БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

INSTALL OIL PUMP ASSEMBLY

1. Install the oil pump with the 3 bolts.

   

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL NO. 2 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. Apply seal packing in a continuous line as shown in the illustration.

   Application Specification
   Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing A - A 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.) B - B -

   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 and tighten the bolts within 10 minutes after applying seal packing.

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

3. Install the No. 2 oil pan with the 10 bolts and 2 nuts.

   

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL ENGINE REAR 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   ( 09951-07100 )

   Note

   • Wipe off any extra grease from the crankshaft.

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

INSTALL VENTILATION VALVE SUB-ASSEMBLY

1. 

   Нанесите герметик на 2-3 витка резьбы сапуна в сборе.

   Герметик
   Фирменный герметик 1324 от компании Toyota, Three Bond 1324 или аналогичный

   Обозначения на рисунке

   *1

   Герметик

2. С помощью ключа для контргайки шарового шарнира на 22 мм установите сапун в сборе.

   

   Torque:

   20 Н*м  { 204 кгс*см, 15 фунт-сила-дюймов }

   Note

   Если совместно с ключом для контргайки шарового шарнира применяется динамометрический ключ, используйте формулу для расчета заданных моментов затяжки (см. стр. Click here).

INSTALL CYLINDER HEAD GASKET

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

   

   Note

   • Remove any oil from the contact surface.

   • Make sure that the gasket is installed in the correct direction.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

1. Place the cylinder head on the cylinder block.

   Note

   • Make sure that no oil is on the mounting surface of the cylinder head.

   • 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:

      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

      Note

      Do not drop the plate washers into the cylinder head.

5. Step 2:

   

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

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

6. Step 3:

   1. Tighten the cylinder head bolts another 45° in the sequence shown in step 1.

7. Check that the paint mark is now at a 135° angle to the front.

INSTALL NO. 2 CAMSHAFT

1. Clean the camshaft journals.

   

2. Apply a light coat of engine oil to the camshaft journals and camshaft housing.

3. Install the camshaft to the camshaft housing.

INSTALL CAMSHAFT

1. Clean the camshaft journals.

   

2. Apply a light coat of engine oil to the camshaft journals and camshaft housing.

3. Install the camshaft to the camshaft housing.

INSTALL CAMSHAFT BEARING CAP

1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.

   

2. Check the marks and numbers on the camshaft bearing caps and place the bearing caps in the proper position and direction.

   Tech Tips

   Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

3. Install the 10 bolts in the order shown in the illustration.

   

   Torque:

   16 N*m  { 163 kgf*cm, 12 ft.*lbf }

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

1. Make sure that the valve rocker arm is installed as shown in the illustration.

   

   Text in Illustration

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

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
   Area Specified Condition Continuous Line 3.5 to 4.5 mm (0.138 to 0.177 in.) A 8.0 mm (0.315 in.) B 7.0 mm (0.276 in.)

   Application Length A and B
   15 mm (0.591 in.)

   Note

   • Remove any oil from the contact surfaces.

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

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

3. Set the camshaft and No. 2 camshaft as shown in the illustration.

   

4. Install the camshaft housing with the 17 bolts and tighten them in the order shown in the illustration.

   Torque:

   27 N*m  { 275 kgf*cm, 20 ft.*lbf }

   Note

   • After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.

   • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.

   • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

   • After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and cylinder head.

INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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

   

   Text in Illustration

   *1	Straight Pin
   *2	Key Groove

   Note

   Do not forcefully push in the camshaft timing gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear.

2. 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.

   

   Text in Illustration

   *1	Straight Pin
   *2	Key Groove

   Note

   Do not turn the camshaft timing gear in the retard direction (clockwise).

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

   

4. Tighten the flange bolt with the camshaft timing gear secured in place.

   

   Torque:

   54 N*m  { 551 kgf*cm, 40 ft.*lbf }

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

   

   Text in Illustration

   *1

   Lock

INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

1. Put the camshaft timing exhaust gear and camshaft together by aligning the pin hole and straight pin.

   

   Text in Illustration

   *1	Straight Pin
   *2	Pin Hole

   Note

   Do not forcefully push in the camshaft timing exhaust gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing exhaust gear.

2. Lightly press the gear against the camshaft and turn the gear. Push further at the position where the pin enters the hole.

