ENGINE UNIT REASSEMBLY
PROCEDURE
INSTALL STIFFENING CRANKCASE RING PIN
*1
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.
*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.)
Using an E5 and E8 "TORX" socket wrench, install the stud bolts.
for stud bolt A
5.0 N*m
51 kgf*cm
44 in.*lbf
for stud bolt B
9.5 N*m
97 kgf*cm
84 in.*lbf
INSTALL ENGINE BALANCER ASSEMBLY
-
*1
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
Driven Gear
*2
Damper Cover
*3
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 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
Key
Rotate the crankshaft clockwise so that the crankshaft key is at the position 270° from the bottom as shown in the illustration.
-
*1
Seal Packing
*a
2.5 to 3.5 mm (0.0984 to 0.138 in.)
*b
7.0 to 9.0 mm (0.276 to 0.354 in.)
Stiffening Crankcase
Cylinder Block
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 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 oil pan 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.
-
*1
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
-
Temporarily install the stiffening crankcase 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.
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 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
-
*1
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 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
-
*1
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 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
SET CAMSHAFT TIMING GEAR ASSEMBLY
INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
*1
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.
Standard protrusion height
2.7 to 3.3 mm (0.106 to 0.130 in.)
INSTALL CAMSHAFT HOUSING STRAIGHT PIN
*1
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.
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.
-
*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.
9.5 N*m
97 kgf*cm
84 in.*lbf
-
INSTALL NO. 1 CAMSHAFT BEARING
-
*1
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
-
*1
Vernier Caliper
Clean the No. 2 camshaft bearing.
Install the camshaft bearing to the camshaft housing.
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 CAMSHAFT
INSTALL CAMSHAFT BEARING CAP
INSTALL VALVE STEM CAP
INSTALL VALVE LASH ADJUSTER ASSEMBLY
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
INSTALL CRANKSHAFT TIMING SPROCKET
Install the crankshaft timing sprocket to the crankshaft.
ADD ENGINE OIL
SET NO. 1 CYLINDER TO TDC/COMPRESSION
INSTALL NO. 1 CHAIN VIBRATION DAMPER
INSTALL CHAIN SUB-ASSEMBLY
INSTALL CHAIN TENSIONER SLIPPER
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
INSTALL TIMING CHAIN GUIDE
CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
INSTALL TIMING CHAIN COVER PLATE
INSTALL TIMING CHAIN COVER TIGHT PLUG
Using a 14 mm hexagon wrench, install a new gasket and timing chain cover tight plug.
30 N*m
306 kgf*cm
22 ft.*lbf
INSTALL TIMING CHAIN COVER ASSEMBLY
INSTALL ENGINE MOUNTING BRACKET RH
INSTALL TIMING CHAIN COVER OIL SEAL
INSTALL SPARK PLUG TUBE GASKET
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
INSTALL CRANKSHAFT PULLEY
-
*a
Hold
*b
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 holdingtool): 91551-80650 (quantity: 2)
-
INSTALL CRANKSHAFT POSITION SENSOR
INSTALL WATER INLET HOUSING
Install a new gasket and the water inlet housing with the 4 bolts and nut.
43 N*m
438 kgf*cm
32 ft.*lbf
INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)
INSTALL ENGINE WATER PUMP ASSEMBLY
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
INSTALL THERMOSTAT
INSTALL WATER INLET
INSTALL NO. 1 WATER BY-PASS PIPE
Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.
10 N*m
102 kgf*cm
7 ft.*lbf
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
-
*1
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 CAMSHAFT POSITION SENSOR (for Intake Side)
INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)
INSTALL OIL FILLER CAP SUB-ASSEMBLY
Install the gasket to the oil filler cap sub-assembly.
Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
INSTALL SPARK PLUG
INSTALL ENGINE COVER JOINT
Install the 3 engine cover joints.
10 N*m
102 kgf*cm
7 ft.*lbf