ENGINE UNIT REASSEMBLY

Tech Tips

Check whether the engine is TMC made or not by referring to the following illustration.

A01CE8JE01
Text in Illustration
*A for TMC Made Engine *B except TMC Made Engine
*1 Engine Oil Level Dipstick Guide *2 Water Inlet Housing
*3 Water Inlet Housing Drain Cock Assembly - -

  1. INSTALL NO. 1 BALANCESHAFT BEARING


    1. A01CAKUE12
      Text in Illustration
      *1 Stiffening Crankcase
      *2 Balanceshaft Housing

      Align the bearing claw with the claw groove, and push in the 8 bearings.

      Note

      Do not apply engine oil to the contact surfaces of the balanceshaft bearing and balanceshaft housing.

    2. Apply a light coat of engine oil to the bearings.

  2. INSTALL NO. 1 AND NO. 2 BALANCESHAFTS


    1. A01CD62E07
      Text in Illustration
      *1 No. 1 Driven Gear
      *2 No. 2 Driven Gear
      *a Matchmark
      *b Rotating Direction

      Rotate the No. 1 driven gear of the No. 1 balanceshaft in the rotating direction until it hits the stopper.

      Note

      Confirm that the matchmarks on the No. 1 and No. 2 driven gears are matched.

    2. A01CDD8E08
      Text in Illustration
      *1 No. 1 Balanceshaft
      *2 No. 2 Balanceshaft
      *3 Alignment Mark

      Confirm that the alignment marks on the No. 1 and No. 2 balanceshafts are aligned.

    3. A01CFWLE04
      Text in Illustration
      *1 No. 1 Balanceshaft
      *2 Alignment Mark
      *3 Adjusting Hole
      *4 Timing Mark
      *5 No. 2 Balanceshaft

      Align the alignment marks on the No. 1 and No. 2 balanceshafts as shown in the illustration.

    4. Place the No. 1 and No. 2 balancshafts onto the crankcase.

    5. Apply a light coat of engine oil to the threads and under the heads of the bolts.

    6. A01CFLUE03

      Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    7. A01CDI4E07
      Text in Illustration
      *1 Paint Mark
      A01CCA7 Engine Front

      Mark the front of the bolts with paint.

    8. A01CDI4E08
      Text in Illustration
      *1 Paint Mark
      A01CCA7 Engine Front

      Further tighten the bolts 90° as shown in the illustration.

    9. Check that the paint mark is now at a 90° angle to the front.

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A01CCHM

      Place a new O-ring on the cylinder block as shown in the illustration.

    2. A01CEVZE06
      Text in Illustration
      *1 No. 1 Crank Pin
      *2 Adjusting Hole

      With the No. 1 crank pin of the crankshaft placed at the TDC position, install the No. 1 and No. 2 balanceshafts and align the adjusting holes as shown in the illustration.

    3. A01CDGSE02

      Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.0984 to 0.118 in.)) as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

      • Install the crankcase within 3 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the crankcase.

    4. A01CCSKE02

      Temporarily install the crankcase with the 11 bolts.

      Item Bolt Length
      A 125 mm (4.92 in.)
      B 45 mm (1.77 in.)
    5. A01CCSKE03

      Uniformly tighten the bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    6. A01CD0TE03
      Text in Illustration
      *1 Timing Mark
      *2 Key

      Confirm that the timing marks on the balanceshafts are aligned when the key groove is placed at the TDC position, as shown in the illustration.

  4. INSTALL OIL PUMP ASSEMBLY


    1. Install a new gasket and the oil pump with the 3 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  5. INSTALL REAR CRANKSHAFT OIL SEAL


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

    2. A01CAOUE02

      Using SST and a hammer, tap in the rear crankshaft oil seal until its surface is flush with the rear oil seal retainer edge.

      SST
      09223-15030
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

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

  6. INSTALL OIL CONTROL VALVE FILTER


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

    2. A01CC5DE04
      Text in Illustration
      *1 Oil Control Valve Filter
      *2 Gasket
      *3 Plug

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

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

  7. INSTALL WATER INLET HOUSING (except TMC Made Engine)


    1. A01CBVJE06
      Text in Illustration
      *1 Water Inlet Housing O-ring
      *2 Water Inlet Housing Gasket

      Install a new water inlet housing O-ring and water inlet housing gasket to the water inlet housing.

