ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL RING PIN

    Note

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


    1. for Camshaft housing sub-assembly side:


      1. A001KFAC01
        *a Protrusion Height

        Using a plastic-faced hammer, tap in 8 new ring pins to the camshaft housing sub-assembly.

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

    2. for Stiffening crankcase assembly side:


      1. A001IKXC01
        *a Protrusion Height

        Using a plastic-faced hammer, tap in 2 new ring pins to the stiffening crankcase assembly.

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

  2. INSTALL STUD BOLT

    Note

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


    1. for Camshaft Housing sub-assembly side:


      1. A001K8YC02
        *a 20 mm (0.787 in.)
        *b 13 mm (0.512 in.)
        *c 35 mm (1.38 in.)

        Apply adhesive to camshaft housing sub-assembly side threads of the stud bolt.

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

        Note

        Install the stud bolt within 3 minutes of applying adhesive.

      2. Using an E8 "TORX" socket wrench, install the stud bolt to the camshaft housing sub-assembly.

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

    2. for Stiffening crankcase assembly side:


      1. A001LDDC01
        *a 8.5 mm (0.335 in.)
        *b 8.0 mm (0.315 in.)
        *c 18 mm (0.709 in.)

        Using an E5 "TORX" socket wrench, install the 2 stud bolts to the stiffening crankcase assembly.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. for Timing Chain Cover Assembly Side:


      1. A001IOJC01
        *a 16 mm (0.630 in.)
        *b 9.0 mm (0.354 in.)
        *c 27 mm (1.063 in.)

        Using an E6 "TORX" socket wrench, install the 4 stud bolts to the timing chain cover assembly.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  3. SET ENGINE BALANCER ASSEMBLY


    1. A001IEGC01
      *a No. 1 Balance Shaft Driven Gear
      *b No. 2 Balance Shaft Driven Gear
      *c Alignment Mark

      Make sure that the alignment marks on the No. 1 balance shaft driven gear and No. 2 balance shaft driven gear are aligned.

    2. A001KYBC01
      *a No. 1 Balance Shaft Driven Gear
      *b No. 2 Balance Shaft Driven Gear

      If the alignment marks are not aligned, hold the No. 2 balance shaft with a wrench at its flat portions, and rotate the No. 1 balance shaft as shown in the illustration to align the marks.

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. Clean the bolts and their installation holes.

    2. Clean and degrease the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.

    3. A001J81C01
      *a Seal Packing
      *b 28 mm (1.10 in.)
      *c 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *d 7.0 to 9.0 mm (0.276 to 0.354 in.)

      Apply seal packing to the areas 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 stiffening crankcase assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

    4. A001IIMC01
      *a

      Timing Mark

      (Balance Shaft Housing Side)
      *b

      Timing Mark

      (Balance Shaft Side)
      *c Crankshaft Pulley Set Key Groove

      Align the crankshaft pulley set key groove, timing marks on the balance shaft and balance shaft housing as shown in the illustration, and then set the stiffening crankcase assembly and engine balancer assembly on the cylinder block sub-assembly.

    5. A001L7RC02
      *a Bolt Type
      *b Tightening Order

      Apply adhesive to the threaded portion of the bolt E shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the bolt within 3 minutes of applying adhesive.

    6. Temporarily install the stiffening crankcase assembly to the cylinder block sub-assembly with the 12 bolts.

      Bolt Length
      Item Length Diameter
      Bolt A 65 mm (2.56 in.) 8.0 mm (0.315 in.)
      Bolt B 85 mm (3.35 in.) 10 mm (0.394 in.)
      Bolt C 140 mm (5.51 in.)
      Bolt D, E 125 mm (4.92 in.)

    7. Tighten the 12 bolts in the sequence shown in the illustration.

      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 }
    8. A001IPM

      Tighten the bolt.

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

  5. INSTALL TEMPERATURE SENSOR

    Click here

  6. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A001KKS

      Install the No. 1 oil pan baffle plate to the engine balancer assembly with the 4 bolts.

