ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A00YUA3C11
    *1 Protrusion Height
    *2 Width
    *3 Height

    Note

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


    1. Using a plastic-faced hammer, tap in 2 new 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.)

      Tech Tips

      The amount of protrusion may vary, but 3.0 mm (0.118 in.) is typical.

  2. INSTALL STUD BOLT

    Note

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


    1. A00YS88C01
      *a 23 mm (0.906 in.)
      *b 9.0 mm (0.354 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. A00YWGGC01
      *a 21 mm (0.827 in.)
      *b 9.0 mm (0.354 in.)
      *c 34 mm (1.34 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 }
    3. A00YVHUC01
      *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 }

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A00YXMBC06
      *1 Seal Packing

      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 A
      56 mm (2.20 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the crankcase 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. A00YUJBN11

      Install the stiffening crankcase 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.)

    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

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  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

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  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

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  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

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  10. INSTALL CYLINDER HEAD GASKET

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  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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  12. INSTALL VALVE STEM CAP


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

    2. Install the 16 valve stem caps to the cylinder head.

      Note

      Do not drop the valve stem caps into the cylinder head.

  13. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect each valve lash adjuster before installing it.

      Click here

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

      Note

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

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


    1. A00YTO3C01
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

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

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A00YXE4C03
    *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 NO. 1 CAMSHAFT BEARING

    Click here

  17. INSTALL OIL CONTROL VALVE FILTER


    1. Check that no foreign matter is on the mesh part of the oil control valve filter.

    2. Install the oil control valve filter.

      Note

      Do not touch the mesh when installing the oil control valve filter.

  18. INSTALL NO. 2 CAMSHAFT BEARING

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  19. INSTALL NO. 2 CAMSHAFT

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  20. INSTALL CAMSHAFT

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  21. INSTALL CAMSHAFT BEARING CAP

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  22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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  23. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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  24. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  25. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A00YX5V

      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.

  26. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00YWPZ

      Install the sensor plate with the "F" mark facing forward.

  27. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

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  28. INSTALL CRANKSHAFT TIMING SPROCKET

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  29. 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 }

  30. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    Click here

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. A00YRKZC05
      *1 Timing Gear Key

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

    3. A00YWU0C02
      *1 Timing Mark

      Check that the timing marks on the camshaft timing gear and camshaft timing exhaust gear assembly are aligned as shown in the illustration.

    4. Remove the crankshaft pulley bolt.

  32. INSTALL CHAIN SUB-ASSEMBLY


    1. A00YX3VC02
      *1 Mark Plate (Orange)
      *2 Timing Mark
      *a Place the Chain on the Sprocket
      *b Pass the Chain through the Damper

      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 engage the chain with the sprocket of the camshaft timing gear. Only place it on the camshaft timing gear.

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

    2. A00YRY0

      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 plates (orange) and timing mark, and then install the chain sub-assembly.

      A00YU10C01
      *1 Mark Plate (Orange) *2 Timing Mark
      *a Apply Tension to the Chain *b Turn

      Tech Tips

      To apply tension to the chain, slowly turn the camshaft timing gear assembly and camshaft timing exhaust gear assembly clockwise to prevent the chain sub-assembly from being misaligned.

    4. A00YUDFC02
      *1 Timing Mark
      *2 Mark Plate (Yellow)

      Align the mark plate (yellow) and timing marks and install the chain sub-assembly to the crankshaft timing sprocket.

  33. INSTALL CHAIN TENSIONER SLIPPER

  34. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Check each timing mark with the No. 1 cylinder at TDC/compression.

      A00YVOBC02
      *1 Timing Mark *2 Mark Plate (Orange)
      *3 Mark Plate (Yellow) - -

  35. INSTALL NO. 1 GENERATOR BRACKET


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

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  36. 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 }

  37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  38. INSTALL TIMING CHAIN COVER OIL SEAL

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  39. INSTALL ENGINE MOUNTING BRACKET STUD BOLT

    A00YTXP

    Note

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


    1. Install the stud bolt.

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

  40. INSTALL CRANKSHAFT PULLEY

    Click here

  41. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00YRRSC01
      *1 Cam
      *2 Hook
      *3 Pin
      *a CORRECT
      *b INCORRECT
      *c Push
      *d Raise

      Release the ratchet pawl. Then fully push in the plunger and attach the hook to the pin so that the plunger is in the position shown in the illustration.

      Note

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

    2. A00YW21

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

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

      Note

      If the hook becomes detached from the plunger while the chain tensioner is being installed, attach the hook again.

    3. A00YVJAC01
      *1 Pin
      *2 Hook
      *a Release
      *b Turn

      Turn the crankshaft counterclockwise slightly and check that the hook is released.

    4. A00YXE3C01
      *1 Plunger
      *a Plunger Extended
      *b Turn

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

  42. INSTALL OIL FILTER CAP ASSEMBLY

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  43. INSTALL SPARK PLUG TUBE GASKET


    1. A00YU4ZC01
      *a Before Cutting
      *b After Cutting
      A00YTV8 Area to be Cut Off

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

    2. A00YXDQC01
      *1 Spark Plug Tube Gasket without Sealing Part
      *2 New Plug Plug Tube Gasket
      *3 Claw

      Using a hammer and the removed spark plug tube gasket which has had the sealing 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 in the spark plug tube gasket at an angle.

      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.

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

  44. INSTALL CYLINDER HEAD COVER GASKET


    1. Install a new cylinder head cover gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surfaces.

  45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


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

    2. A00YV7X

      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 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.

  46. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  47. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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  48. INSTALL KNOCK SENSOR

    Click here

  49. INSTALL CRANKSHAFT POSITION SENSOR

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  50. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

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  51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

    Click here

  52. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  53. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  54. INSTALL SPARK PLUG

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  55. INSTALL ENGINE COVER JOINT


    1. Install the 2 engine cover joints.

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

  56. INSTALL OIL FILLER CAP GASKET


    1. Install the gasket to the oil filler cap.

  57. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly.