ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A01V8CKC05
    *1 Protrusion Height

    Note

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


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

      Standard protrusion height
      4.3 to 5.3 mm (0.169 to 0.209 in.)

  2. INSTALL STIFFENING CRANKCASE STUD BOLT

    Note

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

    A01V73GC01
    *a Front Side *b Lower Side
    *c 20 mm (0.787 in.) *d 35 mm (1.38 in.)
    *e 13 mm (0.512 in.) *f 8.5 mm (0.335 in.)
    *g 18 mm (0.709 in.) *h 8.0 mm (0.315 in.)

    1. Using an E5 and E8 "TORX" socket wrench, install the stud bolts.

      Torque:
      for stud bolt A
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      for stud bolt B
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

  3. INSTALL ENGINE BALANCER ASSEMBLY


    1. A01V9TPC06
      *1 Alignment Mark

      Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

      If the alignment marks are not aligned, realign them.


      1. A01V7VNC06
        *1 Driven Gear
        *2 Damper Cover
        *3 Alignment Mark

        Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place.

      2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.

    2. A01V7KDN01

      Install the engine balancer to the stiffening crankcase with the 3 bolts and tighten the bolts in the sequence shown in the illustration.

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

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01VA3EC01
      *1 Key

      Rotate the crankshaft clockwise so that the crankshaft key is at the position 270° from the bottom as shown in the illustration.

    2. A01VAKSC05
      *1 Seal Packing
      *a 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *b 7.0 to 9.0 mm (0.276 to 0.354 in.)
      A01V7TU Stiffening Crankcase
      A01V8G2 Cylinder Block

      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 Dimension
      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick
      Application length A
      28 mm (1.10 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

      • Do not apply oil for at least 4 hours after the installation.

      • Do not start the engine for at least 4 hours after the installation.

    3. A01V80QC02
      *1 Cutout

      Check that the rear cutouts are as shown in the illustration.

    4. Clean the bolts and their installation holes.

    5. Apply adhesive to 3 threads or more at the end of bolt A.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01V7PEN03

      Temporarily install the stiffening crankcase with the 11 bolts.

      Bolt Length
      Item Specified Condition
      Bolt A 65 mm (2.56 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 125 mm (4.92 in.)
      Bolt D 165 mm (6.50 in.)

      Tech Tips

      Apply adhesive to bolt A before installing it.

    7. A01V7PEN04

      Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase.

      Torque:
      for bolt A
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      except bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  5. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01V97SN05

      Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the sequence shown in the illustration.

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

  6. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01V9AUC03
      *1 Protrusion

      Apply a light coat of engine oil to a new gasket.

    2. Align the protrusion of the gasket with the cutout of the oil strainer and install the gasket to the oil strainer sub-assembly.

    3. Install the oil strainer sub-assembly with the 3 bolts in several steps in the sequence shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  7. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01VAJFC01
      *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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      • Do not apply oil for at least 4 hours after the installation.

      • Do not start the engine for at least 4 hours after the installation.

    2. A01V8X1N03

      Install the oil pan sub-assembly with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration.

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

      Tech Tips

      Bolt A and nut A are tightened twice.

  8. INSTALL OIL FILTER ELEMENT

    Click here

  9. INSTALL REAR ENGINE OIL SEAL

    Click here

  10. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. Install the cylinder block water jacket spacer to the cylinder block.

  11. INSTALL CYLINDER HEAD GASKET

    Click here

  12. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  13. SET CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    A01V8LDC07
    *1 Protrusion Height

    Note

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


    1. Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.

      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A01V9ZCC06
    *1 Protrusion Height

    Note

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


    1. Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing.

      Standard protrusion height
      5.0 to 7.0 mm (0.197 to 0.276 in.)

  16. INSTALL CAMSHAFT HOUSING STUD BOLT

    Note

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


    1. A01VA6BC03
      *a 20 mm (0.787 in.)
      *b 35 mm (1.38 in.)
      *c 13 mm (0.512 in.)

      Using an E8 "TORX" socket wrench, install the stud bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  17. INSTALL NO. 1 CAMSHAFT BEARING


    1. A01V7HMC05
      *1 Vernier Caliper

      Clean the No. 1 camshaft bearing.

    2. Install the camshaft bearing to the No. 1 camshaft bearing cap.

    3. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.

      Dimension A - B or B - A
      0 to 0.7 mm (0 to 0.0276 in.)

  18. INSTALL NO. 2 CAMSHAFT BEARING


    1. A01VAGFC09
      *1 Vernier Caliper

      Clean the No. 2 camshaft bearing.

    2. Install the camshaft bearing to the camshaft housing.

    3. Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

      Standard distance
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  19. INSTALL OIL CONTROL VALVE FILTER


    1. A01V81R

      Install the oil control valve filter to the No. 1 camshaft bearing cap.

  20. INSTALL CAMSHAFT

    Click here

  21. INSTALL CAMSHAFT BEARING CAP

    Click here

  22. INSTALL VALVE STEM CAP

    Click here

  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

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

    Click here

  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  26. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  27. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  28. INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the crankshaft timing sprocket to the crankshaft.

  29. ADD ENGINE OIL

    Click here

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  31. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  32. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  33. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  35. INSTALL TIMING CHAIN GUIDE

    Click here

  36. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  37. INSTALL TIMING CHAIN COVER PLATE

    Click here

  38. INSTALL TIMING CHAIN COVER TIGHT PLUG


    1. Using a 14 mm hexagon wrench, install a new gasket and timing chain cover tight plug.

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

  39. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  40. INSTALL ENGINE MOUNTING BRACKET RH

    Click here

  41. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  42. INSTALL SPARK PLUG TUBE GASKET

    Click here

  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  44. INSTALL CRANKSHAFT PULLEY


    1. A01V85GC01
      *a Hold
      *b Turn

      Align the pulley set key with the key groove of the crankshaft pulley.

    2. Using SST, hold the crankshaft pulley and install the pulley bolt.

      SST
      09213-54015
      09330-00021
      Torque:
      260 N*m  { 2651 kgf*cm, 192 ft.*lbf }

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holdingtool): 91551-80650 (quantity: 2)

  45. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  46. INSTALL WATER INLET HOUSING


    1. Install a new gasket and the water inlet housing with the 4 bolts and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  47. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)

    Click here

  48. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  49. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  50. INSTALL DUST COVER (w/ Cover)

  51. INSTALL THERMOSTAT

    Click here

  52. INSTALL WATER INLET

    Click here

  53. INSTALL NO. 1 WATER BY-PASS PIPE


    1. Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.

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

  54. INSTALL SEPARATOR CASE


    1. Apply a light coat of engine oil to a new gasket.

    2. Install the gasket to the separator case.

    3. Install the separator case with the 2 bolts.

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

  55. INSTALL PCV CASE


    1. A01VAMGC01
      *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
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the PCV case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    2. A01V8WPN04

      Install the PCV case, and then install the 8 bolts and 2 nuts in the order shown in the illustration.

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

      Tech Tips

      Bolt A is tightened twice.

  56. INSTALL PCV VALVE

    Click here

  57. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  58. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

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

    Click here

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

    Click here

  61. INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

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

  62. INSTALL SPARK PLUG

    Click here

  63. INSTALL ENGINE COVER JOINT


    1. Install the 3 engine cover joints.

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