ENGINE UNIT REASSEMBLY

PROCEDURE

  1. INSTALL STIFFENING CRANKCASE RING PIN

    A152991E17
    Note:

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

    1. Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

      Standard Ring Pin

      Item

      Protrusion Height

      Height

      Width

      Ring pin

      3.0 mm (0.118 in.)

      11 mm (0.433 in.)

      8 mm (0.315 in.)

  2. INSTALL STIFFENING CRANKCASE STUD BOLT

    U121286E01
    Note:

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

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

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY

    1. A150919E13

      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

      Item

      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 crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

    2. U110393E02

      Install the stiffening crankcase with the 11 bolts in the sequence 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 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

    Click here

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  6. INSTALL OIL PAN DRAIN PLUG

    1. A150893

      Install a new gasket and the drain plug.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

  7. INSTALL ENGINE REAR OIL SEAL

    Click here

  8. INSTALL NO. 1 TAPER SCREW PLUG

    1. A238906E02

      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 within 1 hour of 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 within 1 hour of installing the plug.

  9. INSTALL VENTILATION VALVE SUB-ASSEMBLY

    Click here

  10. INSTALL CYLINDER HEAD GASKET

    Click here

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  12. 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.

  13. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    1. Inspect each valve lash adjuster before installing it (Click here).

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

      Note:

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

  14. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    1. A131901E07

      Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

    2. Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.

      Table 1. Text in Illustration

      *1

      Lash Adjuster

      *2

      Valve Rocker Arm

      *3

      Valve Stem

      *4

      Valve Stem Cap

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A206181E02
    Note:

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

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

      Standard Straight Pin

      Item

      Protrusion Height

      Height

      Width

      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.)

  16. INSTALL CAMSHAFT HOUSING STUD BOLT

    A173608E04
    Note:

    If a 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

  17. INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY

    1. U121799E01

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

      Table 2. Text in Illustration

      *1

      Protrusion
      Note:

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

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

    2. A173632

      Install the control actuator clip to the control actuator connector.

      Tip:

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

      Note:

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

    3. A173788

      Install the valve lift control actuator connector to the valve rocker shaft.

      Tip:

      There are two types of valve lift control actuator connectors. One type is installed by rotating the connector, and the other type can be installed without being rotated.

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

    5. A209172

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

      18 N*m

      184 kgf*cm

      13 ft.*lbf

      Note:

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

    6. A173790

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

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

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

      A389947E01
      Table 3. Text in Illustration

      *1

      Rocker Shaft

      *2

      Clip

      *3

      Straight Pin Hole

      *4

      Connector

      *5

      Controller Shaft
      Note:

      • Do not forcefully pry the control actuator connector.

      • Do not damage the camshaft housing or camshaft bearing cap.

    9. A173792

      Insert the straight pin into the 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 control actuator connector.

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

      Note:

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

  18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  19. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  20. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  21. 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.

  22. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. A150874

      Install the crankshaft position sensor plate with the "F" mark facing forward.

  23. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  24. INSTALL CRANKSHAFT TIMING SPROCKET

    Click here

  25. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  26. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  27. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  28. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  29. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  30. INSTALL NO. 1 GENERATOR BRACKET

    1. A150905

      Install the generator bracket with the 4 bolts.

      24 N*m

      245 kgf*cm

      18 ft.*lbf

  31. INSTALL WATER INLET HOUSING STUD BOLT

    A150941E03
    Note:

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

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

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  32. 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

  33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  34. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  35. INSTALL ENGINE MOUNTING BRACKET STUD BOLT

    A211980
    Note:

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

    1. Install the stud bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  36. INSTALL CRANKSHAFT PULLEY

    Click here

  37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  38. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  39. INSTALL SPARK PLUG TUBE GASKET

    1. A153838E01

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

      Table 4. Text in Illustration

      *1

      Part to Cut Off
    2. U121332E02

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

      Table 5. Text in Illustration

      *1

      Plug Tube Gasket without Sealing Part

      *2

      New Plug Tube Gasket

      *3

      Claw
      Tip:

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

      Note:

      • Keep the lip free of foreign matter.

      • Do not tap in the plug tube gasket at an angle.

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

  40. INSTALL CYLINDER HEAD COVER GASKET

    1. A179166

      Install a new cylinder head cover gasket to the cylinder head cover.

      Note:

      Remove any oil from the contact surfaces.

  41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A165301

      Install 3 new gaskets to the camshaft bearing cap.

    2. A165302

      Apply seal packing as shown in 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 after applying seal packing.

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

    3. A173472

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  42. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  43. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    1. A206180E04

      Using SST, install a new gasket and the engine coolant temperature sensor.

      09817-33190

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  44. INSTALL KNOCK SENSOR

    1. A150904E01

      Install the knock sensor with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      Note:

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

  45. INSTALL CRANKSHAFT POSITION SENSOR

    1. A157503E04

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

      Table 6. Text in Illustration

      *1

      O-Ring
    2. A150855

      Install the crankshaft position sensor with the bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  46. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. A195062E04

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

      Table 7. Text in Illustration

      *1

      New O-Ring
    2. A150849E02

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

      Table 8. Text in Illustration

      *1

      Bracket

      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.

  47. INSTALL CAMSHAFT POSITION SENSOR

    1. A095434E27

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

      Table 9. Text in Illustration

      *1

      O-Ring
    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 jammed when installing the sensor.

  48. INSTALL SPARK PLUG

    Click here

  49. INSTALL ENGINE COVER JOINT

    1. A150847

      Install the 2 engine cover joints.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  50. INSTALL OIL FILLER CAP GASKET

    1. A128159

      Install the gasket to the oil filler cap.

  51. INSTALL OIL FILLER CAP SUB-ASSEMBLY

    1. A173599

      Install the oil filler cap.