ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tip:

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

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PROCEDURE

  1. INSTALL STIFFENING CRANKCASE RING PIN

    A152991C06

    *a

    Protrusion Height

    *b

    Width

    *c

    Height
    Note:

    It is not necessary to remove a stiffening crankcase ring pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in 2 new stiffening crankcase ring pins until they are seated.

      Standard Ring Pin

      Item

      Protrusion Height

      Height

      Width

      Stiffening crankcase ring pin

      3.0 mm (0.118 in.)

      8 mm (0.315 in.)

      11 mm (0.433 in.)

  2. INSTALL STIFFENING CRANKCASE STUD BOLT

    A289827N02
    Note:

    If a stiffening crankcase stud bolt is deformed or the threads are damaged, replace it.

    1. Using an E6 "TORX" socket wrench, install the stiffening crankcase stud bolts as shown in the illustration.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY

    1. A150919N07

      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

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      A

      4.5 to 5.5 mm (0.177 to 0.217 in.)

      Application Length A

      56 mm (2.20 in.)

      Note:

      • Remove any oil from the contact surfaces.

      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.

    2. A152989N08

      Install the stiffening crankcase assembly with the 11 bolts in the sequence order shown in the illustration.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      Bolt Length

      Item

      Specified Condition

      Bolt A

      138 mm (5.43 in.)

      Bolt B

      35 mm (1.38 in.)

      Bolt C

      70 mm (2.76 in.)

    3. Recheck the torque for the bolts (1) and (2).

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    4. Wipe off any excess seal packing with a clean piece of cloth.

  4. INSTALL OIL PUMP ASSEMBLY

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  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

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  6. INSTALL OIL PAN DRAIN PLUG

    1. A150893

      Install a new gasket and the oil pan drain plug.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

  7. INSTALL REAR ENGINE OIL SEAL

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  8. INSTALL NO. 1 TAPER SCREW PLUG

    1. A235914N05

      Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).

      25 N*m

      255 kgf*cm

      18 ft.*lbf

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note:

      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine at least 1 hour after installing the plug.

    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (B).

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note:

      • Install the plug within 3 minutes of applying adhesive.

      • Do not start the engine at least 1 hour after installing the No. 1 taper screw plug.

  9. INSTALL VENTILATION VALVE SUB-ASSEMBLY

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  10. INSTALL CYLINDER HEAD GASKET

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  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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  12. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A206181C01

    *a

    Protrusion Height

    *b

    Height

    *c

    Width
    Note:

    It is not necessary to remove a camshaft housing straight pin unless it is being replaced.

    1. Using a plastic-faced hammer, tap in a new camshaft housing straight pin to the specified protrusion height.

      Standard Straight Pin

      Item

      Protrusion Height

      Height

      Width

      Camshaft housing straight pin

      6.5 to 7.5 mm (0.256 to 0.295 in.)

      14 mm (0.551 in.)

      6.0 mm (0.236 in.)

  13. INSTALL CAMSHAFT HOUSING STUD BOLT

    A173608N03
    Note:

    If a camshaft housing stud bolt is deformed or the threads are damaged, replace it.

    1. Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.

      9.5 N*m

      97 kgf*cm

      84 in.*lbf

  14. INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY

    1. A209173C01

      *1

      Filter

      *a

      Protrusion

      Install a new O-ring to the continuously variable valve lift controller assembly.

      Note:

      • Align the protrusion of the O-ring with the protrusion of the continuously variable valve lift controller assembly.

      • Make sure that the O-ring is not protruding from the groove in the continuously variable valve lift controller assembly.

      • Make sure that the filter is securely attached in the continuously variable valve lift controller assembly.

    2. A173632

      Install the control actuator clip to the valve lift control actuator connector.

      Tip:

      When the continuously variable valve lift controller assembly is new, a valve lift control actuator connector is attached to it. Remove the valve lift control actuator connector before performing work.

      Note:

      Be sure to insert the protrusions of the control actuator clip into the holes in the valve lift control actuator connector.

    3. A173788

      Install the valve lift control actuator connector to the valve rocker shaft and rotate the valve lift control actuator connector as shown in the illustration.

    4. Insert the continuously variable valve lift controller assembly into the camshaft housing sub-assembly.

    5. A209172

      Install the continuously variable valve lift controller assembly to the camshaft housing sub-assembly with the bolt.

      18 N*m

      184 kgf*cm

      13 ft.*lbf

      Note:

      Do not let the O-ring become pinched between parts.

    6. A173790

      Using a screwdriver, slide the control actuator clip from the valve lift control actuator connector.

    7. Slide only the upper part of the control actuator clip as the straight pin may fall if the control actuator connector clip is completely removed.

    8. A233492

      Using a screwdriver, lightly pry the valve lift control actuator connector and align the hole in the valve lift control actuator connector with the hole in the continuously variable valve lift controller assembly.

      Note:

      • Do not forcibly pry the valve lift control actuator connector.

      • Do not damage the camshaft housing sub-assembly or camshaft bearing cap.

    9. A173792

      Insert the straight pin into the valve lift control actuator connector.

      Note:

      Do not use a tool to insert the straight pin. Insert the straight pin by hand.

      Tip:

      If the straight pin is difficult to insert, insert the straight pin while lightly prying the valve lift control actuator connector.

    10. Using a screwdriver, install the control actuator clip to the valve lift control actuator connector.

      Note:

      Insert the protrusion of the control actuator clip into the hole in the valve lift control actuator connector.

  15. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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  16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  17. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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  18. INSTALL CRANKSHAFT TIMING GEAR KEY

    1. A150910

      Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

      Tip:

      Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

  19. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. A150874

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

  20. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

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  21. INSTALL CRANKSHAFT TIMING SPROCKET

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  22. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  24. INSTALL CHAIN SUB-ASSEMBLY

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  25. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

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  26. INSTALL CHAIN TENSIONER SLIPPER

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  27. INSTALL NO. 1 GENERATOR BRACKET

    1. A150905

      Install the No. 1 generator bracket with the 4 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  28. INSTALL WATER INLET HOUSING STUD BOLT

    A150941N04
    Note:

    If a water inlet housing stud bolt is deformed or the threads are damaged, replace it.

    1. Using an E5 "TORX" socket wrench, install the water inlet housing stud bolts as shown in the illustration.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  29. INSTALL WATER INLET HOUSING

    1. A150906

      Install a new gasket and the water inlet housing with the 3 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  30. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  31. INSTALL TIMING CHAIN COVER OIL SEAL

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  32. INSTALL CRANKSHAFT PULLEY

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  33. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  34. INSTALL OIL FILTER CAP ASSEMBLY

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  35. INSTALL SPARK PLUG TUBE GASKET

    1. A153838C02

      *a

      Part to Cut Off

      Using a cutter knife, cut off the seal part of the removed spark plug tube gasket.

    2. A179168C04

      *a

      Claw

      *1

      Spark Plug Tube Gasket without Seal Part

      *2

      New Spark Plug Tube Gasket

      Using a hammer and the spark plug tube gasket which has had the seal part cut off, uniformly tap in a new spark plug tube gasket all the way.

      Note:

      • Keep the lip free of foreign matter.

      • Do not tap the new spark plug tube gasket.

      Tip:

      If a spark plug tube gasket that will be used to install a new spark plug tube gasket is deformed, and cannot be positioned on a new spark plug tube gasket, correct the deformation using pliers.

    3. Return the claws of the ventilation baffle plate to their original positions.

  36. INSTALL CYLINDER HEAD COVER GASKET

    1. A179166

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

      Note:

      Remove any oil from the contact surfaces.

  37. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A165301

      Install 3 new gaskets to the camshaft bearing cap.

    2. A165302

      Apply seal packing as shown the illustration.

      Seal packing

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

      Standard diameter

      4.0 mm (0.157 in.)

      Note:

      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

    3. A173472

      Install the cylinder head cover sub-assembly with a new seal washer and the 13 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  38. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  39. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    1. A214078

      Install a new gasket and the engine coolant temperature sensor.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

      Tip:

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

      Click hereClick here

  40. INSTALL KNOCK CONTROL SENSOR

    1. A150904N06

      Install the knock control sensor with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      Note:

      Make sure that the knock control sensor is in the correct position.

  41. INSTALL CRANKSHAFT POSITION SENSOR

    1. A157503

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

    2. A150855

      Install the crankshaft position sensor with the bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  42. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. A195062

      Apply a light coat of engine oil to 2 new O-rings and install them to the camshaft timing oil control valve assemblies.

    2. A150849C02

      *a

      Bracket

      Install the 2 camshaft timing oil control valve assemblies and bracket with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Note:

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing oil control valve assembly (surface with cylinder head cover sub-assembly).

      • Make sure that the O-ring is not cracked or moved out of place when installing the camshaft oil control valve assembly.

  43. INSTALL CAMSHAFT POSITION SENSOR

    1. A095434

      Apply a light coat of engine oil to the O-rings of the camshaft position sensors.

    2. A150848

      Install the 2 camshaft position sensors with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Note:

      Make sure that the O-ring is not cracked or pinched when installing the camshaft position sensor.

  44. INSTALL SPARK PLUG

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  45. INSTALL ENGINE COVER JOINT

    1. A150847

      Install the 2 engine cover joints.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  46. INSTALL OIL FILLER CAP GASKET

    1. A128159

      Install the oil filler cap gasket to the oil filler cap.

  47. INSTALL OIL FILLER CAP SUB-ASSEMBLY

    1. A173599

      Install the oil filler cap sub-assembly.