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Reassembly [07/2015 - ]: Procedure

  1. INSTALL RING PIN 
    NOTE:

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

    1. Using a plastic-faced hammer, tap in 2 ring pins until they stop.
      GTY301610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Protrusion Height

      Standard protrusion height

      4.3 to 5.3 mm (0.169 to 0.209 in.)

  2. INSTALL ENGINE BALANCER ASSEMBLY 
    1. Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.
      GTY571395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Driven Gear
      *2 Damper Cover
      *a Alignment Mark

      If the alignment marks are not aligned, align them.

      1. Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the shaft in place.
        GTY579930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Driven Gear
        *2 Damper Cover
        *a Alignment Mark
      2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.
    2. Install the engine balancer assembly to the stiffening crankcase assembly with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.
      GTY597836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

  3. INSTALL STUD BOLT 
    NOTE:

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

    1. Using an E5 and E8 "TORX" socket wrench, install the 3 stud bolts.
      GTY563033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Front Side *b Lower Side

      for Stud Bolt A 

      Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) 

      for Stud Bolt B 

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

  4. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Rotate the crankshaft clockwise so that the crankshaft pulley key is at the position 90° from the bottom as shown in the illustration.
      GTY667791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Key
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY319473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Stiffening Crankcase Assembly
      cylinder block Sub-assembly

      Seal packing

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

      Standard Seal Dimension

      Area Specified Condition
      Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick

      Application Length A

      28 mm (1.10 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the oil pan sub-assembly within 3 minutes after applying seal packing.
      • Do not apply oil for at least 2 hours after the installation.
    3. Check that the rear cutout parts are as shown in the illustration.
      GTY555809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Cutout
    4. Clean the bolts and their installation holes.
    5. Apply adhesive to 3 or more threads of the ends of the bolts A.
      GTY299260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      TEXT IN ILLUSTRATION

      *1 Adhesive
    6. Temporarily install the stiffening crankcase assembly with the 11 bolts.
      GTY649909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt Length

      Item Length
      Bolt A 65 mm (2.56 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 125 mm (4.92 in.)
      Bolt D 165 mm (6.50 in.)

      HINT: 

      Apply adhesive to the bolts A before installation.

    7. Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase assembly.
      GTY619503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for Bolt A 

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

      except Bolt A 

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  5. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. Install the No. 1 oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.
      GTY616761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  6. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new gasket.
    2. Align the protrusion of the gasket with the cutout of the oil strainer sub-assembly, and install the gasket to the oil strainer sub-assembly.
      GTY676971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Protrusion
    3. Install the oil strainer sub-assembly with the 3 bolts in several steps, in the sequence shown in the illustration.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  7. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY167807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
      • Do not apply oil for at least 2 hours after the installation.
    2. Install the oil pan sub-assembly with the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.
      GTY662886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      TEXT IN ILLUSTRATION

      *1 Nut

      HINT: 

      The bolt A and the nut A are tightened twice.

  8. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug to the oil pan sub-assembly.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  9. INSTALL OIL FILTER BRACKET CLIP 
    1. Install the oil filter bracket clip to the stiffening crankcase assembly.
  10. INSTALL OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. INSTALL REAR ENGINE OIL SEAL 

    See step  1

  12. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the cylinder block water jacket spacer to the cylinder block sub-assembly.
      GTY312332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL CYLINDER HEAD GASKET 

    See step  3

  14. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    See step  4

  15. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

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

    1. Using a plastic-faced hammer, tap in 10 camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.
      GTY296316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Protrusion Height

      Standard protrusion height

      2.7 to 3.3 mm (0.106 to 0.130 in.)

  16. INSTALL STRAIGHT PIN 
    NOTE:

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

    1. Using a plastic-faced hammer, tap in 2 straight pins to the camshaft housing sub-assembly.
      GTY297814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Protrusion Height

      Standard protrusion height

      5.0 to 7.0 mm (0.197 to 0.276 in.)

  17. INSTALL STUD BOLT 
    NOTE:

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

    1. When reusing the stud bolt.
      1. Apply adhesive to threads of the stud bolt.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using an E8 "TORX" socket wrench, install the stud bolt.
      GTY630727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

  18. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean the No. 1 camshaft bearing.
    2. Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.
      GTY322780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Vernier Caliper
    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Standard dimension A - B or B - A

      0 to 0.7 mm (0 to 0.0276 in.)

  19. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean the No. 2 camshaft bearing.
    2. Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.
      GTY365097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Vernier Caliper
    3. Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

      Standard distance

      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  20. INSTALL OIL CONTROL VALVE FILTER 
    1. Install the oil control valve filter to the No. 1 camshaft bearing cap.
      GTY384553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL CAMSHAFT 

    See step  12

  22. INSTALL CAMSHAFT BEARING CAP 

    See step  13

  23. INSTALL VALVE STEM CAP 

    See step  5

  24. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    See step  7

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

    See step  8

  26. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    See step  14

  27. INSTALL CAMSHAFT TIMING SPROCKET 

    See step  15

  28. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    See step  16

  29. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket to the crankshaft.
      GTY314227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. ADD ENGINE OIL 

    See step  17

  31. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    See step  18

  32. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    See step  24

  33. INSTALL CHAIN SUB-ASSEMBLY 

    See step  20

  34. INSTALL CHAIN TENSIONER SLIPPER 

    See step  21

  35. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    See step  22

  36. INSTALL TIMING CHAIN GUIDE 

    See step  23

  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    See step  24

  38. INSTALL TIMING CHAIN COVER PLATE 
    1. Install a new gasket and the timing chain cover plate with the 4 bolts.
      GTY312183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  39. INSTALL OIL PUMP RELIEF VALVE PLUG 
    1. Using a 14 mm hexagon wrench, install a new gasket and the oil pump relief valve plug.
      GTY312189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

  40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  41. INSTALL ENGINE MOUNTING BRACKET RH 

    Refer to PROCEDURE - Step 2

  42. INSTALL TIMING CHAIN COVER OIL SEAL 

    See step  1

  43. INSTALL SPARK PLUG TUBE GASKET 
    1. Tap in 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.
      GTY590944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Spark Plug Tube Gasket
      *2 Cylinder Head Cover Sub-assembly
      NOTE:
      • Do not allow foreign matter to contact the lip of the spark plug tube gasket.
      • Do not tap in the spark plug tube gasket at an angle.
  44. INSTALL STUD BOLT 
    NOTE:

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

    1. Using an E6 "TORX" socket wrench, install the 3 stud bolts.
      GTY316810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to 2 new camshaft bearing cap oil hole gaskets.
      GTY508605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 camshaft bearing cap oil hole gaskets.
    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
      NOTE:

      Remove any oil from the contact surface.

    4. Apply seal packing as shown in the illustration.
      GTY319690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      3.0 to 6.0 mm (0.118 to 0.236 in.)

      Application width A

      5.0 mm (0.197 in.)

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      *2 Timing Chain Cover Sub-assembly
      *3 Camshaft Housing Sub-assembly
      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.
    5. Align the cylinder head cover sub-assembly with the pin A. Then align the cylinder head cover sub-assembly with the pin B and install the cylinder head cover sub-assembly.
      GTY545085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      NOTE:

      Do not apply oil for at least 2 hours after the installation.

  46. INSTALL CRANKSHAFT PULLEY 
    1. Align the crankshaft pulley key with the key groove of the crankshaft pulley.
      GTY655844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
    2. Using SST, hold the crankshaft pulley and install the pulley bolt.
      • SST: 09213-54015 
      • SST: 09330-00021 

      HINT: 

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

      Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf) 

  47. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  48. INSTALL SEPARATOR CASE 
    1. Apply a light coat of engine oil to a new gasket.
      GTY430039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the gasket to the separator case.
    3. Install the separator case with the 2 bolts.

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

  49. INSTALL VENTILATION CASE SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY186229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the ventilation case sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
    2. Install the ventilation case sub-assembly, and install the 8 bolts and 2 nuts in the order shown in the illustration.
      GTY596890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      Do not apply oil for at least 2 hours after the installation.

      HINT: 

      The bolt A is tightened twice.

  50. INSTALL VENTILATION VALVE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  51. INSTALL CAMSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  52. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  53. INSTALL OIL FILLER CAP GASKET 
    1. Install a new oil filler cap gasket to the oil filler cap sub-assembly.
  54. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
  55. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  56. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  57. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  58. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  59. INSTALL ENGINE COVER JOINT 
    1. Install the 3 engine cover joints.
      GTY508604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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