ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STIFFENING CRANKCASE RING PIN

    A0059SEE06
    Text in Illustration
    *a Width
    *b Height
    *c Protrusion Height

    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

    A005A7OE01
    *1 9.0 mm (0.354 in.)
    *2 19 mm (0.748 in.)

    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.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY


    1. A005BE9E14
      *1 2.0 to 3.0 mm
      *2 4.5 to 5.5 mm

      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 crankcase 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. A005B4FE05

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

      Torque:
      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.

      Torque:
      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. A005AXH

      Install a new gasket and the drain plug.

      Torque:
      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. A005A10E01

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

      Torque:
      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).

      Torque:
      43 N*m  { 439 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


    1. A005DZWE37
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the threads of the ventilation valve sub-assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Install the ventilation valve sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the ventilation valve sub-assembly.

    2. A005BW3

      Install the ventilation valve sub-assembly.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  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. A005ETLE33
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      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.

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN

    A005CB2E02
    Text in Illustration
    *a Width
    *b Height
    *c Protrusion Height

    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 NO. 1 CAMSHAFT BEARING

    Click here

  17. INSTALL OIL CONTROL VALVE FILTER


    1. A005AG6

      Check that no foreign matter is on the mesh part of the oil control valve filter.

    2. Install the oil control valve filter.

      Note

      Do not touch the mesh when installing the oil control valve filter.

  18. INSTALL NO. 2 CAMSHAFT BEARING

    Click here

  19. INSTALL NO. 2 CAMSHAFT

    Click here

  20. INSTALL CAMSHAFT

    Click here

  21. INSTALL CAMSHAFT BEARING CAP

    Click here

  22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  23. INSTALL CAMSHAFT TIMING SPROCKET

    Click here

  24. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  25. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A005AMU

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

      Tech Tips

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

  26. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A005B3W

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

  27. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  28. INSTALL CRANKSHAFT TIMING SPROCKET

    Click here

  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  31. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  32. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  33. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  34. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    Click here

  35. INSTALL WATER INLET SUB-ASSEMBLY STUD BOLT

    Note

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


    1. A005BRFE05
      *1 9 mm (0.354 in.)
      *2 21 mm (0.827 in.)
      *3 34 mm (1.34 in.)

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  36. INSTALL WATER INLET SUB-ASSEMBLY


    1. A005EJF

      Install a new gasket and the inlet water sub-assembly with the bolt and 2 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  37. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A005EXKE01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

      Note


      • Keep the lip free from foreign matter.

      • Do not tap on the oil seal at an angle.

      • Make sure that the oil seal edge does not stick out of the timing chain case.

      Tech Tips

      Tap in the oil seal so that it is positioned within 1.0 mm (0.0394 in.) from the edge of the timing chain case.

    2. Apply MP grease to the lip of the oil seal.

  38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

      A005EJX
      Text in Illustration
      A005B9E Clean and degrease - -
    2. A005BC2

      Install 3 new O-rings.

    3. Apply seal packing as shown in the illustration.

      A005EAWE01
      *1 5.0 mm
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the chain cover within 3 minutes of applying seal packing.

      • Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.

    4. Apply seal packing to the timing chain cover in a line as shown in the following illustration.

      Note


      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover 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.

      A005C8ZE06
      Seal Packing
      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Application Specification
      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.0 mm (0.0984 to 0.118 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -
      A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      B - B 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Opposite edge of seal packing

      5.0 mm (0.197 in.)

      		 - -
      C - C 7.0 to 8.0 mm (0.276 to 0.315 in.)

      Opposite edge of seal packing

      7.5 mm (0.295 in.)

      		 - -
      F 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.5 mm (0.610 in.) 50.4 mm (1.98 in.)
      G 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 143.1 mm (5.63 in.)
      H 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 153.4 mm (6.04 in.)
      I 4.5 to 5.5 mm (0.177 to 0.217 in.) - 16.0 mm (0.630 in.) 385.8 mm (1.27 ft.)
      J 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      K 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 121.9 mm (4.80 in.)
      L 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 147.2 mm (5.80 in.)
      M 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.1 mm (0.201 in.) 173.0 mm (6.81 in.)
      N 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 385.8 mm (1.27 ft.)
      O 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -

      Note


      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

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

      • After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.

      • Do not add engine oil for at least 2 hours after installation.

    5. Clean the bolt and fitting hole.

    6. Install the timing chain cover.

    7. Temporarily tighten the engine mounting bracket RH with the 3 bolts.

      Note


      • Install the mounting bracket within 10 minutes of installing the chain cover.

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

      Bolt Length
      Item Length
      Bolt 80 mm (3.15 in.)

    8. Install 2 new O-rings.

    9. Temporarily tighten the oil filter bracket with the 4 bolts.

      Note


      • Install the oil filter bracket within 10 minutes of installing the chain cover.

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

      Bolt Length
      Item Length
      Bolt 35 mm (1.38 in.)

    10. Install the timing chain cover with the 25 bolts and a new gasket as shown in the illustration.

      A005EDPE06
      Text in Illustration
      *1 Gasket - -
      *a Torque *b Bolt Torque Order
      Torque:
      Bolt A, E, F
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }
      Bolt B, C
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      Bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • Apply adhesive 1324 to the threads of the bolt F.

      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.

      • Do not add engine oil for at least 2 hours after installing the chain cover.

      • Do not start the engine for at least 2 hours after installing the chain cover.

      Bolt Length
      Item Length
      Bolt A, F 35 mm (1.38 in.)
      Bolt B, E 55 mm (2.16 in.)
      Bolt C 80 mm (3.15 in.)
      Bolt D 40 mm (1.57 in.)
    11. A005AWWE01
      *1 34 mm (1.34 in.)
      *2 92 mm (3.62 in.)
      *3 25 mm (0.98 in.)

      Using a 8mm deep socket wrench, install the stud bolt from the engine mounting bracket RH.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  39. INSTALL CRANKSHAFT PULLEY

    Click here

  40. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  41. INSTALL OIL FILTER CAP ASSEMBLY

    Click here

  42. INSTALL SPARK PLUG TUBE GASKET


    1. A005AUI

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

      Text in Illustration
      A005CWR Part to Cut Off
    2. A005C93E06
      Text in Illustration
      *a Plug Tube Gasket without Sealing Part
      *b New Plug Tube Gasket

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

      Note


      • Keep the lip free of foreign matter.

      • Do not tap in the plug tube gasket.

      Tech Tips

      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.

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

  43. INSTALL CYLINDER HEAD COVER GASKET


    1. A005DTNE01
      Text in Illustration
      *1 Cylinder Head Cover
      *2 Cylinder Head Cover Gasket

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

      Note


      • Remove any oil from the contact surfaces.

      • Misalignment between the center of the cylinder head cover rib and the center of the cylinder head gasket tab should be within 4.0 mm (0.157 in.).

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A005ES8

      Install 2 new gaskets to the camshaft bearing cap.

    2. A005DP3

      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 of applying seal packing.

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

    3. A005E66
      Text in Illustration
      *1 Timing Chain Cover
      *2 Camshaft Housing
      *3 Cylinder Head Cover Gasket

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Misalignment between the contact surfaces of the timing chain cover and the camshaft housing and the center of the cylinder head gasket tab should be within 4.0 mm (0.157 in.).

      A005DK5E03

  45. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A005AWEE02
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note


      • Install the oil pressure switch within 3 minutes after applying adhesive.

      • Do not start the engine within 1 hour after installation.

    2. A005BDG

      Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  46. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A005BYC

      Install a new gasket and the engine coolant temperature sensor.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  47. INSTALL KNOCK SENSOR


    1. A005B7HE01

      Install the knock sensor with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

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

  48. INSTALL CRANKSHAFT POSITION SENSOR


    1. A005DF7

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

    2. A005D1D

      Install the crankshaft position sensor with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  49. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A0059SK

      Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve.

    2. A005CEU

      Install the camshaft timing oil control valve with the bolt.

      Torque:
      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.

  50. INSTALL CAMSHAFT POSITION SENSOR


    1. A005BRU

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

    2. A005ABG

      Install the camshaft position sensor with the bolt.

      Torque:
      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.

  51. INSTALL SPARK PLUG

    Click here

  52. INSTALL ENGINE COVER JOINT BOLT


    1. A005AAL

      Install the 3 engine cover joint bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  53. INSTALL WIRING HARNESS CLAMP BRACKET


    1. A005C64

      Install the wiring harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  54. INSTALL OIL FILLER CAP GASKET


    1. A005D9W

      Install the gasket to the oil filler cap.

  55. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A005EGX

      Install the oil filler cap.