ENGINE UNIT(w/o Glow Plug Controller) REASSEMBLY

PROCEDURE


  1. INSTALL OIL PAN SUB-ASSEMBLY


    1. Apply seal packing to the oil pan sub-assembly in a continuous line as shown in the illustration.

      A01T8YEN01
      *1 φ 2.0 to 3.0 (0.0787 to 0.118)
      *2 Min. 7.0 (0.276)
      *3 Min. 3.0 (0.118)
      *4 mm (in.)
      Standard Seal Packing Diameter
      Area

      Bead Size

      mm (in.)
      A - A

      2.0 to 3.0

      (0.0787 to 0.118)
      B - B

      Min. Width: 7.0 (0.276)

      Min. Height: 3.0 (0.118)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.

    2. A01T9SNE01

      Using several steps, temporarily tighten the 12 bolts, and then tighten them to the specified torque in the order shown in the illustration.

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

      Length

      mm (in.)
      A 35 (1.378)
      B 143.7 (5.657)
      C 119 (4.685)

  2. INSTALL ENGINE REAR OIL SEAL

    Click here

  3. INSTALL ENGINE OIL LEVEL SENSOR


    1. A01T9NHC01
      *1 Gasket
      *2 Engine Oil level Sensor
      *a Engine Oil level Sensor Side
      *b Float Side
      *c Groove

      Install a new gasket to the engine oil level sensor.

      Note

      Securely install the gasket to the engine oil level sensor groove.

    2. A01T9QON01

      Temporarily tighten the engine oil level sensor with the 5 bolts.

      Note

      Do not deform the engine oil level sensor float or allow it to come in contact with other parts.

    3. Fully tighten the 4 bolts (A) first, and then the bolt (B).

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01TCH3C03
      *a Seal Packing

      Apply seal packing (diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.)) to the No. 2 oil pan sub-assembly in a continuous line as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

      • Install the No. 2 oil pan sub-assembly within 3 minutes, and tighten the bolts within 10 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after installing the No. 2 oil pan sub-assembly.

    2. Temporarily tighten the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.

    3. A01T99RC01

      Fully tighten the 10 bolts and 2 nuts, as shown in the illustration.

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

    4. Install a new gasket and oil pan drain plug.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  5. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Check and clean the oil filter bracket sub-assembly installation surface.

    2. A01M159

      Install a new gasket to the oil pan sub-assembly.

    3. A01LX7F

      Install the oil filter bracket sub-assembly with the 2 bolts.

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

  6. INSTALL OIL COOLER ASSEMBLY


    1. Check and clean the oil cooler assembly installation surface.

    2. A01LYBV

      Install 2 new O-rings and a new gasket to the oil filter bracket sub-assembly.

    3. A01M2JQ

      Install the oil cooler assembly with the 2 bolts and 2 nuts.

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

  7. INSTALL OIL FILTER ELEMENT

    Click here

  8. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01M0SK

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

  9. INSTALL CYLINDER HEAD GASKET

    Click here

  10. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. Apply a light coat of engine oil to the threads of the 10 cylinder head set bolts.

    2. A01T8IQC03
      *a Paint Mark
      A01TBGJ Front

      Using several steps, install and uniformly tighten the 10 cylinder head set bolts and 10 plate washers in the order shown in the illustration. (*1)

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

    3. Mark the front of the 10 cylinder head set bolts with paint.

    4. Using the same order as step (*1), tighten the 10 cylinder head set bolts an additional 90°.

    5. Repeat the step above 2 more times as shown in the illustration.

    6. Check that each paint mark is now 270° from the front.

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


    1. A01LX95

      Apply engine oil to the valve stem end caps, No. 1 valve rocker arm sub-assembly pivot top surfaces and No. 1 valve rocker arm sub-assembly roller portions.

    2. Install the 8 No. 1 valve rocker arm sub-assemblies.

  12. INSTALL CAMSHAFT

    Click here

  13. INSTALL CHAIN DAMPER SPRING


    1. A01LZB7

      Install the chain damper spring to the chain tensioner plate.

  14. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. A01TC8UC02
      *1 Key
      *a TDC Mark
      *b Oil Pump Shaft
      *c Flat Side

      Align the crankshaft key with the TDC mark on the cylinder block sub-assembly.

    2. Rotate the oil pump shaft so that the flat side faces left when viewing the cylinder block sub-assembly from the front.

    3. A01T9KKC03
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *a Timing Mark
      *b Orange Mark Plate

      Align the orange mark plates with the timing mark of each gear as shown in the illustration.

    4. A01LZE6

      Install the sprockets onto the crankshaft and oil pump shaft with the No. 2 chain sub-assembly wrapped around the gears.

    5. A01LVE5

      Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    6. A01TB9AC02
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring
      *a Pin
      *b Pivot Hole

      Install the chain tensioner plate with the chain damper spring to the pin.

      Note


      • Push the chain tensioner plate so that the area around the pivot hole reaches the base of the pin.

      • The end of the chain damper spring should contact the side of the oil pan sub-assembly so that tension is applied to the No. 2 chain sub-assembly.

    7. A01T9DEC02
      *1 Key
      *a Timing Mark
      *b Mark Plate
      *c TDC Mark

      Check that the mark plates and timing marks are in the positions shown in the illustration.

  15. INSTALL CHAIN SUB-ASSEMBLY


    1. A01TCP8C02
      *a Straight Pin

      Turn the camshaft to set the straight pin in the position shown in the illustration.

    2. A01TCU5C03
      *1 Key
      *a Turn
      *b TDC Mark

      Turn the crankshaft to set the key in the position shown in the illustration.

    3. A01T9I3C02
      *a Timing Mark
      *b Orange Mark Plate
      *c Yellow Mark Plate

      Align the 2 orange mark plates with the timing mark on the camshaft timing sprocket, and the yellow mark plate with the timing mark on the crankshaft timing sprocket.

    4. A01TA1KC02
      *a Timing Mark
      *b Orange Mark Plate
      *c Yellow Mark Plate

      Install the chain sub-assembly, camshaft timing sprocket and crankshaft timing sprocket together onto the engine.

    5. A01TDHDE01

      w/o Stop And Start System


      1. Using SST, secure the camshaft timing sprocket, and install the camshaft timing sprocket with the 3 bolts.

        SST
        09960-10010   ( 09962-01000, 09963-01000 )
        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A01M38Z

      w/ Stop And Start System


      1. Install the 3 bolts while holding the hexagonal portion of the camshaft, and then install the camshaft timing sprocket and sensor plate.

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

  16. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01LXK7

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

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

  17. INSTALL CHAIN TENSIONER SLIPPER


    1. A01LWKW

      Install the chain tensioner slipper to the cylinder block sub-assembly.

  18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01TDIPC04
      *a Push
      *b Plunger
      *c Groove
      *d Hole

      Push in the plunger until the groove is aligned with the hole, and then insert a 1.1 mm (0.0433 in.) diameter bar.

    2. A01LV8X

      Install the No. 1 chain tensioner assembly with the 2 bolts.

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

    3. Remove the 1.1 mm (0.0433 in.) diameter bar from the No. 1 chain tensioner assembly.

    4. A01T9ZBC02
      *a Timing Mark
      *b Orange Mark Plate
      *c Yellow Mark Plate

      Check that the mark plates and timing marks are in the positions shown in the illustration.

  19. INSTALL INLET WATER HOUSING


    1. Install a new No. 2 water inlet housing gasket to the inlet water housing.

    2. A01LUZM

      Install the inlet water housing to the timing chain cover sub-assembly with the 3 bolts.

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

  20. INSTALL OIL CHECK VALVE SUB-ASSEMBLY


    1. Using a 6 mm hexagon socket wrench, install the oil check valve sub-assembly with the bolt.

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

  21. INSTALL TIMING CHAIN COVER OIL SEAL


    1. Apply MP grease to a new timing chain cover oil seal lip.

      Note

      Keep the lip free from foreign matter.

    2. A01TBMXN01

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

      SST
      09223-22010
      Oil seal tap in depth
      -1.0 to 0 mm (-0.0394 to 0 in.)

      Note


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

      • Wipe off extra grease from the crankshaft.

  22. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01LW01

      Install the new oil pump gasket.

    2. Apply seal packing to the engine body and oil pump as shown in the illustration below.

      A01TB2CC03
      *a Seal Width (Toyota Genuine Seal Packing Black, Three Bond 1207B) *b Seal Width (Toyota Genuine Seal Packing 1282B, Three Bond 1282B)
      *c Width *d Height
      *e Double Line Area - -

      Note


      • Remove any oil from the contact surfaces.

      • Install the timing chain cover sub-assembly within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.

      Seal packing
      Engine water pump assembly: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Other: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

    3. Install the timing chain cover sub-assembly with the 20 bolts and 2 nuts, as shown in the illustration.

      A01TBYHC01
      *1 Nut - -
      Torque:
      Bolt A, B, Nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt C
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      Bolt Length
      Bolt

      Length

      mm (in.)
      A 25 (0.984)
      B 35 (1.378)
      C 40 (1.575)

      Note


      • Make sure that the chain sub-assembly and No. 2 chain sub-assembly do not come into contact with the seal packing when installing the timing chain cover sub-assembly.

      • Install the engine mounting bracket RH within 10 minutes of installing the timing chain cover sub-assembly.

  23. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  24. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. A01T8I6C02
      *a O-ring

      Apply a light coat of engine oil to the O-ring of the oil pressure switching valve assembly.

    2. Install the oil pressure switching valve assembly with the bolt.

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

      Note

      Make sure that the O-ring is not torn or pinched when installing.

  25. INSTALL NO. 2 TIMING CHAIN COVER


    1. A01LYBD

      Install the No. 2 timing chain cover with the harness bracket and bolt.

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

  26. INSTALL ENGINE MOUNTING BRACKET RH


    1. A01TDI6N01

      Temporarily tighten the engine mounting bracket RH with the 4 bolts.

    2. Fully tighten the 4 bolts, as shown in the illustration.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  27. INSTALL OIL PRESSURE SENDER GAGE ASSEMBLY


    1. A01TAC9C04
      *a Adhesive

      Apply adhesive to 2 or 3 threads of the oil pressure sender gage assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01LX5N

      Using a 27 mm deep socket wrench, install the oil pressure sender gage assembly.

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

  28. INSTALL WATER INLET


    1. Install a new No. 1 water inlet housing gasket to the water inlet.

    2. A01LW57

      Install the water inlet with the 3 bolts.

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

  29. INSTALL OUTLET WATER SUB-ASSEMBLY


    1. Install a new water outlet gasket to the cylinder head sub-assembly.

    2. A01M35I

      Install the outlet water sub-assembly with the 2 bolts and 2 nuts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  30. INSTALL WATER TEMPERATURE SENSOR


    1. Install a new gasket to the water temperature sensor.

    2. A01LW5B

      Using a 19 mm deep socket wrench, install the water temperature sensor.

      Torque:
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }

  31. CHECK VALVE CLEARANCE

    Click here

  32. ADJUST VALVE CLEARANCE

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  33. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install the cylinder head gasket to the cylinder head cover sub-assembly.

    2. A01TBCYC01
      A01TCE3 Seal Packing

      Apply seal packing to the 4 locations shown in the illustration, and then install the cylinder head cover sub-assembly.

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

      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 of applying the seal packing.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly.

    3. A01T8LXN01

      Temporarily tighten the cylinder head cover sub-assembly with the 12 bolts.

    4. Fully tighten the 12 bolts in the order shown in the illustration.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  34. INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

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