ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STUD BOLT


    1. Using "TORX" socket wrench E5, install the 4 stud bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      A005M09E04

  2. INSTALL OIL PAN SUB-ASSEMBLY


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

    2. A005JKEE02
      Text in Illustration
      *a Seal Packing
      *b Seal Diameter

      Apply a continuous bead of seal packing to the oil pan mating surface as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Doameter
      2.0 to 3.0 mm (0.08 to 0.12 in)

      Note


      • Remove any oil from the contact surface.

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

      • Do not expose the seal to engine oil for at least 2 hours after the installation.

    3. Install 2 new O-rings onto the cylinder block.

    4. A005JKI

      Using several steps, install and tighten the 13 bolts uniformly in the sequence shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Each bolt length is as follows:

      A: 46 mm (1.811 in.)

      B: 85 mm (3.3465 in.)

      C: 140.7 mm (5.5394 in.)

  3. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer sub-assembly with the 2 nuts and the bolt.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


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

    2. A005KO1E08
      Text in Illustration
      *a Seal Packing

      Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan mating surface as shown in the illustration.

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

      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 expose the seal to engine oil within 2 hours of installation.

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

    3. Install the No. 2 oil pan sub-assembly with the 9 bolts and the 2 nuts.

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

    4. Install the drain plug with a new gasket.

      Torque:
      38 N*m  { 382 kgf*cm, 28 ft.*lbf }

  5. INSTALL ENGINE REAR OIL SEAL

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  6. INSTALL OIL FILTER UNION


    1. Using a 12 mm (0.47 in.) hexagon wrench, install the oil filter union.

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

  7. INSTALL OIL FILTER SUB-ASSEMBLY

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  8. INSTALL CYLINDER HEAD GASKET

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  9. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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  10. INSTALL VALVE STEM CAP

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  11. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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  12. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  13. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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  14. INSTALL CAMSHAFT

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  15. INSTALL CAMSHAFT TIMING SPROCKET

    A005KMC

    1. Clamp the No. 2 camshaft in a vise.

    2. Align the knock pin hole the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket with the fringe bolt.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Note

      Do not damage the No. 2 camshaft.

  16. INSTALL NO. 2 CAMSHAFT


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

    2. Place the camshaft on the cylinder head sub-assembly with the timing mark on the camshaft timing gear facing upward.

    3. A005HYGE03
      Text in Illustration
      *1 No. 1 Bearing Cap
      *2 No. 2 Bearing Cap

      Examine the front marks and numbers on the No. 1 and No. 2 camshaft bearing caps and check that the order is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.

      Torque:
      13 N*m  { 129 kgf*cm, 9 ft.*lbf }
      for No. 2 bearing cap
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
      for No. 1 bearing cap

      Note

      Tighten each bolt uniformly while keeping the camshaft level.

  17. INSTALL CAMSHAFT POSITION SENSOR

    Click here

  18. INSTALL FUEL INJECTOR ASSEMBLY

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  19. INSTALL INJECTOR VIBRATION INSULATOR

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  20. INSTALL NO. 1 DELIVERY PIPE SPACER

    Click here

  21. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

  22. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A005H9B

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

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

  23. INSTALL CHAIN SUB-ASSEMBLY

    A005LVCE02
    Text in Illustration
    *a TDC
    *b Timing Mark

    1. Make sure that all the timing marks are in the positions (TDC) shown in the illustration.

      Tech Tips

      The positions of the timing marks may differ the predetermined positions due to the force of the valve spring.

    2. A005HHKE06
      Text in Illustration
      *a Timing Mark
      *b 40° to140° ATDC

      Set the timing mark of the crankshaft in a position between 40 and 140° ATDC, as illustrated.

    3. A005M8PE02
      Text in Illustration
      *a 20° ATDC
      *b Timing Mark

      Set the camshaft timing gear sub-assembly and the camshaft timing sprocket in the positions (20° ATDC) shown in the illustration.

    4. Set the crankshaft in the position (20° ATDC) shown in the illustration.

    5. A005GZ3E07
      Text in Illustration
      *a Mark Plates
      *b Timing Mark

      Align the timing marks of the camshaft with the mark plates of the chain sub-assembly and install the chain sub-assembly.

      Tech Tips

      Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench.

  24. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  25. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

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

  26. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    A005LWBE01
    Text in Illustration
    *1 Bar

    1. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

    2. Remove the bar from the No. 1 chain tensioner assembly.

  27. INSTALL OIL PUMP SEAL

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  28. INSTALL OIL PUMP ASSEMBLY

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  29. INSTALL ENGINE WATER PUMP ASSEMBLY

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  30. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

    Click here

  31. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

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  32. INSTALL WATER PUMP PULLEY

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  33. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    A005HOR

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

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note

      Do not twist the O-ring.

  34. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    A005I9N

    1. Install the gasket onto the cylinder head cover sub-assembly.

    2. Apply seal packing to the cylinder head sub-assembly, as shown in the illustration.

      Text in Illustration
      A005GO2 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 engine for at least 2 hours after the installation.

    3. Temporarily install the cylinder head cover sub-assembly with the 9 bolts and 2 nuts.

    4. A005GJ8E02
      Text in Illustration
      *1 Nut

      Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.

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

  35. INSTALL VENTILATION VALVE SUB-ASSEMBLY


    1. Install the ventilation valve sub-assembly onto the cylinder head cover sub-assembly.

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

  36. INSTALL CRANKSHAFT POSITION SENSOR


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

      Note

      If the O-ring is damaged, replace the crankshaft position sensor.

    2. Install the crankshaft position sensor with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  37. INSTALL OIL FILLER CAP GASKET


    1. Install the oil filler cap gasket onto the oil filler cap sub-assembly.

  38. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly onto the cylinder head cover sub-assembly.

  39. INSTALL THERMOSTAT

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  40. INSTALL INLET WATER

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  41. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Provisionally install the engine coolant temperature sensor using a new gasket.

    2. A005HNV

      Using SST, tighten the engine coolant temperature sensor.

      SST
      09817-33190
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  42. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    A005LDFE03
    Text in Illustration
    *1 Adhesive

    1. Apply adhesive to the end 2 or 3 threads of the engine oil pressure switch.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Do not start the engine for at least 1 hour after the installation.

    2. A005MHK

      Using a 24 mm deep socket wrench, install the engine oil pressure switch.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  43. INSTALL KNOCK SENSOR

    A005LQNE01

    1. Install the knock sensor with the nut as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  44. INSTALL SPARK PLUG

    Click here