Engine Unit: Reassembly: Reassembly

HINT:

Check whether the engine is TMC made or not by referring to the following illustration.

Fig 1: Identifying Whether The Engine Is TMC Made

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*A	for TMC Made Engine	*B	except TMC Made Engine
*1	Engine Oil Level Dipstick Guide	*2	Water Inlet Housing
*3	Water Inlet Housing Drain Cock Assembly	-	-

INSTALL NO. 1 BALANCESHAFT BEARING

Align the bearing claw with the claw groove, and push in the 8 bearings.

Fig 2: Identifying No. 1 Balanceshaft Bearings

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not apply engine oil to the contact surfaces of the balanceshaft bearing and balanceshaft housing.

TEXT IN ILLUSTRATION

*a	Stiffening Crankcase Side
*b	Balanceshaft Housing Side

Apply a light coat of the engine oil to the bearings.

INSTALL NO. 1 AND NO. 2 BALANCESHAFTS

Rotate the No. 1 driven gear of the No. 1 balanceshaft in the rotating direction until it hits the stopper.

Fig 3: Rotating The No. 1 Driven Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 1 Driven Gear
*2	No. 2 Driven Gear
*a	Matchmark
*b	Rotating Direction

Confirm that the matchmarks on the No. 1 and No. 2 driven gears are aligned.

Confirm that the alignment marks on the No. 1 and No. 2 balanceshafts are aligned.

Fig 4: Aligning Matchmarks On No. 1 And No. 2 Balanceshafts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 1 Balanceshaft
*2	No. 2 Balanceshaft
*a	Alignment Mark

Align the alignment marks on the No. 1 and No. 2 balanceshafts as shown in the illustration.

Fig 5: Identifying Alignment Marks On No. 1 And No. 2 Balanceshafts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 1 Balanceshaft
*2	No. 2 Balanceshaft
*a	Alignment Mark
*b	Adjusting Hole
*c	Timing Mark

Place the No. 1 and No. 2 balancshafts onto the crankcase.
Apply a light coat of engine oil to the threads and under the heads of the bolts.
Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Fig 6: Tightening Bolts In Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 22 N*m (220 kgf*cm, 16 ft.*lbf)

Mark the front of the bolts with paint.

Fig 7: Final Balanceshaft Bolts Torque Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Paint Mark
	Engine Front

Further tighten the bolts by 90° as shown in the illustration.
Check that the paint mark is now at a 90° angle to the front.

INSTALL STIFFENING CRANKCASE ASSEMBLY

Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and crankcase.
Place a new O-ring on the cylinder block as shown in the illustration.

Fig 8: Identifying O-Ring From Cylinder Block
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

With the No. 1 crank pin of the crankshaft placed at the 6 o'clock position, install the No. 1 and No. 2 balanceshafts and align the adjusting holes as shown in the illustration.

Fig 9: Aligning No. 1 And No. 2 Balanceshafts Adjusting Holes

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	No. 1 Crank Pin
*a	Adjusting Hole

Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.098 to 0.118 in.)) as shown in the illustration.

Fig 10: Applying Seal Packing To Crankcase

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Seal Packing

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

NOTE:

Remove any oil from the contact surface.
Install the crankcase within 3 minutes of applying seal packing.
Do not add engine oil for at least 2 hours after installing the crankcase.

TEXT IN ILLUSTRATION

*a	Seal Diameter 2.5 to 3.0 mm (0.098 to 0.118 in.)

Temporarily install the crankcase with the 11 bolts.

Fig 11: Identifying Crankcase Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Item	Bolt Length
A	122 mm (4.80 in.)
B	45 mm (1.77 in.)

Uniformly tighten the bolts.

Fig 12: Bolts Tighten Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Confirm that the timing marks on the balanceshafts are aligned when the key groove the is placed at the 6 o'clock position, as shown in the illustration.

Fig 13: Identifying Balanceshaft Timing Marks

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Key
*a	Timing Mark

INSTALL OIL PUMP ASSEMBLY . Refer to INSTALLATION - Step 1
INSTALL REAR CRANKSHAFT OIL SEAL See step 1
INSTALL NO. 1 TAPER HEAD SCREW PLUG
1. Apply adhesive to 2 or 3 threads of the plug, and install it.
  
  Fig 14: Identifying No. 1 Taper Head Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  NOTE:
  - Install the plug within 3 minutes of applying adhesive.
  - Do not add coolant for at least an hour after installing the plug.

INSTALL OIL CONTROL VALVE FILTER

Check that there are no foreign objects on the mesh part of the oil control valve filter.

Using a 8 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the plug.

Fig 15: Identifying Oil Control Valve Filter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

TEXT IN ILLUSTRATION

*1	Plug
*2	Gasket
*3	Oil Control Valve Filter

INSTALL INLET WATER HOUSING (except TMC Made Engine)

Fig 16: Identifying Inlet Water Housing O-Rings

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the 2 new O-rings onto the inlet water housing.
Using several steps, uniformly install and tighten the 5 bolts in the sequence shown in the illustration.

