INSTALL TIMING CHAIN CASE OIL SEAL
Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing chain cover sub-assembly edge.
Note
Keep the lip free from foreign matter.
Do not tap on the timing chain case oil seal at an angle.
Make sure that the timing chain case oil seal edge does not stick out of the timing chain cover sub-assembly.
Tech Tips
Tap in the timing chain case oil seal so that it is positioned within 1.0 mm from the edge of the timing chain cover sub-assembly.
Apply a light coat of MP grease to the timing chain cover oil seal lip.
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
Apply seal packing in a continuous line to the engine unit as shown in the following illustration.
| *a | Seal Packing Diameter: 3.0 mm (0.118 in.) or more | |
Seal Packing |
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Seal diameter |
|---|
| 3.0 mm (0.118 in.) |
Note
Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.
Install the timing chain cover sub-assembly within 3 minutes.
Do not start the engine for at least 2 hours after installing.
Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.
| *a | Dashed Line Area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) |
*b | Continuous Line Area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) |
| *c | Alternate Long and Short Dashed Line Area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent) |
*d | Diagonal Line Area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) |
|
Be sure to apply seal packing | - | - |
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent |
Note
If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.
Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing.
| Area | Seal Packing Diameter | Application Position from Inside Seal Line |
|---|---|---|
| Continuous Line Area | 4.5 mm or more (0.177 in.) | 1.0 to 2.0 mm (0.0394 to 0.0787 in.) |
| Alternate Long and Short Dashed Line Area | 3.5 mm or more (0.138 in.) | 2.0 to 3.0 mm (0.0787 to 0.118 in.) |
| Dashed Line Area | 3.5 mm or more (0.138 in.) | 3.0 to 4.0 mm (0.118 to 0.157 in.) |
| Diagonal Line Area | 6.0 mm or more (0.236 in.) | 5.0 mm (0.197 in.) |
Install a new gasket.
| *1 | Drive Rotor Spline |
| *2 | Crankshaft |
Align the drive rotor spline and the crankshaft as shown in the illustration. Install the spline and timing chain cover sub-assembly to the crankshaft.
| *1 | Nut |
Temporarily tighten the timing chain cover sub-assembly with the 23 bolts and 2 nuts.
| Item | Length |
|---|---|
| Bolt A | 40 mm (1.57 in.) |
| Bolt B | 55 mm (2.17 in.) |
| Bolt C | 28 mm (1.102 in.) |
Note
Make sure that there is no oil on the threads of bolt B and C.
Fully tighten the bolts in Area 1.
| *a | Area 1 |
| *b | Area 2 |
| *c | Area 3 |
| *d | Area 4 |
Fully tighten the bolts in Area 2.
Fully tighten the bolts and nuts in Area 3.
Tech Tips
Tighten the bolts and nuts from top to bottom as shown in the illustration.
Fully tighten the bolts in Area 4.
Tech Tips
Tighten the bolts from bottom to top as shown in the illustration.
INSTALL OIL PAN SUB-ASSEMBLY
w/ Oil Cooler:
Using an E8 "TORX" socket wrench, install the 4 stud bolts.
| *A | w/ Oil Cooler | - | - |
| *a | Lower Cylinder Block Sub-assembly Side | *b | Timing Chain Cover Sub-assembly Side |
| *c | Oil Pan Sub-assembly LH Side | - | - |
w/o Oil Cooler:
Using an E8 "TORX" socket wrench, install the 2 stud bolts.
Install 2 new O-rings.
| *a | Seal Diameter |
Apply seal packing in a continuous line as shown in the illustration.
| Seal Packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Seal Diameter |
|---|
| 3.0 to 4.0 mm (0.118 to 0.157 in.) |
Note
Remove any oil from the contact surface.
Install the oil pan sub-assembly within 3 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installation.
| *A | w/o Oil Cooler |
| *B | w/ Oil Cooler |
| *1 | Nut |
Install the oil pan sub-assembly with the 16 bolts and 2 nuts.
INSTALL OIL STRAINER SUB-ASSEMBLY
| *a | Timing Chain Cover |
Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
| *1 | Nut |
Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
| *a | Seal Diameter |
Apply seal packing in a continuous line as shown in the illustration.
| Seal Packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Seal Diameter |
|---|
| 3.0 to 4.0 mm (0.118 to 0.157 in.) |
Note
Remove any oil from the contact surface.