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

  7. INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. A001KRFC01
      *a Protrusion

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

    3. Install the oil strainer sub-assembly to the stiffening crankcase assembly with the 3 bolts and engine balancer assembly in several steps in the sequence shown in the illustration.

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

  8. INSTALL OIL PAN SUB-ASSEMBLY


    1. A001K6YC01
      *a 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 sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

    2. A001HRXC02
      B003WAF Bolt
      B003U82 Nut

      Install the oil pan sub-assembly to the stiffening crankcase 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 }

  9. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and the oil pan drain plug to the oil pan sub-assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  10. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  11. INSTALL OIL COOLER ASSEMBLY

    Click here

  12. INSTALL OIL FILTER BRACKET CLIP


    1. Install the oil filter bracket clip to the stiffening crankcase assembly.

  13. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  14. INSTALL REAR ENGINE OIL SEAL

    Click here

  15. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A001HLWC01
      *a Protrusion
      B003WAF Engine Front Side

      Install the cylinder block water jacket spacer to the cylinder block sub-assembly shown in the illustration.

      Note

      Make sure that the protrusion of the cylinder block water jacket spacer is facing up when installing it.

  16. INSTALL CYLINDER HEAD GASKET

    Click here

  17. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  18. INSTALL VALVE STEM CAP


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

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

      Note


      • Install the valve stem cap at the same place it was removed from.

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

  19. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster assembly free from dirt and foreign objects.

    • Only use clean engine oil.

    • If the valve lash adjuster assembly is tilted after bleeding, oil will leak. Make sure to bleed the valve lash adjuster assembly again.


    1. Bleed the valve lash adjuster assembly.

      Click here

    2. If the plunger moves, bleed the valve lash adjuster assembly again.

    3. Place the valve lash adjuster assembly into a container full of new engine oil, and then fill the low pressure chamber with engine oil.

    4. Apply engine oil to the outer surface of the valve lash adjuster body and the tip of the plunger, and then install the valve lash adjuster assembly while turning it.

      Note

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

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


    1. A001HULC43
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

    2. Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.

      Note

      Install the No. 1 valve rocker arm sub-assembly at the same place it was removed from.

  21. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

      Note

      Do not apply engine oil to the No. 1 camshaft bearing or contact surfaces.

    2. A001J9KC02
      *a Vernier Caliper

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

    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Standard dimension
      A - B or B - A = 0 to 0.7 mm (0 to 0.0276 in.)

  22. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

      Note

      Do not apply engine oil to the No. 2 camshaft bearing or contact surfaces.

    2. A001HXIC02
      *a Vernier Caliper

      Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.

    3. Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

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

  23. INSTALL OIL CONTROL VALVE FILTER


    1. Check that there is no foreign matter on the mesh section.

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

      Note

      Do not touch the mesh section on the oil control valve filter.

  24. INSTALL NO. 2 CAMSHAFT

    Tech Tips

    Perform "Inspection After Repair" after replacing the No. 2 camshaft.

    Click here (w/ Canister Pump Module)

    Click here (w/o Canister Pump Module)


    1. Clean the No. 2 camshaft journals and camshaft housing sub-assembly.

    2. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.

    3. A001KY1C02
      *a Thrust Surface

      Clean the thrust surface of the No. 2 camshaft and apply engine oil.

    4. Set the No. 2 camshaft to the camshaft housing sub-assembly.

  25. INSTALL CAMSHAFT

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft.

    Click here (w/ Canister Pump Module)

    Click here


    1. Clean the camshaft journals and camshaft housing sub-assembly.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.

    3. A001KY1C02
      *a Thrust Surface

      Clean the thrust surface of the camshaft and apply engine oil.

    4. Set the camshaft to the camshaft housing sub-assembly.

  26. INSTALL CAMSHAFT BEARING CAP


    1. Clean the camshaft bearing caps.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft bearing caps.

    3. Place the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps to the camshaft housing sub-assembly.

    4. A001HQWC01
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap
      *3 No. 3 Camshaft Bearing Cap
      *4 No. 4 Camshaft Bearing Cap

      Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      After installing the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps, make sure that the camshaft and No. 2 camshaft rotate smoothly.

  27. INSTALL NO. 3 WATER BY-PASS PIPE


    1. A001J3WN01

      Install a new gasket and the No. 3 water by-pass pipe to the cylinder head sub-assembly with the 3 bolts in the order shown in the illustration.

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

      Tech Tips

      Make sure the claws of the gasket face the No. 3 water by-pass pipe.

  28. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A001HULC43
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

    2. A001KJVC02
      *a Seal Packing

      Apply seal packing to the areas as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.158 in.)

      Note


      • Remove any oil from the contact surface.

      • Check the bolts and bolt holes and clean them.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

    3. A001IZHC02
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin

      Position the knock pins of the camshaft and No. 2 camshaft as shown in the illustration.

    4. A001JACN02

      Install the camshaft housing sub-assembly, and then install the 22 bolts in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

      Note

      If the bolts have been loosened during the installation, apply seal packing to the camshaft housing sub-assembly again.

  29. INSTALL OIL PIPE SUB-ASSEMBLY


    1. A001I3G

      Install the oil pipe sub-assembly to the No. 4 camshaft bearing cap with the bolt.

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

  30. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Note

    There are different types of camshaft timing gear bolts. Make sure to check the identification mark on the bolt and use the specified torque value for the bolt when tightening.

    A001LG2C01
    *a Identification Mark
    Identification Mark
    Type Identification Mark
    A A
    B C

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

    Click here (w/ Canister Pump Module)

    Click here (w/o Canister Pump Module)


    1. A001KKVC01
      *a Knock Pin Hole
      *b Knock Pin

      Fit the camshaft timing gear assembly and camshaft together with the knock pin and knock pin hole misaligned as shown in the illustration.

    2. Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the knock pin fits into the knock pin hole, push to ensure a good fit.

      Note

      Do not forcefully press the camshaft timing gear assembly. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly, leading to poor sealing.

    3. A001HUCC02
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Portion A of Camshaft
      *d No Clearance

      Check that there is no clearance between the camshaft timing gear assembly and portion A of the camshaft indicated in the illustration.

    4. A001I19

      Apply engine oil to the areas of the camshaft timing gear bolt indicated in the illustration.

    5. Temporarily install the camshaft timing gear bolt.

      Tech Tips

      When temporarily installing the camshaft timing gear bolt, make sure that it is screwed in approximately 3 threads.

    6. A001IMTC01
      *a Hold
      B003WAF Turn

      Use a wrench to hold the hexagonal portion of the camshaft.

    7. Tighten the camshaft timing gear bolt.

      Torque:
      Type A
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
      Type B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note


      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

  31. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

    Click here (w/ Canister Pump Module)

    Click here (w/o Canister Pump Module)


    1. A001L5GC02
      *a Knock Pin Hole
      *b Knock Pin

      Align the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear assembly and attach the camshaft timing exhaust gear assembly to the No. 2 camshaft.

      Note

      Do not forcefully press the camshaft timing exhaust gear assembly. Otherwise, the tip of knock pin of the No. 2 camshaft may damage the seal surface of the camshaft timing exhaust gear assembly, leading to poor sealing.

    2. A001JO6C02
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c No. 2 Camshaft Flange
      *d No Clearance

      Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

    3. A001I6BC01
      *a Hold
      B003WAF Turn

      Use a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note


      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  32. ADD ENGINE OIL


    1. A001I91

      Add 50 cc (3.1 cu.in.) of engine oil into the oil hole shown in the illustration.

      Note


      • Oil must be added if the valve lash adjuster assemblies were removed.

      • Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.

  33. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. Install the crankshaft timing gear or sprocket to the crankshaft.

  34. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A001JZNN01

      Temporarily install the No. 1 chain vibration damper to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.

    2. Tighten the 2 bolts in the order shown in the illustration.

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

  35. INSTALL CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley set bolt.

    2. A001J86C04
      *1 Crankshaft Pulley Set Key
      *a 40°

      Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley set key as shown in the illustration.

    3. A001IBNC01
      *a Timing Mark (Groove)
      *b Approximately 7°
      *c Approximately 32°

      Check that the timing marks (groove) of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.

    4. Place the chain sub-assembly onto the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

      Tech Tips


      • Make sure the mark plate of the chain sub-assembly faces away from the front of the engine.

      • It is not necessary to install the chain sub-assembly to the teeth of the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

    5. A001L1NC02
      *a Mark Plate (Orange)
      *b Timing Mark (Groove)

      Align the mark plate (orange) of the chain sub-assembly with the timing mark (groove) of the camshaft timing exhaust gear assembly and install the chain sub-assembly to the camshaft timing exhaust gear assembly.

    6. A001KFZC01
      *a Mark Plate (Yellow)
      *b Timing Mark

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

    7. A001KQF

      Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.

    8. A001KL9C01
      *a Mark Plate (Orange)
      *b Timing Mark (Groove)

      Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench, align the timing mark (groove) of the camshaft timing gear assembly with the mark plate (orange) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      Hold the camshaft in place with a wrench until the No. 1 chain tensioner assembly is installed.

    9. A001HXV

      Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.

      Note

      Make sure the chain sub-assembly is secure.

  36. INSTALL CHAIN TENSIONER SLIPPER


    1. A001K68

      Install the chain tensioner slipper to the cylinder head sub-assembly with the bolt.

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

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A001HN6C02
      B003WAF Bolt
      B003U82 Nut

      Install a new gasket and the No. 1 chain tensioner assembly to the cylinder block sub-assembly with the bolt and nut.

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

    2. Remove the pin from the stopper plate.

  38. INSTALL TIMING CHAIN GUIDE


    1. A001IX1

      Install the timing chain guide to the No. 1 camshaft bearing cap with the bolt.

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

  39. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  40. INSTALL TIMING CHAIN COVER PLATE


    1. A001KPV

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

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

  41. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  42. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

    Click here

  43. INSTALL CRANKSHAFT PULLEY ASSEMBLY


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

    2. A001JX5C01
      *a Hold
      B003WAF Turn

      Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley set 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 holding tool): 91551-80650 (quantity: 2)

  44. INSTALL CRANK POSITION SENSOR

    Click here

  45. INSTALL WATER OUTLET SUB-ASSEMBLY


    1. Install a new O-ring to the timing chain cover assembly.

    2. Install the water outlet sub-assembly to the timing chain cover assembly with the nut and 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A001K5OC01
      *a Upper Side
      *b Front Side
      *c 45°

      Connect the No. 6 water by-pass hose to the water outlet sub-assembly with the clip as shown in the illustration.

      Tech Tips

      Install the clip so that it is positioned as shown in the illustration.

  46. INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  47. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

    Click here

  48. INSTALL SPARK PLUG TUBE GASKET


    1. A001KDWC03
      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly
      *a No Clearance

      Install the 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

      Note


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

      • Keep the lip free from foreign matter.

  49. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET

    Click here

  50. INSTALL CYLINDER HEAD COVER GASKET

    Click here

  51. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  52. INSTALL NO. 1 VENTILATION CASE


    1. A001HLRC02
      *a Seal Packing

      Apply seal packing to a new No. 1 ventilation case in the areas indicated 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


      • Do not reuse the No. 1 ventilation case

      • Remove any oil from the contact surface.

      • Install the No. 1 ventilation case within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

      Tech Tips

      Make sure to apply seal packing so that there are no gaps in the areas indicated by A in the illustration.

    2. A001IQEC02
      B003WAF Bolt
      B003U82 Nut

      Install the No. 1 ventilation case, and then tighten the 6 bolts and 2 nuts in the order shown in the illustration.

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

  53. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

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

    Click here

  55. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  56. INSTALL KNOCK CONTROL SENSOR

    Click here

  57. INSTALL SPARK PLUG

    Click here