ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. Clean and degrease the contact surfaces of the rear engine oil seal retainer and cylinder block sub-assembly.

    2. B003NSDC01
      *a Seal Packing

      Apply seal packing in a continuous bead as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the rear engine oil seal retainer within 3 minutes after applying seal packing.

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

    3. Install the rear engine oil seal retainer with the 6 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  2. INSTALL REAR ENGINE OIL SEAL

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  3. INSTALL NO. 1 TAPER SCREW PLUG (w/o Oil Cooler)


    1. Install the No. 1 taper screw plug to the cylinder block sub-assembly.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

  4. INSTALL UNION (w/ Oil Cooler)


    1. Install the union to the cylinder block sub-assembly.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

  5. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Using a hexagon wrench, install the oil filter bracket union.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

    2. Install a new oil filter bracket gasket to the oil filter bracket sub-assembly.

    3. Install a new O-ring to the oil filter bracket union.

      Note

      Apply a light coat of engine oil to a new O-ring and oil filter bracket sub-assembly.

    4. Install 2 new gaskets and the 2 screw plugs to the oil filter bracket sub-assembly.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    5. Install the oil filter bracket sub-assembly with the 2 bolts and nut.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  6. INSTALL OIL FILTER UNION (w/o Oil Cooler)


    1. Using a 27 mm socket wrench, install the oil filter union.

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }

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

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  8. INSTALL OIL FILTER SUB-ASSEMBLY

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  9. INSTALL NO. 4 WATER BY-PASS HOSE (w/ Oil Cooler)


    1. Install the No. 4 water by-pass hose to the oil cooler assembly and union, and slide the clips to secure the hoses.

  10. INSTALL NO. 4 WATER BY-PASS PIPE (w/ Oil Cooler)


    1. Install the No. 4 water by-pass pipe with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the No. 5 water by-pass hose to the oil cooler assembly, and slide the clip to secure the hose.

  11. INSTALL CRANKSHAFT PULLEY SET KEY


    1. Install the 2 crankshaft pulley set keys to the crankshaft.

  12. INSTALL NO. 4 CHAIN VIBRATION DAMPER


    1. Install the No. 4 chain vibration damper with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  13. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. B003RAM

      Install the No. 2 crankshaft timing sprocket as shown in the illustration.

      Note

      Check that the No. 1 cylinder is at TDC and that the weights of the No. 1 and No. 2 balanceshafts are at the bottom side.

      Tech Tips

      Install the No. 2 crankshaft timing sprocket with the front mark facing forward.

    2. B003NAZC03
      *a Mark Plate (Yellow)
      *b Timing Mark

      As shown in the illustration, install the No. 2 chain sub-assembly on the No. 2 crankshaft timing sprocket and No. 2 balanceshaft driven gear with the painted marks aligned with the timing marks on the sprocket and gear.

    3. B003P4BC05
      *a Mark Plate
      *b Timing Mark

      Fit the other mark link of the No. 2 crankshaft timing sprocket behind the large timing mark of the balanceshaft drive gear sub-assembly.

    4. Insert the balanceshaft drive gear shaft through the balanceshaft drive gear sub-assembly so that it fits into the thrust plate hole.

    5. B003M5EC04
      *a Mark Plate
      *b Large Timing Mark
      *c Small Timing Mark

      Align the small timing mark of the balanceshaft drive gear sub-assembly with the timing mark of the No. 1 balanceshaft driven gear.

    6. Install the bolt to the balanceshaft drive gear sub-assembly and tighten it.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    7. B003KJQC05
      *a Mark Plate
      *b Timing Mark
      *c Large Timing Mark
      *d Small Timing Mark

      Check that each timing mark is aligned with the corresponding mark plate.

      Note

      Check that the No. 1 cylinder is at TDC and that the weights of the No. 1 balanceshaft and No. 2 balanceshaft are at the bottom side.

  14. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. Install the No. 2 chain tensioner assembly with the nut.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      Assemble the No. 2 chain tensioner assembly with the pin installed, then remove the pin after assembly. When doing this, do not push the chain vibration damper against the No. 2 chain sub-assembly.

    2. B003S25C11
      *a Plunger
      *b Stopper Plate
      *c Hexagon Wrench

      Move the stopper plate downward to release the lock and push the plunger deep into the tensioner.

    3. Move the stopper plate upward to set the lock and insert a hexagon wrench into the stopper plate hole.

  15. INSTALL NO. 3 CHAIN VIBRATION DAMPER


    1. Install the No. 3 chain vibration damper with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  16. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

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

  17. INSTALL OIL CONTROL VALVE FILTER


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

      If foreign matter is present, clean the part thoroughly.

    2. Using an 8 mm hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.

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

  18. INSTALL CYLINDER HEAD GASKET

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  19. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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  20. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  21. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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  22. INSTALL VALVE STEM CAP

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  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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

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  25. INSTALL NO. 2 CAMSHAFT

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  26. INSTALL CAMSHAFT

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  27. INSTALL CAMSHAFT BEARING CAP

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  28. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. B003NVB

      Install the crankshaft timing gear or sprocket as shown in the illustration.

  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. Install the No. 1 chain vibration damper with the bolt and nut.

      Torque:
      for bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Remove the hexagon wrench from the No. 2 chain tensioner assembly and release the plunger.

  30. INSTALL CHAIN SUB-ASSEMBLY


    1. B003JD6C01
      *1 Crankshaft Pulley Set Key
      *a Timing Mark
      *b Mark Plate (Pink)
      *c Mark Plate (Yellow)
      *d Approximately 13°
      *e Approximately 30°

      As shown in the illustration, install the chain sub-assembly to the camshaft timing exhaust gear assembly and camshaft timing gear assembly with the mark plates aligned with the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly.

      Tech Tips


      • The camshaft mark plate is pink.

      • The crankshaft mark plate is yellow.

    2. B003NIW

      Use a rope to tie the chain sub-assembly of the crankshaft timing gear or sprocket. Tie the rope near the crankshaft timing gear or sprocket.

      Note

      After the chain tensioner has been installed, the rope must be removed.

      Tech Tips

      The rope is tied so that the chain sub-assembly will not jump a tooth.

  31. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B003L80C26
      *a Plunger
      *b Stopper Plate
      *c Hexagon Wrench

      Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

    3. 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 }

    4. Remove the hexagon wrench from the No. 1 chain tensioner assembly and release the plunger.

  33. INSTALL TIMING CHAIN GUIDE


    1. Install a new O-ring to the No. 1 camshaft bearing cap.

    2. Install the timing chain guide with the 2 bolts.

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

  34. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B003M83C01
      *1 Crankshaft Pulley Set Key
      *a Timing Mark
      *b Approximately 13°
      *c Approximately 30°

      Check that the No. 1 cylinder is set to TDC/compression.


      1. Rotate the crankshaft two full rotations, and then check that all timing marks are in the position shown in the illustration.

        If the timing marks do not match, set the chain sub-assembly again.

  35. INSTALL CYLINDER HEAD COVER CONNECTOR SUB-ASSEMBLY


    1. Install a new No. 2 camshaft bearing cap oil hole gasket and 3 new No. 3 camshaft bearing cap oil hole gaskets to the No. 1 camshaft bearing cap.

    2. Install the cylinder head cover connector sub-assembly with the 2 bolts.

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

  36. INSTALL ENGINE WATER PUMP ASSEMBLY

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  37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  38. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  39. INSTALL TIMING CHAIN CASE OIL SEAL

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  40. INSTALL OIL PAN STUD BOLT

    Note

    If an oil pan stud bolt is deformed or its threads are damaged, replace it.

    B003S1XC01
    *a 16 mm (0.630 in.) *b 9.0 mm (0.354 in.)
    *c 27 mm (1.06 in.) *d 8.5 mm (0.335 in.)
    *e 8.0 mm (0.315 in.) *f 18 mm (0.709 in.)

    1. Using E5 and E6 "TORX" socket wrenches, install the oil pan stud bolts.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

  41. INSTALL OIL PAN SUB-ASSEMBLY

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  42. INSTALL OIL STRAINER SUB-ASSEMBLY

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  43. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

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  44. INSTALL OIL PAN COVER SILENCER

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  45. INSTALL CRANKSHAFT PULLEY

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  46. INSTALL THERMOSTAT

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  47. INSTALL WATER INLET

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  48. INSTALL NO. 1 VENTILATION CONNECTOR


    1. Install the No. 1 ventilation connector to the cylinder head cover sub-assembly with the 2 bolts.

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

  49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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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)

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  52. INSTALL CRANKSHAFT POSITION SENSOR

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  53. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

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  54. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

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  55. INSTALL PCV VALVE SUB-ASSEMBLY

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  56. 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.

  57. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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  58. INSTALL KNOCK SENSOR

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  59. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  60. INSTALL SPARK PLUG

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