    2. A01CEVWE06

      Install the water inlet housing to the cylinder block with the 5 bolts in the order shown in the illustration.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  8. REPLACE STUD BOLT

    Tech Tips

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


    1. Using an E5 "TORX" socket, remove the stud bolts.

    2. Using an E5 "TORX" socket, install the stud bolts as shown the illustration.

      A01CAQXE05
      Text in Illustration
      *1 LH Side *2 Front Side
      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  9. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (for TMC Made Engine without Engine Oil Cooler)


    1. A01CFSDE14
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the drain cock.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01CCDRE01

      Install the water drain cock as shown in the illustration.

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

      Note


      • Install the drain cock within 3 minutes.

      • Do not add coolant for 1 hour after installation.

      • Be sure to only tighten the drain cock up to 360 degrees to position the pipe. Do not loosen the drain cock to position the pipe.

      • Make sure to position the pipe within the range shown in the illustration.

    3. Install the water drain cock plug to the water drain cock.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  10. INSTALL WATER INLET HOUSING DRAIN COCK ASSEMBLY (except TMC Made Engine)


    1. A01CFSDE14
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the drain cock.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01CF98E01

      Install the water inlet housing drain cock within the range shown in the illustration.

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

      Note


      • Install the drain cock within 3 minutes.

      • Do not add coolant for 1 hour after installation.

      • Be sure to only tighten the drain cock up to 360 degrees to position the pipe. Do not loosen the drain cock to position the pipe.

      • Make sure to position the pipe within the range shown in the illustration.

    3. Install the water drain cock plug to the water drain cock.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  11. INSTALL CYLINDER BLOCK WATER JACKET SPACER (for TMC Made Engine)


    1. A01CFSSE03
      Text in Illustration
      *1 Slope

      Install the water jacket spacer as shown in the illustration.

      Tech Tips

      Be sure to face the slope to the front of the engine.

  12. INSTALL CYLINDER BLOCK WATER JACKET SPACER (except TMC Made Engine)


    1. A01CG5TE02
      Text in Illustration
      *1 Slope

      Install the water jacket spacer as shown in the illustration.

      Tech Tips

      Be sure to face the slope to the front of the engine.

  13. INSTALL CYLINDER HEAD GASKET


    1. A01CCMVE03
      Text in Illustration
      *1 Lot No.

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

      Note


      • Remove any oil from the contact surfaces.

      • Be careful of the installation direction.

  14. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. Place the cylinder head on the cylinder head gasket.

      Note

      Place the cylinder head gently in order to avoid damaging the cylinder head gasket.

    2. Install the cylinder head bolts.

      Note

      The cylinder head bolts are tightened in 2 successive steps.


      1. A01CBVRE03

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

      2. Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.

        Torque:
        70 N*m  { 714 kgf*cm, 52 ft.*lbf }
    3. A01CDINE05
      Text in Illustration
      *1 Paint Mark
      A01CCA7 Engine Front

      Mark the front of the cylinder head bolts with paint.

    4. Further tighten the cylinder head bolts 90° as shown in the illustration.

    5. Check that the paint mark is now at a 90° angle to the front.

  15. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. Apply a light coat of engine oil onto a new O-ring.

    2. A01CFM8E12
      Text in Illustration
      *1 O-ring

      Install the O-ring to the camshaft timing oil control valve.

    3. Install the camshaft timing oil control valve with the bolt.

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

  16. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01CG20E03
      Text in Illustration
      *1 Straight Pin
      *2 Key Groove

      Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.

    2. A01CAKAE05
      Text in Illustration
      *1 Straight Pin
      *2 Key Groove
      *a View A

      Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

      Note

      Be sure not to turn the camshaft timing gear to the retard direction (clockwise).

    3. A01CCKGE07
      Text in Illustration
      *a Incorrect
      *b Correct

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

    4. A01CCNW

      Tighten the flange bolt with the camshaft timing gear assembly fixed in place.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
    5. A01CFJHE01

      Check that the camshaft timing gear assembly can move to the retard direction (clockwise) and is locked in the most retarded position.