Install the No. 2 oil pan sub-assembly within 3 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installation.
| *1 | Nut |
Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Apply seal packing as shown in the illustration.
|
Seal Packing |
| Seal Packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Note
Remove any oil from the contact surface.
Install the cylinder head cover sub-assembly within 3 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installation.
Install 3 new gaskets as shown in the illustration.
Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
| *1 | Seal Washer |
Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.
Tech Tips
After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
Apply seal packing as shown in the illustration.
|
Seal Packing |
| Seal Packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Note
Remove any oil from the contact surfaces.
Install the cylinder head cover sub-assembly LH within 3 minutes of applying seal packing.
Do not start the engine for at least 2 hours after installation.
Install 3 new gaskets as shown in the illustration.
Install a new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly LH.
| *1 | Seal Washer |
Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.
Tech Tips
After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
INSTALL WATER INLET HOUSING
Install 2 new O-rings.
Tech Tips
Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.
Install the 2 stud bolts.
| *1 | Nut |
| *2 | Bolt |
Install the water inlet housing with the 2 bolts and nut.
Note
Be careful that the O-ring does not get caught between the parts.
Connect the No. 1 water by-pass hose to the water inlet housing and slide the clip to secure it.
Apply adhesive around the drain cock assembly.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Install the drain cock assembly to the water inlet housing.
Install the drain cock plug to the drain cock assembly.
Install a new gasket to the thermostat.
Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat into the water inlet housing.
Tech Tips
The thermostat jiggle valve may be set within 10° of either side of the prescribed position.
Install the water inlet with the 2 nuts.
INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
| *1 | Stud Bolt |
Using an E8 "TORX" socket wrench, install the 2 stud bolts.
Install the No. 1 front engine mounting bracket LH with the 6 bolts.
Note
Install the water inlet and No. 1 front engine mounting bracket LH within 15 minutes of installing the timing chain cover sub-assembly.
Do not start the engine for at least 2 hours after installation.
INSTALL CRANKSHAFT PULLEY
Align the pulley set key with the key groove of the crankshaft pulley, and slide on the crankshaft pulley.
| *a | Hold |
|
Turn |
Using SST, install the pulley bolt.
INSTALL NO. 1 OIL PIPE
Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
Note
Do not touch the mesh when installing the oil control valve filter LH.
| *1 | Oil Pipe Union |
Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe (on the cylinder head cover sub-assembly side) with the oil pipe union.
Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head sub-assembly side) with the oil pipe union.
Tighten the oil pipe union (on the cylinder head cover sub-assembly side).
Tighten the oil pipe union (on the cylinder head sub-assembly side).
Note
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
INSTALL OIL PIPE
Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
Note
Do not touch the mesh when installing the oil control valve filter RH.
| *1 | Oil Pipe Union |
| *2 | Bolt |
Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the cylinder head cover sub-assembly side) with the oil pipe union.
Install a new gasket and temporarily install the oil pipe (on the cylinder head sub-assembly side) with the oil pipe union.
Install the bolt to the cylinder head sub-assembly.
Tighten the oil pipe union (on the cylinder head cover sub-assembly side).
Tighten the oil pipe union (on the cylinder head sub-assembly side).
Note
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
INSTALL CRANK POSITION SENSOR
Clean and degrease the threads of the bolt for the crank position sensor.
| *1 | O-ring |
Apply a light coat of engine oil to the O-ring on the crank position sensor.
Install the crank position sensor with the bolt.
Note
Make sure that the O-ring is not cracked or does not move out of place during installation.
Connect the crank position sensor connector.
INSTALL NO. 1 VACUUM SWITCHING VALVE
Install the No. 1 vacuum switching valve with the bolt.
INSTALL WATER PUMP PULLEY
Temporarily install the water pump pulley with the 4 bolts.
Using SST, hold the water pump pulley.
Tighten the 4 bolts.
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.
INSTALL NO. 2 TIMING GEAR COVER
Remove the 2 bolts and No. 2 timing gear cover.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.
w/ Oil Cooler:
Install the engine oil level dipstick guide.
w/o Oil Cooler
Install the engine oil level dipstick guide with the bolt.
