БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

INSTALL ENGINE REAR OIL SEAL

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

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

INSTALL CYLINDER HEAD GASKET

1. 

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

   Text in Illustration

   *1

   Lot No.

   Note

   • Remove any oil from the contact surface.

   • Be careful of the installation direction.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

1. Place the cylinder head on the head gasket.

   Note

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

2. Install the cylinder head bolts.

   Note

   The cylinder head bolts are tightened in 2 successive steps.

   1. 

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

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

      Torque:

      79 N*m  { 800 kgf*cm, 58 ft.*lbf }

3. 

   Mark the front of the cylinder head bolts with paint.

4. 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.

INSTALL NO. 1 CAMSHAFT BEARING

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

   Note

   Do not apply engine oil to the bearing or its contact surfaces.

2. 

   Align the claw of the No. 1 camshaft bearing and the cutout of the No. 1 camshaft bearing cap and install the bearing onto the bearing cap.

   Text in Illustration

   *1

   Claw

INSTALL NO. 2 CAMSHAFT BEARING

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

   Note

   Do not apply engine oil to the bearing or its contact surfaces.

2. 

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

INSTALL CAMSHAFT

1. Apply a light coat of engine oil to the journals of the camshaft.

2. 

   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.

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

4. 

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

   Torque:

   for No. 1 bearing cap

   30 N*m  { 301 kgf*cm, 22 ft.*lbf }

   for No. 3 bearing cap

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

INSTALL NO. 2 CAMSHAFT

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

2. 

   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.

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

4. 

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

   Torque:

   for No. 2 bearing cap

   30 N*m  { 301 kgf*cm, 22 ft.*lbf }

   for No. 3 bearing cap

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

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 }

INSTALL NO. 2 CHAIN SUB-ASSEMBLY

1. 

   Set the crankshaft key to the left horizontal position.

2. Turn the cutout of the drive shaft so that it faces upward.

3. 

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

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

5. Temporarily install the oil pump drive shaft sprocket with the nut.

   Text in Illustration

   *1	Mark Link
   *2	Timing Mark
   *3	Oil Pump Drive Sprocket
   *4	Oil Pump Drive Shaft Sprocket

6. 

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

   Text in Illustration

   *1	Damper Spring
   *2	Chain Tensioner Plate
   *3	Bolt

   Torque:

   12 N*m  { 122 kgf*cm, 9 ft.*lbf }

7. 

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

   Text in Illustration

   *1

   Groove

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  { 301 kgf*cm, 22 ft.*lbf }

INSTALL CRANKSHAFT TIMING SPROCKET

INSTALL NO. 1 CHAIN VIBRATION DAMPER

1. 

   Install the chain vibration damper with the 2 bolts.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

INSTALL CHAIN SUB-ASSEMBLY

1. 

   Set the No. 1 cylinder to TDC/compression.

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

      Text in Illustration

      *1

      Mark

   2. 

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

2. 

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

   Text in Illustration

   *1	Mark Link
   *2	Timing Mark

3. 

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

   SST

   09309-37010

4. 

   Align the gold or yellow links with the timing mark located on each camshaft timing sprocket and install the chain.

   Text in Illustration

   *1

   Mark

INSTALL CHAIN TENSIONER SLIPPER

1. 

   Install the chain tensioner slipper with the bolt.

   Torque:

   19 N*m  { 194 kgf*cm, 14 ft.*lbf }

   Text in Illustration

   *1

   Hold

INSTALL TIMING CHAIN GUIDE

1. 

   Install the timing chain guide with the bolt.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

1. 

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

INSTALL TIMING CHAIN COVER OIL SEAL

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

   

   SST

   09223-22010

   Note

   • Keep the lip free from foreign matter.

   • Do not tap the oil seal at an angle.

2. Apply MP grease to the lip of the oil seal.

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. Apply seal packing as shown in the illustration.

   

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

   Standard seal diameter
   4.0 to 4.5 mm (0.157 to 0.177 in.)

   Text in Illustration

   *1	Seal Packing

   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.

   

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

   Application Specification

   Area Seal Packing Diameter (Round) Distance from Edge of Cover to Edge of Seal Packing Diameter Measured from Center of Seal Packing A 4.0 mm (0.157 in.) - - B 5.5 to 6.0 mm (0.217 to 0.236 in.) - - C 3.0 mm (0.118 in.) - - D 2.5 to 3.0 mm (0.0984 to 0.118 in.) 2.5 mm (0.0984 in.) - E 4.0 to 4.5 mm (0.157 to 0.177 in.) - - F 4.5 to 5.0 mm (0.177 to 0.197 in.) - - G 2.5 to 3.0 mm (0.0984 to 0.118 in.) - - H 4.0 mm (0.157 in.) - 17.5 mm (0.689 in.) I 2.5 to 3.0 mm (0.0984 to 0.118 in.) - 13.0 mm (0.512 in.)

   Note

   • Remove any oil from the contact surface.

   • 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 bolt A.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

   

   Bolt length
   Item Specified Condition Bolt A 30 mm (1.18 in.) 10 mm head Bolt B 30 mm (1.18 in.) 12 mm head Bolt C 40 mm (1.57 in.) 14 mm head

   Text in Illustration

   *1

   Nut

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

   

7. Tighten the 15 bolts and 2 nuts in the sequence shown in the illustration.

   

   Text in Illustration

   *1

   Nut

   Torque:

   for bolt A

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

   for bolt B

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   for bolt C

   55 N*m  { 561 kgf*cm, 41 ft.*lbf }

   for 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  { 219 kgf*cm, 16 ft.*lbf }

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. 

   Check that the paint marks on the chain are aligned with the timing mark on each camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover.

   Text in Illustration

   *1	7 Links
   *2	Paint Mark
   *3	Timing Mark
   *4	Groove

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

1. 

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

2. 

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

   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.

INSTALL CRANKSHAFT PULLEY

1. 

   Using SST, fix 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. 

   Turn the crankshaft counterclockwise and disconnect the hook from the plunger knock pin.

3. 

   Turn the crankshaft clockwise and check that the plunger is extended.

INSTALL WATER PUMP ASSEMBLY

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

2. 

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

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

   Standard seal diameter
   2.2 to 2.5 mm (0.0866 to 0.0984 in.)

   Distance from edge of water pump to center of seal packing
   0.5 to 1.0 mm (0.0197 to 0.0394 in.)

   Note

   • Remove any oil from the contact surface.

   • The water pump must be installed within 3 minutes after applying seal packing. Otherwise, the material must be removed and reapplied.

3. 

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

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

   Text in Illustration

   *1

   Bracket

4. 

   Connect the wire of the crankshaft position sensor to the clamp bracket.

   Text in Illustration

   *1

   Bracket

5. Connect the clamp of the crankshaft position sensor to the water pump.

INSTALL WATER PUMP PULLEY

1. 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 }

INSTALL OIL FILTER SUB-ASSEMBLY

1. Check and clean the oil filter installation surface.

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

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

4. 

   Using SST, tighten the oil filter.

   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.

      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 a 3/4 turn by hand or use a common wrench.

5. 

   except Rough Road Area Specification Vehicles:

   Attach the 2 clips to close the engine under cover.

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

1. 

   Install the V-ribbed belt tensioner with the bolt and nut.

   Torque:

   60 N*m  { 607 kgf*cm, 44 ft.*lbf }