Engine Unit: Reassembly

1. Apply seal packing in a continuous bead (diameter: 2.5 mm (0.0984 in.)) to the places shown in the illustration.

   Seal packing: 

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

   NOTE:

   • Remove any oil from the contact surfaces.
   • Install the crankcase within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing the stiffening crankcase.
   Fig 1: Identifying Stiffening Crankcase Assembly

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2. Install the stiffening crankcase with the 11 bolts.

   Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

   Bolt Length 

   BOLT LENGTH CHART
   
   

   Item	Length
   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, 16 ft.*lbf) 

   Fig 2: Locating Stiffening Crankcase With Bolts

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4. Wipe off any excess seal packing with a clean piece of cloth.

1. Using SST and a hammer, evenly tap the 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 of foreign matter.
   • Do not tap on the oil seal at an angle.
2. Apply MP grease to a new oil seal lip.

Fig 3: Installing Rear Engine Oil Seal

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1. Install a new gasket and the oil pan drain plug.

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

   Fig 4: Locating Oil Pan Drain Plug

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1. Apply adhesive to the threads of the drain cock.

   Adhesive: 

   Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

   Fig 5: Applying Adhesive To Threads Of Drain Cock

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2. Install the water drain cock as shown in the illustration.

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

   NOTE:

   • Do not rotate the drain cock more than 1 revolution (360°) after tightening it to the specified torque.
   • Install the water drain cock within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing the water drain cock.
3. Install the water drain cock plug to the water drain cock.

   Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

   Fig 6: Locating Water Drain Cock Plug To Water Drain Cock

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1. Apply adhesive to the threads of the ventilation valve.

   Adhesive: 

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

   Fig 7: Applying Adhesive To Threads Of Ventilation Valve

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2. Install the ventilation valve.

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

   NOTE:

   • Install the crankcase within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing the ventilation valve.
     Fig 8: Locating Ventilation Valve

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1. Place the lash adjuster into a container filled with engine oil.
2. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

   SST 09276-75010 

3. Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed it.

   OK: 

   Plunger moves up and down  .

   NOTE: When bleeding the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.
5. After bleeding, remove SST. Then, try to press the plunger quickly and firmly by hand.

   OK: 

   Plunger is very difficult to move  .

   If the result is not as specified, replace the lash adjuster.

6. Install the lash adjusters.

Fig 9: Identifying Plunger Correct And Incorrect Position

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1. Apply engine oil to the lash adjuster tip and valve stem cap end.
2. Make sure that the valve rocker arms are installed as shown in the illustration.

1. Clean the both surfaces of the bearings.
2. Install the 2 No. 1 camshaft bearings.
   Fig 10: Installing Camshaft Housing Sub-Assembly

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3. Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.

   Dimension (A - B): 

   0.7 mm (0.0276 in.) or less 

   NOTE: Position the bearings to the center of the bearing cap by measuring dimensions A and B.

1. Check that no foreign matter is on the mesh part of the filter.
   Fig 11: Measuring Distance Between Bearing Cap Edge And Camshaft Bearing Edge

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2. Install the oil control valve filter.

1. Clean both surfaces of the bearings.
2. Install the 2 No. 2 camshaft bearings.
   Fig 12: Locating Oil Control Valve Filter

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3. Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.

   Dimension (A): 

   1.05 to 1.75 mm (0.041 to 0.069 in.) 

   NOTE: Position the bearings to the center of the bearing cap by measuring dimension A.
   Fig 13: Measuring Distance Between Bearing Cap Edge And Camshaft Bearing Edge

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1. Clean the camshaft journals.
2. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
3. Install the No. 2 camshaft to the camshaft housing.

1. Clean the camshaft journals.
2. Apply a light coat of engine oil to the camshaft journals and camshaft housing.
   Fig 14: Identifying No. 2 Camshaft

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3. Install the camshaft to the camshaft housing.
   Fig 15: Identifying Camshaft

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1. Apply engine oil to the bearing caps.
   Fig 16: Identifying Numbers On Camshaft Bearing Caps

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2. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

   HINT:

   Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

3. Tighten the 10 bolts in the order shown in the illustration.

   Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

   Fig 17: Identifying Camshaft Bearing Bolt Tighten Sequence

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1. Make sure that the valve rocker arms are installed as shown in the illustration.
   Fig 18: Installing Camshaft Housing Sub-Assembly

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2. Apply seal packing in a continuous bead as shown in the illustration.

   Seal packing: 

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

   Bead diameter: 

   3.5 to 4.0 mm (0.138 to 0.158 in.) 

   NOTE:

   • Remove any oil from the contact surfaces.
   • Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
   Fig 19: Identifying Camshaft Housing Seal Packing Area

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3. Set the camshaft and No. 2 camshaft as shown in the illustration.
4. Install the camshaft housing and tighten the 17 bolts in the order shown in the illustration.

   Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

   NOTE:

   • After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
   • If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
   • If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
   • After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.
   Fig 20: Locating No. 2 Camshaft Bolt Tighten Sequence

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1. Check that the knock pin is installed on the camshaft.
2. Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
   NOTE: Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear assembly.
   Fig 21: Identifying Straight Pin And Key Groove

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3. Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
   NOTE: Do not turn the camshaft timing gear in the retard direction (clockwise).
   Fig 22: Turning Camshaft Timing Gear

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4. Measure the clearance between the gear and the camshaft flange.

   Clearance: 

   0.1 to 0.4 mm (0.004 to 0.016 in.) 

