ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the engine coolant temperature sensor or knock sensor.

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PROCEDURE


  1. INSTALL RING PIN

    Note

    It is not necessary to remove the ring pins unless they are being replaced.


    1. B0044P9N02
      *1 12.48 to 12.50 mm (0.4913 to 0.4921 in.)
      *2 8.0 mm (0.315 in.)
      *3 2.7 to 3.3 mm

      Using a plastic-faced hammer, tap in 10 new ring pins to the specified protrusion height.

      Protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  2. INSTALL STRAIGHT PIN

    Note

    It is not necessary to remove the straight pins unless they are being replaced.


    1. B0042S3N01
      *1 8.0 mm (0.315 in.)
      *2 15.0 mm (0.591 in.)
      *3 5.0 to 7.0 mm

      Using a plastic-faced hammer, tap in 2 new straight pins to the specified protrusion height.

      Protrusion height
      5.0 to 7.0 mm (0.197 to 0.276 in.)

  3. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. B00448Z

      Install the oil strainer sub-assembly to the oil pan sub-assembly with the 2 bolts.

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

  4. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. B00431G

      Install the No. 1 oil pan baffle plate to the oil pan sub-assembly with the 5 bolts.

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

  5. INSTALL OIL PAN SUB-ASSEMBLY


    1. B0042KU

      Install a new gasket to the cylinder block sub-assembly.

    2. Apply seal packing to the places shown in the illustration.

      B0043L3C02
      *a Continuous Line Area *b Dashed Line Area
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan sub-assembly within 3 minutes of applying seal packing.

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

    3. Apply adhesive to the threads of the bolt (C).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Tech Tips

      Apply adhesive to the bolt (C) more than 7.0 mm (0.276 in.) from the bolt end.

    4. B0042YQN04

      Install the oil pan sub-assembly with the 10 bolts in the sequence shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 55 mm (2.165 in.)
      Bolt B 30 mm (1.181 in.)
      Bolt C 30 mm (1.181 in.)

    5. Wipe off any excess seal packing with a clean piece of cloth.

  6. INSTALL OIL PAN DRAIN PLUG


    1. B0044XZ

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

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

  7. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. B0044T6

      Install the cylinder block water jacket spacer to the cylinder block sub-assembly as shown in the illustration.

  8. INSTALL CYLINDER HEAD GASKET

    Click here

  9. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  10. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster assembly free of dirt and foreign matter.

    • Only use clean engine oil.


    1. B0042D4C04
      *a Correct
      *b Incorrect
      *c Taper Part
      *d Low Pressure Chamber
      *e High Pressure Chamber
      *f Plunger
      *g Check Ball

      Place the valve lash adjuster assembly into a container filled with engine oil.

    2. Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed it.

      OK
      Plunger moves up and down.

      Note

      When bleeding the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.

    5. After bleeding, remove SST. Then, try to press the plunger quickly and firmly by hand.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster assembly.

    6. Install the valve lash adjuster assemblies.

      Note

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

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


    1. Apply engine oil to the valve lash adjuster assembly tip and valve stem cap end.

    2. B0042H4C01
      *1 No. 1 Valve Rocker Arm sub-assembly
      *2 Valve Lash Adjuster assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    3. B00436U

      Fill the cylinder head sub-assembly with engine oil through the holes indicated in the illustration.

  12. INSTALL CAMSHAFT

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  13. INSTALL NO. 2 CAMSHAFT

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  14. INSTALL OIL CONTROL VALVE FILTER


    1. B0043VF

      Install the oil control valve filter to the camshaft bearing cap.

  15. INSTALL CAMSHAFT BEARING CAP

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  16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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  17. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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  18. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  19. INSTALL TIMING CHAIN GUIDE

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  20. INSTALL CHAIN SUB-ASSEMBLY

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  21. INSTALL TIMING CHAIN TENSION ARM

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  22. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  23. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  24. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. B0043ZOC16
      *a Adhesive

      Apply adhesive to 2 or 3 threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. B0043XP

      Using an 8 mm socket hexagon wrench, install the plug.

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

      Note


      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour after installation.

    3. Remove any old seal packing remaining on the sealing surfaces before applying seal packing.

    4. Clean the contact surfaces of the timing chain cover sub-assembly, camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly and oil pan sub-assembly and confirm that no oil, moisture, or other foreign matter is on the surfaces.

      B004305C03
      B0042HM Surface to be cleaned - -
    5. B0042QB

      Install 2 new O-rings to the oil pan sub-assembly and oil strainer sub-assembly.

    6. Apply seal packing to the timing chain cover sub-assembly as shown in the following illustration.

      B0041OJC03
      *a Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent *b Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • If there is oil on the contact surfaces, wipe them with oil-free cloth 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.

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

      Tech Tips

      Areas A - A and B - B are the joints between the cylinder block sub-assembly and oil pan sub-assembly, cylinder block sub-assembly and cylinder head sub-assembly, and cylinder head sub-assembly and camshaft housing sub-assembly.

      Seal Packing Specification
      Area Seal Packing Diameter Seal packing

      Continuous Line Area

      Except A - A and B - B

      		 3.5 to 4.5 mm (0.138 to 0.177 in.) Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Dashed Line Area 2.0 to 3.0 mm (0.0787 to 0.118 in.) Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

    7. Align the oil pump drive rotor and crankshaft as shown in the illustration.

      B0042IC

    8. Install the timing chain cover sub-assembly to the crankshaft.

    9. B0043CUN01

      Temporarily install the engine mounting bracket RH with the 3 bolts.

