ENGINE UNIT REASSEMBLY

INSTALL ENGINE OIL LEVEL SENSOR

1. Install the engine oil level sensor with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Engage the clamp.

3. Install a new clip to the engine oil level sensor.

4. Connect the engine oil level sensor connector.

INSTALL OIL FILTER CAP ASSEMBLY

1. Clean the inside of the oil filter cap assembly, the threads and O-ring groove.

2. 

   Text in Illustration

   *1	O-ring
   *a	Correct
   *b	Incorrect

   Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap assembly.

   Note

   
   

   • Be sure to install the O-ring in the proper location, otherwise engine oil may leak.

   • Do not twist the O-ring.

3. Set a new oil filter element in the oil filter cap assembly.

4. Remove any dirt or foreign matter from the installation surface of the engine.

5. Apply a small amount of engine oil to the O-ring again and install the oil filter cap assembly.

   Note

   Make sure that the O-ring does not get caught between the parts.

6. 

   Text in Illustration

   *1	Oil Filter Cap Assembly
   *2	O-ring
   *3	Oil Filter Bracket
   *a	No Gap

   Using SST, tighten the oil filter cap assembly.

   SST

   09228-06501

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Note

   
   

   • After tightening the oil filter cap assembly, make sure that there is no gap and that the O-ring is not protruding.

   • Do not cross thread the oil filter cap assembly.

7. 

   Text in Illustration

   *1

   O-ring

   Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap assembly.

   Note

   Remove any dirt or foreign matter from the installation surface.

8. Install the oil filter drain plug to the oil filter cap assembly.

   Torque:

   13 N*m  { 133 kgf*cm, 10 ft.*lbf }

   Note

   Make sure that the O-ring does not get caught between the parts.

INSTALL REAR ENGINE OIL SEAL

1. Using height adjustment attachments and plate lift attachments, place the engine assembly on a flat level surface.

   Note

   
   

   • Using height adjustment attachments and plate lift attachments, place the engine assembly horizontally.

   • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly.

   • Using an engine sling device and engine lift, secure the engine assembly before service.

2. Remove any old seal packing.

3. 

   Text in Illustration

   *a	Seal Packing
   *b	3.0 mm (0.118 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

   Note

   
   

   • Remove any oil from the contact surfaces.

   • Install a new rear engine oil seal within 3 minutes of applying seal packing.

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

4. Apply MP grease to the lip of a new rear engine oil seal.

   Note

   
   

   • Keep the lip free from foreign matter.

   • Do not allow MP grease to contact the dust seal.

5. 

   Text in Illustration

   *a	Standard Depth (from edge of cylinder block sub-assembly)

   Using SST and a hammer, tap in the rear engine oil seal.

   SST

   09223-15030

   09950-70010   ( 09951-07150 )

   Standard Depth
   -0.2 to 0.9 mm (-0.00787 to 0.0354 in.)

   Note

   
   

   • Keep the lip free from foreign matter.

   • Do not tap in the rear engine oil seal at an angle.

INSTALL CYLINDER HEAD GASKET

1. Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

2. 

   Text in Illustration

   *1	Cylinder Head Gasket
   *a	Lot No.
   *b	3.0 to 5.0 mm (0.118 to 0.197 in.)
   *c	152.5 mm (6.00 in.)
   *d	38 mm (1.50 in.)
   *e	7.0 to 9.0 mm (0.276 to 0.354 in.)
   *f	5.0 to 7.0 mm (0.197 to 0.276 in.)
   	Front
   	Seal Packing

   Apply a continuous line of seal packing to a new cylinder head gasket 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 cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

3. Place the cylinder head gasket on the cylinder block sub-assembly with the Lot No. stamp facing upward.

   Note

   Pay attention to the installation direction.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

1. 

   Text in Illustration

   *1	Oil Pump Gasket
   *2	Oil Hole Cover Gasket

   Apply a light coat of engine oil to 2 new oil pump gaskets and a new oil hole cover gasket.

2. Install the 2 oil pump gaskets and oil hole cover gasket to the stiffening crankcase assembly.

3. 

   Text in Illustration

   *1	Drive Rotor Spline
   *2	Crankshaft Timing Sprocket

   Align the drive rotor spline and the crankshaft timing sprocket as shown in the illustration.

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

   

   Text in Illustration

   *a	3.0 mm or more	*b	7.0 mm or more
   *c	13 mm or more	-	-

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

   Seal Packing Application Chart

   Area Seal Packing Diameter (Round) Distance from Edge of Cover to Center of Seal Packing Seal Packing Application Length Seal Packing Dimension (Flat) Dashed Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) - - A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) - - B - B 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 28 mm (1.10 in.) 7.0 mm (0.276 in.) or wider and 3.0 mm (0.118 in.) or thicker C - C 7.0 mm (0.276 in.) 5.0 mm (0.197 in.) 25 mm (0.984 in.) 13 mm (0.512 in.) or wider and 3.0 mm (0.118 in.) or thicker D - D 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 26 mm (1.02 in.) 7.0 mm (0.276 in.) or wider and 3.0 mm (0.118 in.) or thicker E 2.5 to 3.5 mm (0.0984 to 0.138 in.) 3.0 mm (0.118 in.) - -

   Note

   
   

   • Clean the surfaces with non-residue solvent 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.

   • After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

   • Do not add oil for at least 2 hours after installation.

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

5. Temporarily install the timing chain cover sub-assembly with the 17 bolts and 2 nuts.

   

   Text in Illustration

   *a	Torque	*b	Tightening Order
   	Bolt		Nut

   Bolt Length
   Item Length Thread Diameter Bolt (A) 30 mm (1.18 in.) 8.0 mm (0.315 in.) Bolt (B) 35 mm (1.38 in.) 10 mm (0.394 in.) Bolt (C) 45 mm (1.77 in.) 8.0 mm (0.315 in.)

   Note

   Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

6. Tighten the 17 bolts and 2 nuts in several steps, in the order shown in the illustration.

   Torque:

   Bolt (A), (C) and Nut

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

   Bolt (B)

   55 N*m  { 561 kgf*cm, 41 ft.*lbf }

INSTALL ENGINE MOUNTING BRACKET RH

INSTALL TIMING CHAIN COVER PLATE

1. Install a new gasket and the timing chain cover plate with the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

1. 

   Text in Illustration

   *1

   O-ring

   Apply engine oil to a new O-ring and install it to the camshaft timing oil control solenoid assembly as shown in the illustration.

   Note

   Do not damage the O-ring.

2. 

   Text in Illustration

   *a	Adhesive 1324

   Apply adhesive to 2 or 3 threads of 2 new bolts.

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

3. Install the camshaft timing oil control solenoid assembly to the timing chain cover sub-assembly with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   
   

   • If the camshaft timing oil control solenoid assembly has been struck or dropped, replace it.

   • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft timing oil control solenoid assembly.

4. Connect the camshaft timing oil control solenoid assembly connector.

INSTALL TIMING CHAIN COVER OIL SEAL

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

   Note

   
   

   • Keep the lip free from foreign matter.

   • Do not allow MP grease to contact the dust seal.

2. 

   Text in Illustration

   *a	Standard Depth (from edge of the timing chain cover sub-assembly)

   Using SST and a hammer, tap in the timing chain cover oil seal.

   SST

   09636-20010

   Standard Depth
   -0.75 to -1.45 mm (-0.0295 to -0.0571 in.)

   Note

   
   

   • Keep the lip free from foreign matter.

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

INSTALL CRANKSHAFT POSITION SENSOR

1. Clean and degrease the threads of the bolt for the crankshaft position sensor.

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

   Note

   If reusing the crankshaft position sensor, be sure to inspect the O-ring.

3. 

   Text in Illustration

   *a	Adhesive 1324

   Apply adhesive to 2 or 3 threads of the bolt.

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

4. Install the crankshaft position sensor to the timing chain cover sub-assembly with the bolt.

   Torque:

   6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

   Note

   
   

   • If the crankshaft position sensor has been struck or dropped, replace it.

   • Make sure that the O-ring is not cracked or moved out of place when installing the crankshaft position sensor.