   Fig 23: Measuring Clearance Between Gear And Camshaft Flange

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5. Tighten the flange bolt with the camshaft timing gear secured in place.

   Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

   Fig 24: Tightening Flange Bolt

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6. Check that the camshaft timing gear can move in the retard direction (clockwise) and locks in the most retarded position.

1. Check that the knock pin is installed on the camshaft.
   Fig 25: Checking Camshaft Timing Gear

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2. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
   Fig 26: Identifying Straight Pin And Key Groove

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3. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
   NOTE: Be sure not to turn the camshaft timing exhaust gear in the retard direction (clockwise).
4. Check that there is no clearance between the gear and the camshaft flange.
5. Tighten the flange bolt with the camshaft timing exhaust gear fixed.

   Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

   Fig 27: Tightening Flange Bolt

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6. Check the camshaft timing exhaust gear lock.
   1. Make sure that the camshaft timing exhaust gear is locked.

1. Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

HINT:

Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

Fig 28: Identifying Crankshaft Timing Gear Key

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1. Install the sensor plate with the "F" mark facing forward.
   Fig 29: Locating No. 1 Crankshaft Position Sensor Plate

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1. Install the No. 1 generator bracket with the 4 bolts.

   Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

   Fig 30: Locating No. 1 Generator Bracket Bolt

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1. Install the gasket.
2. Install the water inlet housing with the 3 bolts.

   Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

   Fig 31: Locating Water Inlet Housing

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1. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

   SST 09223-22010 

2. Apply a light coat of MP grease to the lip of the oil seal.

Fig 32: Installing Timing Chain Cover Oil Seal

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1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

   Adhesive: 

   Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

   Fig 33: Applying Adhesive To Threads Of Oil Pressure Switch

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2. Using a 24 mm deep socket wrench, install the oil pressure switch.

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

   NOTE:

   • Install the oil pressure switch within 3 minutes after applying adhesive.
   • Do not start the engine within 1 hour after installation.
   Fig 34: Locating Engine Oil Pressure Switch Assembly

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1. Install a new gasket to the engine coolant temperature sensor.
2. Using a 19 mm deep socket wrench, install the temperature sensor.

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

   Fig 35: Identifying Engine Coolant Temperature Sensor

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1. Install the knock control sensor with the bolt.

   Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

   NOTE: Make sure that the knock control sensor is in the correct position.
   Fig 36: Locating Knock Control Sensor With Bolt

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1. Apply adhesive to 2 or 3 threads of the plug, and install the plug.

   Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

   NOTE:

   • Install the plug within 3 minutes after applying adhesive.
   • Do not start the engine within 1 hour after installation.

   Adhesive: 

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

   Fig 37: Locating No. 1 Taper Screw Plug

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1. Apply a light coat of engine oil to the O-ring of the sensor.
   Fig 38: Identifying O-ring Of Sensor

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2. Install the crankshaft position sensor with the bolt.

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

   Fig 39: Locating Crankshaft Position Sensor

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1. Release the ratchet pawl, then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.
   NOTE: Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.
   Fig 40: Installing No. 1 Chain Tensioner Assembly

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2. Install a new gasket, bracket and No. 1 chain tensioner with the 2 nuts.

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

   NOTE: If the hook releases the plunger while the chain tensioner is being installed, engage the hook again.
   Fig 41: Locating No. 1 Chain Tensioner With Nuts

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3. Turn the crankshaft counterclockwise, then disconnect the hook from the plunger knock pin.
   Fig 42: Turning Crankshaft Of Plunger Knock Pin

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4. Turn the crankshaft clockwise, then check that the plunger is extended.
   Fig 43: Turning Crankshaft Of Plunger

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1. Install a new gasket to the cylinder head cover.
   NOTE: Remove any oil from the contact surfaces.
   Fig 44: Identifying Cylinder Head Cover Gasket

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2. Install 3 new gaskets to the No. 1 camshaft bearing cap.
   Fig 45: Locating Camshaft Bearing Cap

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3. Apply seal packing as shown the illustration.

   Seal packing: 

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

   NOTE:

   • Remove any oil from the contact surfaces.
   • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after the installation.
   Fig 46: Locating Cylinder Head Sealing Area

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4. Install the cylinder head cover with a new seal washer and the 13 bolts.

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

   Fig 47: Locating Cylinder Head Cover Bolts

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1. Apply a light coat of engine oil to 2 new O-rings, then install them onto the camshaft timing oil control valves.
   Fig 48: Identifying O-rings

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2. Install the 2 camshaft timing oil control valves and bracket with the 2 bolts.

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

   Fig 49: Locating Camshaft Timing Oil Control Valves And Bracket

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1. Apply a light coat of engine oil to the O-rings of the sensors.
   Fig 50: Identifying O-ring

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2. Install the 2 sensors with the 2 bolts.

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

   Fig 51: Locating No. 1 Crank Position Sensor Bolt

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1. Using a 14 mm spark plug wrench, install the 4 spark plugs.

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

   Fig 52: Installing Spark Plug

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1. Install the 2 engine cover joints.

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

   Fig 53: Locating Engine Cover Joints

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1. Install the gasket to the cap.

Fig 54: Locating Oil Filler Cap Gasket

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1. Install the oil filler cap.

Fig 55: Locating Oil Filler Cap

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1. Install the 2 engine hangers with the 2 bolts.

   Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

   Fig 56: Locating Engine Hangers With Bolts

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