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БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

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PROCEDURE


  1. Click here

    INSTALL RING PIN

    Note:

    It is not necessary to remove the ring pins unless they are being replaced.


    1. A01UER7C07
      *a Protrusion Height

      Using a plastic 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. Click here

    INSTALL STUD BOLT

    Note:

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


    1. A01UFAKC02
      *a 16 mm (0.63 in.)
      *b 9 mm (0.354 in.)
      *c 27 mm (1.06 in.)

      Using an E6 "TORX" socket wrench, install the 3 stud bolts to the cylinder head cover sub-assembly.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    2. When reusing the stud bolt:


      1. A01UDTXC05
        *a 20 mm (0.787 in.)
        *b 35 mm (1.38 in.)
        *c 13 mm (0.512 in.)

        Apply adhesive 1324 to the threaded portion (camshaft housing sub-assembly side) of the stud bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      9.0 N*m 92 kgf*cm 80 in.*lbf
    4. A01UDQ2C03
      *a 34 mm (1.34 in.)
      *b 25 mm (0.984 in.)
      *c 76 mm (2.99 in.)

      Install the stud bolt to the engine mounting bracket RH.

      15 N*m 153 kgf*cm 11 ft.*lbf
    5. A01UCZJC03
      *a Front Side *b Bottom Side
      *c 20 mm (0.787 in.) *d 13 mm (0.512 in.)
      *e 35 mm (1.38 in.) *f 8.5 mm (0.335 in.)
      *g 8.0 mm (0.315 in.) *h 18 mm (0.709 in.)

      Using E5 and E8 "TORX" socket wrenches, install the 3 stud bolts to the stiffening crankcase assembly.

      Stud Bolt (A)
      9.5 N*m 97 kgf*cm 84 in.*lbf
      Stud Bolt (B)
      4.0 N*m 41 kgf*cm 35 in.*lbf
    6. A01UD92C03
      *a 46 mm (1.81 in.)
      *b 19 mm (0.748 in.)
      *c 67 mm (2.64 in.)

      Using an E10 "TORX" socket wrench, install the stud bolt to the cylinder block sub-assembly.

      15 N*m 153 kgf*cm 11 ft.*lbf
    7. A01UDVUC03
      *a 14 mm (0.551 in.)
      *b 13 mm (0.512 in.)
      *c 29 mm (1.14 in.)

      Using an E8 "TORX" socket wrench, install the 2 stud bolts to the cylinder block sub-assembly.

      9.5 N*m 97 kgf*cm 84 in.*lbf
  3. Click here

    INSTALL STRAIGHT PIN

    Note:

    It is not necessary to remove the straight pins unless they are being replaced.


    1. A01UELRC07
      *a Protrusion Height

      Using a plastic hammer, tap in 2 straight pins to the camshaft housing sub-assembly.

      Standard Protrusion Height
      5.0 to 7.0 mm (0.197 to 0.276 in.)
  4. Click here

    INSTALL ENGINE BALANCER ASSEMBLY


    1. A01UF27C17
      *a Alignment Mark

      Check that the alignment marks of the balance shaft damper cover and No. 1 balance shaft driven gear are aligned.

      If the alignment marks are not aligned, realign them.


      1. A01UE1HC17
        *a No. 1 Balance Shaft Driven Gear
        *b Balance Shaft Damper Cover
        *c Alignment Mark

        Using a wrench, securely hold the No. 2 balance shaft.

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

    2. A01UDYTN07

      Install the engine balancer assembly to the stiffening crankcase assembly with the 3 bolts in the order shown in the illustration.

      24 N*m 245 kgf*cm 18 ft.*lbf
  5. Click here

    INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01UEBAC03
      *1 Crankshaft Pulley Key

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

    2. A01UF89C05
      *a Seal Packing
      *b 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *c 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *d 28 mm (1.10 in.)
      A01UEV3 Stiffening Crankcase Assembly
      A01UF59 Cylinder Block Sub-assembly

      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 Packing 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
      Note:

      • Remove any oil from the contact surfaces.

      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

    3. A01UEEGC12
      *a Cutout

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

    4. Clean the bolts and bolt holes.

    5. A01UE8EC12
      *a Adhesive

      Apply adhesive to 3 or more threads at the tips of the bolts (A).

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01UF3KC01
      *a Bolt Type

      Temporarily install the stiffening crankcase assembly with the 11 bolts.

      Bolt Length
      Item Length
      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.)
      Tip:

      Apply adhesive to the bolts (A) before installation.

    7. A01UF3KC02
      *a Tightening Order

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

      Bolt (A)
      24 N*m 245 kgf*cm 18 ft.*lbf
      except Bolt (A)
      43 N*m 438 kgf*cm 32 ft.*lbf
  6. Click here

    INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A01UE5VN06

      Install the No. 1 oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the order shown in the illustration.

      10 N*m 102 kgf*cm 7 ft.*lbf
  7. Click here

    INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. A01UDGRC06
      *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 with the 3 bolts in several steps in the order shown in the illustration.

      9.0 N*m 92 kgf*cm 80 in.*lbf
  8. Click here

    INSTALL OIL PAN SUB-ASSEMBLY


    1. A01UCIGC03
      *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 Packing Diameter
      2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Note:

      • Remove any oil from the contact surfaces.

      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.

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

    2. A01UCPIC04
      *a Nut

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

      10 N*m 102 kgf*cm 7 ft.*lbf
      Tip:

      Bolt (A) and nut (A) are tightened twice.

  9. Click here

    INSTALL OIL PAN DRAIN PLUG


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

      40 N*m 408 kgf*cm 30 ft.*lbf
  10. Click here

    INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  11. Click here

    INSTALL REAR ENGINE OIL SEAL

    Click here

  12. Click here

    INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. Install the cylinder block water jacket spacer to the cylinder block sub-assembly.

  13. Click here

    INSTALL CYLINDER HEAD GASKET

    Click here

  14. Click here

    INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  15. Click here

    INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note:

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.


    1. A01UEWFC09
      *a Protrusion Height

      Using a plastic hammer, tap in 10 camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.

      Standard Protrusion Height
      2.7 to 3.3 mm (0.106 to 0.130 in.)
  16. Click here

    INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

    2. A01UCREC12
      *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.

      Difference between (A) and (B)
      0 to 0.7 mm (0 to 0.0276 in.)
  17. Click here

    INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. A01UDLEC20
      *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
      1.15 to 1.85 mm (0.0453 to 0.0728 in.)
  18. Click here

    INSTALL OIL CONTROL VALVE FILTER


    1. A01UE0U

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

  19. Click here

    INSTALL NO. 2 CAMSHAFT

    Tip:

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

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

  20. Click here

    INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  21. Click here

    INSTALL CAMSHAFT

    Tip:

    Perform "Inspection After Repair" after replacing the camshaft.

    Click here


    1. Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

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

    3. Install the camshaft to the camshaft housing sub-assembly.

  22. Click here

    INSTALL CAMSHAFT BEARING CAP


    1. A01UD5CN01

      Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps in their correct locations.

    2. A01UEBVN01

      Uniformly tighten the 11 bolts in several steps in the order shown in the illustration.

      16 N*m 163 kgf*cm 12 ft.*lbf

    3. Check the torque of each bolt again.

  23. Click here

    INSTALL VALVE STEM CAP


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

    2. Install the 16 valve stem caps to the cylinder head sub-assembly.

      Note:

      Be careful not to drop the valve stem caps into the cylinder head sub-assembly.

  24. Click here

    INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect the 16 valve lash adjuster assemblies before installing them.

      Click here

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

      Tip:

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

  25. Click here

    INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A01UDG3C48
      *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.

  26. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01UE00C27
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash Adjuster Assembly
      *a Incorrect
      *b Correct

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

    2. A01UFA6C02
      *a Seal Packing
      *b 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *c 3.5 to 4.0 mm (0.138 to 0.157 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
      Standard Seal Packing Diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)
      Note:

      • Remove any oil from the contact surfaces.

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

    3. A01UD6CC11
      *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. A01UEXGN02

      Install the camshaft housing sub-assembly, and then install the 20 bolts in the order shown in the illustration.

      27 N*m 275 kgf*cm 20 ft.*lbf
      Note:

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

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

      • After installation, if the seal packing has seeped out, wipe it off.

  27. Click here

    INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tip:

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

    Click here


    1. A01UFECC08
      *a Knock Pin Hole
      *b Alignment Mark

      Check the camshaft timing gear assembly position. If the camshaft timing gear assembly is not set to the advanced position, release the lock pin and reset the camshaft timing gear assembly.

    2. A01UCLUC76
      *a Knock Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

    3. A01UDRKC93
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

      Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

    4. Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing gear assembly with the bolt.

      85 N*m 867 kgf*cm 63 ft.*lbf
      Note:

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

      • Do not disassemble the camshaft timing gear assembly.

      Tip:

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

      Click here

  28. Click here

    INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tip:

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

    Click here


    1. Secure the No. 2 camshaft in a vise by clamping the hexagonal part between aluminum plates.

      Note:

      Do not damage the No. 2 camshaft by tightening the vise excessively.

    2. A01UD38C32
      *a Knock Pin Hole
      *b Knock Pin

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

    3. A01UDRKC94
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

      Check that there is no gap between the camshaft timing exhaust gear assembly and camshaft flange.

    4. A01UD0XC08
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing exhaust gear assembly with the bolt.

      85 N*m 867 kgf*cm 63 ft.*lbf
      Note:

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

      • Do not disassemble the camshaft timing exhaust gear assembly.

  29. Click here

    INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01UE1O

      Install the crankshaft timing sprocket to the crankshaft.

  30. Click here

    ADD ENGINE OIL


    1. A01UCN5

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

      Note:

      • Engine oil must be added if the valve lash adjusters were removed.

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

  31. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. A01UDDHC03
      *1 Crankshaft Pulley Key

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

    3. A01UCNTC10
      *a Timing Mark
      *b Approximately 7°
      *c Approximately 32°

      Check that the timing marks of the camshaft timing sprocket and camshaft timing gear assembly are as shown in the illustration.

      Tip:

      "A" is not a timing mark.

  32. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01UEAJN02

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

      21 N*m 214 kgf*cm 15 ft.*lbf
  33. Click here

    INSTALL CHAIN SUB-ASSEMBLY


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

      Tip:

      • Make sure the paint mark of the chain sub-assembly is facing away from the engine assembly.

      • It is not necessary to install the chain sub-assembly to the teeth of the gears and sprocket.

    2. A01UCHMC14
      *a Paint Mark (Orange)
      *b Timing Mark

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

    3. A01UESTC22
      *a Paint Mark (Yellow)
      *b Timing Mark

      Align the paint mark (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.

    4. A01UCNG

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

    5. A01UEFEC14
      *a Paint Mark (Orange)
      *b Timing Mark

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

      Tip:

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

    6. A01UCMV

      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 securely installed.

  34. Click here

    INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  35. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01UCPOC02
      *a Pin

      Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Remove the pin from the stopper plate.

  36. Click here

    INSTALL TIMING CHAIN GUIDE


    1. Install the timing chain guide with the bolt.

      21 N*m 214 kgf*cm 15 ft.*lbf
  37. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  38. Click here

    INSTALL TIMING CHAIN COVER PLATE


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

      10 N*m 102 kgf*cm 7 ft.*lbf
  39. Click here

    INSTALL OIL PUMP RELIEF VALVE PLUG


    1. Using a 14 mm hexagon wrench, install a new gasket and the oil pump relief valve plug.

      37.5 N*m 382 kgf*cm 28 ft.*lbf
  40. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  41. Click here

    INSTALL ENGINE MOUNTING BRACKET RH


    1. A01UE8NN02

      Install the engine mounting bracket RH with the 4 bolts in the order shown in the illustration.

      Bolt (1), (2) and (3)
      55 N*m 561 kgf*cm 41 ft.*lbf
      Bolt (4)
      21 N*m 214 kgf*cm 15 ft.*lbf
      Note:

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

  42. Click here

    INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  43. Click here

    INSTALL SPARK PLUG TUBE GASKET


    1. A01UCYQ

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

      Note:

      After pressing in the spark plug tube gasket, make sure the gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover sub-assembly.

  44. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01UFC4C02
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *a Gasket

      Apply a light coat of engine oil to a new camshaft bearing cap oil hole gasket and a new gasket.

    2. Install the 2 camshaft bearing cap oil hole gaskets to the No. 1 camshaft bearing cap.

    3. Install the gasket to the No. 2 camshaft bearing cap.

    4. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

      Note:

      Remove any oil from the contact surfaces.

    5. A01UER8C01
      *1 Timing Chain Cover Sub-assembly
      *2 Camshaft Housing Sub-assembly
      *a Application Width 5.0 mm (0.197 in.)
      *b Seal Packing Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
      A01UFKZ Seal Packing

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application Width
      10.0 mm (0.394 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 of applying seal packing.

    6. A01UCPKC04
      *a Pin (A)
      *b Pin (B)
      *c Seal Washer

      Align the cylinder head cover sub-assembly with the pin (A). Then align the cylinder head cover sub-assembly with the pin (B) and install the cylinder head cover sub-assembly.

    7. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

      12 N*m 122 kgf*cm 9 ft.*lbf
      Note:

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

  45. Click here

    INSTALL CRANKSHAFT PULLEY


    1. A01UCIAC04
      *a Hold
      *b Turn

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

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

      09213-54015
      09330-00021
      260 N*m 2651 kgf*cm 192 ft.*lbf
      Tip:

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

  46. Click here

    INSTALL SEPARATOR CASE


    1. A01UDFX

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

    2. Install the gasket to the separator case.

    3. Install the separator case to the ventilation case sub-assembly with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  47. Click here

    INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. A01UCKHC04
      *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 Packing Diameter
      2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Note:

      • Remove any oil from the contact surfaces.

      • Install the ventilation case sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.

    2. A01UDQ0N08

      Install the ventilation case sub-assembly with the 8 bolts and 2 nuts in the order shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf
      Tip:

      The bolts (A) are tightened twice.

  48. Click here

    INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  49. Click here

    INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  50. Click here

    INSTALL OIL FILLER CAP GASKET


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

  51. Click here

    INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

  52. Click here

    INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

    Click here

  53. Click here

    INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

    Click here

  54. Click here

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

    Click here

  55. Click here

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

    Click here

  56. Click here

    INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  57. Click here

    INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  58. Click here

    INSTALL KNOCK CONTROL SENSOR

    Click here

  59. Click here

    INSTALL SPARK PLUG

    Click here

  60. Click here

    INSTALL ENGINE COVER JOINT


    1. A01UCMD

      Install the 3 engine cover joints.

      10 N*m 102 kgf*cm 7 ft.*lbf