ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE

INSTALL STIFFENING CRANKCASE RING PIN

*a	Protrusion Height
*b	Width
*c	Height

Note

It is not necessary to remove a stiffening crankcase ring pin unless it is being replaced.

Using a plastic-faced hammer, tap in 2 new stiffening crankcase ring pins until they are seated.

Standard Ring Pin

Item	Protrusion Height	Height	Width
Stiffening crankcase ring pin	3.0 mm (0.118 in.)	8 mm (0.315 in.)	11 mm (0.433 in.)

INSTALL STIFFENING CRANKCASE STUD BOLT


*1	8.5 mm (0.335 in.)
*2	8.0 mm (0.315 in.)
*3	18 mm (0.709 in.)

Note

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

Using an E6 "TORX" socket wrench, install the stiffening crankcase stud bolts as shown in the illustration.

Torque:

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

INSTALL STIFFENING CRANKCASE ASSEMBLY


*1	2.0 to 3.0 mm (0.0787 to 0.118 in.)
*2	4.5 to 5.5 mm (0.177 to 0.217 in.)

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

Area	Specified Condition
Continuous Line	2.0 to 3.0 mm (0.0787 to 0.118 in.)
A	4.5 to 5.5 mm (0.177 to 0.217 in.)

Application Length A
56 mm (2.20 in.)

Note

Remove any oil from the contact surfaces.
Install the stiffening crankcase 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 installing the stiffening crankcase assembly.

Install the stiffening crankcase assembly with the 11 bolts in the sequence order shown in the illustration.

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

Bolt Length

Item	Specified Condition
Bolt A	138 mm (5.43 in.)
Bolt B	35 mm (1.38 in.)
Bolt C	70 mm (2.76 in.)

Recheck the torque for the bolts (1) and (2).

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Wipe off any excess seal packing with a clean piece of cloth.

INSTALL OIL PUMP ASSEMBLY

Click here
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

Click here
INSTALL OIL PAN DRAIN PLUG
1. Install a new gasket and the oil pan drain plug.
  
  Torque:
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
INSTALL REAR ENGINE OIL SEAL

Click here
INSTALL NO. 1 TAPER SCREW PLUG
1. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Adhesive
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  Note
  
  Install the plug within 3 minutes of applying adhesive.
  
  Do not start the engine at least 1 hour after installing the plug.
2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (B).
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  Note
  - Install the plug within 3 minutes of applying adhesive.
  - Do not start the engine at least 1 hour after installing the No. 1 taper screw plug.
INSTALL VENTILATION VALVE SUB-ASSEMBLY

Click here
INSTALL CYLINDER HEAD GASKET

Click here
INSTALL CYLINDER HEAD SUB-ASSEMBLY

Click here

Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

INSTALL CAMSHAFT HOUSING STRAIGHT PIN

*a	Protrusion Height
*b	Height
*c	Width

Note

It is not necessary to remove a camshaft housing straight pin unless it is being replaced.

Using a plastic-faced hammer, tap in a new camshaft housing straight pin to the specified protrusion height.

Standard Straight Pin

Item	Protrusion Height	Height	Width
Camshaft housing straight pin	6.5 to 7.5 mm (0.256 to 0.295 in.)	14 mm (0.551 in.)	6.0 mm (0.236 in.)

INSTALL CAMSHAFT HOUSING STUD BOLT


*1	12 mm (0.472 in.)
*2	18 mm (0.709 in.)
*3	48.5 mm (1.91 in.)

Note

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

Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.

Torque:

9.5 N*m { 97 kgf*cm, 84 in.*lbf }

INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY
1. *1 Filter
  
  *a Protrusion
  
  Install a new O-ring to the continuously variable valve lift controller assembly.
  Note
  
  Align the protrusion of the O-ring with the protrusion of the continuously variable valve lift controller assembly.
  
  Make sure that the O-ring is not protruding from the groove in the continuously variable valve lift controller assembly.
  
  Make sure that the filter is securely attached in the continuously variable valve lift controller assembly.
2. Install the control actuator clip to the valve lift control actuator connector.
  
  Tech Tips
  
  When the continuously variable valve lift controller assembly is new, a valve lift control actuator connector is attached to it. Remove the valve lift control actuator connector before performing work.
  
  Note
  
  Be sure to insert the protrusions of the control actuator clip into the holes in the valve lift control actuator connector.
3. Install the valve lift control actuator connector to the valve rocker shaft and rotate the valve lift control actuator connector as shown in the illustration.
4. Insert the continuously variable valve lift controller assembly into the camshaft housing sub-assembly.
5. Install the continuously variable valve lift controller assembly to the camshaft housing sub-assembly with the bolt.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
  
  Note
  
  Do not let the O-ring become pinched between parts.
6. Using a screwdriver, slide the control actuator clip from the valve lift control actuator connector.
7. Slide only the upper part of the control actuator clip as the straight pin may fall if the control actuator connector clip is completely removed.
8. Using a screwdriver, lightly pry the valve lift control actuator connector and align the hole in the valve lift control actuator connector with the hole in the continuously variable valve lift controller assembly.
  Note
  
  Do not forcibly pry the valve lift control actuator connector.
  