5. Connect the crankshaft position sensor connector.

INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

1. Clean and degrease the threads of the PCV valve (ventilation valve sub-assembly).

2. Apply adhesive to 2 or 3 threads of the PCV valve (ventilation valve sub-assembly).

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

3. Using a 19 mm deep socket wrench, install the PCV valve (ventilation valve sub-assembly) to the cylinder head cover sub-assembly.

   Torque:

   27 N*m  { 275 kgf*cm, 20 ft.*lbf }

   Note

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

INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

1. Clean and degrease the threads of the bolt for the camshaft position sensor.

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

   Note

   If reusing the camshaft position sensor, be sure to inspect the O-ring.

3. 

   Text in Illustration

   *a	Adhesive 1324

   Apply adhesive to 2 or 3 threads of the bolt.

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

4. Install the camshaft position sensor to the cylinder head cover sub-assembly with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   
   

   • If the camshaft position sensor has been struck or dropped, replace it.

   • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft position sensor.

5. Connect the camshaft position sensor connector.

INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

1. Clean and degrease the threads of the bolt for the camshaft position sensor.

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

   Note

   If reusing the camshaft position sensor, be sure to inspect the O-ring.

3. 

   Text in Illustration

   *a	Adhesive 1324

   Apply adhesive to 2 or 3 threads of the bolt.

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

4. Install the camshaft position sensor to the cylinder head cover sub-assembly with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   
   

   • If the camshaft position sensor has been struck or dropped, replace it.

   • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft position sensor.

5. Connect the camshaft position sensor connector.

INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

1. Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve assembly.

   Note

   Do not damage the O-ring.

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

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   
   

   • If the camshaft timing oil control valve assembly has been struck or dropped, replace it.

   • Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (connecting surface with the cylinder head cover subassembly).

   • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft timing oil control valve assembly.

3. Connect the camshaft timing oil control valve assembly connector.

INSTALL SPARK PLUG

1. Install the 4 spark plugs to the cylinder head sub-assembly.

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Note

   If a spark plug has been struck or dropped, replace it.

   Tech Tips

   Install the same parts to their original positions.

INSTALL ENGINE COOLANT TEMPERATURE SENSOR

INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

1. 

   Text in Illustration

   *a	Adhesive 1344
   *b	Oil Inlet Port

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

   Adhesive
   Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

   Note

   
   

   • Do not apply adhesive to the oil inlet port of the oil pressure sender gauge assembly.

   • Install the oil pressure sender gauge assembly within 3 minutes of applying adhesive.

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

   Torque:

   15 N*m  { 153 kgf*cm, 11 ft.*lbf }

3. Connect the oil pressure sender gauge assembly connector.

INSTALL KNOCK CONTROL SENSOR

1. 

   Text in Illustration

   *a	Top
   *b	Engine Front
   *c	7°
   *d	10°

   Install the knock control sensor to the cylinder block sub-assembly with the bolt so that the knock control sensor installation position is as shown in the illustration.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   Note

   If the knock control sensor has been struck or dropped, replace it.

2. Connect the knock control sensor connector.

INSTALL VACUUM PUMP ASSEMBLY

1. When installing a new vacuum pump assembly:

   
   
   1. 

      Text in Illustration

      *1	No. 2 O-ring
      *2	No. 3 O-ring
      	Engine Oil

      Apply engine oil to the No. 3 O-ring.

      Note

      Do not apply engine oil to the No. 2 O-ring.

2. When reusing the vacuum pump assembly:

   
   
   1. 

      Text in Illustration

      *1	No. 2 O-ring
      *2	No. 3 O-ring
      	Engine Oil

      Install a new No. 2 O-ring to the vacuum pump assembly.

   2. Apply engine oil to a new No. 3 O-ring and install it to the vacuum pump assembly.

      Note

      Do not apply engine oil to the No. 2 O-ring.

3. 

   Text in Illustration

   *a	Coupling Teeth
   *b	Groove
   	Engine Oil

   Apply engine oil to the inner surface of the installation hole.

4. Align the coupling teeth of the vacuum pump assembly with the groove of the camshaft and install the vacuum pump assembly with the 4 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

   Note

   After tightening the bolts, ensure that the contact surface of the vacuum pump assembly is flush with the cylinder head.