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Engine Unit: Reassembly: Reassembly

  1. INSTALL ENGINE BALANCER ASSEMBLY 
    1. Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.
      Fig 1: Aligning Balance Shaft Damper Cover Mark & Balance Shaft Driven Gear Mark
      GTY313714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Alignment Mark

      If the alignment marks are not aligned, realign them.

      1. Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place.
        Fig 2: Rotating Balance Shaft Driven Gear
        GTY310279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Driven Gear
        *2 Damper Cover
        *3 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 to the stiffening crankcase with the 3 bolts and tighten the bolts in the sequence shown in the illustration.
      Fig 3: Identifying Engine Balancer Bolts With Tightening Sequence
      GTY195094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  2. INSTALL STIFFENING CRANKCASE STUD BOLT 
    NOTE:

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

    Fig 4: Stiffening Crankcase Stud Bolts
    GTY311649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *A Front Side *B Lower Side
    1. Using an E5 and E8 "TORX" socket wrench, install the stud bolts.

      for stud bolt A 

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

      for stud bolt B 

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

  3. INSTALL STIFFENING CRANKCASE RING PIN 
    NOTE:

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

    Fig 5: Stiffening Crankcase Ring Pin
    GTY312456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

      Standard protrusion height

      4.3 to 5.3 mm (0.169 to 0.209 in.)

      TEXT IN ILLUSTRATION

      *1 Protrusion Height
  4. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Rotate the crankshaft clockwise so that the crankshaft key is at the position 270° from the bottom as shown in the illustration.
      Fig 6: Rotating Crankshaft
      GTY312846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Key
    2. Apply seal packing in a continuous line as shown in the illustration.
      Fig 7: Applying Seal Packing
      GTY313115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.)

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      *2 Continuous Line
      *3 Dashed Line
      Stiffening Crankcase
      Cylinder Block
      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
      • Do not apply oil for at least 4 hours after the installation.
      • Do not start the engine for at least 4 hours after the installation.
    3. Check that the rear cutouts are as shown in the illustration.
      Fig 8: Checking Rear Cutouts
      GTY312138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Cutout
    4. Clean the bolts and their installation holes.
    5. Apply adhesive to 3 threads or more at the end of bolt A.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Temporarily install the stiffening crankcase with the 11 bolts.
      Fig 9: Stiffening Crankcase Bolts Tightening Sequence
      GTY195128Courtesy 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 bolt A before installing it

    7. Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase.
      Fig 10: Stiffening Crankcase Bolts Tightening Sequence
      GTY186518Courtesy 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 oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the sequence shown in the illustration.
      Fig 11: No. 1 Oil Pan Baffle Plate Bolts Tightening Sequence
      GTY195092Courtesy 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.
      Fig 12: Aligning Oil Strainer Gasket
      GTY312979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protrusion
    2. Align the protrusion of the gasket with the cutout of the oil strainer and install the gasket to the oil strainer.
    3. Install the oil strainer 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.
      Fig 13: Applying Packing Seal
      GTY310773Courtesy 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.)

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
      • Do not apply oil for at least 4 hours after the installation.
      • Do not start the engine for at least 4 hours after the installation.
    2. Install the oil pan with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration.
      Fig 14: Oil Pan Bolts And Nuts Tightening Sequence
      GTY195091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      Bolt A and nut A are tightened twice.

  8. INSTALL OIL FILTER ELEMENT  . Refer to REPLACEMENT - Step 4
  9. INSTALL ENGINE REAR OIL SEAL  See step  1
  10. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the water jacket spacer to the cylinder block.
  11. INSTALL CYLINDER HEAD GASKET  See step  1
  12. INSTALL CYLINDER HEAD SUB-ASSEMBLY  See step  2
  13. SET CAMSHAFT TIMING GEAR ASSEMBLY  See step  4
  14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

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

    Fig 15: Camshaft Housing Ring Pins
    GTY312763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.

      Standard protrusion height

      2.7 to 3.3 mm (0.106 to 0.130 in.)

      TEXT IN ILLUSTRATION

      *1 Protrusion Height
  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE:

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

    Fig 16: Camshaft Housing Strait Pins
    GTY311076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing.

      Standard protrusion height

      5.0 to 7.0 mm (0.197 to 0.276 in.)

      TEXT IN ILLUSTRATION

      *1 Protrusion Height
  16. INSTALL CAMSHAFT HOUSING STUD BOLT 
    NOTE:

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

    Fig 17: Locating Camshaft Housing Stud Bolt
    GTY184176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using an E8 "TORX" socket wrench, install the stud bolt.

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

  17. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean the No. 1 camshaft bearing.
      Fig 18: Measuring No. 1 Camshaft Bearing
      GTY312110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

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

      Dimension A - B or B - A

      0 to 0.7 mm (0 to 0.0276 in.)

  18. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean the No. 2 camshaft bearing.
      Fig 19: Measuring No. 2 Camshaft Bearing
      GTY311450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Vernier Caliper
    2. Install the camshaft bearing to the camshaft housing.
    3. Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

      Standard distance

      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  19. INSTALL OIL CONTROL VALVE FILTER 
    1. Install the oil control valve filter to the No. 1 camshaft bearing cap.
      Fig 20: Removing/Installing Oil Control Valve Filter
      GTY179582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL CAMSHAFT  See step  10
  21. INSTALL CAMSHAFT BEARING CAP  See step  11
  22. INSTALL VALVE STEM CAP  See step  3
  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY  See step  5
  24. INSTALL VALVE ROCKER ARM SUB-ASSEMBLY  See step  6
  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY  See step  12
  26. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY  See step  13
  27. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY  See step  14
  28. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket to the crankshaft.
  29. ADD ENGINE OIL  See step  15
  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION  See step  16
  31. INSTALL NO. 1 CHAIN VIBRATION DAMPER  See step  17
  32. INSTALL CHAIN SUB-ASSEMBLY  See step  18
  33. INSTALL CHAIN TENSIONER SLIPPER  See step  19
  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  See step  20
  35. INSTALL TIMING CHAIN GUIDE  See step  21
  36. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION  See step  22
  37. INSTALL TIMING CHAIN COVER PLATE 
    1. Install a new gasket and the timing chain cover plate with the 4 bolts.

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

  38. INSTALL TIMING CHAIN COVER TIGHT PLUG 
    1. Using a 14 mm hexagon wrench, install a new gasket and plug.

      Torque: 30 N*m (306 kgf*cm, 20 ft.*lbf) 

  39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 1
  40. INSTALL ENGINE MOUNTING BRACKET RH  . Refer to INSTALLATION - Step 2
  41. INSTALL TIMING CHAIN COVER OIL SEAL  See step  1
  42. INSTALL SPARK PLUG TUBE GASKET  . Refer to INSTALLATION - Step 7
  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 8
  44. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the crankshaft pulley.
      Fig 21: View Of Holding Crankshaft Pulley Using SST
      GTY234895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, hold the crankshaft pulley and install the pulley bolt.
      • SST: 09213-54015 
      • SST: 91551-80650 
      • SST: 09330-00021 

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

  45. INSTALL CRANKSHAFT POSITION SENSOR  . Refer to INSTALLATION - Step 1
  46. INSTALL WATER INLET HOUSING 
    1. Install a new gasket and the water inlet housing with the 4 bolts and nut.

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

  47. INSTALL WATER PUMP ASSEMBLY  . Refer to INSTALLATION - Step 1
  48. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY  . Refer to INSTALLATION - Step 2
  49. INSTALL THERMOSTAT  . Refer to INSTALLATION - Step 1
  50. INSTALL WATER INLET  . Refer to INSTALLATION - Step 2
  51. INSTALL NO. 1 WATER BY-PASS PIPE 
    1. Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.

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

  52. INSTALL SEPARATOR CASE 
    1. Apply a light coat of engine oil to a new gasket.
    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) 

  53. INSTALL PCV CASE 
    1. Apply seal packing in a continuous line as shown in the illustration.
      Fig 22: Applying Packing Seal
      GTY311480Courtesy 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.)

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Install the PCV case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
    2. Install the PCV case, and then install the 8 bolts and 2 nuts in the order shown in the illustration.
      Fig 23: Ventilation Case Bolts And Nuts Tightening Sequence
      GTY238526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      Bolt A is tightened twice.

  54. INSTALL PCV VALVE  . Refer to INSTALLATION - Step 1
  55. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)  . Refer to INSTALLATION - Step 2
  56. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)  . Refer to INSTALLATION - Step 1
  57. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)  . Refer to INSTALLATION - Step 2
  58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)  . Refer to INSTALLATION - Step 1
  59. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install a new gasket to the oil filler cap.
    2. Install the oil filler cap to the cylinder head.
  60. INSTALL SPARK PLUG  . Refer to INSTALLATION - Step 1
  61. INSTALL ENGINE COVER JOINT 
    1. Install the 3 joints.

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

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