ENGINE UNIT REASSEMBLY


  1. INSTALL NO. 1 BALANCE SHAFT BEARING


    1. A01EV6AE12
      Text in Illustration
      *1 Stiffening Crankcase
      *2 Balance Shaft Housing

      Align the bearing claw with the claw groove, and push in the 8 No. 1 balance shaft bearing.

      Note

      Do not apply engine oil to the contact surfaces of the No. 1 balance shaft bearing and balance shaft housing.

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

  2. INSTALL NO. 1 AND NO. 2 BALANCE SHAFTS


    1. A01ETR9E07
      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 balance shaft 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. A01EW67E10
      Text in Illustration
      *1 No. 1 Balance Shaft
      *2 No. 2 Balance Shaft
      *a Alignment Mark

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

    3. A01ETQ6E05
      Text in Illustration
      *1 No. 1 Balance Shaft
      *2 No. 2 Balance Shaft
      *a Alignment Mark
      *b Adjusting Hole
      *c Timing Mark

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

    4. Place the No. 1 and No. 2 balance shafts onto the stiffening crankcase assembly.

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

  3. INSTALL BALANCE SHAFT HOUSING


    1. A01EXIJE03

      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 }
    2. A01ETLQE01
      Text in Illustration
      *a Paint Mark
      A01ETOA Engine Front

      Mark the front of the bolts with paint.

    3. A01EUQQE01
      Text in Illustration
      *a Paint Mark
      A01ETOA Engine Front

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

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

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. Temporarily tighten the pulley set bolt.

    2. A01EV7NE06
      Text in Illustration
      *1 Drive Gear
      *a Front View
      *b No. 1 and No. 4 Crank Pin
      *c Approx. 16°
      *d Timing Mark

      Turn the crankshaft to set the No. 1 cylinder to the TDC position.

      Tech Tips

      Make sure that the timing mark on the balance shaft drive gear is positioned as shown in the illustration.

    3. A01EXK0E02

      Apply seal packing in a continuous bead (diameter: 2.5 to 3.0 mm (0.098 to 0.118 in.)) to the places 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 and tighten the bolts within 15 minutes of applying seal packing.

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

    4. A01EY82E05
      Text in Illustration
      *a Timing Mark
      *b Adjusting Hole

      Install the stiffening crankcase so that the adjusting holes on the balance shafts are positioned as shown in the illustration.

    5. A01EY1YE06

      Apply adhesive to the threads of bolts C and D.

      Item Bolt Length
      A, C 125 mm (4.92 in.)
      B, D 45 mm (1.77 in.)
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Temporarily install the stiffening crankcase assembly with the 11 bolts.

    7. A01EY1YE03

      Uniformly tighten the 11 bolts in the sequence shown in the illustration.

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

    8. Wipe off the excess seal packing with a clean piece of cloth.

    9. A01EURME06
      Text in Illustration
      *1 Key Groove
      *a Approx. 5°
      *b Timing Mark
      *c Adjusting Hole

      Turn the crankshaft to set the No. 1 cylinder to the TDC position. Make sure that the timing marks are aligned as shown in the illustration.

      Tech Tips

      An '○' is stamped as a timing mark.

    10. Remove the pulley set bolt.

  5. INSTALL OIL PUMP ASSEMBLY


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

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

  6. INSTALL REAR ENGINE OIL SEAL


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

      Note

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

    2. A01EVXME01

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

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

      Note


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

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

  7. INSTALL NO. 1 TAPER SCREW PLUG


    1. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. A01EXBJ

      Install the No. 1 taper screw plug to the cylinder block.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  8. INSTALL OIL CONTROL VALVE FILTER


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

    2. A01EV54E04
      Text in Illustration
      *1 Oil Control Valve Filter
      *2 Gasket
      *3 Screw Plug

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

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

  9. INSTALL WATER INLET HOUSING


    1. A01EVA5E06
      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. A01ETQZE06

      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 }

  10. 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.

      A01EYLIE09
      Text in Illustration
      *a LH Side *b Front Side
      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  11. INSTALL WATER INLET HOUSING DRAIN COCK ASSEMBLY


    1. A01EYYLE14
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the water inlet housing drain cock assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01ETTVE01

      Install the water inlet housing drain cock assembly 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 inlet housing drain cock plug to the water inlet housing drain cock assembly.

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

  12. INSTALL CYLINDER BLOCK WATER JACKET SPACER


    1. A01EVRSE03
      Text in Illustration
      *a Slope

      Install the cylinder block 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. A01EWMAE01
      Text in Illustration
      *a 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

    Tech Tips

    The cylinder head set bolts are tightened in 2 progressive steps.


