ASSEMBLY


    1. B001G7D

      Install the balanceshaft with the 2 bolts.

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

  9. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old seal packing (FIPG material).

    2. B001E66E10
      Text in Illustration
      *1 New Gasket
      *2 Seal Packing

      Apply seal packing to the timing gear case as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      5 mm (0.197 in.)

      Note

      After applying seal packing, install the timing gear case assembly within 3 minutes and tighten the bolts within 15 minutes.

    3. B001I8GE04
      Text in Illustration
      *1 New Gasket

      Install a new gasket to the groove of the timing gear case.

    4. B001FYQE02
      Text in Illustration
      *1 New O-Ring

      Install 2 new O-rings to the cylinder block.

    5. B001I6K

      Align the "2" marks of the balanceshaft driven gear No. 1 and oil pump drive gear.

    6. Align the mark on the oil pump drive gear with the mark on the timing gear case.

    7. B001HBWE03

      Install the timing gear case with the union bolt and 8 bolts.

      Torque:
      for union bolt (A)
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    8. B001HBX

      Remove the screw plug and gasket.

    9. Pour approximately 50 cc (3.05 cu. in.) of engine oil into the oil pump.

    10. Install a new gasket and the screw plug.

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

  10. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

    2. Install a new gasket to the cylinder block.

    3. B001DIGE01
      Text in Illustration
      *1 Seal Packing

      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
      4 mm (0.157 in.)

      Note


      • Remove any oil from the contact surface.

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

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

    4. Install the oil pan with the 22 bolts and 2 nuts.

      Torque:
      15 N*m  { 148 kgf*cm, 11 ft.*lbf }

  11. INSTALL OIL STRAINER SUB-ASSEMBLY


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

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

  12. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing (FIPG material).

    2. B001CJ0E01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the No. 2 oil pan as shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

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

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

    3. Install the No. 2 oil pan with the 13 bolts and 2 nuts.

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

  13. INSTALL CRANKSHAFT TIMING GEAR

    B001HY2E02

    1. Position the crankshaft timing gear with timing mark 1 facing forward.

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

    3. Using SST and a hammer, tap on the timing gear to install it.

      SST
      09223-00010

  14. INSTALL INJECTION GEAR


    1. Install a new O-ring and the supply pump with the 2 nuts.

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

    2. Temporarily install the injection gear with the nut.

      Tech Tips

      Fit the key (protrusion) of the supply pump into the key slot of the injection gear.

    3. B001DK7

      Align the "3" marks of the balanceshaft driven gear No. 2 and injection gear.

    4. B001DVFE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the injection gear.

    5. B001HB3E02

      Install the injection gear set nut.

    6. Using SST, tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  15. INSTALL NO. 2 IDLE SUB GEAR


    1. B001DQRE03
      Text in Illustration
      *1 Cutout Mark

      Mount the No. 1 idle gear in a vise.

      Tech Tips

      Make sure the cutout mark of the idle gear faces down.

      Note

      Be careful not to damage the gear.

    2. B001GMKE03
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

    3. Install the No. 2 idle sub gear.

    4. Install the wave washer.

      Tech Tips

      Fit the pins on the gears between the spring ends.

    5. B001FEF

      Using snap ring pliers, install the shaft snap ring.

    6. B001HV1E03
      Text in Illustration
      *1 Service Bolt

      Using SST, align the holes of the No. 1 idle gear and No. 2 idle sub gear by turning the No. 2 idle sub gear clockwise and install a service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    7. Remove the No. 1 idle gear from the vise and turn it upside down.

  16. INSTALL NO. 1 IDLE SUB GEAR


    1. B001IBDE02
      Text in Illustration
      *1 Upward

      Mount the No. 1 idle gear and No. 2 idle sub gear in a vise.

      Note

      Be careful not to damage the gears.

    2. B001DKQE02
      Text in Illustration
      *1 Service Bolt

      Remove the service bolt.

    3. B001D6IE03
      Text in Illustration
      *1 Wave Washer
      *2 No. 1 Idle Sub Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

    4. Install the No. 1 idle sub gear.

    5. Install the wave washer.

      Tech Tips

      Fit the pins on the gears between the spring ends.

    6. B001HJT

      Using a snap ring pliers, install the shaft snap ring.

    7. B001EFHE02
      Text in Illustration
      *1 Service Bolt
      *2 Upward

      Using SST, align the holes of the No. 1 idler gear and No. 1 idle sub gear by turning the No. 1 idle sub gear clockwise, and install the service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )

  17. INSTALL NO. 1 IDLE GEAR SHAFT


    1. B001GX9E01
      Text in Illustration
      *1 Engine Oil

      Apply a coat of engine oil to the No. 1 idle gear shaft.

    2. B001DANE07
      Text in Illustration
      *1 Oil Hole

      Install the gear shaft as shown in the illustration.

  18. INSTALL NO. 1 IDLE GEAR


    1. B001ER3E03
      Text in Illustration
      *1 Turn

      Align the "5" timing marks of the idle gear and crankshaft timing gear.

    2. Using SST, turn the injection gear and align the "4" timing marks of the idle gear and injection gear, and then mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    3. B001IG7E02
      Text in Illustration
      *1 Service Bolt

      Position the thrust plate with the protrusion facing forward.

    4. Align the bolt holes and install the thrust plate with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    5. Remove the service bolt.

  19. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    B001GCD

    1. Align the key groove of the sensor plate with the set key.

    2. Install the sensor plate with the cupped side facing outward.

  20. INSTALL TIMING GEAR COVER


    1. Remove any old seal packing (FIPG material).

    2. B001IMZE01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the timing gear cover as shown in the illustration.

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

      Note

      After applying seal packing, install the timing gear cover within 3 minutes and tighten the bolts within 15 minutes.

    3. B001F7TE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the timing gear case.

    4. B001EH9

      Install the timing gear cover with the 14 bolts and 2 nuts.

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

  21. INSTALL WATER PUMP ASSEMBLY


    1. B001DBB

      Install a new gasket and the water pump with the 5 bolts and 2 nuts.

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

  22. INSTALL CYLINDER HEAD GASKET

    Click here

  23. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  24. INSTALL VALVE LIFTER


    1. Install the valve lifter.

    2. Check that the valve lifter rotates smoothly by hand.

  25. INSTALL CAMSHAFT

    Click here

  26. INSPECT AND ADJUST VALVE CLEARANCE

    Click here

  27. INSTALL CYLINDER BLOCK INSULATOR

    Click here

  28. INSTALL NO. 2 TIMING BELT COVER

    Click here

  29. INSTALL CAMSHAFT TIMING PULLEY

    Click here

  30. INSTALL INJECTOR ASSEMBLY

    Click here

  31. INSPECT FOR FUEL LEAK

    Click here

  32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  33. INSTALL NOZZLE HOLDER SEAL

    Click here

  34. INSTALL OIL FILLER CAP SUB-ASSEMBLY