ENGINE UNIT REASSEMBLY

INSTALL OIL FILTER CAP ASSEMBLY

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

   

   Text in Illustration

   *1	O-ring
   *a	Correct
   *b	Incorrect

   Note

   • Be sure to install the O-ring in the proper location, otherwise oil may leak.

   • Do not twist the O-ring.

3. Set a new oil filter element into the oil filter cap assembly.

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

5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap assembly.

   Note

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

6. Using SST, tighten the oil filter cap assembly.

   

   Text in Illustration

   *1	Oil Filter Cap Assembly
   *2	O-ring
   *3	Oil Filter Bracket
   *a	No Gap

   SST

   09228-06501

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Note

   After tightening the oil filter cap assembly, make sure that there is no gap and that the O-ring is not protruding.

7. Apply a small amount of engine oil to a new O-ring, and install it to the oil filter cap assembly.

   

   Text in Illustration

   *1

   O-ring

   Note

   Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap assembly.

8. Install the oil filter drain plug.

   Torque:

   13 N*m  { 127 kgf*cm, 10 ft.*lbf }

   Note

   Be careful that the O-ring does not get caught between any surrounding parts.

INSTALL REAR ENGINE 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   ( 09951-07150 )

   Note

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

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

INSTALL CYLINDER HEAD GASKET

1. Clean the cylinder block and cylinder head with solvent.

   

   Text in Illustration

   *1	Cylinder Head Gasket
   *2	Cylinder Block
   *a	Lot No.
   *b	3.0 mm or more
   *c	20 mm or more
   	Seal Packing
   	Front

2. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

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

   Standard seal dimension
   3.0 to 7.0 mm (0.118 to 0.276 in.) wide and 3.0 mm (0.118 in.) thick

   Tech Tips

   Apply at least 20 mm (0.787 in.) of seal packing from the inside edge of the protrusion of the cylinder block.

   Note

   • Remove any oil from the contact surface.

   • Install the cylinder head gasket within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

   Note

   Pay attention to the installation direction.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

1. Place the cylinder head on the cylinder block.

   Note

   • Ensure 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:

      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

      Note

      Do not drop the plate washer for the cylinder head bolt into the cylinder head.

5. Step 2:

   1. Tighten the cylinder head bolts again in the sequence shown in the illustration to make sure that they are tightened to the specified torque.

      Torque:

      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

6. Step 3:

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

      

      Text in Illustration

      	Front
      *a	Painted Mark

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

7. Step 4:

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

   2. Check that the paint marks are now facing rearward.

      Note

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

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

      • After installation, if the seal packing has seeped out, wipe it off.

      Tech Tips

      Perform "Inspection After Repair" after replacing the cylinder head sub-assembly Click here.

INSTALL CAMSHAFT

1. Clean the camshaft journals, camshaft housing and bearing caps.

2. Apply a light coat of engine oil to the camshaft journal, camshaft housing and bearing caps.

3. Install the camshaft and No. 2 camshafts to the camshaft housing.

   Tech Tips

   Perform "Inspection After Repair" after replacing the camshaft or No. 2 camshaft Click here.

INSTALL CAMSHAFT BEARING CAP

1. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

   

2. Install the 11 bolts in the order shown in the illustration.

   

   Torque:

   16 N*m  { 163 kgf*cm, 12 ft.*lbf }

   Note

   Make sure that the camshaft rotates smoothly after installing the bearing caps.

INSTALL VALVE STEM CAP

1. Apply a light coat of engine oil to the valve stem ends.

2. Install the 16 valve stem caps to the cylinder head.

   Note

   Do not drop the valve stem caps into the cylinder head.

INSTALL VALVE LASH ADJUSTER ASSEMBLY

1. Inspect the valve lash adjuster before installing it Click here.

2. Install the 16 lash adjusters to the cylinder head.

   Note

   Install the lash adjuster to the same place it was removed from.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

1. Apply engine oil to the lash adjuster tips and valve stem caps.

   

   Text in Illustration

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

2. Install the 16 valve rocker arms as shown in the illustration.

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

1. Check that the valve rocker arms are installed as shown in the illustration.

   

   Text in Illustration

   *1	Valve Rocker Arm
   *2	Valve Stem Cap
   *3	Valve Lash Adjuster
   *a	INCORRECT
   *b	CORRECT

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
   3.0 to 4.0 mm (0.118 to 0.157 in.)

   Note

   • Remove any oil from the contact surface.

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

3. Position the knock pin of the No. 1 and No. 2 camshafts as shown in the illustration.

   

   Text in Illustration

   *1	Knock Pin
   *a	Approximately 17°
   *b	Approximately 2°

4. Install the camshaft housing, and then install the 20 bolts in the order shown in the illustration.

   

   Torque:

   27 N*m  { 275 kgf*cm, 20 ft.*lbf }

   Note

   • Do not apply oil for at least 2 hours after the installation.

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

   • Thoroughly wipe clean any seal packing.

INSTALL CAMSHAFT TIMING SPROCKET

1. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, and install the camshaft timing sprocket with the bolt.

   

   Text in Illustration

   *a	Hold
   *b	Turn

   Torque:

   85 N*m  { 867 kgf*cm, 63 ft.*lbf }

   Note

   Be careful not to damage the cylinder head or spark plug tube with the wrench.

INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

1. Check the camshaft timing gear position.

   

   Text in Illustration

   *1	Knock Pin Hole
   *2	Alignment Mark

   If the camshaft timing gear is not set to the advanced position, release the lock pin and reset the camshaft timing gear (Refer to the "Set Camshaft Timing Gear Assembly" procedure").

2. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

   

   Text in Illustration

   *1	Pin Hole
   *2	Knock Pin

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

   

   Text in Illustration

   *1	Camshaft Timing Gear
   *2	Flange
   *a	INCORRECT
   *b	CORRECT
   *c	Clearance
   *d	No Clearance

4. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the bolt.

   

   Text in Illustration

   *a	Hold
   *b	Turn

   Torque:

   85 N*m  { 867 kgf*cm, 63 ft.*lbf }

   Note

   • Be careful not to damage the cylinder head or spark plug tube with the wrench.

   • Do not disassemble the camshaft timing gear.

   Tech Tips

   Perform "Inspection After Repair" after replacing the camshaft timing gear assembly Click here.

ADD ENGINE OIL

1. Add 50 cc (3.1 cu. in) of engine oil into the oil hole shown in the illustration.

   

   Note

   • Oil must be added if the lash adjusters were removed.

   • Make sure that the low pressure chamber and oil paths of the lash adjusters are full of engine oil.

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 }

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

   

2. Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.

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

   

   Text in Illustration

   *a	Timing Mark
   *b	Approximately 7°
   *c	Approximately 32°

   Tech Tips

   "A" is not a timing mark.

INSTALL CHAIN SUB-ASSEMBLY

1. Place the chain onto the camshaft timing gears and crankshaft timing sprocket.

   Tech Tips

   • Make sure the mark plate of the chain faces away from the engine.

   • It is not necessary to install the chain to the teeth of the gears and sprocket.

2. Align the mark plate (yellow or gold) of the chain with the timing mark of the camshaft timing sprocket and install the chain to the camshaft timing sprocket.

   

   Text in Illustration

   *a	Mark Plate
   *b	Timing Mark

3. Align the mark plate (pink or gold) of the chain with the timing mark of the crankshaft timing sprocket and install the chain to the crankshaft timing sprocket.

   

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

4. Tie a string above the crankshaft timing sprocket so that the chain is secure.

   

5. Using the hexagonal portion of the intake camshaft, rotate the intake camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear with the mark plate (yellow or gold) of the chain and install the chain to the camshaft timing gear.

   

   Text in Illustration

   *1	Mark Plate
   *2	Timing Mark

   Tech Tips

   Hold the intake camshaft in place with a wrench until the chain tensioner is installed.

6. Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain so that the chain tensioner slipper can be installed.

   

   Note

   Make sure the chain is secure.

INSTALL CHAIN TENSIONER SLIPPER

1. Install the chain tensioner slipper with the bolt.

   

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

1. Install a new gasket and the chain tensioner with the 2 bolts.

   

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Remove the pin from the stopper plate.

INSTALL TIMING CHAIN GUIDE

1. Install the timing chain guide with the bolt.

   

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

   

   Text in Illustration

   *a	Approximately 7°	*b	Approximately 32°
   *c	Timing Mark	*d	Crankshaft pulley set key

2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

   Tech Tips

   "A" is not a timing mark.

3. Remove the crankshaft pulley bolt.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

1. Apply a light coat of engine oil to 3 new gaskets.

   

2. Install the 3 gaskets to the stiffening crankcase assembly.

3. Align the drive rotor spline and the crankshaft timing sprocket as shown in the illustration.

   

   Text in Illustration

   *1	Drive Rotor Spline
   *2	Crankshaft Timing Sprocket

4. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.

   

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

   Apply Seal Packing as Follows

   Area Seal Packing Diameter (Round) Distance from Edge of Cover to Center of Seal Packing Seal Packing Application Length Seal Pacing Dimension (Flat) Dashed Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) - - A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.5 mm (0.0984 in.) - - B - B 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 28 mm (1.10 in.) 7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick C - C 7.0 mm (0.276 in.) 5.0 mm (0.197 in.) 25 mm (0.984 in.) 13.0 mm (0.512 in.) or more wide and 3.0 mm (0.118 in.) or more thick D - D 5.0 mm (0.197 in.) 3.0 mm (0.118 in.) 26 mm (1.02 in.) 7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick E 2.5 to 3.5 mm (0.0984 to 0.138 in.) 3.0 mm (0.118 in.) - -

   Note

   • When there is oil on the contact surfaces, clean the surfaces with non-residue solvent before applying seal packing.

   • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

   • After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

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

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

5. Temporarily install the timing chain cover sub-assembly with the 17 bolts and 2 nuts.

   

   Text in Illustration

   *1

   Nut

   -

   -

   Bolt Length
   Item Length Thread Diameter Bolt A 30 mm (1.18 in.) 8 mm (0.315 in.) Bolt B 35 mm (1.38 in.) 10 mm (0.394 in.) Bolt C 45 mm (1.77 in.) 8 mm (0.315 in.)

   Note

   Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

6. Tighten the 17 bolts and 2 nuts in several steps, in the order shown in the illustration.

   Torque:

   for bolt A, C, and Nut

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

   for bolt B

   55 N*m  { 561 kgf*cm, 41 ft.*lbf }

INSTALL ENGINE MOUNTING BRACKET RH

1. Install the engine mounting bracket RH with the 5 bolts in the order shown in the illustration.

   

   Torque:

   for bolt 1, 2 and 3

   55 N*m  { 561 kgf*cm, 41 ft.*lbf }

   for bolt 4 and 5

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

   Note

   After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.

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

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

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

INSTALL CRANKSHAFT POSITION SENSOR

1. Clean and degrease the threads of the bolt for the crankshaft position sensor.

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

   

   Text in Illustration

   *1

   O-ring

3. Apply adhesive to 2 or 3 threads of the bolt.

   

   Text in Illustration

   *1

   Adhesive

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

4. Install the sensor with the bolt.

   Torque:

   6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

   Note

   Make sure that the O-ring is not cracked or does not jump out of position during installation.

5. Connect the sensor connector.

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 19 mm deep socket wrench, install the ventilation valve sub-assembly.

   Torque:

   27 N*m  { 275 kgf*cm, 20 ft.*lbf }

3. Install the No. 2 ventilation hose.

INSTALL CAMSHAFT POSITION SENSOR

1. Clean and degrease the threads of the bolt for the camshaft position sensor.

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

   Note

   Make sure that the O-ring is not cracked or does not jump out of position during installation.

3. Apply adhesive to 2 or 3 threads of the bolt.

   

   Text in Illustration

   *1

   Adhesive

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

4. Install the sensor with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

5. Connect the sensor connector.

INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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

   

   Text in Illustration

   *1	New O-ring

2. Install the oil control valve with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   • Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover).

   • Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.

3. Connect the oil control valve connector.

INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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

   

   Text in Illustration

   *1

   Adhesive

   Adhesive
   TOYOTA Genuine Adhesive 1344, Three Bond 1344 or equivalent.

   Note

   Do not let adhesive adhere to the oil hole.

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

   Torque:

   15 N*m  { 153 kgf*cm, 11 ft.*lbf }

   Note

   Do not start the engine within 1 hour of installation.

3. Connect the connector.

INSTALL ENGINE COOLANT TEMPERATURE SENSOR

1. Install a new gasket to the engine coolant temperature sensor.

2. Using a 19 mm ball joint lock nut wrench, install the engine coolant temperature sensor.

   Torque:

   20 N*m  { 204 kgf*cm, 15 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.

   Tech Tips

   Perform "Inspection After Repair" after replacing the engine coolant temperature sensor Click here.

3. Connect the engine coolant temperature sensor connector.

4. Install the wire harness with the 2 bolts.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

5. Connect the ventilation hose to the cylinder head cover.

INSTALL KNOCK CONTROL SENSOR

1. Install the sensor with the bolt so that the sensor is angled as shown in the illustration.

   

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   Text in Illustration

   *a	Front of Engine
   *b	Up
   *c	7°
   *d	10°

   Note

   The acceptable installation angle of the sensor is between 7° upward and 10° downward from the horizontal position.

   Tech Tips

   Perform "Inspection After Repair" after replacing the knock control sensor Click here

2. Connect the sensor connector.

INSTALL SPARK PLUG

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

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Tech Tips

   Perform "Inspection After Repair" after replacing the spark plug Click here.