    1. Place the cylinder head sub-assembly on the cylinder head gasket.

      Note

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

    2. Apply a light coat of engine oil to the threads and under the heads of the 10 cylinder head set bolts.

    3. Set the 10 plate washers and 10 cylinder head set bolts.

    4. Step 1:


      1. A01EUV2E02

        Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 cylinder head set bolts in several steps, in the order shown in the illustration.

        Torque:
        70 N*m  { 714 kgf*cm, 51 ft.*lbf }

    5. Step 2:


      1. A01EWDSE08
        Text in Illustration
        *a Paint Mark
        A01ETOA Engine Front

        Mark the front of the cylinder head set bolts with paint.

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

    6. 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. A01EX7ZE12
      Text in Illustration
      *1 O-ring

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

    3. A01EUIP

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

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

  16. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EYUFE11
      Text in Illustration
      *a Straight Pin
      *b Key Groove

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

    2. A01EWSGE01
      Text in Illustration
      *a View A
      *b Straight Pin
      *c Key Groove

      Turn the camshaft timing gear assembly 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 assembly to the retard direction (clockwise).

    3. A01EYC0E08
      Text in Illustration
      *a INCORRECT
      *b CORRECT
      *c Flange

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

    4. A01EXEY

      Tighten the bolt with the camshaft timing gear assembly secured in place.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
    5. A01ETX8E03
      Text in Illustration
      *a Lock

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

  17. INSTALL CAMSHAFT TIMING SPROCKET


    1. A01EWB4

      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. A01ETI3E06
      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. A01EUDRE01

      Install the No. 2 camshaft bearing onto the cylinder head sub-assembly.

  20. INSTALL CAMSHAFT


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

    2. A01EY6D

      Place the camshaft on the cylinder head sub-assembly with the No. 1 cam lobes facing the direction 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. A01EV6S

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

    5. A01EXRHE02
      Text in Illustration
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 3 Camshaft Bearing Cap

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

      Torque:
      No. 1 camshaft bearing cap
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      No. 3 camshaft 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. A01EUMM

      Place the camshaft on the cylinder head sub-assembly with the No. 2 cam lobes facing the direction 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. A01ET81

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

    5. A01EWFLE02
      Text in Illustration
      *1 No. 2 Camshaft Bearing Cap
      *2 No. 3 Camshaft Bearing Cap

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

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

  22. INSTALL CRANKSHAFT PULLEY SET KEY


    1. A01ETLW

      Install the 2 crankshaft pulley set keys to the crankshaft.

  23. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. A01EVG0

      Set the crankshaft key into the left horizontal position.

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

    3. A01EY7GE11
      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 No. 2 chain sub-assembly on the gears.

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

    6. A01EV9BE09
      Text in Illustration
      *1 Spring
      *2 Chain Tensioner Plate
      *3 Bolt

      Insert the chain 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. A01EUSTE09
      Text in Illustration
      *1 Groove

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

    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. A01EWH6

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

  24. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01EZ3R

      Install the crankshaft timing sprocket to the crankshaft.

  25. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. 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. A01EWGNE01
        Text in Illustration
        *a Timing Mark
        *b Front Mark

        Using the hexagonal portion of the camshafts, rotate the camshafts with a wrench, align the timing marks on the camshaft timing gear assembly and camshaft timing sprocket with the front marks located on the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap as shown in the illustration.

      2. A01EYTFE02
        Text in Illustration
        *1 Crankshaft Key
        A01EUL1 Up

        Check that the crankshaft is positioned with the crankshaft key facing up as shown in the illustration.

    2. A01EWD4E08
      Text in Illustration
      *1 Mark Link
      *a Timing Mark

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

    3. A01EVKRE01

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

      SST
      09309-37010
    4. A01EUYUE07
      Text in Illustration
      *1 Mark Link
      *a Timing Mark

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

  27. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper with the bolt.

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

  28. INSTALL TIMING CHAIN GUIDE


    1. 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. A01EUEJ

      Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.

  30. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A01EXJBE03

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

      SST
      09223-22010

    2. Apply a light coat of MP grease to the lip of the timing chain cover oil seal.

      Note

      Keep the gap between the edge of the timing chain cover sub-assembly and the timing chain cover oil seal free of foreign matter.

  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 sub-assembly, cylinder head and cylinder block.

