ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tip:

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly or engine coolant temperature sensor.

Click here

PROCEDURE

  1. INSTALL RING PIN

    Note:

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

    1. A152991C12

      *a

      Protrusion Height

      Install 2 new ring pins to the stiffening crankcase assembly.

      Standard protrusion

      3 mm (0.118 in.)

      Tip:

      Standard protrusion may vary, but 3 mm is typical.

  2. INSTALL STUD BOLT

    Note:

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

    1. for Stiffening crankcase assembly:

      1. A296219N02

        Using an E5 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

        5.0 N*m

        51 kgf*cm

        44 in.*lbf

    2. for Water inlet housing:

      1. A150941N07

        Using an E5 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

        5.0 N*m

        51 kgf*cm

        44 in.*lbf

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY

    1. A150919N10

      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 stiffening crankcase 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 installing the stiffening crankcase assembly.

    2. A152989N08

      Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.

      21 N*m

      214 kgf*cm

      16 ft.*lbf

      Bolt Length

      Item

      Length

      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

      16 ft.*lbf

    4. Wipe off any excess seal packing with a clean piece of cloth.

  4. INSTALL REAR ENGINE OIL SEAL

  5. INSTALL OIL PUMP ASSEMBLY

  6. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

  7. INSTALL OIL PAN DRAIN PLUG

    1. A150893

      Install a new gasket and the oil pan drain plug.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

  8. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

  9. INSTALL CYLINDER HEAD GASKET

  10. INSTALL CYLINDER HEAD SUB-ASSEMBLY

  11. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Note:
    • Keep the valve lash adjuster assembly free of dirt and foreign matter.

    • Only use clean engine oil.

    1. Place the valve lash adjuster assembly into a container filled with engine oil.

    2. A286731C06

      *a

      Correct

      *b

      Incorrect

      *c

      Taper Part

      *d

      Low Pressure Chamber

      *e

      High Pressure Chamber

      *f

      Plunger

      *g

      Check Ball

      Insert the SST tip into the valve lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      09276-75010

    3. Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed it.

      OK

      Plunger moves up and down.

      Note:

      When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.

    5. After bleeding, remove SST. Then, try to press the plunger quickly and firmly with a finger.

      OK

      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster assembly.

    6. Install the valve lash adjuster assemblies.

      Note:

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

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

    1. Apply engine oil to each valve lash adjuster assembly tip and valve stem cap end.

    2. A131901C17

      *1

      Valve Rocker Arm

      *2

      Valve Lash Adjuster

      *3

      Valve Stem

      *4

      Valve Stem Cap

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

  13. INSTALL NO. 1 CAMSHAFT BEARING

  14. INSTALL OIL CONTROL VALVE FILTER

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

    2. A152596

      Install the oil control valve filter.

      Note:

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

  15. INSTALL NO. 2 CAMSHAFT BEARING

    1. Clean both surfaces of the 2 No. 2 camshaft bearings.

      Note:

      Do not apply engine oil to the No. 2 camshaft bearings or the contact surfaces.

    2. Install the 2 No. 2 camshaft bearings to the camshaft housing sub-assembly.

    3. A153850C01

      *1

      Vernier Caliper

      Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the No. 2 camshaft bearing edge.

      Dimension (A)

      1.05 to 1.75 mm (0.0413 to 0.0689 in.)

      Note:

      Position the No. 2 camshaft bearings to the center of the camshaft bearing cap by measuring dimension A.

  16. INSTALL NO. 2 CAMSHAFT

    1. Clean the camshaft journals.

    2. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    3. A196595

      Install the No. 2 camshaft to the camshaft housing sub-assembly.

      Tip:

      Perform "Inspection After Repair" after replacing the No. 2 camshaft.

      Click here

  17. INSTALL CAMSHAFT

    1. Clean the camshaft journals.

    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.

    3. A196594

      Install the camshaft to the camshaft housing sub-assembly.

      Tip:

      Perform "Inspection After Repair" after replacing the camshaft.

      Click here

  18. INSTALL CAMSHAFT BEARING CAP

    1. Apply engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    2. A153400C01

      *1

      Straight Pin

      *2

      Camshaft

      *3

      No. 2 Camshaft

      Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

      Tip:

      Make sure that the straight pin of each camshaft is positioned as shown in the illustration.

    3. A153453N03

      Tighten the 10 bolts in the order shown in the illustration.

      16 N*m

      163 kgf*cm

      12 ft.*lbf

  19. INSTALL NO. 1 TAPER SCREW PLUG

    1. A235914N07

      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 No. 1 taper screw plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour after installing the No. 1 taper screw 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 No. 1 taper screw plug within 3 minutes of applying adhesive.

      • Do not start the engine within 1 hour after installing the No. 1 taper screw plug.

  20. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    1. A131901C17

      *1

      Valve Rocker Arm

      *2

      Lash Adjuster

      *3

      Valve Stem

      *4

      Valve Stem Cap

      Make sure that the valve rocker arm is installed as shown in the illustration.

    2. A206178N02

      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

      3.5 to 4.5 mm (0.138 to 0.177 in.)

      A

      8.0 mm (0.315 in.)

      B

      7.0 mm (0.276 in.)

      Application Length A and B

      15 mm (0.591 in.)

      Note:
      • Remove any oil from the contact surfaces.

      • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

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

    3. A404241N01

      Set the camshaft and No. 2 camshaft as shown in the illustration.

    4. Install the camshaft housing sub-assembly and tighten the 17 bolts in the order shown in the illustration.

      27 N*m

      275 kgf*cm

      20 ft.*lbf

      Note:
      • After installing the camshaft housing sub-assembly, make sure that the cam lobes are positioned as shown in the illustration.

      • If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly, clean the installation surfaces, and reapply seal packing.

      • If the camshaft housing sub-assembly is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

      • After installing the camshaft housing sub-assembly, wipe off any seal packing that seeped out from between the camshaft housing sub-assembly and the cylinder head sub-assembly.

  21. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. Check that the straight pin is installed on the No. 2 camshaft.

    2. A215318C10

      *a

      Straight Pin

      *b

      Key Groove

      Put the camshaft timing exhaust gear assembly and No. 2 camshaft together by aligning the key groove and straight pin.

    3. Lightly press the camshaft timing exhaust gear assembly against the No. 2 camshaft, and turn the camshaft timing exhaust gear assembly. Push further at the position where the pin enters the groove.

      Note:

      Be sure not to turn the camshaft timing exhaust gear assembly in the retard direction (clockwise).

    4. Check that there is no clearance between the gear and the No. 2 camshaft flange.

    5. A153891

      Tighten the flange bolt while holding the hexagonal portion of the No. 2 camshaft.

      54 N*m

      551 kgf*cm

      40 ft.*lbf

    6. Check the lock of the camshaft timing exhaust gear assembly.

      1. Make sure that the camshaft timing exhaust gear assembly is locked.

        Tip:

        Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

        Click here

  22. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    1. Check that the straight pin is installed on the camshaft.

    2. A146265C17

      *a

      Straight Pin

      *b

      Key Groove

      Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.

      Note:

      Do not forcibly push in the camshaft timing gear assembly. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear assembly.

    3. A215319C09

      *a

      Straight Pin

      *b

      Key Groove

      Turn the camshaft timing gear assembly as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

      Note:

      Do not turn the camshaft timing gear assembly assembly in the retard direction (clockwise).

    4. A146267C14

      *1

      Camshaft Timing Gear Assembly

      *a

      Clearance

      *b

      No clearance

      *c

      Flange

      Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

    5. A153890

      Tighten the flange bolt while holding the hexagonal portion of the camshaft.

      54 N*m

      551 kgf*cm

      40 ft.*lbf

    6. A153896C01

      *a

      Lock

      Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and is locked in the most retarded position.

      Tip:

      Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

      Click here

  23. INSTALL CRANKSHAFT TIMING GEAR KEY

    1. A296221

      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.

  24. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. A150874

      Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.

  25. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

  26. INSTALL CRANKSHAFT TIMING SPROCKET

  27. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    1. A172409N01

      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

  28. INSTALL CHAIN SUB-ASSEMBLY

    1. Check that the No. 1 cylinder is at TDC/compression.

      1. Temporarily tighten the crankshaft pulley bolt.

      2. A153029C07

        *1

        Timing Gear Key

        Turn the crankshaft counterclockwise to position the timing gear key to the top.

      3. Remove the crankshaft pulley bolt.

      4. A153030C03

        *a

        Timing Mark

        Check that the timing marks on each camshaft timing gear assembly are aligned as shown in the illustration.

    2. A150935C01

      *a

      Place the Chain Sub-assembly on the Sprocket

      *b

      Pass the Chain Sub-assembly through the Damper

      *c

      Mark Plate (Orange)

      *d

      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 sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.

      • Pass the chain sub-assembly through the No. 1 vibration damper.

    3. A172410

      Place the chain sub-assembly on the crankshaft without passing it around the shaft.

    4. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plates (orange) and timing mark.

      Tip:
      • Be sure to position the mark plates at the front of the engine.

      • The mark plates on the camshaft side are colored orange.

      A296489C01

      *a

      Turn

      *b

      Tension the Chain Sub-assembly

      *c

      Mark Plate (Orange)

      *d

      Timing Mark

    5. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

      Tip:

      To tension the chain sub-assembly, slowly turn the camshaft timing gear assembly clockwise to prevent the chain sub-assembly from being misaligned.

    6. A172418C01

      *a

      Timing Mark

      *b

      Mark Plate (Yellow)

      Align the mark plates (yellow) and timing marks and install the chain sub-assembly to the crankshaft timing gear.

      Tip:

      The mark plates on the crankshaft side are colored yellow.

    7. Recheck each timing mark at TDC/compression.

      A172417C03

      *a

      Timing Mark

      *b

      Mark Plate (Orange)

      *c

      Mark Plate (Yellow)

      -

      -

  29. INSTALL CHAIN TENSIONER SLIPPER

    1. A296232

      Install the chain tensioner slipper to the cylinder block sub-assembly.

  30. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    1. A153395

      Install the No. 2 chain vibration damper with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  31. INSTALL NO. 1 GENERATOR BRACKET

    1. A150905

      Install the No. 1 generator bracket with the 4 bolts.

      24 N*m

      245 kgf*cm

      18 ft.*lbf

  32. INSTALL WATER INLET HOUSING

    1. A150906

      Install a new gasket and water inlet housing with the 3 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  33. INSTALL TIMING CHAIN COVER OIL SEAL

    1. A150934N02

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

      09223-22010

    2. Apply a light coat of MP grease to the lip of the timing chain cover oil seal.

      Note:
      • Keep the lip free of foreign matter.

      • Do not tap in the timing chain cover oil seal at an angle.

      • Make sure that the timing chain cover oil seal edge does not stick out of the timing chain cover sub-assembly.

  34. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

  35. INSTALL CRANKSHAFT PULLEY

  36. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A234703C03

      *a

      Correct

      *b

      Incorrect

      *c

      Push

      *d

      Raise

      *e

      Cam

      *f

      Hook

      *g

      Pin

      Release the ratchet pawl, 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.

    2. A150932

      Install a new gasket, the bracket and No. 1 chain tensioner assembly 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, engage the hook again.

    3. A234711C02

      *a

      Turn

      *b

      Disconnect

      *c

      Hook

      *d

      Pin

      Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.

    4. A234712C02

      *a

      Turn

      *b

      Push

      *c

      Plunger

      Turn the crankshaft clockwise, then check that the plunger is extended.

  37. INSTALL OIL FILTER CAP ASSEMBLY

  38. INSTALL SPARK PLUG TUBE GASKET

    1. A296490C02

      *a

      Plug Tube Gasket without Sealing Part

      *b

      New Plug Tube Gasket

      *c

      Claw

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

      Note:
      • Keep the lip free of foreign matter.

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

      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.

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

  39. INSTALL CYLINDER HEAD COVER GASKET

    1. A296222

      Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

      Note:

      Remove any oil from the contact surfaces.

  40. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A150852

      Install 3 new gaskets to the camshaft bearing cap.

    2. A150944

      Apply seal packing as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      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 installing the cylinder head cover sub-assembly.

    3. A150850

      Install the cylinder head cover sub-assembly to the camshaft housing sub-assembly with a new seal washer and the 13 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  41. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    1. A085603C18

      *a

      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 of applying adhesive.

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

    2. A150856

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

      15 N*m

      153 kgf*cm

      11 ft.*lbf

  42. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    1. A296220

      Install a new gasket to the engine coolant temperature sensor.

    2. Install the engine coolant temperature sensor.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

      Tip:

      Perform "Inspection After Repair" after replacing the engine coolant temperature sensor.

      Click here

  43. INSTALL KNOCK CONTROL SENSOR

    1. A150904N08

      Install the knock control sensor with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      Note:

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

  44. INSTALL CRANKSHAFT POSITION SENSOR

    1. A157503C05

      *1

      O-ring

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

    2. A150855

      Install the crankshaft position sensor with the bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  45. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. A294057C02

      *1

      O-ring

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

    2. A150849C01

      *1

      Bracket

      Install the 2 camshaft timing oil control valves and bracket to the cylinder head cover sub-assembly with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Note:
      • Do not allow foreign matter to contact the oil seal face of the camshaft oil control valve assembly (surface that contacts cylinder head cover sub-assembly).

      • Be careful that the O-ring is not cracked or moved out of place when installing the camshaft oil control valve assembly.

  46. INSTALL CAMSHAFT POSITION SENSOR

    1. A095434C02

      *1

      O-ring

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

    2. A150848

      Install the 2 camshaft position sensors to the cylinder head cover sub-assembly with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Note:

      Make sure that the O-rings are not cracked or jammed when installing the camshaft position sensors.

  47. INSTALL SPARK PLUG

  48. INSTALL ENGINE COVER JOINT

    1. A150847

      Install the 2 engine cover joints to the cylinder head cover sub-assembly.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  49. INSTALL OIL FILLER CAP GASKET

    1. A128159

      Install the oil filler cap gasket to the oil filler cap sub-assembly.

  50. INSTALL OIL FILLER CAP SUB-ASSEMBLY

    1. A150846

      Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.