ENGINE UNIT REASSEMBLY

PROCEDURE

  1. INSTALL CYLINDER BLOCK WATER JACKET SPACER

    1. A324425

      Install the cylinder block water jacket spacer to the cylinder block sub-assembly.

  2. INSTALL CYLINDER HEAD GASKET

    Click here

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  4. INSTALL VALVE LIFTER

    1. A324329

      Apply engine oil to the circumference of the valve lifters.

    2. Install the valve lifters to the lifter holes.

      Note:

      Check that the valve lifters turn smoothly after installing them.

  5. INSTALL STUD BOLT

    Tip:

    Perform this procedure only when replacement of the stud bolt is necessary.

    1. A324327

      Using an E6 "TORX" socket wrench, install the stud bolt to the rear engine oil seal retainer.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  6. INSTALL REAR ENGINE OIL SEAL

    A235330C03
    V100144

    Apply engine oil

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

    2. A324341N02

      Using SST, tap in the rear engine oil seal.

      09223-15020

      09950-70010

      09951-07200

      Standard Depth

      -1.0 to 0.5 mm (-0.0394 to 0.0197 in.)

      Note:

      • Keep the lip free from foreign matter.

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

  7. INSTALL REAR ENGINE OIL SEAL RETAINER

    1. A324342C01

      *a

      Seal Packing (3.0 to 4.0 mm (0.118 to 0.157 in.))

      Apply a continuous bead of seal packing to the rear engine oil seal retainer as shown in the illustration.

      Seal Packing

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

    2. A324326

      Install the rear engine oil seal retainer with the 4 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Note:

      • Install the rear engine oil seal retainer 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 installation.

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

  8. INSTALL CAMSHAFT

    1. A324321C02
      V100135

      Turn

      Before installing the camshaft, set the No. 1 piston to TDC/exhaust, and then turn the crankshaft approximately 90° clockwise so that a lifted valve and piston do not touch each other when the camshaft and No. 2 camshaft are installed.

    2. A324343C01

      *a

      Apply engine oil

      Apply engine oil to the contact areas of the cams and journals of the camshaft and No. 2 camshaft.

    3. A324501C02

      *1

      Camshaft

      *a

      No. 1 Cylinder

      *b

      No. 3 Cylinder

      Install the camshaft as shown in the illustration.

  9. INSTALL NO. 2 CAMSHAFT

    1. A324502C02

      *1

      No. 2 Camshaft

      *a

      No. 1 Cylinder

      *b

      No. 2 Cylinder

      Install the No. 2 camshaft as shown in the illustration.

  10. INSTALL CAMSHAFT BEARING CAP

    1. A324344C02

      *1

      No. 1 Camshaft Bearing Cap

      *2

      No. 2 Camshaft Bearing Cap

      Set the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps.

      Note:

      • Install the camshaft bearing caps with the front marks facing the front of the engine.

      • Install the bolts to the correct positions by referring to the numbers inscribed on the bolts and the following table.

      Table 1. Installation Position of No. 2 Bearing Cap

      Installation Position

      Inscribed No.

      Intake No. 1 cylinder

      I2

      Intake No. 2 cylinder

      I3

      Intake No. 3 cylinder

      I4

      Exhaust No. 1 cylinder

      E2

      Exhaust No. 2 cylinder

      E3

      Exhaust No. 3 cylinder

      E4
    2. A324345N01

      Install the bolts in the order shown in the illustration.

      No. 1 Camshaft Bearing Cap

      15 N*m

      153 kgf*cm

      11 ft.*lbf

      No. 2 Camshaft Bearing Cap

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

  11. INSTALL CAMSHAFT TIMING GEAR

    1. A324346

      Insert the camshaft timing gear so that the knock pin on the No. 2 camshaft end fits into the groove.

    2. A324347

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt to install the camshaft timing gear.

      47 N*m

      479 kgf*cm

      35 ft.*lbf

  12. INSTALL CAMSHAFT TIMING SPROCKET ASSEMBLY

    1. A324348C01
      V100135

      Apply engine oil

      Apply engine oil to the camshaft timing sprocket installation portion of the camshaft.

    2. A324349

      Insert the knock pin on the camshaft end into the pin hole in the camshaft timing sprocket assembly.

