ENGINE UNIT REASSEMBLY

Info Added 2017-08-02

PROCEDURE


  1. INSTALL RING PIN

    Note

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


    1. A0006GAE03
      Text in Illustration
      *a Protrusion Height

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

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

  2. INSTALL ENGINE BALANCER ASSEMBLY


    1. A0004W3E12
      Text in Illustration
      *1 Driven Gear
      *2 Damper Cover
      *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, align them.


      1. A0009AQE13
        Text in Illustration
        *1 Driven Gear
        *2 Damper Cover
        *a Alignment Mark

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

      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.

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

  3. INSTALL STUD BOLT

    Note

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


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

      A000453E03
      Text in Illustration
      *a Front Side *b Lower Side
      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 }

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A0007TOE09
      Text in Illustration
      *1 Key

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

    2. A0009ADE06
      *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.

      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
      Text in Illustration
      *a Cutout

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

    4. Clean the bolts and their installation holes.

    5. A0008BYE03
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A0004TCE06

      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.)

      Tech Tips

      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.

      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 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.

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

  6. INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. A00098KE04
      Text in Illustration
      *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:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  7. INSTALL OIL PAN SUB-ASSEMBLY


    1. A0009IKE01
      *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
      Text in Illustration
      *1 Nut

      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 }

      Tech Tips

      The bolt A and the nut A are tightened twice.

  8. 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 }

  9. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  10. INSTALL REAR ENGINE OIL SEAL

    Click here

  11. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A0004Y8

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

  12. INSTALL CYLINDER HEAD GASKET

    Click here

  13. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

    Note

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


    1. A0007W4E03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced 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.)

  15. INSTALL STRAIGHT PIN

    Note

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


    1. A0009FFE03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced 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.)

  16. 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
      *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.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  17. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the No. 1 camshaft bearing.

    2. A0005CRE02
      Text in Illustration
      *1 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.)

  18. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the No. 2 camshaft bearing.

    2. A00061DE10
      Text in Illustration
      *1 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.)

  19. INSTALL OIL CONTROL VALVE FILTER


    1. A0007OI

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

  20. INSTALL CAMSHAFT

    Click here

  21. INSTALL CAMSHAFT BEARING CAP

    Click here

  22. INSTALL VALVE STEM CAP

    Click here

  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

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

    Click here

  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  26. INSTALL CAMSHAFT TIMING SPROCKET

    Click here

  27. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  28. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A0004LX

      Install the crankshaft timing sprocket to the crankshaft.

  29. ADD ENGINE OIL

    Click here

  30. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  32. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  33. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  35. INSTALL TIMING CHAIN GUIDE

    Click here

  36. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  37. INSTALL TIMING CHAIN COVER PLATE


    1. A0005K7

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

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

  38. 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.

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

  39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  40. INSTALL ENGINE MOUNTING BRACKET RH

    Click here

  41. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  42. INSTALL SPARK PLUG TUBE GASKET


    1. A0008NME04
      Text in Illustration
      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly

      Tap in 4 new spark plug tube gaskets to the 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. INSTALL STUD BOLT

    Note

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


    1. A00081TE03
      *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.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  44. 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
      Text in Illustration
      *1 Seal Packing
      *2 Timing Chain Cover Sub-assembly
      *3 Camshaft Housing Sub-assembly

      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.)

      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.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

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

  45. INSTALL CRANKSHAFT PULLEY


    1. A0005G8E01
      Text in Illustration
      *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 pulley bolt.

      SST
      09213-54015
      09330-00021
      Torque:
      260 N*m  { 2651 kgf*cm, 192 ft.*lbf }

      Tech Tips

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

  46. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  47. 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.

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

  48. INSTALL VENTILATION CASE SUB-ASSEMBLY


    1. A0008PKE01
      *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.

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

      Note

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

      Tech Tips

      The bolt A is tightened twice.

  49. INSTALL VENTILATION VALVE SUB-ASSEMBLY

    Click here

  50. INSTALL CAMSHAFT POSITION SENSOR

    Click here

  51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  52. INSTALL OIL FILLER CAP GASKET


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

  53. INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

  54. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  55. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  56. INSTALL KNOCK CONTROL SENSOR

    Click here

  57. INSTALL SPARK PLUG

    Click here

  58. INSTALL ENGINE COVER JOINT


    1. A0006ML

      Install the 3 engine cover joints.

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