ENGINE UNIT REASSEMBLY

INSTALL OIL FILTER CAP ASSEMBLY

1. Clean the inside of the oil filter cap, threads and O-ring groove.

2. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

   

   Text in Illustration

   *1	O-ring
   *a	CORRECT
   *b	INCORRECT

   Note

   • Be sure to install the O-ring in the proper location, otherwise oil may leak.

   • Do not twist the O-ring.

3. Set a new oil filter element into the oil filter cap.

4. Remove any dirt or foreign matter from the installation surface of the engine.

5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

   Note

   Make sure that the O-ring does not get caught between the parts.

6. Using SST, tighten the oil filter cap.

   

   Text in Illustration

   *1	Oil Filter Cap
   *2	O-ring
   *3	Oil Filter Bracket
   *a	No Gap

   SST

   09228-06501

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Note

   After tightening the oil filter cap, make sure that there is no gap and that the O-ring is not protruding.

7. Apply a small amount of engine oil to a new O-ring, and install it to the oil filter cap.

   

   Text in Illustration

   *1

   O-ring

   Note

   Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

8. Install the oil filter drain plug.

   Torque:

   13 N*m  { 127 kgf*cm, 9 ft.*lbf }

   Note

   Be careful that the O-ring does not get caught between any surrounding parts.

INSTALL REAR ENGINE OIL SEAL

1. Apply MP grease to the lip of a new oil seal.

   Note

   • Do not allow foreign matter to contact the lip of the oil seal.

   • Do not allow MP grease to contact the dust seal.

2. Using SST and a hammer, tap in the oil seal until its surface is flush with the edges of the cylinder block and crankcase.

   

   SST

   09223-15030

   09950-70010   ( 09951-07150 )

   Note

   • Keep the lip of the oil seal free from foreign matter.

   • Do not tap in the oil seal at an angle.

INSTALL CYLINDER HEAD GASKET

1. Clean the cylinder block and cylinder head with solvent.

   

   Text in Illustration

   *1	Cylinder Head Gasket
   *2	Cylinder Block
   *a	Lot No.
   *b	3.0 mm or more
   *c	20 mm or more
   	Seal Packing
   	Front

2. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

   Seal packing
   Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

   Standard seal dimension
   3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) thick

   Tech Tips

   Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block.

   Note

   • Remove any oil from the contact surface.

   • Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

3. Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp facing upward.

   Note

   Pay attention to the installation direction.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

1. Place the cylinder head on the cylinder block.

   Note

   • Ensure that no oil is on the mounting surface of the cylinder head sub-assembly.

   • Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

2. Install the plate washers to the cylinder head bolts.

3. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

4. Step 1:

   1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration.

      

      Torque:

      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

      Note

      Do not drop the plate washer for the cylinder head bolt into the cylinder head sub-assembly.

5. Step 2:

   1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

      Torque:

      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

6. Step 3:

   1. Mark each cylinder head bolt head with paint as shown in the illustration.

      

      Text in Illustration

      	Front
      *a	Painted Mark

   2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.

7. Step 4:

   1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

   2. Check that the paint marks are now facing rearward.

      Note

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

      • Do not start the engine for at least 2 hours after installation.

      • After installation, if the seal packing has seeped out, wipe it off.

      Tech Tips

      Perform "Inspection After Repair" after replacing the cylinder head sub-assembly Click here.

SET CAMSHAFT TIMING GEAR ASSEMBLY

1. Check the camshaft timing gear position.

   

   Text in Illustration

   *1	Knock Pin Hole
   *2	Alignment Mark
   *a	Advanced Position:
   *b	Retarded Position:

   Note

   If the camshaft timing gear is set to the advanced position, do not let the camshaft timing gear rotate clockwise during installation.

   If the camshaft timing gear rotates to the retarded position, release the lock pin and set the camshaft timing gear to the advanced position.

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

   

   Text in Illustration

   *1	Pin Hole
   *2	Knock Pin

3. Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

   

   Text in Illustration

   *1	Camshaft Timing Gear Assembly
   *2	Flange
   *a	INCORRECT
   *b	CORRECT
   *c	Clearance
   *d	No Clearance

4. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

   Note

   Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

5. Release the lock pin.

   

   Text in Illustration

   *1	Rubber
   *2	Vinyl Tape
   *3	Knock Pin
   *a	Retard Side Path
   *b	Advance Side Path
   *c	Open
   *d	Close

   1. Clean the camshaft journal with non-residue solvent.

   2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

      Tech Tips

      There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.

   3. Open a hole at port A shown in the illustration.

   4. While applying approximately 200 kPa (2.0 kgf/ cm², 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

      

      CAUTION:

      Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

      Note

      Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

      Tech Tips

      • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

      • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

   5. Remove the vinyl tape and rubber pieces from the camshaft.

6. Remove the bolt and camshaft timing gear.

   Note

   Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

INSTALL CAMSHAFT

1. Clean the camshaft journals, camshaft housing and bearing caps.

2. Apply a light coat of engine oil to the camshaft journal, camshaft housing and bearing caps.

3. Install the camshaft and No. 2 camshaft to the camshaft housing.

   Tech Tips

   Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft Click here.

INSTALL CAMSHAFT BEARING CAP

1. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

   

2. Install the 11 bolts in the order shown in the illustration.

   

   Torque:

   16 N*m  { 163 kgf*cm, 12 ft.*lbf }

   Note

   Make sure that the camshaft rotates smoothly after installing the bearing caps.

INSTALL VALVE STEM CAP

1. Apply a light coat of engine oil to the valve stem ends.

2. Install the 16 valve stem caps to the cylinder head.

   Note

   Do not drop the valve stem caps into the cylinder head.

INSTALL VALVE LASH ADJUSTER ASSEMBLY

1. Inspect the valve lash adjuster before installing it Click here.

2. Install the 16 lash adjusters to the cylinder head.

   Note

   Install the lash adjuster to the same place it was removed from.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

1. Apply engine oil to the lash adjuster tips and valve stem caps.

   

   Text in Illustration

   *1	Valve Rocker Arm
   *2	Valve Lash Adjuster
   *3	Valve Stem Cap

2. Install the 16 valve rocker arms as shown in the illustration.

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

1. Check that the valve rocker arms are installed as shown in the illustration.

   

   Text in Illustration

   *1	Valve Rocker Arm
   *2	Valve Stem Cap
   *3	Valve Lash Adjuster
   *a	INCORRECT
   *b	CORRECT

2. 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
   3.0 to 4.0 mm (0.118 to 0.157 in.)

   Note

   • Remove any oil from the contact surface.

   • Install the camshaft housing within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

   

   Text in Illustration

   *1	Knock Pin
   *a	Approximately 17°
   *b	Approximately 2°

4. Install the camshaft housing, and then install the 20 bolts in the order shown in the illustration.

   

   Torque:

   27 N*m  { 275 kgf*cm, 20 ft.*lbf }

   Note

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

   • Do not start the engine for at least 2 hours after the installation.

   • Thoroughly wipe clean any seal packing.

INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

1. Check the camshaft timing gear position.

   

   Text in Illustration

   *1	Knock Pin Hole
   *2	Alignment Mark

   If the camshaft timing gear is not set to the advanced position, release the lock pin and reset the camshaft timing gear (Refer to the "Set Camshaft Timing Gear Assembly" procedures").

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

   

   Text in Illustration

   *1	Pin Hole
   *2	Knock Pin

3. Check that there is no clearance between the camshaft timing gear and camshaft flange.

   

   Text in Illustration

   *1	Camshaft Timing Gear
   *2	Flange
   *a	INCORRECT
   *b	CORRECT
   *c	Clearance
   *d	No Clearance

4. Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

   

   Text in Illustration

   *a	Hold
   *b	Turn

   Torque:

   85 N*m  { 867 kgf*cm, 63 ft.*lbf }

   Note

   • Be careful not to damage the cylinder head or spark plug tube with the wrench.

   • Do not disassemble the camshaft timing gear assembly.

   Tech Tips

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

INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

1. Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

   

   Text in Illustration

   *1	Pin Hole
   *2	Knock Pin

2. Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.

   

   Text in Illustration

   *1	Camshaft Timing Exhaust Gear
   *2	Flange
   *a	INCORRECT
   *b	CORRECT
   *c	Clearance
   *d	No Clearance

3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the bolt.

   

   Text in Illustration

   *a	Hold
   *b	Turn

   Torque:

   85 N*m  { 867 kgf*cm, 63 ft.*lbf }

   Note

   • Be careful not to damage the cylinder head or spark plug tube with the wrench.

   • Do not disassemble the camshaft timing exhaust gear assembly.

   Tech Tips

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

ADD ENGINE OIL

1. 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 lash adjusters were removed.

   • Make sure that the low pressure chamber and oil paths of the lash adjusters are full of engine oil.

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

   

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

3. Check that the timing marks of the camshaft timing gears are as shown in the illustration.

   

   Text in Illustration

   *1	Timing Mark
   *a	Approximately 7°
   *b	Approximately 32°

   Tech Tips

   "A" is not a timing mark.

INSTALL NO. 1 CHAIN VIBRATION DAMPER

1. Install the chain vibration damper with the 2 bolts.

   

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL CHAIN SUB-ASSEMBLY

1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

   Tech Tips

   • Make sure the mark plate of the chain faces away from the engine.

   • It is not necessary to install the chain to the teeth of the gears and sprocket.

2. Align the mark plate (yellow or gold) of the chain with the timing mark of the camshaft timing exhaust gear and install the chain to the camshaft timing exhaust gear.

   

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

3. Align the mark plate (pink or gold) of the chain with the timing mark of the crankshaft timing sprocket and install the chain to the crankshaft timing sprocket.

   

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

4. Tie a string above the crankshaft timing sprocket so that the chain is secure.

   

5. Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.

   

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

   Tech Tips

   Hold the intake camshaft in place with a wrench until the chain tensioner is installed.

6. Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain so that the chain tensioner slipper can be installed.

   

   Note

   Make sure the chain is secure.

INSTALL CHAIN TENSIONER SLIPPER

1. Install the chain tensioner slipper with the bolt.

   

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

1. Install a new gasket and the chain tensioner with the 2 bolts.

   

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Remove the pin from the stopper plate.

INSTALL TIMING CHAIN GUIDE

1. Install the timing chain guide with the bolt.

   

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

   

   Text in Illustration

   *a	Approximately 7°	*b	Approximately 32°
   *c	Timing Mark	*d	Key

2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

   Tech Tips

   "A" is not a timing mark.

3. Remove the crankshaft pulley bolt.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

1. Apply a light coat of engine oil to 3 new gaskets.

   

2. Install the 3 gaskets to the stiffening crankcase assembly.

3. Align the drive rotor spline and the crankshaft timing sprocket as shown in the illustration.

   

   Text in Illustration

   *1	Drive Rotor Spline
   *2	Crankshaft Timing Sprocket

4. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.

   

   Seal packing
   Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.

   Apply Seal Packing as Follows

   Area Seal Packing Diameter (Round) Distance from Edge of Cover to Center of Seal Packing Seal Packing Application Length Seal Pacing Dimension (Flat) Dashed Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) - - A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) - - B - B 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 28 mm (1.10 in.) 7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick C - C 7.0 mm (0.276 in.) 5.0 mm (0.197 in.) 25 mm (0.984 in.) 13.0 mm (0.512 in.) or more wide and 3.0 mm (0.118 in.) or more thick D - D 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 26 mm (1.02 in.) 7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick E 2.5 to 3.5 mm (0.0984 to 0.138 in.) 3.0 mm (0.118 in.) - -

   Note

   • When there is oil on the contact surfaces, clean the surfaces with non-residue solvent before applying seal packing.

   • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

   • After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

   • Do not add oil for at least 4 hours after the installation.

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

5. Temporarily install the timing chain cover sub-assembly with the 17 bolts and 2 nuts.

   

   Text in Illustration

   *1

   Nut

   -

   -

   Bolt Length
   Item Length Thread Diameter Bolt A 30 mm (1.18 in.) 8 mm (0.315 in.) Bolt B 35 mm (1.38 in.) 10 mm (0.394 in.) Bolt C 45 mm (1.77 in.) 8 mm (0.315 in.)

   Note

   Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

6. Tighten the 17 bolts and 2 nuts in several steps, in the order shown in the illustration.

   Torque:

   for bolt A, C, and Nut

   21 N*m  { 214 kgf*cm, 16 ft.*lbf }

   for bolt B

   55 N*m  { 561 kgf*cm, 41 ft.*lbf }

INSTALL ENGINE MOUNTING BRACKET RH

1. Install the engine mounting bracket RH with the 5 bolts in the order shown in the illustration.

   

   Torque:

   for bolt 1, 2 and 3

   55 N*m  { 561 kgf*cm, 41 ft.*lbf }

   for bolt 4 and 5

   21 N*m  { 214 kgf*cm, 16 ft.*lbf }

   Note

   After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

INSTALL TIMING CHAIN COVER OIL SEAL

1. Apply MP grease to the lip of a new oil seal.

   Note

   • Do not allow foreign matter to contact the lip of the oil seal.

   • Do not allow MP grease to contact the dust seal.

2. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.

   

   SST

   09223-22010

   Note

   • Keep the lip of the oil seal free from foreign matter.

   • Do not tap in the oil seal at an angle.

INSTALL CRANKSHAFT POSITION SENSOR

1. Clean and degrease the threads of the bolt for the crankshaft position sensor.

2. Apply a light coat of engine oil to the O-ring of the sensor.

   

   Text in Illustration

   *1

   O-ring

3. Apply adhesive to 2 or 3 threads of the bolt.

   

   Text in Illustration

   *1

   Adhesive

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

4. Install the sensor with the bolt.

   Torque:

   6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

   Note

   Make sure that the O-ring is not cracked or does not jump out of position during installation.

5. Connect the sensor connector.

INSTALL ENGINE WATER PUMP ASSEMBLY

1. Install a new gasket and the engine water pump with the 7 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL THERMOSTAT

1. Install a new gasket to the thermostat.

2. Install the thermostat with the jiggle valve facing upward.

   

   Text in Illustration

   *1	Jiggle valve
   *a	10°

   Tech Tips

   The jiggle valve may be set to within 10° on either side of the prescribed position.

INSTALL WATER INLET

1. Install the water inlet with the 2 nuts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL VENTILATION VALVE SUB-ASSEMBLY

1. Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly.

   Adhesive
   Toyota genuine adhesive 1324, three bond 1324 or equivalent

2. Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly.

   Torque:

   27 N*m  { 275 kgf*cm, 20 ft.*lbf }

3. Connect the No. 2 ventilation hose to the ventilation valve sub-assembly.

INSTALL CAMSHAFT POSITION SENSOR

1. Camshaft position sensor (for Intake Side)

   1. Clean and degrease the threads of the bolt for the camshaft position sensor.

   2. Apply a light coat of engine oil to the O-ring of the sensor.

      Note

      Make sure that the O-ring is not cracked or does not jump out of position during installation.

   3. Apply adhesive to 2 or 3 threads of the bolt.

      

      Text in Illustration

      *1

      Adhesive

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

   4. Install the sensor with the bolt.

      Torque:

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

   5. Connect the sensor connector.

2. Camshaft position sensor (for Exhaust Side)

   1. Clean and degrease the threads of the bolt for the camshaft position sensor.

   2. Apply a light coat of engine oil to the O-ring of the sensor.

      Note

      Make sure that the O-ring is not cracked or does not jump out of position during installation.

   3. Apply adhesive to 2 or 3 threads of the bolt.

      

      Text in Illustration

      *1

      Adhesive

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

   4. Install the sensor with the bolt.

      Torque:

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

   5. Connect the sensor connector.

INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

1. Camshaft timing oil control valve assembly (for exhaust side)

   1. Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve.

      

      Text in Illustration

      *1	New O-ring

   2. Install the oil control valve with the bolt.

      Torque:

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

      Note

      • Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with the cylinder head cover).

      • Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

   3. Connect the oil control valve connector.

2. Camshaft timing oil control valve assembly (for intake side)

   1. Apply a light coat of engine oil to a new O-ring, and install it to the oil control valve.

      

      Text in Illustration

      *1	New O-ring

   2. Install the oil control valve with the bolt.

      Torque:

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

      Note

      • Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover).

      • Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

   3. Connect the oil control valve connector.

INSTALL SPARK PLUG

1. Using a spark plug wrench, install the 4 spark plugs.

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Tech Tips

   Perform "Inspection After Repair" after replacing the spark plug Click here.