ENGINE UNIT REASSEMBLY
PROCEDURE
INSTALL STIFFENING CRANKCASE RING PIN
*1
Protrusion Height
*2
Width
*3
Height
Note:It is not necessary to remove a stiffening cranckcase ring pin unless it is being replaced.
Using a plastic-faced hammer, tap in 2 new stiffening cranckcase ring pins until they stop.
Standard Ring Pin
Protrusion Height
Height
Width
3.0 mm (0.118 in.)
11 mm (0.433 in.)
8.0 mm (0.315 in.)
INSTALL STUD BOLT
Note:If a stud bolt is deformed or the threads are damaged, replace it.
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*1
Stud Bolt
*a
9.0 mm (0.354 in.)
*b
19 mm (0.748 in.)
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
-
*a
15 mm (0.591 in.)
*b
12 mm (0.472 in.)
*c
34 mm (1.34 in.)
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
-
*a
12 mm (0.472 in.)
*b
9.0 mm (0.354 in.)
*c
23 mm (0.906 in.)
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
-
*a
12 mm (0.472 in.)
*b
18 mm (0.709 in.)
*c
48.5 mm (1.91 in.)
Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.
9.5 N*m
97 kgf*cm
84 in.*lbf
-
INSTALL STIFFENING CRANKCASE ASSEMBLY
-
*1
Seal Packing
*a
Area A
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
except Area A
2.0 to 3.0 mm (0.0787 to 0.118 in.)
for Area A
4.5 to 5.5 mm (0.177 to 0.217 in.)
Application Length (Area 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 after applying seal packing.
Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.
-
Install the stiffening crankcase assembly 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.)
Note:Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.
Recheck the torque for bolts 1 and 2.
21 N*m
214 kgf*cm
15 ft.*lbf
Wipe off any excess seal packing with a clean piece of cloth.
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INSTALL OIL PUMP ASSEMBLY
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
INSTALL OIL PAN DRAIN PLUG
Install a new gasket and the oil pan drain plug.
37 N*m
377 kgf*cm
27 ft.*lbf
INSTALL ENGINE REAR OIL SEAL
INSTALL NO. 1 TAPER SCREW PLUG
Clean the No. 1 taper screw plug and plug hole.
Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug. Then install the No. 1 taper screw plug.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
25 N*m
255 kgf*cm
18 ft.*lbf
Note:Install the plug within 3 minutes of applying adhesive.
Do not start the engine within 1 hour of installing the plug.
INSTALL PCV VALVE SUB-ASSEMBLY
INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY
INSTALL VALVE STEM CAP
Apply a light coat of engine oil to the valve stem cap end.
Install the 16 valve stem caps to the valve stems.
Note:Do not drop the valve stem caps into the cylinder head sub-assembly.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
Inspect each valve lash adjuster assembly before installing it.
Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.
Note:Install the valve lash adjuster assembly 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
*4
Valve Stem Cap
Apply engine oil to the valve lash adjuster assembly tip and valve stem cap end.
Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
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INSTALL CAMSHAFT HOUSING STRAIGHT PIN
*1
Protrusion Height
*2
Height
*3
Width
Note:It is not necessary to remove a straight pin unless it is being replaced.
Using a plastic-faced hammer, tap in a new straight pin to the specified protrusion height.
Standard Straight Pin
Protrusion Height
Height
Width
6.5 to 7.5 mm (0.256 to 0.295 in.)
14 mm (0.551 in.)
6.0 mm (0.236 in.)
INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY
-
*1
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.
-
Install the control actuator clip to the control actuator connector.
Note:Be sure to insert the protrusions of the control actuator clip into the holes in the control actuator connector.
Tip:When the continuously variable valve lift controller assembly is new, a control actuator connector is attached to it. Remove the control actuator connector before performing these procedures.
-
Install the control actuator connector to the valve rocker shaft.
Insert the continuously variable valve lift controller assembly into the camshaft housing sub-assembly.
Install the continuously variable valve lift controller 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 jammed between parts.
-
Using a screwdriver, slide the control actuator clip from the control actuator connector.
Slide only the upper part of the control actuator clip as the straight pin may fall if the control actuator clip is completely removed.
-
Using 2 screwdrivers, 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 assembly.
Note:Do not forcefully pry the control actuator connector.
Do not damage the camshaft housing sub-assembly and camshaft bearing cap.
-
*1
Continuously Variable Valve Lift Controller Assembly
*2
Valve Lift Control Actuator Connector
*3
Valve Lift Control Actuator Connector Clip
*4
Valve Rocker Shaft
*5
Straight Pin
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.
-
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.
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INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
INSTALL CRANKSHAFT TIMING GEAR KEY
-
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.
-
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.
INSTALL NO. 2 CHAIN SUB-ASSEMBLY
INSTALL CRANKSHAFT TIMING SPROCKET
INSTALL NO. 1 CHAIN VIBRATION DAMPER
Install the No. 1 chain vibration damper with the 2 bolts.
21 N*m
214 kgf*cm
15 ft.*lbf
SET NO. 1 CYLINDER TO TDC/COMPRESSION
Temporarily install the crankshaft pulley bolt.
-
*1
Timing Gear Key
Turn the crankshaft counterclockwise to position the timing gear key at the top.
-
*1
Timing Mark
Check that the timing marks on the camshaft timing gears are aligned as shown in the illustration.
Remove the crankshaft pulley bolt.
INSTALL CHAIN SUB-ASSEMBLY
-
*1
Mark Plate (Orange)
*2
Timing Mark
Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain sub-assembly.
Tip:Be sure to position the mark plate at the front of the engine.
The mark plate on the camshaft side is colored orange.
Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.
Pass the chain through the No. 1 vibration damper.
-
Place the chain on the crankshaft without passing it around the shaft.
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain sub-assembly.
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.
Tip:To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.
-
*1
Timing Mark
*2
Mark Plate (Pink)
Align the mark plates (pink) and timing marks and install the chain to the crankshaft timing gear.
Tip:The mark plates on the crankshaft side are colored pink.
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INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper to the cylinder block assembly.
CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
Check each timing mark at TDC/compression.
*1
Timing Mark
*2
Mark Plate (Orange)
*3
Mark Plate (Pink)
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INSTALL NO. 1 GENERATOR BRACKET
Install the No. 1 generator bracket with the 4 bolts.
24 N*m
245 kgf*cm
18 ft.*lbf
INSTALL WATER INLET HOUSING
-
Install a new gasket and the water inlet housing with the 3 bolts.
21 N*m
214 kgf*cm
15 ft.*lbf
-
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
INSTALL TIMING CHAIN COVER OIL SEAL
INSTALL ENGINE MOUNTING BRACKET STUD BOLT
Install the engine mounting bracket stud bolt.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL CRANKSHAFT PULLEY
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
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*1
Cam
*2
Hook
*3
Pin
*a
CORRECT
*b
INCORRECT
*c
Push
*d
Raise
Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.
Note:Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.
-
Install a new gasket, the No. 1 chain tensioner assembly and the bracket with the 2 nuts.
12 N*m
122 kgf*cm
9 ft.*lbf
Note:If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, set the hook again.
-
*1
Pin
*2
Hook
*a
Release
*b
Turn
Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.
-
*1
Plunger
*a
Plunger Extended
*b
Turn
Turn the crankshaft clockwise and check that the plunger is extended.
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INSTALL OIL FILTER CAP ASSEMBLY
INSTALL SPARK PLUG TUBE GASKET
-
*1
Part to Cut Off
Using a cutter knife, cut off the seal part of the removed spark plug tube gasket.
-
*1
Spark Plug Tube Gasket without Sealing Part
*2
New Spark Plug Tube Gasket
*3
Claw
Using the removed spark plug tube gasket, uniformly press in a new spark plug tube gasket all the way.
Note:Keep the lip free of foreign matter.
Do not press in the spark plug tube gasket at an angle.
Tip:If the removed spark plug tube gasket does not fit on the new one, correct the removed one with pliers.
Return the claws of the ventilation baffle plate to their original positions.
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INSTALL CYLINDER HEAD COVER GASKET
Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
Note:Remove any oil from the contact surfaces.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Install 3 new gaskets to the camshaft bearing cap.
-
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.
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
Note:Do not start the engine for at least 2 hours after the installation.
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
INSTALL KNOCK SENSOR
INSTALL CRANKSHAFT POSITION SENSOR
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
for Intake Side:
for Exhaust Side:
INSTALL CAMSHAFT POSITION SENSOR
for Intake Side:
for Exhaust Side:
INSTALL SPARK PLUG
INSTALL ENGINE COVER JOINT
Install the 2 engine cover joints.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL OIL FILLER CAP GASKET
Install the oil filler cap gasket to the oil filler cap sub-assembly.
INSTALL OIL FILLER CAP SUB-ASSEMBLY
Install the oil filler cap sub-assembly.