INSTALL OIL COOLER PIPE (w/ Oil Cooler)
Install a new gasket to the oil pan sub-assembly.
Install the oil cooler pipe with the bolt and 2 nuts.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.
Tech Tips
Each bolt length is as follows:
A: 70 mm (2.76 in.)
B: 33 mm (1.30 in.)
Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Tighten the other bolts.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
Install a new gasket as shown in the illustration.
|
Engine Front |
Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
Install a new gasket as shown in the illustration.
|
Engine Front |
Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
INSTALL NO. 2 MANIFOLD STAY
Tighten the bolt and nut in the order shown in the illustration.
INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
Install a new O-ring to the No. 2 engine oil level dipstick guide.
Apply a light coat of engine oil to the O-ring.
Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.
Install the No. 2 engine oil level dipstick guide with the bolt.
Install the engine oil level dipstick.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
Install a new gasket as shown in the illustration.
|
Engine Front |
Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
INSTALL IGNITION COIL ASSEMBLY
Install the 6 ignition coil assemblies with the 6 bolts.
Tech Tips
Perform "Inspection After Repair" after replacing an ignition coil assembly Click here.
Connect the 6 ignition coil assembly connectors.
Connect the 2 wire harness clamps.
Install the nut.
INSTALL THROTTLE BODY BRACKET
Note
Do not apply oil to the bolt as listed below:
| Oil Application Prohibited Bolt |
|---|
| Bolt for throttle body bracket and cylinder head cover |
Install the throttle body bracket with the bolt.
INSTALL NO. 1 SURGE TANK STAY
Note
Do not apply oil to the bolt as listed below:
| Oil Application Prohibited Bolt |
|---|
| Bolt for No. 1 surge tank stay and cylinder head cover |
Install the No. 1 surge tank stay with the bolt.
INSTALL INTAKE AIR SURGE TANK ASSEMBLY
Note
Do not apply oil to the bolts listed below:
| Oil Application Prohibited Bolt |
|---|
| Bolt for Intake Air Surge Tank Assembly and Intake Manifold |
| Bolt for No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly |
| Bolt for Throttle Body Bracket and Intake Air Surge Tank Assembly |
Install 3 new gaskets to the intake air surge tank assembly.
Temporarily install the intake air surge tank assembly with the 4 bolts and 2 nuts.
Using a 5 mm hexagon socket wrench, in several steps, uniformly tighten the 4 bolts and 2 nuts in the order shown in the illustration.
Install the No. 1 surge tank stay to the intake air surge tank assembly with the bolt.
Install the throttle body bracket to the intake air surge tank assembly with the bolt.
Install the vacuum hose clamp to the throttle body bracket with the bolt.
Tech Tips
Install the vacuum hose clamp so that its tab is in contact with the No. 1 surge tank stay.
Connect the intake air control valve assembly connector.
Connect the fuel vapor feed hose to the intake air surge tank assembly.
Connect the 2 water by-pass hoses to the throttle body assembly and slide the 2 clips to secure them.
Connect the throttle body assembly connector.
Engage the wire harness clamp.
for LHD:
Engage the hose clamp.
Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.
for RHD:
Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.
Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.
INSTALL ENGINE HANGERS
Install the 2 engine hangers with the 4 bolts.
| Item | Part No. |
|---|---|
| No. 1 Engine Hanger | 12281-31120 |
| No. 2 Engine Hanger | 12282-31100 |
| Bolt | 91671-10825 |
Attach an engine sling device and hang the engine with a chain block.
REMOVE ENGINE STAND
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Using SST, hold the crankshaft pulley.
Clean the 8 bolts and 8 bolt holes.
Install the front drive plate spacer.
Tech Tips
Align the pin of the front drive plate spacer with the pin hole of the crankshaft.
| *1 | Drive Plate |
| *2 | Rear Spacer |
|
Transaxle Side |
Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft.
| *1 | Adhesive |
Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 8 bolts.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Install and uniformly tighten the 8 bolts in several steps in the sequence shown in the illustration.
Note
Do not start the engine for at least an hour after installing the drive plate and ring gear sub-assembly.
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY