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. B005924C02
        *a Protrusion Height

        Using a plastic-faced hammer, tap in 10 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 Sub-assembly Side:


      1. B0058SMC02
        *a Protrusion Height

        Using a plastic-faced hammer, tap in 2 new ring pins to the stiffening crankcase sub-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. B0057YGC02
        *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.

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

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

    2. for Transverse Engine Mounting Bracket Side:


      1. B0059UTC02
        *a 34 mm (1.34 in.)
        *b 25 mm (0.984 in.)
        *c 76 mm (2.99 in.)

        Install the stud bolt.

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

    3. for Stiffening Crankcase Sub-assembly Side:


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

        Torque:
        for stud bolt A
        9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
        for stud bolt B
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
        B0057RUC02
        *a Front Side *b Lower 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.)

  3. INSTALL ENGINE BALANCER ASSEMBLY


    1. B005A3YC16
      *1 Balance Shaft Damper Cover
      *2 Balance Shaft Driven Gear
      *a 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.

    2. B005BCWC15
      *1 Balance Shaft Damper Cover
      *2 Balance Shaft Driven Gear
      *a Alignment Mark

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

    3. 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.

    4. B0058GKC02
      *a Bolt Type
      *b Tightening Order

      Install the engine balancer assembly to the stiffening crankcase sub-assembly with the 4 bolts and tighten the bolts in the sequence shown in the illustration.

      Torque:
      for bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for bolt B
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Bolt Length
      Item Specified Condition
      Bolt A 55 mm (2.17 in.)
      Bolt B 45 mm (1.77 in.)

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. B0058AEC02
      *1 Crankshaft Pulley Set Key

      Rotate the crankshaft clockwise so that the crankshaft pulley set key is at the position 90° from the bottom as shown in the illustration.

    2. Clean the stiffening crankcase assembly and cylinder block sub-assembly.

    3. B00573SC01
      *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. B0059Q5C11
      *a Cutout

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

    5. Clean the bolts and their installation holes.

      Note

      Check that there is no oil in the installation holes indicated in the illustration. Remove if there is any oil.

      B00586Y
    6. B0057FMC02
      *a Bolt Type
      *b Tightening Order

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the bolt within 3 minutes of applying adhesive.

    7. Temporarily install the stiffening crankcase assembly 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.)

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

      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 ENGINE OIL TEMPERATURE SENSOR

    Click here

  6. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. B00590VN02

      Install the No. 1 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 }

  7. INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. B005AX8C02
      *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 sequence shown in the illustration.

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

  8. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  9. INSTALL OIL PAN SUB-ASSEMBLY


    1. B0059WAC02
      *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. B0058NBN02

      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 }

  10. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and the oil pan drain plug.

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

  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. B005AXKC02
      *a Engine Front Side
      *b Protrusion

      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 cylinder head sub-assembly.

      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. B005AHHC43
      *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-assemblies 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. B005AP2C02
      *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. B0059NWC02
      *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.



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

  25. INSTALL CAMSHAFT

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft.



    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. 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 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

    4. B005AMXN05

      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 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap, make sure that the camshaft and No. 2 camshaft rotate smoothly.

  27. INSTALL NO. 3 WATER BY-PASS PIPE


    1. B00580PN03

      Install a new gasket and the No. 3 water by-pass pipe 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.

    2. Connect the No. 6 water by-pass hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.

  28. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B005AHHC43
      *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. B00598QC02
      *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. B0057UBC02
      *a Approximately 17°
      *b Approximately 2°
      *c Knock Pin

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

    4. B005AC7N02

      Install the camshaft housing sub-assembly, and then install the 22 bearing cap 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 black to the camshaft housing sub-assembly again.

  29. INSTALL OIL PIPE SUB-ASSEMBLY


    1. Install the oil pipe sub-assembly with the bolt.

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

  30. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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



    1. B00573WC02
      *a Knock Pin Hole
      *b Knock Pin

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

      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.

    2. B00579TC02
      *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.

    3. B005937

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

    4. 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 2 threads.

    5. B00582XC02
      *a Hold
      B0057RX Turn

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

    6. Tighten the camshaft timing gear bolt.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 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.



    1. B0059FCC02
      *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. B00597UC02
      *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. B005AGMC02
      *a Hold
      B0057RX 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. INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the crankshaft timing sprocket to the crankshaft.

  33. ADD ENGINE OIL


    1. B005AFS

      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.

  34. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. B0058C7N02

      Temporarily install the No. 1 chain vibration damper 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. B00588GC01
      *1 Crankshaft Pulley Set Key

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

    3. B0057DWC02
      *a Timing Mark
      *b Approximately 7°
      *c Approximately 32°

      Check that the timing marks 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 front of the engine.

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

    5. B0059V2C02
      *a Mark Plate (Orange)
      *b Timing Mark

      Align the mark plate (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.

    6. B005A4BC02
      *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. B00582W

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

    8. B0059XKC02
      *a Mark Plate (Orange)
      *b Timing Mark

      Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench, align the timing mark 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. B00582E

      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. Install the chain tensioner slipper with the bolt.

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

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Install a new gasket and the No. 1 chain tensioner 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. Install the timing chain guide with the bolt.

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

  39. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  40. INSTALL TIMING CHAIN COVER PLATE


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

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

  41. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  42. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

    Click here

  43. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET

    Click here

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

    Click here

  45. INSTALL SPARK PLUG TUBE GASKET

    Note

    w/ Canister Pump Module:

    Be sure not to disconnect the PCV hose or the No. 4 PCV hose from the cylinder head cover sub-assembly.


    1. B0058UCC01
      *A w/o Canister Pump Module
      *B w/ Canister Pump Module
      *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.

  46. INSTALL NO. 4 PCV HOSE (w/o Canister Pump Module)


    1. Install the No. 4 PCV hose to the cylinder head cover sub-assembly, and slide the clamp to secure the hose.

  47. INSTALL PCV HOSE (w/o Canister Pump Module)


    1. Install the PCV hose to the cylinder head cover sub-assembly, and slide the clamp to secure the hose.

  48. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  49. INSTALL CRANKSHAFT PULLEY ASSEMBLY


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

    2. B00584EC02
      *a Hold
      B0057RX 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)

  50. INSTALL NO. 1 PCV CASE


    1. B0057ZGC02
      *a Seal Packing

      Apply seal packing to a new No. 1 PCV 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 PCV case

      • Remove any oil from the contact surface.

      • Install the No. 1 PCV 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. B0057FSN02

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

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

  51. INSTALL PCV VALVE SUB-ASSEMBLY

    Click here

  52. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  53. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  54. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  55. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  56. INSTALL KNOCK SENSOR

    Click here

  57. INSTALL SPARK PLUG

    Click here

  58. INSTALL THERMOSTAT (for Cylinder Block)

    Click here

  59. INSTALL WATER INLET HOUSING

    Click here

  60. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY

    Click here

  61. INSTALL NO. 4 WATER BY-PASS PIPE


    1. B0057L7C02
      *a Bolt
      *b Nut

      Install a new gasket and the No. 4 water by-pass pipe with the 2 nuts and bolt in the order shown in the illustration.

      Torque:
      for nut
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Connect the No. 4 water by-pass hose to the oil cooler assembly, and slide the clamp to secure the hose.

  62. INSTALL NO. 1 WATER BY-PASS PIPE

    Click here

  63. INSTALL NO. 4 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  64. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  65. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  66. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  67. INSTALL FUEL INJECTOR SEAL (for Direct Injection)

    Click here

  68. INSTALL FUEL INJECTOR SET (for Direct Injection)

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  69. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection)

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  70. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)

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  71. INSTALL FUEL DELIVERY PIPE (for Port Injection)

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  72. SET FUEL PUMP ASSEMBLY (for High Pressure)

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  73. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)

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  74. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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  75. TIGHTEN NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)

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