ENGINE UNIT REASSEMBLY
PROCEDURE
INSTALL STIFFENING CRANKCASE RING PIN
*a
Protrusion Height
Note:It is not necessary to remove the ring pin unless it is being replaced.
Using a plastic-faced hammer, tap in 2 new ring pins until they stop.
Standard protrusion height
4.3 to 5.3 mm (0.169 to 0.209 in.)
INSTALL STIFFENING CRANKCASE STUD BOLT
Note:If a stud bolt is deformed or its threads are damaged, replace it.
Using an E5 and E8 "TORX" socket wrench, install the stud bolts.
*a
Front Side
*b
Lower Side
*c
20 mm (0.787 in.)
*d
35 mm (1.38 in.)
*e
13 mm (0.512 in.)
*f
8.5 mm (0.335 in.)
*g
18 mm (0.709 in.)
*h
8.0 mm (0.315 in.)
for stud bolt A
9.5 N*m
97 kgf*cm
84 in.*lbf
for stud bolt B
4.0 N*m
41 kgf*cm
35 in.*lbf
INSTALL CYLINDER BLOCK STUD BOLT
-
*a
46 mm (1.81 in.)
*b
19 mm (0.748 in.)
*c
67 mm (2.64 in.)
Using an E10 "TORX" socket wrench, install the stud bolts.
15 N*m
153 kgf*cm
11 ft.*lbf
-
*a
14 mm (0.551 in.)
*b
13 mm (0.512 in.)
*c
29 mm (1.14 in.)
w/ EGR System:
Using an E8 "TORX" socket wrench, install the stud bolt.
9.5 N*m
97 kgf*cm
84 in.*lbf
Tip:The stud bolt may be installed at either A or B.
-
INSTALL ENGINE BALANCER ASSEMBLY
-
*1
Balance Shaft Damper Cover
*2
Balance Shaft Driven Gear
*a
Alignment Mark
Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.
If the alignment marks are not aligned, realign them.
-
*1
Balance Shaft Damper Cover
*2
Balance Shaft Driven Gear
*a
Alignment Mark
Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place.
Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.
-
-
Install the engine balancer assembly to the stiffening crankcase with the 3 bolts and tighten the bolts in the sequence shown in the illustration.
24 N*m
245 kgf*cm
18 ft.*lbf
-
INSTALL STIFFENING CRANKCASE ASSEMBLY
-
*1
Crankshaft Pulley Key
Rotate the crankshaft clockwise so that the crankshaft pulley key is at the position 270° from the bottom as shown in the illustration.
-
*a
Seal Packing
*b
2.5 to 3.5 mm (0.0984 to 0.138 in.)
*c
7.0 to 9.0 mm (0.276 to 0.354 in.)
Stiffening Crankcase
Cylinder Block
Apply seal packing to the areas as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard Seal Dimension
Area
Specified Condition
Continuous Line
2.5 to 3.5 mm (0.0984 to 0.138 in.)
Dashed Line
7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick
Application length A
28 mm (1.10 in.)
Note:Remove any oil from the contact surface.
Install the stiffening crankcase assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
Do not apply oil for at least 4 hours after the installation.
Do not start the engine for at least 4 hours after the installation.
-
*a
Cutout
Check that the rear cutouts are as shown in the illustration.
Clean the bolts and their installation holes.
Apply adhesive to 3 threads or more at the end of bolt A.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
-
*a
Bolt Type
*b
Tightening Order
Temporarily install the stiffening crankcase assembly with the 11 bolts.
Bolt Length
Item
Specified Condition
Bolt A
65 mm (2.56 in.)
Bolt B
35 mm (1.38 in.)
Bolt C
125 mm (4.92 in.)
Bolt D
165 mm (6.50 in.)
Tip:Apply adhesive to bolt A before installing it.
Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase assembly.
for bolt A
24 N*m
245 kgf*cm
18 ft.*lbf
except bolt A
43 N*m
438 kgf*cm
32 ft.*lbf
-
INSTALL NO. 1 OIL PAN BAFFLE PLATE
-
Install the No. 1 oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the sequence shown in the illustration.
10 N*m
102 kgf*cm
7 ft.*lbf
-
INSTALL OIL STRAINER SUB-ASSEMBLY
-
*a
Protrusion
Apply a light coat of engine oil to a new gasket.
Align the protrusion of the gasket with the cutout of the oil strainer sub-assembly and install the gasket to the oil strainer sub-assembly.
Install the oil strainer sub-assembly with the 3 bolts in several steps in the sequence shown in the illustration.
9.0 N*m
92 kgf*cm
80 in.*lbf
-
INSTALL OIL PAN SUB-ASSEMBLY
-
*a
Seal Packing
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
2.5 to 3.5 mm (0.0984 to 0.138 in.)
Note:Remove any oil from the contact surface.
Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
Do not apply oil for at least 4 hours after the installation.
Do not start the engine for at least 4 hours after the installation.
-
Install the oil pan sub-assembly with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration.
10 N*m
102 kgf*cm
7 ft.*lbf
Tip:Bolt A and nut A are tightened twice.
-
INSTALL OIL FILTER ELEMENT
INSTALL REAR ENGINE OIL SEAL
INSTALL CYLINDER BLOCK WATER JACKET SPACER
Install the cylinder block water jacket spacer to the cylinder block.
INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY
INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
*a
Protrusion Height
Note:It is not necessary to remove the ring pin unless it is being replaced.
Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing sub-assembly.
Standard protrusion height
2.7 to 3.3 mm (0.106 to 0.130 in.)
INSTALL CAMSHAFT HOUSING STRAIGHT PIN
*a
Protrusion Height
Note:It is not necessary to remove the straight pin unless it is being replaced.
Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing sub-assembly.
Standard protrusion height
5.0 to 7.0 mm (0.197 to 0.276 in.)
INSTALL CAMSHAFT HOUSING STUD BOLT
Note:If a stud bolt is deformed or its threads are damaged, replace it.
Apply adhesive to the camshaft housing side threads of the stud bolt.
Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
-
*a
20 mm (0.787 in.)
*b
35 mm (1.38 in.)
*c
13 mm (0.512 in.)
Using an E8 "TORX" socket wrench, install the stud bolt.
6.5 N*m
66 kgf*cm
58 in.*lbf
INSTALL NO. 1 CAMSHAFT BEARING
-
*a
Vernier Caliper
Clean the No. 1 camshaft bearing.
Install the camshaft bearing to the No. 1 camshaft bearing cap.
Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.
Dimension A - B or B - A
0 to 0.7 mm (0 to 0.0276 in.)
-
INSTALL NO. 2 CAMSHAFT BEARING
-
*a
Vernier Caliper
Clean the No. 2 camshaft bearing.
Install the camshaft bearing to the camshaft housing sub-assembly.
Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.
Standard distance
1.15 to 1.85 mm (0.0453 to 0.0728 in.)
-
INSTALL OIL CONTROL VALVE FILTER
Install the oil control valve filter to the No. 1 camshaft bearing cap.
INSTALL NO. 2 CAMSHAFT
Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
Apply a light coat of engine oil to the camshaft journal, camshaft housing sub-assembly and camshaft bearing caps.
Install the No. 2 camshaft to the camshaft housing sub-assembly.
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
INSTALL CAMSHAFT
Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
Apply a light coat of engine oil to the camshaft journal, camshaft housing sub-assembly and camshaft bearing caps.
Install the camshaft to the camshaft housing sub-assembly.
INSTALL CAMSHAFT BEARING CAP
-
Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.
-
Install the 11 bearing cap bolts in the order shown in the illustration.
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
Apply a light coat of engine oil to the valve stem ends.
Install the 16 valve stem caps to the cylinder head sub-assembly.
Note:Do not drop the valve stem caps into the cylinder head sub-assembly.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
Inspect the valve lash adjuster before installing it.
Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.
Note:Install the valve lash adjuster to the same place it was removed from.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
-
*1
No. 1 Valve Rocker Arm Sub-assembly
*2
Valve Lash Adjuster Assembly
*3
Valve Stem Cap
Apply engine oil to the valve lash adjuster tips and valve stem caps.
Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
-
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
-
*1
No. 1 Valve Rocker Arm Sub-assembly
*2
Valve Lash Adjuster Assembly
*3
Valve Stem Cap
*a
INCORRECT
*b
CORRECT
Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
-
*a
Seal Packing
*b
Dashed Line
*c
Groove
*d
2.5 to 3.5 mm (0.0984 to 0.138 in.)
*e
3.5 to 4.0 mm (0.138 to 0.157 in.)
Apply seal packing to the areas as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Apply Seal Packing as Follows
Area
Seal Packing Diameter
Application Position
Continuous Line
3.0 to 4.0 mm (0.118 to 0.157 in.)
Distance from edge of camshaft housing sub-assembly to center of seal packing: 3.5 to 4.0 mm (0.138 to 0.157 in.)
Dashed Line
Distance from outside edge of groove to center of seal packing: 2.5 to 3.5 mm (0.0984 to 0.138 in.)
Note:Remove any oil from the contact surface.
Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
-
*a
Approximately 17°
*b
Approximately 2°
*c
Knock Pin
Position the knock pin of the camshaft and No. 2 camshaft as shown in the illustration.
-
Install the camshaft housing sub-assembly, and then install the 20 bearing cap bolts in the order shown in the illustration.
27 N*m
275 kgf*cm
20 ft.*lbf
Note:Do not apply oil for at least 4 hours after the installation.
Do not start the engine for at least 4 hours after the installation.
Thoroughly wipe clean any seal packing.
-
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
-
*a
Knock Pin Hole
*b
Alignment Mark
Check the camshaft timing gear position.
If the camshaft timing gear assembly is not set the advanced position, release the lock pin and reset the camshaft timing gear assembly (refer to Set Camshaft Timing Gear Assembly procedures).
-
*1
Knock Pin
*a
Knock Pin Hole
Align the knock pin of the camshaft with the knock pin hole of the camshaft timing gear assembly and attach the gear assembly to the camshaft.
-
*1
Camshaft Timing Gear Assembly
*a
INCORRECT
*b
CORRECT
*c
Clearance
*d
No Clearance
*e
Camshaft Flange
Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.
-
*a
Hold
Turn
Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.
85 N*m
867 kgf*cm
63 ft.*lbf
Note:Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
Do not disassemble the camshaft timing gear assembly.
-
INSTALL CAMSHAFT TIMING SPROCKET
-
*a
Hold
Turn
Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing sprocket with the bolt.
85 N*m
867 kgf*cm
63 ft.*lbf
Note:Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
-
INSTALL CRANKSHAFT TIMING SPROCKET
Install the crankshaft timing sprocket to the crankshaft.
ADD ENGINE OIL
-
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 valve lash adjuster assemblies were removed.
Make sure that the low pressure chamber and oil paths of the valve lash adjuster assemblies are full of engine oil.
-
SET NO. 1 CYLINDER TO TDC/COMPRESSION
-
*1
Crankshaft Pulley Key
Temporarily install the crankshaft pulley bolt.
Rotate the crankshaft 40° counterclockwise to position the crankshaft pulley key as shown in the illustration.
-
*a
Approximately 7°
*b
Approximately 32°
*c
Timing Mark
Check that the timing marks of the camshaft timing gear assembly and camshaft timing sprocket are as shown in the illustration.
Tip:"A" in the illustration is not a timing mark.
Remove the crankshaft pulley bolt.
-
INSTALL NO. 1 CHAIN VIBRATION DAMPER
-
Install the No. 1 chain vibration damper with the 2 bolts in the order shown in the illustration.
21 N*m
214 kgf*cm
15 ft.*lbf
-
INSTALL CHAIN SUB-ASSEMBLY
Tip:
*a
for Intake Side
*b
for Exhaust Side
*c
for Crankshaft
Confirm the color of each mark plate before installing the chain sub-assembly.
Type of Chain Sub-assembly
for Exhaust Side
for Intake Side
for Crankshaft
Type A
Gold
Gold
Gold
Type B
Orange
Orange
Yellow
Place the chain sub-assembly onto the camshaft timing gear assembly, camshaft timing sprocket and crankshaft timing sprocket.
Tip:Make sure the mark plate of the chain faces away from the engine.
It is not necessary to install the chain sub-assembly to the teeth of the gear and sprockets.
-
*a
Mark Plate (for Exhaust Side)
*b
Timing Mark
Align the mark plate (for Exhaust Side) of the chain sub-assembly with the timing mark of the camshaft timing sprocket and install the chain sub-assembly to the camshaft timing sprocket.
-
*a
Mark Plate (for Crankshaft)
*b
Timing Mark
Align the mark plate (for Crankshaft) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.
-
Tie a string above the crankshaft timing sprocket so that the chain sub-assembly is secure.
-
*a
Mark Plate (for Intake Side)
*b
Timing Mark
Using the hexagonal portion of the camshaft, rotate the camshaft counterclockwise with a wrench, align the timing mark of the camshaft timing gear assembly with the mark plate (for Intake Side) of the chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly.
Tip:Hold the camshaft in place with a wrench until the chain tensioner is installed.
-
Remove the string above the crankshaft timing sprocket, rotate the crankshaft clockwise, and loosen the chain sub-assembly so that the chain tensioner slipper can be installed.
Note:Make sure the chain sub-assembly is secure.
INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper with the bolt.
21 N*m
214 kgf*cm
15 ft.*lbf
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
Remove the pin from the stopper plate.
INSTALL TIMING CHAIN GUIDE
Install the timing chain guide with the bolt.
21 N*m
214 kgf*cm
15 ft.*lbf
CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
Temporarily install the crankshaft pulley bolt.
Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket, camshaft timing gear assembly and camshaft timing sprocket are as shown in the illustration.
*1
Crankshaft Pulley Key
-
-
*a
Approximately 7°
*b
Approximately 32°
*c
Timing Mark
-
-
Tip:"A" in the illustration is not a timing mark.
Remove the crankshaft pulley bolt.
INSTALL TIMING CHAIN COVER PLATE
Install a new gasket and the timing chain cover plate with the 4 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL TIMING CHAIN COVER TIGHT PLUG
Using a 14 mm hexagon wrench, install a new gasket and the timing chain cover tight plug.
30 N*m
306 kgf*cm
22 ft.*lbf
INSTALL TIMING CHAIN COVER ASSEMBLY
INSTALL ENGINE MOUNTING BRACKET RH STUD BOLT
Note:If a stud bolt is deformed or its threads are damaged, replace it.
-
*a
34 mm (1.34 in.)
*b
25 mm (0.984 in.)
*c
76 mm (2.99 in.)
Using an E8 "TORX" socket wrench, install the stud bolt.
15 N*m
153 kgf*cm
11 ft.*lbf
-
INSTALL ENGINE MOUNTING BRACKET RH
-
Temporarily install the engine mounting bracket RH with the 4 bolts.
Tighten the 4 bolts in the order shown in the illustration.
for bolt 1, bolt 2 and bolt 3
55 N*m
561 kgf*cm
41 ft.*lbf
for bolt 4
21 N*m
214 kgf*cm
15 ft.*lbf
Note:After applying seal packing to the timing chain cover assembly, install the engine mounting bracket RH within 10 minutes.
-
INSTALL TIMING CHAIN COVER OIL SEAL
INSTALL SPARK PLUG TUBE GASKET
-
*1
Spark Plug Tube Gasket
*2
Cylinder Head Cover Sub-assembly
*a
1.0 mm (0.0394 in.) or less
Install the 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.
Note:Keep the lip free of foreign matter.
Do not install the oil seal at an angle.
After pressing in the spark plug tube gasket, make sure the gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover sub-assembly.
-
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Apply a light coat of engine oil to 2 new gaskets.
-
Install the gasket to the No. 2 camshaft bearing cap.
Install the gaskets to the No. 1 camshaft bearing cap.
Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
Note:Remove any oil from the contact surface.
-
*1
Timing Chain Cover Sub-assembly
*2
Camshaft Housing Sub-assembly
*a
Seal Packing
Apply seal packing as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter
3.0 to 6.0 mm (0.118 to 0.236 in.)
Application width A
5.0 mm (0.197 in.)
Note:Remove any oil from the contact surface.
Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
-
*1
Seal Washer
*a
Pin A
*b
Pin B
Align the cylinder head cover sub-assembly with pin A. Then align the cylinder head cover sub-assembly with pin B and install the cylinder head cover sub-assembly.
Install the 3 new seal washers and 16 bolts, and then tighten the bolts in the order shown in the illustration.
12 N*m
122 kgf*cm
9 ft.*lbf
Note:Do not add oil for at least 4 hours after the installation.
Do not start the engine for at least 4 hours after the installation.
INSTALL CRANKSHAFT PULLEY
-
*a
Hold
Turn
Align the pulley set key with the key groove of the crankshaft pulley.
Using SST, hold the crankshaft pulley and install the pulley bolt.
09213-54015
09330-00021
260 N*m
2651 kgf*cm
192 ft.*lbf
Tip:Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)
-
INSTALL SEPARATOR CASE
Apply a light coat of engine oil to a new gasket.
Install the gasket to the separator case.
Install the separator case with the 2 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL PCV CASE
-
*a
Seal Packing
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
2.5 to 3.5 mm (0.0984 to 0.138 in.)
Note:Remove any oil from the contact surface.
Install the PCV case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
-
Install the PCV case, and then install the 8 bolts and 2 nuts in the order shown in the illustration.
21 N*m
214 kgf*cm
15 ft.*lbf
Tip:Bolt A is tightened twice.
-
INSTALL PCV VALVE
INSTALL CRANKSHAFT POSITION SENSOR
INSTALL OIL FILLER CAP SUB-ASSEMBLY
Install the oil filler cap gasket to the oil filler cap sub-assembly.
Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
INSTALL CAMSHAFT POSITION SENSOR
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
INSTALL KNOCK CONTROL SENSOR
INSTALL SPARK PLUG
INSTALL ENGINE COVER JOINT
Install the 3 engine cover joints.
10 N*m
102 kgf*cm
7 ft.*lbf