    2. A01EVLYE05

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

      Text in Illustration
      A01EUL1 Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

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

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

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

      A01ESR5E01
      Text in Illustration
      *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.)
      A01ESWR Seal Packing - -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

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

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

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

      Seal packing
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A01EXGRE02
      Text in Illustration
      *1 Nut

      Temporarily install the timing chain cover sub-assembly 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. A01ETQ5E01

      Fully tighten the bolts and nuts in the order shown in the illustration.

      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 }
    7. A01EY5M

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

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

  32. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01EVVME03
      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. A01EUGTE03
      Text in Illustration
      *1 Pin

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

      Torque:
      60 N*m  { 607 kgf*cm, 44 ft.*lbf }

      Note


      • Tighten the bolt and nut within 15 minutes of installing the timing chain cover sub-assembly.

      • 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.

  33. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01EWM0E07
      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. A01ET5H

      Install a new chain tensioner gasket and the No. 1 chain tensioner assembly with the 2 nuts.

      Text in Illustration
      A01EUL1 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.

  34. INSTALL CRANK POSITION SENSOR


    1. A01EX05E12
      Text in Illustration
      *1 New O-ring

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

    2. A01EX86

      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.

  35. 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 sub-assembly.

    2. A01ETAIE07
      Text in Illustration
      *1 Seal Packing
      *a Seal Diameter: 4.0 to 4.5 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 sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.

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

    3. Install the oil pan sub-assembly onto the cylinder block.

    4. A01ETB4E01

      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 }

  36. INSTALL OIL PAN DRAIN PLUG


    1. A01ESP8

      Install the oil pan drain plug with a new gasket.

      Torque:
      40 N*m  { 408 kgf*cm, 29 ft.*lbf }

  37. INSTALL ENGINE WATER PUMP ASSEMBLY


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

    2. A01EUGXE02
      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. A01EY1JE03
      Text in Illustration
      *1 Wire Harness Clamp Bracket

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

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

  38. INSTALL WATER PUMP PULLEY


    1. A01EZ4OE02

      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 }

  39. INSTALL CRANKSHAFT PULLEY


    1. A01EUT8E01

      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. A01EYWCE08
      Text in Illustration
      *1 Hook
      *2 Pin
      *a Turn
      *b Disconnect

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

    3. A01EWTPE11
      Text in Illustration
      *1 Plunger
      *a Extend
      *b Turn

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

  40. CHECK VALVE CLEARANCE


    1. A01EWFGE05
      Text in Illustration
      *a No. 1 Cylinder TDC/Compression
      *b Intake Side
      *c Exhaust Side

      Check only the valves indicated.


      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.

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

    3. A01EY57E07
      Text in Illustration
      *a No. 4 Cylinder TDC/Compression
      *b Intake Side
      *c Exhaust Side

      Check only the valves indicated.


      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.

  41. ADJUST VALVE CLEARANCE


    1. Remove the camshaft Click here.

    2. Remove the valve lifters.

      Tech Tips

      Arrange the valve lifters in the same order as removed.

    3. A01EVM8E01

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

    4. Calculate the thickness of a new lifter so that the valve clearance comes within the specified range.

      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 (0.207 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 (0.207 in.) = 5.410 mm (0.2130 in.)

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


        • Select No. 42 lifter

    5. A01ETL3E01

      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.).

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

    6. Valve lifter selection chart (intake).

      A01EYFWE02
      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:

      A 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.

    7. Valve lifter selection chart (exhaust).

      A01EYZPE01
      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:

      A 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.

    8. Install the selected valve lifter.

    9. Install the camshaft Click here.

  42. INSTALL CAMSHAFT POSITION SENSOR


    1. A01EUJFE09
      Text in Illustration
      *1 O-ring

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

    2. A01EZ0H

      Install the camshaft position sensor with the bolt.

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

  43. INSTALL CYLINDER HEAD COVER GASKET


    1. A01EYATE01

      Install a new cylinder head cover gasket onto the cylinder head cover sub-assembly.

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


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

    2. A01EWD3E01
      Text in Illustration
      *a 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 sub-assembly within 3 minutes of applying seal packing.

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

    3. A01EUK3E04
      Text in Illustration
      *1 Nut

      Install the cylinder head cover sub-assembly 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 }

  45. INSTALL OIL FILTER UNION


    1. A01EV14

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

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }

  46. 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  { 173 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.

  47. INSTALL SPARK PLUG


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

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

  48. 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 ball joint lock nut wrench (22 mm), install the ventilation valve sub-assembly.

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

      Note

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a ball joint lock nut wrench Click here.

  49. INSTALL OIL FILLER CAP GASKET


    1. A01EX3S

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

  50. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A01EVBX

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