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Engine Unit: Reassembly: Reassembly

  1. INSTALL STIFFENING CRANKCASE RING PIN 
    NOTE:

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

    Fig 1: Installing Stiffening Crankcase Ring Pin
    GTY227160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *a Width
    *b Height
    *c Protrusion Height
    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.) 8 mm (0.315 in.) 11 mm (0.433 in.)
  2. INSTALL STIFFENING CRANKCASE STUD BOLT 
    NOTE:

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

    Fig 2: Identifying Stiffening Crankcase Stud Bolt
    GTY291748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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. Apply seal packing in a continuous line as shown in the illustration.
      Fig 3: Identifying Stiffening Crankcase Seal Packing Points
      GTY234606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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. Install the stiffening crankcase with the 11 bolts in the sequence shown in the illustration.
      Fig 4: Identifying Stiffening Crankcase Bolts And Tightening Sequence
      GTY217966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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  . Refer to INSTALLATION - Step 1
  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY  . Refer to INSTALLATION - Step 2
  6. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the drain plug.
      Fig 5: Identifying Oil Pan Drain Plug
      GTY166811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

  7. INSTALL ENGINE REAR OIL SEAL  See step  1
  8. INSTALL NO. 1 TAPER SCREW PLUG 
    1. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).
      Fig 6: Identifying No. 1 Taper Screw Plug
      GTY293451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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. Apply adhesive to the threads of the ventilation valve sub-assembly.
      Fig 7: Applying Adhesive To Threads Of Ventilation Valve Sub-Assembly
      GTY217811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Adhesive

      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. Install the ventilation valve sub-assembly.
      Fig 8: Identifying Ventilation Valve
      GTY164619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

  10. INSTALL CYLINDER HEAD GASKET  See step  5
  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY  See step  6
  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 See step  2.
    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. Apply engine oil to the valve lash adjuster tips and valve stem cap ends.
      Fig 9: Identifying Valve Rocker Arm
      GTY237479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Valve Rocker Arm
      *2 Valve Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap
    2. Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.
  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE:

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

    Fig 10: Identifying Camshaft Straight Pin And Installation Specifications
    GTY224480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *a Width
    *b Height
    *c Protrusion Height
    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  See step  1
  17. INSTALL OIL CONTROL VALVE FILTER 
    1. Check that no foreign matter is on the mesh part of the oil control valve filter.
      Fig 11: Identifying Oil Control Valve Filter
      GTY219657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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  See step  2
  19. INSTALL NO. 2 CAMSHAFT  See step  3
  20. INSTALL CAMSHAFT  See step  4
  21. INSTALL CAMSHAFT BEARING CAP  See step  5
  22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY  See step  6
  23. INSTALL CAMSHAFT TIMING SPROCKET  See step  7
  24. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY  See step  8
  25. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.
      Fig 12: Identifying Crankshaft Timing Gear Keys
      GTY161232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      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. Install the crankshaft position sensor plate with the "F" mark facing forward.
      Fig 13: Identifying No. 1 Crankshaft Position Sensor Plate
      GTY161345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 2 CHAIN SUB-ASSEMBLY  . Refer to INSTALLATION - Step 6
  28. INSTALL CRANKSHAFT TIMING SPROCKET  . Refer to INSTALLATION - Step 7
  29. INSTALL NO. 1 CHAIN VIBRATION DAMPER  See step  9
  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION  See step  10
  31. INSTALL CHAIN SUB-ASSEMBLY  See step  11
  32. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION  See step  12
  33. INSTALL CHAIN TENSIONER SLIPPER  See step  14
  34. INSTALL NO. 2 CHAIN VIBRATION DAMPER  See step  13
  35. INSTALL INLET WATER SUB-ASSEMBLY STUD BOLT 
    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.
      Fig 14: Identifying Inlet Water Sub-Assembly Stud Bolts And Installation Specifications
      GTY218860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  36. INSTALL INLET WATER SUB-ASSEMBLY 
    1. Install a new gasket and the inlet water sub-assembly with the bolt and 2 nuts.
      Fig 15: View Of Inlet Water Sub-Assembly, Nuts And Bolts
      GTY223182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 15
  38. INSTALL TIMING CHAIN COVER OIL SEAL  See step  1
  39. INSTALL CRANKSHAFT PULLEY  See step  2
  40. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  See step  18
  41. INSTALL OIL FILTER CAP ASSEMBLY  . Refer to REPLACEMENT - Step 4
  42. INSTALL SPARK PLUG TUBE GASKET 
    1. Using a cutter knife, cut off the seal part of the removed gasket.
      Fig 16: Identifying Spark Plug Tube Gasket
      GTY214249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Part to Cut Off
    2. 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.
      Fig 17: Identifying Plug Tube Gasket And Sealing Part
      GTY215326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Plug Tube Gasket without Sealing Part
      *2 New Plug Tube Gasket
      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap in the plug tube gasket.

      HINT: 

      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. Install a new cylinder head cover gasket to the cylinder head cover.
      Fig 18: Identifying Cylinder Head Cover Gasket
      GTY232049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Cylinder Head Cover
      *2 Cylinder Head Cover Gasket
      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. Install 2 new gaskets to the camshaft bearing cap.
      Fig 19: Identifying Gaskets On Camshaft Bearing Cap
      GTY218254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing as shown in the illustration.
      Fig 20: Applying Seal Packing
      GTY219673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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. Install the cylinder head cover with a new seal washer and the 13 bolts.
      Fig 21: Identifying Cylinder Head Cover, Seal Washer And Bolts
      GTY210794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.).

      Fig 22: Identifying Timing Chain Cover, Camshaft Housing, And Cylinder Head Cover Gasket
      GTY228217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Timing Chain Cover
      *2 Camshaft Housing
      *3 Cylinder Head Cover Gasket
  45. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.
      Fig 23: Applying Adhesive To Threads Of Engine Oil Pressure Switch Assembly
      GTY229396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Adhesive

      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. Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.
      Fig 24: Identifying Engine Oil Pressure Switch Assembly
      GTY161341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

  46. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    1. Install a new gasket and the engine coolant temperature sensor.
      Fig 25: Identifying Engine Coolant Temperature Sensor And Gasket
      GTY216741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

  47. INSTALL KNOCK SENSOR 
    1. Install the knock sensor with the bolt.
      Fig 26: Identifying Knock Sensor With Bolt
      GTY165847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      NOTE:

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

  48. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Apply a light coat of engine oil to the O-ring of the sensor.
      Fig 27: Applying A Light Coat Of Engine Oil To O-Ring Of Sensor
      GTY220373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the crankshaft position sensor with the bolt.
      Fig 28: Identifying Bolt And Crankshaft Position Sensor
      GTY164151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  49. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve.
      Fig 29: Applying A Light Coat Of Engine Oil To A New O-Ring
      GTY214680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the camshaft timing oil control valve with the bolt.
      Fig 30: Identifying Camshaft Timing Oil Control Valve Assembly
      GTY210771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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. Apply a light coat of engine oil to the O-ring of the sensor.
      Fig 31: Identifying Camshaft Position Sensor O-Ring
      GTY212751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the camshaft position sensor with the bolt.
      Fig 32: Identifying Camshaft Position Sensor And Bolt
      GTY211832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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  . Refer to INSTALLATION - Step 1
  52. INSTALL ENGINE COVER JOINT BOLT 
    1. Install the 3 engine cover joint bolts.
      Fig 33: Identifying Engine Cover Joint Bolts
      GTY221306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  53. INSTALL WIRING HARNESS CLAMP BRACKET 
    1. Install the wiring harness clamp bracket with the bolt.
      Fig 34: Identifying Wiring Harness Clamp Bracket And Bolt
      GTY234193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  54. INSTALL OIL FILLER CAP GASKET 
    1. Install the gasket to the oil filler cap.
      Fig 35: Identifying Oil Filler Cap Gasket
      GTY161447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap.
      Fig 36: View Of Oil Filler Cap
      GTY211679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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