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ENGINE UNIT REASSEMBLY

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Info Added 2017-08-02

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PROCEDURE


  1. Click here

    INSTALL RING PIN

    Note:

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


    1. A0006GAE03

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

      Table 1. Text in Illustration
      *a Protrusion Height
      Standard protrusion height
      4.3 to 5.3 mm (0.169 to 0.209 in.)
  2. Click here

    INSTALL ENGINE BALANCER ASSEMBLY


    1. A0004W3E12

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

      Table 2. Text in Illustration
      *1 Driven Gear
      *2 Damper Cover
      *a Alignment Mark

      If the alignment marks are not aligned, align them.


      1. A0009AQE13

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

        Table 3. Text in Illustration
        *1 Driven Gear
        *2 Damper Cover
        *a Alignment Mark

      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. A00088UE01

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

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

    INSTALL STUD BOLT

    Note:

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


    1. A000453E03

      Using an E5 and E8 "TORX" socket wrench, install the 3 stud bolts.

      Table 4. Text in Illustration
      *a Front Side *b Lower Side
      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
  4. Click here

    INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A0007TOE07

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

      Table 5. Text in Illustration
      *1 Key
    2. A0009ADE04
      Table 6.
      *1 2.5 to 3.5 mm
      *2 28 mm
      *3 7.0 to 9.0 mm

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

      Table 7. Text in Illustration
      A0003KI Stiffening Crankcase Assembly
      A0007U0 cylinder block Sub-assembly
      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 surfaces.

      • Install the oil pan sub-assembly within 3 minutes after applying seal packing.

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

    3. A00076RE03

      Check that the rear cutout parts are as shown in the illustration.

      Table 8. Text in Illustration
      *a Cutout

    4. Clean the bolts and their installation holes.

    5. A0008BYE03

      Apply adhesive to 3 or more threads of the ends of the bolts A.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Table 9. Text in Illustration
      *1 Adhesive
    6. A0004TCE04

      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. A000605E02

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

      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. Click here

    INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. A0004V9E05

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

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

    INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. A00098KE04

      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.

      Table 10. Text in Illustration
      *a Protrusion

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

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

    INSTALL OIL PAN SUB-ASSEMBLY


    1. A0009IKE01
      Table 11.
      *1 2.5 to 3.5 mm

      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 apply oil for at least 2 hours after the installation.

    2. A0005VDE04

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

      10 N*m 102 kgf*cm 7 ft.*lbf
      Table 12. Text in Illustration
      *1 Nut
      Tip:

      The bolt A and the nut A are tightened twice.

  8. 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
  9. Click here

    INSTALL OIL FILTER CAP ASSEMBLY

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  10. Click here

    INSTALL REAR ENGINE OIL SEAL

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  11. Click here

    INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A0004Y8

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

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    INSTALL CYLINDER HEAD GASKET

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  13. Click here

    INSTALL CYLINDER HEAD SUB-ASSEMBLY

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  14. Click here

    INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note:

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


    1. A0007W4E03

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

      Table 13. Text in Illustration
      *a Protrusion Height
      Standard protrusion height
      2.7 to 3.3 mm (0.106 to 0.130 in.)
  15. Click here

    INSTALL STRAIGHT PIN

    Note:

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


    1. A0009FFE03

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

      Table 14. Text in Illustration
      *a Protrusion Height
      Standard protrusion height
      5.0 to 7.0 mm (0.197 to 0.276 in.)
  16. Click here

    INSTALL STUD BOLT

    Note:

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


    1. When reusing the stud bolt.


      1. Apply adhesive to threads of the stud bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A0008BFE10
      Table 15.
      *1 20 mm (0.787 in.)
      *2 35 mm (1.38 in.)
      *3 13 mm (0.512 in.)

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

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

    INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

    2. A0005CRE02

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

      Table 16. Text in Illustration
      *1 Vernier Caliper

    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.)
  18. Click here

    INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. A00061DE10

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

      Table 17. Text in Illustration
      *1 Vernier Caliper

    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.)
  19. Click here

    INSTALL OIL CONTROL VALVE FILTER


    1. A0007OI

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

  20. Click here

    INSTALL CAMSHAFT

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  21. Click here

    INSTALL CAMSHAFT BEARING CAP

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  22. Click here

    INSTALL VALVE STEM CAP

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  23. Click here

    INSTALL VALVE LASH ADJUSTER ASSEMBLY

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  24. Click here

    INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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  25. Click here

    INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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  26. Click here

    INSTALL CAMSHAFT TIMING SPROCKET

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  27. Click here

    INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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  28. Click here

    INSTALL CRANKSHAFT TIMING SPROCKET


    1. A0004LX

      Install the crankshaft timing sprocket to the crankshaft.

  29. Click here

    ADD ENGINE OIL

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  30. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  31. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  32. Click here

    INSTALL CHAIN SUB-ASSEMBLY

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  33. Click here

    INSTALL CHAIN TENSIONER SLIPPER

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  34. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  35. Click here

    INSTALL TIMING CHAIN GUIDE

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  36. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  37. Click here

    INSTALL TIMING CHAIN COVER PLATE


    1. A0005K7

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

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

    INSTALL OIL PUMP RELIEF VALVE PLUG


    1. A0005FN

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

      30 N*m 306 kgf*cm 22 ft.*lbf
  39. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  40. Click here

    INSTALL ENGINE MOUNTING BRACKET RH

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  41. Click here

    INSTALL TIMING CHAIN COVER OIL SEAL

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  42. Click here

    INSTALL SPARK PLUG TUBE GASKET


    1. A0008NME04

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

      Table 18. Text in Illustration
      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly
      Note:

      • Do not allow foreign matter to contact the lip of the spark plug tube gasket.

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

  43. Click here

    INSTALL STUD BOLT

    Note:

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


    1. A00081TE03
      Table 19.
      *1 16 mm (0.63 in.)
      *2 9 mm (0.354 in.)
      *3 27 mm (1.06 in.)

      Using an E6 "TORX" socket wrench, install the 3 stud bolts.

      5.0 N*m 51 kgf*cm 44 in.*lbf
  44. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00093X

      Apply a light coat of engine oil to 2 new camshaft bearing cap oil hole gaskets.

    2. Install the 2 camshaft bearing cap oil hole gaskets.

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

      Note:

      Remove any oil from the contact surface.

    4. A0005JQE03

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)
      Application width A
      5.0 mm (0.197 in.)
      Table 20. Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover Sub-assembly
      *3 Camshaft Housing Sub-assembly
      Note:

      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.

    5. A0004E6E03

      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.

    6. 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 apply oil for at least 2 hours after the installation.

  45. Click here

    INSTALL CRANKSHAFT PULLEY


    1. A0005G8E01

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

      Table 21. Text in Illustration
      *a Hold
      *b Turn

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

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

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

  46. Click here

    INSTALL CRANKSHAFT POSITION SENSOR

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  47. Click here

    INSTALL SEPARATOR CASE


    1. A000855

      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.

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

    INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. A0008PKE01
      Table 22.
      *1 2.5 to 3.5 mm

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

    2. A00040RE04

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

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

      Do not apply oil for at least 2 hours after the installation.

      Tip:

      The bolt A is tightened twice.

  49. Click here

    INSTALL VENTILATION VALVE SUB-ASSEMBLY

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  50. Click here

    INSTALL CAMSHAFT POSITION SENSOR

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  51. Click here

    INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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  52. Click here

    INSTALL OIL FILLER CAP GASKET


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

  53. Click here

    INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

  54. Click here

    INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  55. Click here

    INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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  56. Click here

    INSTALL KNOCK CONTROL SENSOR

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  57. Click here

    INSTALL SPARK PLUG

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  58. Click here

    INSTALL ENGINE COVER JOINT


    1. A0006ML

      Install the 3 engine cover joints.

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