      Note:

      • Slightly turn the camshaft timing sprocket assembly to make sure that the knock pin is securely inserted after installing the camshaft timing sprocket assembly.

      • The end surface of the camshaft timing sprocket assembly may be damaged if the camshaft timing sprocket assembly is turned with excessive force when the knock pin is not inserted into the pin hole.

    3. A324350

      Using a wrench to hold the hexagonal portion of the camshaft, tighten the bolt to install the camshaft timing sprocket assembly.

      47 N*m

      479 kgf*cm

      35 ft.*lbf

  13. INSTALL CRANKSHAFT STRAIGHT PIN

    1. A324320

      Install the crankshaft straight pin into the crankshaft groove.

  14. INSTALL CRANKSHAFT TIMING SPROCKET

    1. A324351

      Align the groove of the crankshaft timing sprocket with the key of the crankshaft and install the crankshaft timing sprocket.

  15. INSTALL TIMING CHAIN GUIDE

    1. A324318

      Install the timing chain guide with the 2 bolts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  16. INSTALL CHAIN SUB-ASSEMBLY

    1. A324561C01

      *a

      Mark Plate (Yellow)

      *b

      Timing Mark

      Align the mark plate (yellow) with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly as shown in the illustration.

    2. A105062C08

      *a

      Timing Mark

      *b

      Mark Plate (Orange)

      Align the 2 mark plates (orange) with the timing marks of the camshaft timing sprocket assembly and camshaft timing gear, and install the chain sub-assembly as shown in the illustration.

  17. INSTALL TIMING CHAIN TENSION ARM

    1. A324317

      Install the timing chain tension arm with the bolt.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

  18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A324352C02
      V100135

      Turn

      Using a wrench, slightly turn the hexagonal portion of the camshaft assembly (intake side) counterclockwise so that there is some slack in the chain sub-assembly on the No. 1 chain tensioner assembly side.

    2. A324625

      Install a new chain tensioner gasket to the No. 1 chain tensioner assembly.

    3. A324353C02

      *a

      Hexagon Wrench

      Temporarily install the No. 1 chain tensioner assembly and chain tensioner gasket to the cylinder block sub-assembly with the 2 bolts and then tighten the 2 bolts in the order shown in the illustration.

      10.5 N*m

      107 kgf*cm

      8 ft.*lbf

    4. Remove the hexagon wrench, turn the crankshaft 2 complete revolutions and adjust the chain tension.

    5. A324312C02

      *a

      Timing Mark

      Make sure that the timing mark of the camshaft timing gear is at the top with the chain sub-assembly tensioned (set No. 1 piston to TDC/ exhaust).

  19. INSTALL TIMING CHAIN COVER OIL SEAL

    A104994C04
    V100145

    Apply engine oil

    1. Apply engine oil to the lip of a new timing chain cover oil seal.

    2. A324480N01

      Using SST and a hammer, tap in the timing chain cover oil seal as shown in the illustration.

      09950-60010

      09951-00500

      09952-06010

      09950-70010

      09951-07200

      Standard Depth

      -1.0 to 0.5 mm (-0.0394 to 0.0197 in.)

      Note:

      Do not tap in the timing chain cover oil seal at an angle.

  20. INSTALL STUD BOLT

    Tip:

    Perform this procedure only when replacement of the stud bolt is necessary.

    1. A324481C01

      *a

      Adhesive 1324

      Apply adhesive to 2 or 3 threads (timing chain cover sub-assembly side) of the 2 stud bolts.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. A324478

      Install the 2 stud bolts to the timing chain cover sub-assembly.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  21. INSTALL VENTILATION CASE SUB-ASSEMBLY

    1. A324476

      Install the ventilation case sub-assembly to the timing chain cover sub-assembly with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  22. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  23. INSTALL CYLINDER BLOCK DRAIN COCK PLUG

    1. A324313

      Install a new gasket and the cylinder block drain cock plug.

      17.5 N*m

      178 kgf*cm

      13 ft.*lbf

  24. INSTALL TIMING GEAR COVER TIGHT PLUG

    Click here

  25. INSTALL CRANKSHAFT PULLEY

    Click here

  26. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  27. INSTALL THERMOSTAT

    Click here

  28. INSTALL WATER INLET

    Click here

  29. INSTALL OIL STRAINER SUB-ASSEMBLY

    1. A324301

      Install a new oil strainer gasket to the oil strainer sub-assembly.

    2. A324300

      Install the oil strainer sub-assembly to the timing chain cover sub-assembly with the 3 bolts.

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

  30. INSTALL RING PIN

    Tip:

    Perform this procedure only when replacement of the ring pin is necessary.

    1. A324415C02

      *a

      Protrusion Height

      Using a plastic hammer, tap in 2 new ring pins to the specified protrusion height.

      Protrusion Height

      3.0 to 5.0 mm (0.118 to 0.197 in.)

  31. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    1. A324303

      Install the No. 2 oil pan sub-assembly to the oil pan sub-assembly with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  32. INSTALL NO. 1 OIL PAN BAFFLE PLATE

    1. A324302

      Temporarily install the No. 1 oil pan baffle plate to the No. 2 oil pan sub-assembly with the 4 bolts.

    2. A324416N01

      Temporarily tighten the bolt (A), then tighten the bolt (B).

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    3. A324417

      Tighten the 3 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  33. INSTALL OIL PAN SUB-ASSEMBLY

    Click here

  34. INSTALL OIL PAN DRAIN PLUG

    A322752

    1. Install a new oil pan drain plug gasket and the oil pan drain plug.

      29.5 N*m

      301 kgf*cm

      22 ft.*lbf

  35. INSTALL GROMMET

    1. A324494

      Install the 2 grommets to the cylinder head cover sub-assembly.

  36. INSTALL VENTILATION SYSTEM GROMMET

    Click here

  37. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  38. INSTALL VENTILATION HOSE

    Click here

  39. INSTALL CYLINDER HEAD COVER GASKET

    1. A323235C01

      *a

      Boss

      Install a new cylinder head cover gasket into the groove of the cylinder head cover sub-assembly and to the center bosses.

      Note:

      Insert the cylinder head cover gasket securely into the bosses.

  40. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. Clean the cylinder head cover sub-assembly, cylinder head sub-assembly and timing chain cover sub-assembly.

    2. A324421C02

      *a

      Seal Packing

      *b

      Diameter

      Apply a continuous bead of seal packing to the contact surface between the cylinder head sub-assembly and timing chain cover sub-assembly as shown in the illustration.

      Seal Packing

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

      Standard Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note:

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

    3. A323234N01

      Temporarily install the cylinder head cover sub-assembly with the 16 bolts.

    4. Fully tighten the 16 bolts in the order shown in the illustration.

      7.7 N*m

      79 kgf*cm

      68 in.*lbf

  41. INSTALL OIL FILLER CAP SUB-ASSEMBLY

    1. A324292

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

    2. A324291

      Install the oil filler cap sub-assembly.

  42. INSTALL OIL CONTROL VALVE FILTER

    A322749C01

    *1

    Oil Control Valve Filter

    *2

    Gasket

    *3

    Head Taper Screw Plug

    1. Install the oil control valve filter to the head taper screw plug.

    2. A258551C01

      *a

      8 mm Hexagon Socket Wrench

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

      24.5 N*m

      250 kgf*cm

      18 ft.*lbf

  43. INSTALL KNOCK CONTROL SENSOR

    Click here

  44. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  45. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  46. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  47. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  48. INSTALL CAMSHAFT POSITION SENSOR

    Click here

  49. INSTALL SPARK PLUG

    Click here

  50. INSTALL WATER BY-PASS PIPE

    1. A324562C02

      *a

      Folded Tab

      *b

      Apply water

      Install 2 new water by-pass pipe gaskets to the water by-pass pipe as shown in the illustration.

      Note:

      Install the water by-pass pipe gasket with its folded tab towards the water by-pass pipe.

      Tip:

      Apply water to the water by-pass pipe before installing the water by-pass gaskets to the water by-pass pipe.

    2. A324304N01

      Temporarily install the water by-pass pipe with the 3 bolts.

    3. Fully tighten the 3 bolts in the order shown in the illustration.

      24 N*m

      245 kgf*cm

      18 ft.*lbf