Engine Unit: Replacement

REPLACE RING PIN
1. Remove the 2 ring pins.
2. Using a plastic-faced hammer, tap in 2 new ring pins to the crankcase.
  Standard protrusion: 3 mm (0.1181 in.)
  
  Fig 1: Locating Ring Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE STUD BOLT
1. for Crankcase:
  1. Remove the 2 stud bolts.
  2. Using "TORX" socket wrench E5, install the 2 stud bolts as shown in the illustration.
    Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
    
    Fig 2: Locating Stud Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for water inlet housing:
  1. Remove the 2 stud bolts.
  2. Using a "TORX" socket E5, install the 2 stud bolts as shown in the illustration.
    Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
    
    Fig 3: Identifying Stud Bolts Dimension
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE SPARK PLUG TUBE GASKET
1. Pry up the claws of the ventilation baffle plate.
  NOTE: Do not deform the claws of the baffle plate more than necessary.
  
  Fig 4: Identifying Claws Of Baffle Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 gaskets from the cylinder head covers.
  NOTE:
  - Try not to deform the plug tube gaskets. The removed gaskets will be used when reinstalling the gaskets.
  - Do not damage the connection of the cylinder head cover.
3. Using a cutter, cut off the sealing part of the removed plug tube gasket.
  
  Fig 5: Identifying Plug Tube Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plug tube gasket which has had the sealing part cut off, uniformly tap in a plug tube gasket all the way.
  NOTE:
  - Keep the lip free of foreign matter.
  - Do not tap on the oil seal at an angle.
  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.
  
  Fig 6: Installing Plug Tube Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Return the claws of the ventilation baffle plate to their original positions.
REPLACE TIMING CHAIN OR BELT COVER OIL SEAL
1. Using a screwdriver and hammer, remove the oil seal.
  NOTE: Be careful not to damage the timing chain cover sub-assembly.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 7: Removing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
  SST 09223-22010
  
  Fig 8: Installing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply a light coat of MP grease to the lip of the oil seal.
  NOTE:
  - Keep the lip free of 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 cover.
REPLACE ENGINE REAR OIL SEAL
1. Using a knife, cut off the oil seal lip.
2. Using a screwdriver with its tip taped, pry out the oil seal.
  NOTE: After removing the oil seal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.
  
  Fig 9: Prying Out Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply MP grease to the new oil seal lip.
4. Using SST and a hammer, evenly tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
  SST 09223-15030, 09950-70010 (09951-07100)
  NOTE:
  - Keep the lip free from foreign materials.
  - Do not tap on the oil seal at an angle.
  - Wipe off any grease that is on the crankshaft.
    
    Fig 10: Installing Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002