Fig 17: Identifying Inlet Water Housing Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)

Using E5 "TORX" socket wrench, remove the 6 stud bolts from the inlet water housing.

Fig 18: Identifying Inlet Water Housing Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

RH Side

Front Side

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

INSTALL INLET WATER HOUSING DRAIN COCK ASSEMBLY (except TMC Made Engine)

Fig 19: Applying Adhesive To Drain Cock Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply adhesive to 2 or 3 threads of the drain cock.
  Adhesive
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  TEXT IN ILLUSTRATION
  
  *1 Adhesive
2. After tightening the drain cock to the specified torque, further tighten it one turn or less to set the drain cock pipe as specified in the illustration.
  
  Fig 20: Identifying Plug Onto Water Drain Cock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  NOTE:
  - Install the drain cock within 3 minutes of applying adhesive.
  - Do not add coolant for at least an hour after installing the drain cock.
  - Do not turn the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque.
  - Do not loosen the drain cock after setting it correctly.
3. Install the plug onto the water drain cock.
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
INSTALL CYLINDER BLOCK WATER JACKET SPACER (for TMC Made Engine)
1. Install the cylinder block water jacket spacer into the cylinder block as shown in the illustration.
  
  Fig 21: Install Cylinder Block Water Jacket Spacer (For TMC Made Engine)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Be sure to face the slope to the front of the engine.
  TEXT IN ILLUSTRATION
  
  *a Slope
INSTALL CYLINDER BLOCK WATER JACKET SPACER (except TMC Made Engine)
1. Install the cylinder block water jacket spacer into the cylinder block as shown in the illustration.
  
  Fig 22: Install Cylinder Block Water Jacket Spacer (Except TMC Made Engine)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Be sure to face the slope to the front of the engine.
  TEXT IN ILLUSTRATION
  
  *a Slope
INSTALL CYLINDER HEAD GASKET See step 1
INSTALL CYLINDER HEAD SUB-ASSEMBLY See step 2
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Apply a light coat of engine oil onto the O-ring.
  
  Fig 23: Identifying Camshaft Timing Oil Control Valve Assembly O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 O-Ring
2. Install the camshaft timing oil control valve with the bolt.
  
  Fig 24: Location of Camshaft Timing Oil Control Valve Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY See step 1
INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
1. Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.
  
  Fig 25: Installing Camshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
INSTALL NO. 1 CAMSHAFT BEARING
1. Clean the installation surfaces and the inner and outer surfaces of the bearing.
  NOTE:
  Keep the installation surfaces and the back surfaces of the bearing free of engine oil.
2. Align the claws and install No. 1 camshaft bearing onto No. 1 camshaft bearing cap.
  
  Fig 26: Install No. 1 Camshaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Claw
INSTALL NO. 2 CAMSHAFT BEARING
1. Clean the installation surfaces and the inner and outer surfaces of the bearing.
  NOTE:
  Keep the installation surfaces and the back surfaces of the bearing free of engine oil.
2. Install the No. 2 camshaft bearing onto the cylinder head.
  
  Fig 27: Identifying No. 2 Camshaft Bearing Onto Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CAMSHAFT

Apply a light coat of engine oil to the journal portion.
Place the camshaft on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.

Fig 28: Placing Camshaft On Cylinder Head
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

Fig 29: Camshaft Bolt Tightening Sequence

No. 1 bearing cap

Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf)

No. 3 bearing cap

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

NOTE:

Determine the thrust direction of the camshaft by checking the location of the No. 1 bearing cap. Then tighten the bolts.
Install the camshaft with the timing with the timing mark of the camshaft timing gear on top.

TEXT IN ILLUSTRATION

*1	No. 1 Bearing Cap
*2	No. 3 Bearing Cap

INSTALL NO. 2 CAMSHAFT

Apply a light coat of engine oil to the journal portion.
Place the camshaft on the cylinder head with the No. 2 cam lobes facing the directions shown in the illustration.

Fig 30: Identifying No. 2 Cam Lobes Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

Fig 31: No. 2 Camshaft Bolt Tightening Sequence

No. 2 bearing cap

Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf)

No. 3 bearing cap

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

NOTE:

Determine the thrust direction of the camshaft by checking the location of the No. 2 bearing cap. Then tighten the bolts.
Install the camshaft with the timing with the timing mark of the camshaft timing gear on top.

TEXT IN ILLUSTRATION

*1	No. 2 Bearing Cap
*2	No. 3 Bearing Cap

INSTALL NO. 2 CHAIN SUB-ASSEMBLY See step 11
INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET See step 12
INSTALL NO. 1 CHAIN VIBRATION DAMPER See step 13
INSTALL CHAIN SUB-ASSEMBLY See step 14
INSTALL CHAIN TENSIONER SLIPPER See step 15
INSTALL TIMING CHAIN GUIDE See step 16
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE See step 17
INSTALL FRONT CRANKSHAFT OIL SEAL
1. Apply MP grease to the tip of a oil seal.
  NOTE:
  Keep the lip free of foreign objects.
2. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge.
  
  Fig 32: Tapping Timing Chain Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09223-22010
  NOTE:
  Do not tap the oil seal at an angle.
INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY See step 18
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 19
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY See step 20
INSTALL CRANKSHAFT POSITION SENSOR (for TMC Made Engine)

Fig 33: Identifying Crankshaft Position Sensor O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply a light coat of engine oil onto the O-ring.
  TEXT IN ILLUSTRATION
  
  *1 O-Ring
2. Install the crankshaft position sensor with the bolt.
  
  Fig 34: Identifying Crankshaft Position Sensor Wire And Clamps (For TMC Made Engine)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
3. Engage the clamp and connect the crankshaft position sensor wire to the water pump.
4. Connect the crankshaft position sensor wire to the wire harness clamp bracket.
5. Engage the clamp and connect the crankshaft position sensor connector to the connector clamp bracket.
6. Connect the crankshaft position sensor wire to the rib portion of the timing chain cover.
  TEXT IN ILLUSTRATION
  
  *a Timing Chain Cover Rib Portion
INSTALL CRANKSHAFT POSITION SENSOR (except TMC Made Engine)

Fig 35: Identifying Crankshaft Position Sensor O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply a light coat of engine oil onto the O-ring.
  TEXT IN ILLUSTRATION
  
  *1 O-Ring
2. Install the crankshaft position sensor with the bolt.
  
  Fig 36: Identifying Crankshaft Position Sensor Connector And Clamps (Except TMC Made Engine)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
3. Connect the crankshaft position sensor wire to the wire harness clamp bracket.
4. Engage the clamp and connect the crankshaft position sensor connector to the connector clamp bracket.

INSTALL OIL PAN SUB-ASSEMBLY

Remove any old packing material from the contact surface.

Apply a continuous bead of seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) to the oil pan mating surface as shown in the illustration.

Fig 37: Applying Oil Pan Seal Packing

Seal packing

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

NOTE:

Remove any oil from the contact surface.
Install the oil pan within 3 minutes of applying seal packing.
Do not expose the seal to engine oil within 2 hours of installation.
Do not start the engine for at least 2 hours after the installation

TEXT IN ILLUSTRATION

*1	Seal Packing
*a	Seal Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)

Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

Fig 38: Identifying Oil Pan With Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

*1 Nut

INSTALL OIL PAN DRAIN PLUG
1. Install the oil drain plug with a new gasket.
  
  Fig 39: Location of Oil Pan Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
INSTALL ENGINE WATER PUMP ASSEMBLY (for TMC Made Engine) . Refer to INSTALLATION - Step 1
INSTALL ENGINE WATER PUMP ASSEMBLY (except TMC Made Engine) . Refer to INSTALLATION - Step 2
INSTALL WATER PUMP PULLEY . Refer to INSTALLATION - Step 3
INSTALL CRANKSHAFT PULLEY See step 22
INSPECT VALVE CLEARANCE See step 7
ADJUST VALVE CLEARANCE See step 8
INSTALL CAMSHAFT POSITION SENSOR
1. Apply a light coat of engine oil onto the O-ring.
  
  Fig 40: Identifying Camshaft Position Sensor O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 O-Ring
2. Install the camshaft position sensor with the bolt.
  
  Fig 41: Location of Camshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL CYLINDER HEAD COVER GASKET
1. Install a new cylinder head cover gasket onto the cylinder head cover.
  
  Fig 42: Identifying Packing Material From Contact Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove any old packing material from the contact surface.
2. Apply seal packing to the 2 locations shown in the illustration.
  
  Fig 43: Applying Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal Packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  NOTE:
  - Remove any oil from the contact surface.
  - Install the oil pan within 3 minutes of applying seal packing.
  - Do not add engine oil for at least 2 hours after installing the oil pan.
  TEXT IN ILLUSTRATION
  
  *a Seal Packing
3. Install the cylinder head cover with the 8 bolts and 2 nuts.
  
  Fig 44: Identifying Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt A
  
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Bolt B
  
  Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf)
  
  Nut
  
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  TEXT IN ILLUSTRATION
  
  *1 Nut
INSTALL OIL FILTER UNION
1. Using a 12 mm socket hexagon wrench, install the oil filter union.
  
  Fig 45: Location of Oil Filter Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
INSTALL OIL FILTER SUB-ASSEMBLY . Refer to REPLACEMENT - Step 4
INSTALL SPARK PLUG . Refer to INSTALLATION - Step 1
INSTALL VENTILATION VALVE SUB-ASSEMBLY
1. Apply adhesive to the threads of the ventilation valve.
  
  Fig 46: Apply Adhesive To Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  TEXT IN ILLUSTRATION
  
  *1 Adhesive
2. Using a deep socket wrench 22 mm, install the ventilation valve onto the cylinder head cover.
  
  Fig 47: Location of Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
INSTALL OIL FILLER CAP GASKET
1. Install the oil filler cap gasket onto the oil filler cap.
  
  Fig 48: Location of Oil Filler Cap Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install the oil filler cap onto the cylinder head cover.
  
  Fig 49: Location of Oil Filler Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002