ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A01KCJ0C09
    *1 Protrusion Height
    *2 Width
    *3 Height

    Note

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


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

      Standard Ring Pin
      Protrusion Height Height Width
      3.0 mm (0.118 in.) 11 mm (0.433 in.) 8.0 mm (0.315 in.)

  2. INSTALL STUD BOLT

    Note

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


    1. A01KAWCC04
      *1 Stud Bolt
      *a 9.0 mm (0.354 in.)
      *b 19 mm (0.748 in.)

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. A01KCW5C03
      *a 15 mm (0.591 in.)
      *b 12 mm (0.472 in.)
      *c 34 mm (1.34 in.)

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    3. A01KDIIC01
      *a 12 mm (0.472 in.)
      *b 9.0 mm (0.354 in.)
      *c 23 mm (0.906 in.)

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A01KCV7C01
      *a 12 mm (0.472 in.)
      *b 18 mm (0.709 in.)
      *c 48.5 mm (1.91 in.)

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

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

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01KDDSC05
      *1 Seal Packing
      *a Area A

      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
      except Area A 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      for Area A 4.5 to 5.5 mm (0.177 to 0.217 in.)
      Application Length (Area 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 after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.

    2. A01KCLEN09

      Install the stiffening crankcase assembly with the 11 bolts in the sequence 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.)

      Note

      Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.

    3. Recheck the torque for bolts 1 and 2.

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

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

  4. INSTALL OIL PUMP ASSEMBLY

    Click here

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  6. 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 }

  7. INSTALL ENGINE REAR OIL SEAL

    Click here

  8. INSTALL NO. 1 TAPER SCREW PLUG


    1. Clean the No. 1 taper screw plug and plug hole.

    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug. Then install the No. 1 taper screw plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note


      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour of installing the plug.

  9. INSTALL PCV VALVE SUB-ASSEMBLY

    Click here

  10. INSTALL CYLINDER HEAD GASKET

    Click here

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  12. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem cap end.

    2. Install the 16 valve stem caps to the valve stems.

      Note

      Do not drop the valve stem caps into the cylinder head sub-assembly.

  13. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect each valve lash adjuster assembly before installing it.

      Click here

    2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

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

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


    1. A01KDG3C02
      *1 Valve Lash Adjuster Assembly
      *2 No. 1 Valve Rocker Arm Sub-assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

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

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A01KBUSC02
    *1 Protrusion Height
    *2 Height
    *3 Width

    Note

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


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

      Standard Straight Pin
      Protrusion Height Height Width
      6.5 to 7.5 mm (0.256 to 0.295 in.) 14 mm (0.551 in.) 6.0 mm (0.236 in.)

  16. INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY


    1. A01KCANC02
      *1 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.

    2. A01KDMS

      Install the control actuator clip to the control actuator connector.

      Note

      Be sure to insert the protrusions of the control actuator clip into the holes in the control actuator connector.

      Tech Tips

      When the continuously variable valve lift controller assembly is new, a control actuator connector is attached to it. Remove the control actuator connector before performing these procedures.

    3. A01KCGM

      Install the control actuator connector to the valve rocker shaft.

    4. Insert the continuously variable valve lift controller assembly into the camshaft housing sub-assembly.

    5. Install the continuously variable valve lift controller 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 jammed between parts.

    6. A01KBH1

      Using a screwdriver, slide the control actuator clip from the control actuator connector.

    7. Slide only the upper part of the control actuator clip as the straight pin may fall if the control actuator clip is completely removed.

    8. A01KBLE

      Using 2 screwdrivers, lightly pry the control actuator connector and align the hole in the control actuator connector with the hole in the continuously variable valve lift controller assembly.

      Note


      • Do not forcefully pry the control actuator connector.

      • Do not damage the camshaft housing sub-assembly and camshaft bearing cap.

    9. A01KC6XC02
      *1 Continuously Variable Valve Lift Controller Assembly
      *2 Valve Lift Control Actuator Connector
      *3 Valve Lift Control Actuator Connector Clip
      *4 Valve Rocker Shaft
      *5 Straight Pin

      Insert the straight pin into the 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 control actuator connector.

    10. A01KB04

      Using a screwdriver, install the control actuator clip to the control actuator connector.