  17. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET


    1. Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  18. INSTALL NO. 1 CAMSHAFT BEARING


    1. Clean the installation surfaces of the cap and the inner and outer surfaces of the bearing.

      Note

      Keep the installation surfaces and the back surfaces of the bearing free of engine oil.

    2. A01CAPVE06
      Text in Illustration
      *a Claw

      Align the claws and install the No. 1 camshaft bearing onto the No. 1 camshaft bearing cap.

  19. INSTALL NO. 2 CAMSHAFT BEARING


    1. Clean the installation surfaces of the cap and the inner and outer surfaces of the bearing.

      Note

      Keep the installation surfaces and the back surfaces of the bearing free of engine oil.

    2. A01CG0NE01

      Install the No. 2 camshaft bearing onto the cylinder head.

  20. INSTALL CAMSHAFT


    1. Apply a light coat of engine oil to the journal portion.

    2. A01CG2H

      Place the camshaft on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.

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

    4. A01CF42E03

      Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.

    5. A01CF42E10
      Text in Illustration
      *a No. 1

      Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

      Torque:
      No. 1 Bearing cap
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      No. 3 Bearing cap
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  21. INSTALL NO. 2 CAMSHAFT


    1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

    2. A01CGGB

      Place the camshaft on the cylinder head with the No. 2 cam lobes facing the directions shown in the illustration.

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

    4. A01CEB0E05

      Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

    5. A01CEB0E14
      Text in Illustration
      *a No. 2

      Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

      Torque:
      No. 2 Bearing cap
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      No. 3 Bearing cap
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  22. INSTALL KEYS


    1. A01CEWS

      Install the 2 keys.

  23. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. A01CCV9

      Set the crankshaft key into the left horizontal position.

    2. Turn the oil pump drive shaft so that the cutout faces upward.

    3. A01CBW3E11
      Text in Illustration
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *3 Mark Link
      *4 Timing Mark

      Align the yellow mark links with the timing marks of each gear as shown in the illustration.

    4. Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.

    5. Temporarily tighten the oil pump drive shaft gear with the nut.

    6. A01CF6FE09
      Text in Illustration
      *1 Spring
      *2 Chain Tensioner Plate
      *3 Bolt

      Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    7. A01CG5DE09
      Text in Illustration
      *1 Groove

      Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.

    8. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    9. A01CFYZ

      Rotate the crankshaft 90° clockwise, and position the crankshaft key to face up as shown in the illustration.

  24. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01CC5L

      Install the crankshaft timing gear or sprocket to the crankshaft.

  25. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01CF5G

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

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

  26. INSTALL CHAIN SUB-ASSEMBLY


    1. Set the No. 1 cylinder to TDC/compression.


      1. A01CEAGE02
        Text in Illustration
        *1 Timing Mark

        Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks on the camshaft timing gear with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.

      2. A01CFKIE01

        Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.

    2. A01CCHVE05
      Text in Illustration
      *1 Timing Mark
      *2 Mark Link

      Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

    3. A01CEW2E01

      Using SST and a hammer, tap in the crankshaft timing sprocket.

      SST
      09309-37010
    4. A01CDZKE04
      Text in Illustration
      *1 Mark Link
      *2 Timing Mark

      Align the gold or yellow links with the timing marks located on the camshaft timing gear and sprocket, then install the chain.

  27. INSTALL CHAIN TENSIONER SLIPPER


    1. A01CAWPE05
      Text in Illustration
      *a Hold

      Install the chain tensioner slipper with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  28. INSTALL TIMING CHAIN GUIDE


    1. A01CFN4E01

      Install the timing chain guide with the bolt.

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

  29. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01CFA0

      Install the sensor plate with the "F" mark facing forward.

  30. INSTALL FRONT CRANKSHAFT OIL SEAL


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

    2. A01CFXVE01

      Using SST and a hammer, tap in the front crankshaft oil seal until its surface is flush with the front oil seal retainer edge.

      SST
      09223-22010

      Note


      • Keep the lip free from foreign matter.

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

  31. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

    2. A01CB3QE05

      Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the illustration.

      Text in Illustration
      A01CFEA Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the chain cover within 3 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the chain cover.

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

      A01CD1NE10
      Text in Illustration
      *1 Seal Packing - -
      *a Seal Diameter: 2.5 to 3.0 mm (0.0984 to 0.118 in.) *b Seal Diameter: 3.0 mm (0.118 in.)
      *c Seal Diameter: 4.0 mm (0.157 in.) *d Seal Diameter: 4.0 to 4.5 mm (0.157 to 0.177 in.)
      *e Seal Diameter: 4.5 to 5.0 mm (0.177 to 0.197 in.) *f Seal Diameter: 5.5 to 6.0 mm (0.217 to 0.236 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the chain cover within 3 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the chain cover.

    4. Apply adhesive to the threads of the bolt A.

      Seal packing
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A01CFL9E10
      Text in Illustration
      *1 Nut

      Temporarily install the timing chain cover with the 12 bolts and 2 nuts.

      Bolt Length
      Item Length
      Bolt A 30 mm (1.18 in.) length for 10 mm head
      Bolt B 30 mm (1.18 in.) length for 12 mm head
      Bolt C 40 mm (1.57 in.) length for 14 mm head
    6. A01CG6C

      Temporarily install the engine mounting bracket RH with the 3 bolts.

    7. Fully tighten the timing chain cover with the 15 bolts and 2 nuts as shown in the illustration.

      A01CFXOE01
      Torque:
      Bolt A
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      Bolt B
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Bolt C
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      Nut
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    8. Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }

  32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01CGD9E07
      Text in Illustration
      *1 Pin
      *2 Hook
      *a Raise
      *b Push

      Release the ratchet pawl, then fully push in the plunger and set the hook to the pin so that the plunger is in the position shown in the illustration.

    2. A01CFT0

      Install a new gasket and the chain tensioner with the 2 nuts.

      Text in Illustration
      A01CFEA Engine Front
      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Note

      When installing the chain tensioner, set the hook again if the hook releases the plunger.

  33. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01CC9OE02
      Text in Illustration
      *1 Bolt
      *2 Nut

      Temporarily install the V-ribbed belt tensioner assembly with the nut.

      Note

      Do not lift the engine more than necessary.

    2. Slightly push down on the V-ribbed belt tensioner assembly at part (A) to align the holes of the engine and tensioner as shown in the illustration, and temporarily install the bolt.

    3. A01CFXPE03
      Text in Illustration
      *1 Pin

      Tighten the bolt and nut to install the V-ribbed belt tensioner.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note


      • When replacing the V-ribbed belt tensioner with a new one, do not pull out the pin.

      • The pin will be removed in a later step.

  34. INSTALL CRANK POSITION SENSOR (for TMC Made Engine)


    1. A01CEJOE11
      Text in Illustration
      *1 New O-ring

      Apply a light coat of engine oil to the O-ring on the crank position sensor.

    2. A01CCT1

      Install the crank position sensor with the bolt.

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

      Note

      Do not twist the O-ring.

    3. Install the 2 wire harness clamps.

    4. Install the connector to the connector bracket.

  35. INSTALL CRANK POSITION SENSOR (except TMC Made Engine)


    1. A01CEJOE12
      Text in Illustration
      *1 New O-ring

      Apply a light coat of engine oil to the O-ring on the crank position sensor.

    2. A01CG06

      Install the crank position sensor with the bolt.

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

      Note

      Do not twist the O-ring.

    3. Install the wire harness clamp.

    4. Install the connector to the connector bracket.

  36. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

    2. A01CB5AE07
      Text in Illustration
      *1 Seal Packing
      *a Seal Diameter: 3.0 to 4.0 mm

      Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan within 3 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the oil pan.

    3. Install the oil pan onto the cylinder block.

    4. A01CCAEE01

      Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

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

  37. INSTALL OIL PAN DRAIN PLUG


    1. Install the oil pan drain plug with a new gasket.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  38. INSTALL WATER PUMP ASSEMBLY (for TMC Made Engine)


    1. Remove any old seal packing material from the contact surfaces.

    2. A01CC9EE14
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Standard seal diameter
      2.2 to 2.5 mm (0.0866 to 0.0984 in.)

      Note


      • Remove any oil from the contact surfaces.

      • The parts must be set within 3 minutes after applying seal packing. Otherwise, the material must be removed and reapplied.

    3. A01CAL5E05
      Text in Illustration
      *1 Clamp Bracket

      Install the water pump assembly and clamp bracket with the 4 bolts and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    4. A01CBBL

      Install the wire of the crankshaft position sensor onto the clamp bracket.

    5. Install the clamp of the crankshaft position sensor onto the water pump.

  39. INSTALL WATER PUMP ASSEMBLY (except TMC Made Engine)


    1. Remove any old seal packing material from the contact surfaces.

    2. A01CFM9E02
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Standard seal diameter
      2.2 to 2.5 mm (0.0866 to 0.0984 in.)

      Note


      • Remove any oil from the contact surfaces.

      • The parts must be set within 3 minutes after applying seal packing. Otherwise, the material must be removed and reapplied.

    3. A01CD6YE03
      Text in Illustration
      *1 Clamp Bracket

      Install the water pump assembly and 2 clamp brackets with the 4 bolts and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    4. A01CD7LE02

      Install the wire of the crankshaft position sensor onto the clamp bracket.

    5. Connect the connector of the crankshaft position sensor.

  40. INSTALL WATER PUMP PULLEY


    1. A01CBGYE02

      Using SST, install the water pump pulley with the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  41. INSTALL CRANKSHAFT PULLEY


    1. A01CC44E01

      Using SST, secure the pulley in place and tighten the bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      180 N*m  { 1835 kgf*cm, 133 ft.*lbf }
    2. A01CCT5E07
      Text in Illustration
      *1 Hook
      *2 Pin
      *a Disconnect

      Turn the crankshaft counterclockwise, then disconnect the hook from the pin.

    3. A01CF8EE11
      Text in Illustration
      *1 Plunger
      *a Extend
      *b Turn

      Turn the crankshaft clockwise, then check that the plunger is extended.

  42. INSPECT VALVE CLEARANCE


    1. A01CEA3E07
      Text in Illustration
      *a No. 1 Cylinder TDC/Compression
      *b Intake
      *c Exhaust

      Check only the valves indicated in the illustration.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard Valve Clearance (Cold)
        Item Specified Condition
        Intake 0.19 to 0.29 mm (0.00748 to 0.0114 in.)
        Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.)

      2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters.

    2. Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to TDC/Compression.

    3. A01CG6QE09
      Text in Illustration
      *a No. 4 Cylinder TDC/Compression
      *b Intake
      *c Exhaust

      Check only the valves indicated in the illustration.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard Valve Clearance (Cold)
        Item Specified Condition
        Intake 0.19 to 0.29 mm (0.00748 to 0.0114 in.)
        Exhaust 0.38 to 0.48 mm (0.0150 to 0.0189 in.)

      2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.

  43. ADJUST VALVE CLEARANCE


    1. Set No. 1 cylinder to TDC/compression Click here.

    2. Remove the No. 1 chain tensioner Click here.

    3. Loosen the camshaft timing sprocket Click here.

    4. Remove the No. 2 camshaft Click here.

    5. Remove the camshaft Click here.

    6. Remove the valve lifters.

    7. A01CBSEE01

      Using a micrometer, measure the thickness of the removed valve lifters.

    8. Calculate the thickness of a new lifter so that the valve clearance comes within the specified values.

      New Lifter Thickness
      Item Specification
      Intake A = B + (C - 0.24 mm (0.00945 in.))
      Exhaust A = B + (C - 0.43 mm (0.0169 in.))
      A New lifter thickness
      B Used lifter thickness
      C Measured valve clearance

      CALCULATION EXAMPLE (Intake):


      1. Measured intake valve clearance = 0.40 mm (0.0157 in.)

        (Measured - Specification = Excess clearance)


        1. 0.40 mm (0.0157 in.) - 0.24 mm (0.00945 in.) = 0.16 mm (0.00630 in.)

      2. Measured used lifter thickness = 5.250 mm (0.2067 in.)

      3. New lifter thickness = 5.410 mm (0.2130 in.)

        (Excess clearance + Used lifter thickness = Ideal new lifter)


        1. 0.16 mm (0.00630 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.)

      4. Closest new lifter = 5.420 mm (0.2134 in.)


        • Select No. 42 lifter

    9. Select a new lifter with a thickness as close as possible to the calculated values.

      Tech Tips


      • Lifters are available in 35 sizes in increments of 0.020 mm (0.000787 in.), from 5.060 to 5.740 mm (0.1992 to 0.2260 in.).

      • A01CEHGE01

        The identification number inside the valve lifters shows the value to 2 decimal places. (The illustration shows 5.420 mm (0.2134 in.)

    10. Valve lifter selection chart (intake).

      A01CBBNE02
      New Lifter Thickness
      Lifter No.

      Thickness

      mm (in.)

      		 Lifter No.

      Thickness

      mm (in.)

      		 Lifter No.

      Thickness

      mm (in.)
      06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
      08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)
      10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)
      12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)
      14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)
      16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)
      18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)
      20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
      22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
      24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
      26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
      28 5.280 (0.2079) 52 5.520 (0.2173) - -
      Standard intake valve clearance (cold)
      0.19 to 0.29 mm (0.00748 to 0.0114 in.)

      EXAMPLE:

      The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter.

    11. Valve lifter selection chart (exhaust).

      A01CE28E01
      New Lifter Thickness
      Lifter No.

      Thickness

      mm (in.)

      		 Lifter No.

      Thickness

      mm (in.)

      		 Lifter No.

      Thickness

      mm (in.)
      06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
      08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)
      10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)
      12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)
      14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)
      16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)
      18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)
      20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
      22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
      24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
      26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
      28 5.280 (0.2079) 52 5.520 (0.2173) - -
      Standard exhaust valve clearance (cold)
      0.38 to 0.48 mm (0.0150 to 0.0189 in.)

      EXAMPLE:

      The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.510 mm (0.0201 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 42 lifter.

    12. Install the selected valve lifter.

    13. Install the camshaft Click here.

    14. Install the No. 2 camshaft Click here.

    15. Install the No. 1 chain tensioner Click here.

  44. INSTALL CAMSHAFT POSITION SENSOR


    1. A01CBRGE09
      Text in Illustration
      *1 O-ring

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

    2. Install the camshaft position sensor with the bolt.

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

  45. INSTALL CYLINDER HEAD COVER GASKET


    1. A01CDI6E01

      Install the cylinder head cover gasket onto the cylinder head cover.

  46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing material from the contact surfaces.

    2. A01CARIE03
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the 2 locations shown in the illustration.

      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 within 3 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover.

    3. A01CD2IE04
      Text in Illustration
      *1 Nut

      Install the cylinder head cover with the 8 bolts and 2 nuts.

      Torque:
      Bolt A
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Bolt B
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Nut
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  47. INSTALL OIL FILTER UNION (except TMC Made Engine with Engine Oil Cooler)


    1. Using a 12 mm socket hexagon wrench, install the oil filter union.

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

  48. INSTALL ENGINE OIL COOLER (for TMC Made Engine with Engine Oil Cooler)


    1. Clean the oil cooler contact surface on the cooler mounting.

    2. Install a new O-ring to the oil cooler.

    3. Apply a light coat of engine oil on the threads and under the head of the oil cooler union.

    4. A01CEU1

      Install the oil cooler with the plate washer, oil cooler union and nut.

      Torque:
      Oil cooler union
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      Nut
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  49. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Check and clean the oil filter sub-assembly installation surface.

    2. Apply clean engine oil to the gasket of a new oil filter sub-assembly.

    3. Lightly screw the oil filter sub-assembly into place by hand. Tighten it until the gasket contacts the seat.

    4. Using SST, tighten the oil filter sub-assembly.

      SST
      09228-06501

      1. Depending on the work space available, choose from the following:


        • If enough space is available, use a torque wrench to tighten the oil filter sub-assembly.

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

        • If enough space is not available to use a torque wrench, tighten the oil filter sub-assembly a 3/4 turn by hand or use a common wrench.

  50. INSTALL SPARK PLUG


    1. A01CF85

      Install the 4 spark plugs.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  51. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. A01CDT1E09
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the threads of the ventilation valve.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using a 22 mm deep socket wrench, install the ventilation valve onto the cylinder head cover.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  52. INSTALL OIL FILLER CAP GASKET


    1. Install the oil filler cap gasket onto the oil filler cap.

  53. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap onto the cylinder head cover.