   Note

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

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

   

4. Tighten the flange bolt with the camshaft timing exhaust gear secured in place.

   

   Torque:

   54 N*m  { 551 kgf*cm, 40 ft.*lbf }

5. Check the camshaft timing exhaust gear lock.

   1. Make sure that the camshaft timing exhaust gear is locked.

INSTALL NO. 2 CHAIN SUB-ASSEMBLY

1. Temporarily install the crankshaft pulley bolt.

   

2. Set the crankshaft key as shown in the illustration.

3. Turn the drive shaft so that the cutout faces upward.

4. Remove the crankshaft pulley bolt.

5. Align the yellow mark plates with the timing mark of each gear as shown in the illustration.

   

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

7. Temporarily install the oil pump drive shaft gear with the nut.

8. Install the damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

   

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

9. Temporarily install the crankshaft pulley with the pulley bolt.

   

10. Using SST, hold the crankshaft. Then tighten the drive shaft gear nut.

    SST

    09330-00021

    09213-58014   ( 91551-80840 )

    Torque:

    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

11. Remove SST, the crankshaft pulley bolt and crankshaft pulley.

INSTALL CRANKSHAFT TIMING SPROCKET

1. Install the crankshaft timing sprocket as shown in the illustration.

   

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 NO. 2 CHAIN VIBRATION DAMPER

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

   

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

   

2. Turn the crankshaft counterclockwise to position the timing gear key at the top.

   Text in Illustration

   *1	Timing Gear Key

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

   

   Text in Illustration

   *1	Timing Mark

4. Remove the crankshaft pulley bolt.

INSTALL CHAIN SUB-ASSEMBLY

1. Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

   

   Tech Tips

   • Be sure to position the mark plate at the front of the engine.

   • The mark plate on the camshaft side is colored orange.

   • Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.

   • Pass the chain through the No. 1 vibration damper.

2. Place the chain on the crankshaft without passing it around the shaft.

   

3. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plates (orange) and timing mark, and then install the chain.

   

   Tech Tips

   • Be sure to position the mark plates at the front of the engine.

   • The mark plates on the camshaft side are colored orange.

4. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.

   Tech Tips

   To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.

5. Align the mark plates (yellow) and timing marks and install the chain to the crankshaft timing gear.

   

   Text in Illustration

   *1	Timing Mark
   *2	Mark Plate (Yellow)

   Tech Tips

   The mark plates on the crankshaft side are colored yellow.

INSTALL CHAIN TENSIONER SLIPPER

1. Install the chain tensioner slipper to the cylinder block.

   

CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

1. Check each timing mark at TDC/compression.

   

   Text in Illustration

   *1	Timing Mark	*2	Mark Plate (Orange)
   *3	Mark Plate (Yellow)	-

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

1. Install a new gasket.

   

   Note

   Remove any oil from the contact surface.

2. Install the water pump with the 3 bolts.

   

   Torque:

   24 N*m  { 241 kgf*cm, 17 ft.*lbf }

3. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, camshaft housing, stiffening crankcase and cylinder block.

   

4. Install 3 new O-rings.

   

5. Apply seal packing as shown in the illustration.

   

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

   Standard seal diameter
   5.0 mm (0.197 in.)

   Note

   • Remove any oil from the contact surface.

   • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

6. Apply seal packing to the timing chain cover in a continuous line as shown in the following illustration.

   

   Seal Packing
   Item Seal Packing Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Continuous line Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

   Application Specification

   Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing Dashed line 2.5 to 3.0 mm (0.0984 to 0.118 in.) Center of seal packing 2.5 mm (0.0984 in.) - - Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - - Alternate long and short dashed line 4.0 mm (0.157 in.) Center of seal packing 3.0 mm (0.118 in.) - - A - A 2.5 to 3.0 mm (0.0984 to 0.118 in.) Center of seal packing 2.5 mm (0.0984 in.) - - B - B 4.5 to 5.5 mm (0.177 to 0.217 in.) Opposite edge of seal packing 5.0 mm (0.197 in.) - - C - C 7.0 to 8.0 mm (0.276 to 0.315 in.) Opposite edge of seal packing 7.5 mm (0.295 in.) - - F 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.8 mm (0.622 in.) 50.1 mm (1.97 in.) G 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 155.1 mm (6.11 in.) H 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 165.4 mm (6.51 in.) I 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (1.31 ft.) J 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.) K 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 133.9 mm (5.27 in.) L 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 159.2 mm (6.28 in.) M 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.0 mm (0.197 in.) 185.0 mm (7.28 in.) N 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (1.31 ft.) O 4.0 mm (0.157 in.) Center of seal packing 3.0 mm (0.118 in.) - -

   Note

   • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.

   • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

   • After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.

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

7. Clean the bolts and their installation holes.

8. Install the timing chain cover.

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

   

   Note

   • Install the mounting bracket within 10 minutes after installing the timing chain cover.

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

10. Install 2 new O-rings.

    

11. Temporarily install the oil filter bracket with the 4 bolts.

    

    Note

    • Install the oil filter bracket within 10 minutes after installing the timing chain cover.

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

12. Apply adhesive to 5 and a half threads or more of the end of bolt E.

    

    Text in Illustration

    *1

    Adhesive

    Adhesive
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

13. Install the timing chain cover with the 26 bolts and seal washer in the order shown in the illustration.

    

    Torque:

    for bolt A, E

    26 N*m  { 260 kgf*cm, 19 ft.*lbf }

    for bolt B

    51 N*m  { 520 kgf*cm, 38 ft.*lbf }

    for bolt C

    51 N*m  { 520 kgf*cm, 38 ft.*lbf }

    for bolt D

    10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    Note

    • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.

    • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying the seal packing.

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

    Bolt Length
    Item Length Thread Diameter Bolt A, E 35 mm (1.38 in.) 8 mm (0.315 in.) Bolt B 55 mm (2.17 in.) 10 mm (0.394 in.) Bolt C 80 mm (3.15 in.) 10 mm (0.394 in.) Bolt D 40 mm (1.57 in.) 6 mm (0.236 in.)

    Tech Tips

    Apply adhesive to bolt E before installing it.

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

   • Wipe off any extra grease from the crankshaft.

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

INSTALL CRANKSHAFT PULLEY

1. Align the key groove of the pulley with the pulley set key.

   

2. Temporarily install the pulley with the pulley bolt.

3. Using SST, hold the pulley in place and tighten the bolt.

   Text in Illustration

   *1	Hold
   *2	Turn

   SST

   09330-00021

   09213-58014   ( 91551-80840 )

   Torque:

   190 N*m  { 1940 kgf*cm, 140 ft.*lbf }

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

1. Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

   

   Note

   Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

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

   

   Torque:

   12 N*m  { 122 kgf*cm, 9 ft.*lbf }

   Note

   If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

3. Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.

   

   Text in Illustration

   *1	Release
   *2	Pin
   *3	Hook
   *4	Turn

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

   

   Text in Illustration

   *1	Plunger
   *2	Plunger Extended
   *3	Turn

INSTALL OIL FILTER CAP ASSEMBLY

1. Clean the inside of the oil filter cap, its 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

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

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

5. Reapply a small amount of engine oil to the O-ring of the oil filter cap. Align the oil filter cap with the oil filter bracket so that the cutout portion of the cap threads is in a position 90° from the groove in the bracket, and then temporarily install the cap.

   Note

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

   

6. Using SST, tighten the oil filter cap.

   

   SST

   09228-06501

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Note

   • After tightening the oil filter cap, check for gaps between the installation surfaces.

   • Do not remove the oil filter bracket clip when installing the oil filter cap.

   • Do not cross thread the oil filter cap.

INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

1. Нанесите герметик на 2–3 витка резьбы контактного датчика давления масла.

   

   Обозначения на рисунке

   *1

   Герметик

   Герметик
   Фирменный герметик 1344 от компании Toyota, Three Bond 1344 или аналогичный

   Note

   Не допускайте, чтобы герметик приставал к масляному отверстию.

2. С помощью удлиненной торцевой головки на 22 мм установите контактный датчик давления масла.

   

   Torque:

   15 Н*м  { 153 кгс*см, 11 фунт-сила-дюймов }

   Note

   Не запускайте двигатель в течение 1 часа после установки.

3. Подсоедините разъем контактного датчика давления жидкости.

INSTALL SPARK PLUG

1. Using a 14 mm spark plug wrench and 100 mm extension bar, install the 4 spark plugs.

   

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }