ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STRAIGHT PIN

    Note

    If a straight pin is deformed or damaged, replace it.


    1. A000QYTE02
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced hammer, install 2 new straight pins.

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

  2. INSTALL RING PIN

    Note

    If a ring pin is deformed or damaged, replace it.


    1. Stiffening crankcase assembly lower side:


      1. A000SYCE02
        Text in Illustration
        *a Protrusion Height

        Using a plastic-faced hammer, install 2 new ring pins.

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

    2. Camshaft housing sub-assembly lower side:


      1. A000PAEE01
        Text in Illustration
        *a Protrusion Height

        Using a plastic-faced hammer, install 8 new ring pins.

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

  3. INSTALL STUD BOLT

    Note

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


    1. Timing chain cover sub-assembly front side:


      1. A000MY5E02
        Text in Illustration
        *a 16 mm (0.630 in.)
        *b 9 mm (0.354 in.)
        *c 27 mm (1.06 in.)

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

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Stiffening crankcase assembly lower and LH sides:


      1. Using an E5 and E8 "TORX" socket wrench, install the 4 stud bolts.

        A000O3FE02
        Test in Illustration
        *a 14 mm (0.551 in.) *b 13 mm (0.512 in.)
        *c 29 mm (1.14 in.) *d 8.5 mm (0.334 in.)
        *e 8.0 mm (0.315 in.) *f 18 mm (0.709 in.)
        Torque:
        for Stud Bolt A
        6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
        for Stud Bolt B
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Camshaft housing sub-assembly front side:


      1. When reusing the camshaft housing stud bolts:

        Apply adhesive 1324 to the threaded portion (camshaft housing sub-assembly side) of the stud bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        Note

        Install the stud bolt within 3 minutes of applying adhesive.

      2. A000N40E01
        Text in Illustration
        *a 20 mm (0.787 in.)
        *b 13 mm (0.512 in.)
        *c 35 mm (1.38 in.)

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

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

    4. Camshaft housing sub-assembly upper side:


      1. A000OGTE01
        Text in Illustration
        *a 16 mm (0.630 in.)
        *b 9 mm (0.354 in.)
        *c 27 mm (1.06 in.)

        Using an E6 "TORX" socket wrench, install the 2 stud bolts.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    5. Cylinder head cover sub-assembly upper side:


      1. A000PBQE02
        Text in Illustration
        *a 16 mm (0.630 in.)
        *b 9 mm (0.354 in.)
        *c 27 mm (1.06 in.)

        Using an E6 "TORX" socket wrench, install the 5 stud bolts.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  4. SET ENGINE BALANCER ASSEMBLY


    1. A000SABE03
      Text in Illustration
      *1 Balance Shaft Damper Cover
      *2 No. 1 Balance Shaft Driven Gear
      *a Alignment Mark

      Make sure that the alignment marks on the No. 1 balance shaft driven gear and No. 2 balance shaft driven gear are aligned.

    2. A000PZGE02
      Text in Illustration
      *1 No. 2 Balance Shaft

      If the alignment marks are not aligned, hold the No. 2 balance shaft with a wrench at its flat portions, and rotate the No. 1 balance shaft as shown in the illustration to align the marks.

  5. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. Clean the bolts and their installation holes.

    2. Clean and degrease the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.

    3. A000SOFE02
      Text in Illustration
      *a 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
      2.5 to 3.5 mm (0.0984 to 0.1378 in.)

      Note


      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

    4. Align the pins on the cylinder block sub-assembly with the holes in the stiffening crankcase assembly, and then install the stiffening crankcase assembly to the cylinder block sub-assembly.

      A000QOJE03
      Test in Illustration
      *1 Straight Pin - -
      *a Rear Side *b Front Side
      *c RH Side *d LH Side

    5. After installing the stiffening crankcase assembly, check that the seal packing has come out at the locations shown in the illustration.

      A000SFFE02
      Test in Illustration
      *a Rear Side *b Front Side
      *c RH Side *d LH Side
      *e Areas where the seal packing comes out - -

      Note

      If the seal packing does not come out, reapply seal packing and install the stiffening crankcase assembly.

    6. Wipe off the seal packing that comes out at the joint of the stiffening crankcase assembly and the cylinder block sub-assembly.

      Note

      Wipe off the seal packing within 5 minutes after installing the stiffening crankcase assembly.

    7. A000MYJE06
      Text in Illustration
      *a Timing Mark
      *b Crankshaft Pulley Set Crankshaft Key Groove

      Align the crankshaft pulley set crankshaft key groove, timing marks on the balance shaft and balance shaft housing as shown in the illustration, and then set the stiffening crankcase assembly on the cylinder block sub-assembly.

    8. A000NY9E03
      Text in Illustration
      *a Bolt Type
      *b Tightening sequence
      *c Apply Adhesive 1344

      Apply adhesive 1344 to the threaded portion of bolt D (*c) shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the bolt within 3 minutes of applying adhesive.

    9. Temporarily install the stiffening crankcase assembly with the 11 bolts.

    10. Tighten the 11 bolts in the sequence shown in the illustration.

      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 }
      Bolt Length
      Item Length Diameter
      Bolt A 65 mm (2.56 in.) 8 mm (0.315 in.)
      Bolt B 65 mm (2.56 in.) 10 mm (0.394 in.)
      Bolt C 140 mm (5.51 in.)
      Bolt D 125 mm (4.92 in.)
      Bolt E 35 mm (1.38 in.)
    11. A000P5M

      Tighten the bolt.

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

    12. Temporarily install the crankshaft pulley set bolt.

    13. A000T5CE03
      Text in Illustration
      *a No. 1 Cylinder TDC/Compression
      *b Crankshaft Pulley Set Crankshaft Key Groove

      Rotate the crankshaft clockwise to set the No. 1 cylinder TDC/Compression.

    14. Remove the crankshaft pulley set bolt.

  6. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. Install the No. 1 oil pan baffle plate with the 4 bolts.

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

  7. INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. A000R4GE03
      Text in Illustration
      *a Protrusion

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

    3. Temporarily install the oil strainer sub-assembly with the 3 bolts.

    4. Tighten the 2 bolts labeled A.

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

    5. Tighten the bolt labeled B.

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

  8. INSTALL OIL PAN SUB-ASSEMBLY


    1. Clean and degrease the contact surfaces of the oil pan sub-assembly and stiffening crankcase assembly.

    2. A000NU2E01
      Text in Illustration
      *a 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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

    3. A000PYWE02

      Install the oil pan sub-assembly 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 }
      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

  9. INSTALL OIL PAN DRAIN PLUG


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

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

  10. INSTALL OIL COOLER ASSEMBLY

    Click here

  11. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  12. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  13. INSTALL REAR ENGINE OIL SEAL

    Click here

  14. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A000NUN

      Install the cylinder block water jacket spacer to the cylinder block sub-assembly.

      Text in Illustration
      B002B6O Engine front side

  15. INSTALL CYLINDER HEAD GASKET

    Click here

  16. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  17. INSTALL VALVE STEM CAP

    Click here

  18. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

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

    Click here

  20. INSTALL NO. 2 CAMSHAFT BEARING

    Click here

  21. INSTALL NO. 2 CAMSHAFT

    Click here

  22. INSTALL CAMSHAFT

    Click here

  23. INSTALL NO. 1 CAMSHAFT BEARING

    Click here

  24. INSTALL OIL CONTROL VALVE FILTER

    Click here

  25. INSTALL CAMSHAFT BEARING CAP

    Click here

  26. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  27. INSTALL OIL PIPE SUB-ASSEMBLY


    1. Install the oil pipe sub-assembly with the bolt.

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

  28. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  29. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  30. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

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  31. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  32. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY


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

  33. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. Align the crankshaft timing gear or sprocket groove with crankshaft pulley set crankshaft key, and install the crankshaft timing gear or sprocket to the crankshaft.

  34. POUR ENGINE OIL

    Note


    • Oil must be added if the valve lash adjuster assemblies or No. 1 valve rocker arm sub-assemblies were removed.

    • Make sure that the oil passage is full of engine oil.


    1. A000Q11

      Pour 100 cc (6.1 cu. in.) of engine oil into the oil hole shown in the illustration.

  35. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A000O1KE02

      Install the No. 1 chain vibration damper by tightening the 2 bolts in the order shown in the illustration.

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

  36. INSTALL CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley set bolt.

    2. A000OEZE01

      Rotate the crankshaft 40° counterclockwise.

    3. A000N0OE03
      Text in Illustration
      *a Timing Mark
      *b Identification Groove
      *c Approximately 7°
      *d Approximately 32°

      Check that the timing marks of the camshaft timing gears are as shown in the illustration.

      Tech Tips

      The camshaft timing gear assembly and the camshaft timing exhaust gear assembly have both timing marks and identification grooves. Use the timing marks for alignment.

    4. Place the chain sub-assembly onto the camshaft timing gears and crankshaft timing gear or sprocket.

      Note


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

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

    5. A000NV3E03
      Text in Illustration
      *a Mark Plate (Orange)
      *b Timing Mark

      Align the mark plate (orange) of the chain sub-assembly with the timing mark of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

    6. A000QXQE03
      Text in Illustration
      *a Mark Plate (Yellow)
      *b Timing Mark

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

    7. A000PMGE03
      Text in Illustration
      *a String

      Tie the chain sub-assembly with a string above the crankshaft timing gear or sprocket to secure the chain sub-assembly.

    8. A000O9HE03
      Text in Illustration
      *a Mark Plate (Orange)
      *b Timing Mark

      Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench.

      Align the timing mark of the camshaft timing gear assembly with the mark plate (orange) 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.

    9. A000NHV

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

      Note

      Make sure that the chain sub-assembly is securely installed.

  37. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  38. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new chain tensioner 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.

    3. A000P7SE03
      Text in Illustration
      *a Lock Pin Released
      *b Lock Pin Locked
      *c Pin Hole
      *d Lock Check Point

      Rotate the camshaft counterclockwise, and then check that the camshaft timing gear assembly locks at the most retarded position.

      Note

      If the camshaft timing gear assembly is not locked, make sure to lock it securely.

  39. INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

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

  40. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  41. INSTALL TIMING CHAIN COVER PLATE


    1. Install a new No. 1 timing belt cover gasket and the timing chain cover plate with the 4 bolts.

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

  42. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  43. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

    Click here

  44. INSTALL CRANKSHAFT PULLEY ASSEMBLY

    Click here

  45. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  46. INSTALL SPARK PLUG TUBE GASKET


    1. A000QX3E03
      Text in Illustration
      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly
      *a 0 mm (0 in.)

      Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly as shown in the illustration.

      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.

  47. INSTALL PCV CASE SUB-ASSEMBLY


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

    2. A000QA9E06
      Text in Illustration
      *1 O-ring
      *a O-ring Groove

      Install the O-ring to the PCV case sub-assembly as shown in the illustration.

      Note

      Securely install the O-ring to the O-ring groove of the PCV case sub-assembly.

    3. Install the PCV case sub-assembly to the cylinder head cover sub-assembly with the 2 bolts.

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

    4. Install a new gasket to the PCV case sub-assembly.

  48. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  49. INSTALL OIL FILLER CAP GASKET


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

  50. INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

  51. INSTALL PCV VALVE SUB-ASSEMBLY


    1. Degrease the threaded portion of the PCV valve sub-assembly.

    2. Apply adhesive 1324 to the PCV valve sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the PCV valve sub-assembly within 3 minutes of applying adhesive.

    3. Using a 19 mm deep socket wrench, install the PCV valve sub-assembly.

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

      Note

      Do not start the engine for at least 1 hour after the installation.

  52. INSTALL VVT SENSOR

    Click here

  53. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  54. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  55. INSTALL KNOCK CONTROL SENSOR

    Click here

  56. INSTALL SPARK PLUG

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  57. INSTALL NO. 4 WATER BY-PASS PIPE


    1. Install the No. 4 water by-pass pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A000P2CE03
      Text in Illustration
      *1 No. 7 Water By-pass Hose
      *2 No. 8 Water By-pass Hose
      *a Paint Mark
      *b Upper Side

      Connect the No. 7 water by-pass hose and No. 8 water by-pass hose to the oil cooler assembly with the 2 hose clamps as shown in the illustration.

    3. A000PM7E03
      Text in Illustration
      *a Paint Mark
      *b Upper Side

      Connect the No. 9 water by-pass hose to the cylinder head sub-assembly with the hose clamp as shown in the illustration.