      Bolt Length
      Item Length
      Bolt A 80 mm (3.150 in.)
      Bolt B 40 mm (1.575 in.)
    10. B0043UZN05

      Temporarily install the engine water pump assembly and a new gasket to the timing chain cover sub-assembly with the 9 bolts.

      Bolt Length
      Item Length
      Bolt A 18 mm (0.709 in.)
      Bolt B 40 mm (1.575 in.)
      Bolt C 40 mm (1.575 in.) or 50 mm (1.969 in.)

    11. Tighten the 6 bolts (A) shown in the illustration.

      Torque:
      Bolt A
      9.1 N*m  { 93 kgf*cm, 81 in.*lbf }
    12. B0041QEC39
      *a Adhesive

      Apply adhesive to the threads of the bolt (E).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Tech Tips

      Apply adhesive to the bolt (E) more than 7.0 mm (0.276 in.) from the bolt end.

    13. Temporarily tighten the timing chain cover sub-assembly with the 21 bolts and seal washer.

      B0042S2C04
      *1 Seal Washer - -
      Bolt Length
      Item Length
      Bolt A 40 mm (1.575 in.) or 50 mm (1.969 in.)
      Bolt B 40 mm (1.575 in.)
      Bolt C 35 mm (1.378 in.)
      Bolt D, E 25 mm (0.984 in.)
      Bolt F 80 mm (3.150 in.)

    14. Fully tighten the timing chain cover sub-assembly with the 27 bolts in the order shown in the illustration.

      Torque:
      Bolt A, F
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      Bolt B, D, E
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Bolt C
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  25. INSTALL THERMOSTAT

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  26. INSTALL NO. 2 WATER INLET HOUSING GASKET

    Click here

  27. INSTALL WATER INLET

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  28. INSTALL OIL FILTER ELEMENT

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  29. INSTALL CRANKSHAFT PULLEY

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  30. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. B0044L7

      Using a 19 mm deep socket wrench, install a new gasket and engine coolant temperature sensor to the cylinder head sub-assembly.

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

      Tech Tips

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

      Click here

  31. INSTALL KNOCK CONTROL SENSOR


    1. B004232N03

      Install the knock control sensor to the cylinder block sub-assembly with the bolt.

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

      Note

      Make sure that the knock control sensor is at the position shown in the illustration.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the knock sensor.

      Click here

  32. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. B0044PWC16
      *a Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. B0042RV

      Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly to the cylinder block sub-assembly.

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

      Note


      • Install the engine oil pressure switch assembly within 3 minutes of applying adhesive.

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

  33. INSTALL CRANK POSITION SENSOR


    1. B0043XL

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

    2. B00426A

      Install the crank position sensor with the bolt.

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

  34. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0042UY

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

      Note


      • Remove any oil from the contact surfaces.

      • Check that no camshaft bearing cap oil hole gaskets are stuck to the cylinder head cover sub-assembly.

    2. B0043T0

      Install the 2 new camshaft bearing cap oil hole gaskets to the camshaft bearing cap.

      Tech Tips

      The camshaft bearing cap oil hole gaskets can be installed with either side facing upward.

    3. B00421FC10
      *a Seal Diameter 2.0 mm

      Apply seal packing as shown the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      2.0 mm (0.0787 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 of applying seal packing.

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

    4. B00432HC02
      *1 Seal Washer

      Apply adhesive to 2 or 3 threads at the end of the bolt (A).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Tech Tips


      • If the removed bolt did not have adhesive applied to it, make sure to apply adhesive to the threads of the bolt before installing it.

      • If the removed bolt had adhesive applied to it, make sure to clean the bolt and bolt hole and apply adhesive to the threads of the bolt before installing it.

    5. Temporarily install the cylinder head cover sub-assembly with 2 new seal washers and the 17 bolts.

    6. B0043YI

      Apply a light coat of engine oil to the 2 O-rings of the 2 camshaft position sensors.

    7. Apply adhesive to 2 or 3 threads at the end of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Tech Tips


      • If the removed bolt did not have adhesive applied to it, make sure to apply adhesive to the threads of the bolt before installing it.

      • If the removed bolt had adhesive applied to it, make sure to clean the bolt and bolt hole and apply adhesive to the threads of the bolt before installing it.

    8. B0043W9

      Temporarily install the 2 camshaft position sensors with the 2 bolts.

    9. B0043IZN02

      Install the 19 bolts in the order shown in the illustration.

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

  35. INSTALL REAR ENGINE OIL SEAL

    Click here

  36. INSTALL VENTILATION SYSTEM GROMMET


    1. B00451R

      Install the ventilation system grommet to the cylinder head cover sub-assembly.

  37. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. B004480

      Install the ventilation valve sub-assembly to the cylinder head cover sub-assembly.

  38. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. B0043BZ

      Apply a light coat of engine oil to 2 new O-rings, then install them onto the 2 camshaft timing oil control valve assemblies.

    2. B0044JE

      Install the 2 camshaft timing oil control valve assemblies to the cylinder head cover sub-assembly with the 2 bolts.

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

  39. INSTALL SPARK PLUG

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  40. INSTALL OIL FILLER CAP GASKET


    1. B0042QE

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

  41. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. B0043OP

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