  Do not damage the camshaft housing sub-assembly or camshaft bearing cap.
9. Insert the straight pin into the valve lift control actuator connector.
  
  Note
  
  Do not use a tool to insert the straight pin. Insert the straight pin by hand.
  
  Tech Tips
  
  If the straight pin is difficult to insert, insert the straight pin while lightly prying the valve lift control actuator connector.
10. Using a screwdriver, install the control actuator clip to the valve lift control actuator connector.
  
  Note
  
  Insert the protrusion of the control actuator clip into the hole in the valve lift control actuator connector.
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

Click here
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Click here
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

Click here
INSTALL CRANKSHAFT TIMING GEAR KEY
1. Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.
  
  Tech Tips
  
  Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
1. Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.
INSTALL NO. 2 CHAIN SUB-ASSEMBLY

Click here
INSTALL CRANKSHAFT TIMING SPROCKET

Click here
INSTALL NO. 1 CHAIN VIBRATION DAMPER

Click here
SET NO. 1 CYLINDER TO TDC/COMPRESSION

Click here
INSTALL CHAIN SUB-ASSEMBLY

Click here
CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

Click here
INSTALL CHAIN TENSIONER SLIPPER

Click here
INSTALL NO. 1 GENERATOR BRACKET
1. Install the No. 1 generator bracket with the 4 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }

INSTALL WATER INLET HOUSING STUD BOLT


*1	15 mm (0.591 in.)
*2	12 mm (0.472 in.)
*3	34 mm (1.34 in.)

Note

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

Using an E5 "TORX" socket wrench, install the water inlet housing stud bolts as shown in the illustration.

Torque:

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

INSTALL WATER INLET HOUSING
1. Install a new gasket and the water inlet housing with the 3 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Click here
INSTALL TIMING CHAIN COVER OIL SEAL

Click here
INSTALL CRANKSHAFT PULLEY

Click here
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Click here
INSTALL OIL FILTER CAP ASSEMBLY

Click here

INSTALL SPARK PLUG TUBE GASKET

*a Part to Cut Off

Using a cutter knife, cut off the seal part of the removed spark plug tube gasket.

*a	Claw
*1	Spark Plug Tube Gasket without Seal Part
*2	New Spark Plug Tube Gasket

Using a hammer and the spark plug tube gasket which has had the seal part cut off, uniformly tap in a new spark plug tube gasket all the way.

Note

Keep the lip free of foreign matter.
Do not tap the new spark plug tube gasket.

Tech Tips

If a spark plug tube gasket that will be used to install a new spark plug tube gasket is deformed, and cannot be positioned on a new spark plug tube gasket, correct the deformation using pliers.

Return the claws of the ventilation baffle plate to their original positions.

INSTALL CYLINDER HEAD COVER GASKET
1. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
  
  Note
  
  Remove any oil from the contact surfaces.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install 3 new gaskets to the camshaft bearing cap.
2. Apply seal packing as shown the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Standard diameter
  
  4.0 mm (0.157 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 installation.
3. Install the cylinder head cover sub-assembly with a new seal washer and the 13 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

Click here
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
1. Install a new gasket and the engine coolant temperature sensor.
  
  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
INSTALL KNOCK CONTROL SENSOR
1. Install the knock control sensor with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Make sure that the knock control sensor is in the correct position.
INSTALL CRANKSHAFT POSITION SENSOR
1. Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.
2. Install the crankshaft position sensor with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Apply a light coat of engine oil to 2 new O-rings and install them to the camshaft timing oil control valve assemblies.
2. *a Bracket
  
  Install the 2 camshaft timing oil control valve assemblies and bracket with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  Note
  
  Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (surface with cylinder head cover sub-assembly).
  
  Make sure that the O-ring is not cracked or moved out of place when installing the camshaft oil control valve assembly.
INSTALL CAMSHAFT POSITION SENSOR
1. Apply a light coat of engine oil to the O-rings of the camshaft position sensors.
2. Install the 2 camshaft position sensors with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Note
  
  Make sure that the O-ring is not cracked or pinched when installing the camshaft position sensor.
INSTALL SPARK PLUG

Click here
INSTALL ENGINE COVER JOINT
1. Install the 2 engine cover joints.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL OIL FILLER CAP GASKET
1. Install the oil filler cap gasket to the oil filler cap.
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install the oil filler cap sub-assembly.

*1	Filter
*a	Protrusion