      Note

      Insert the protrusion of the control actuator clip into the hole in the control actuator connector.

  17. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  18. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  19. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  20. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A01KDJ5

      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.

  21. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.

  22. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  23. INSTALL CRANKSHAFT TIMING SPROCKET

    Click here

  24. INSTALL NO. 1 CHAIN VIBRATION DAMPER


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

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

  25. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. A01KCFSC01
      *1 Timing Gear Key

      Turn the crankshaft counterclockwise to position the timing gear key at the top.

    3. A01KAR7C04
      *1 Timing Mark

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

    4. Remove the crankshaft pulley bolt.

  26. INSTALL CHAIN SUB-ASSEMBLY


    1. A01KC2YC01
      *1 Mark Plate (Orange)
      *2 Timing Mark

      Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain sub-assembly.

      Tech Tips


      • Be sure to position the mark plate at the front of the engine.

      • The mark plate on the camshaft side is colored orange.

      • Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.

      • Pass the chain through the No. 1 vibration damper.

    2. A01KBW7

      Place the chain on the crankshaft without passing it around the shaft.

    3. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain sub-assembly.

    4. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.

      Tech Tips

      To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.

    5. A01KBZ1C03
      *1 Timing Mark
      *2 Mark Plate (Pink)

      Align the mark plates (pink) and timing marks and install the chain to the crankshaft timing gear.

      Tech Tips

      The mark plates on the crankshaft side are colored pink.

  27. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper to the cylinder block assembly.

  28. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Check each timing mark at TDC/compression.

      A01KB5PC01
      *1 Timing Mark *2 Mark Plate (Orange)
      *3 Mark Plate (Pink) - -

  29. INSTALL NO. 1 GENERATOR BRACKET


    1. A01KB43C01
      *a Bolt A
      *b Bolt B

      Install the No. 1 generator bracket with the 4 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 45 mm (1.77 in.)

  30. INSTALL WATER INLET HOUSING


    1. A01KAON

      Install a new gasket and the water inlet housing with the 3 bolts.

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

  31. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  32. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  33. INSTALL ENGINE MOUNTING BRACKET STUD BOLT


    1. Install the engine mounting bracket stud bolt.

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

  34. INSTALL CRANKSHAFT PULLEY

    Click here

  35. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01KC6AC02
      *1 Cam
      *2 Hook
      *3 Pin
      *a CORRECT
      *b INCORRECT
      *c Push
      *d Raise

      Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

      Note

      Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

    2. A01KAVQ

      Install a new gasket, the No. 1 chain tensioner assembly and the bracket with the 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, set the hook again.

    3. A01KCSMC02
      *1 Pin
      *2 Hook
      *a Release
      *b Turn

      Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.

    4. A01KD01C02
      *1 Plunger
      *a Plunger Extended
      *b Turn

      Turn the crankshaft clockwise and check that the plunger is extended.

  36. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  37. INSTALL SPARK PLUG TUBE GASKET


    1. A01KBEWC04
      *1 Part to Cut Off

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

    2. A01KD47C03
      *1 Spark Plug Tube Gasket without Sealing Part
      *2 New Spark Plug Tube Gasket
      *3 Claw

      Using the removed spark plug tube gasket, uniformly press in a new spark plug tube gasket all the way.

      Note


      • Keep the lip free of foreign matter.

      • Do not press in the spark plug tube gasket at an angle.

      Tech Tips

      If the removed spark plug tube gasket does not fit on the new one, correct the removed one with pliers.

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

  38. 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.

  39. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install 3 new gaskets to the camshaft bearing cap.

    2. A01KD51

      Apply seal packing as shown in 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 after applying seal packing.

    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 }

      Note

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

  40. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  41. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  42. INSTALL KNOCK SENSOR

    Click here

  43. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  44. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. for Intake Side:

      Click here

    2. for Exhaust Side:

      Click here

  45. INSTALL CAMSHAFT POSITION SENSOR


    1. for Intake Side:

      Click here

    2. for Exhaust Side:

      Click here

  46. INSTALL SPARK PLUG

    Click here

  47. INSTALL ENGINE COVER JOINT


    1. Install the 2 engine cover joints.

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

  48. INSTALL OIL FILLER CAP GASKET


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

  49. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly.