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Engine Unit: Replacement

WARNING: This page is about a different car, the 2007 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
  1. REPLACE TIMING CHAIN COVER OIL SEAL 

    HINT:

    There are 2 methods to replace the oil seal.

    1. If the timing chain cover is removed from the cylinder block:
      1. Using a screwdriver and hammer, tap out the oil seal.
        Fig 1: Taping Out Oil Seal
        G04484970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Apply multi-purpose grease to the lip of a new oil seal.
        NOTE: Keep the lip free of foreign objects.
      3. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge.

        SST 09223-22010 

        NOTE: Do not tap the oil seal at an angle.
        Fig 2: Taping In New Oil Seal
        G04484971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. If the timing chain cover oil seal is installed to the cylinder block:
      1. Remove the fan and generator V belt (see appropriate step(s) under REMOVAL ).
      2. Remove the crankshaft pulley (see appropriate step(s) under REMOVAL ).
      3. Using a knife, cut off the lip of the oil seal.
      4. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.
        NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
        Fig 3: Prying Out Oil Seal
        G04484972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Apply multi-purpose grease to the lip of a new oil seal.
        NOTE: Keep the lip free of foreign objects.
      6. Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge.

        SST 09223-22010 

        NOTE: Do not tap the oil seal at an angle.
      7. Install the crankshaft pulley (see appropriate step(s) under INSTALLATION ).
      8. Install the fan and generator V belt (see appropriate step(s) under INSTALLATION ).
        Fig 4: Taping In New Oil Seal
        G04484973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REPLACE ENGINE REAR OIL SEAL 
    1. Using a knife, cut off the lip of the oil seal.
    2. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.
      NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
      Fig 5: Prying Out Rear Oil Seal
      G04484974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply multi-purpose grease to the lip of a new oil seal.
      NOTE: Keep the lip free of foreign objects.
    4. Using SST and a hammer, tap in the new oil seal until its surface is flush with the rear oil seal retainer edge.

      SST 09223-15030, 09950-70010 (09951-07100) 

      NOTE:
      • Wipe any extra grease off the crankshaft.
      • Do not tap the oil seal at an angle.
      Fig 6: Taping In New Rear Oil Seal
      G04484975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REPLACE STUD BOLT (for Cylinder Block) 
    NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
    1. Remove the 8 stud bolts.
    2. Install the 8 stud bolts into the cylinder block.

      Torque 

      TORQUE SPECIFICATIONS

      Item Specified Condition
      A 5.0 N*m (51 kgf*cm, 44 in.*lbf)
      B 21.5 N*m (219 kgf*cm, 16 ft.*lbf)
      C 5.0 N*m (51 kgf*cm, 44 in.*lbf)
      D 5.0 N*m (51 kgf*cm, 44 in.*lbf)
      Fig 7: Identifying Engine Front And Right Side & Stud Placement
      G04484976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REPLACE TIGHT PLUG (for Cylinder Block) 
    NOTE: If water leaks from the tight plug or the plug corrodes, replace it.
    1. Remove the 2 tight plugs from the engine front and rear side.
    2. Apply adhesive around new tight plugs.

      Adhesive: Toyota Genuine Adhesive 1342, Three Bond 1342 or Equivalent 

      Fig 8: Applying Adhesive Around Tight Plugs
      G04484977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the 2 tight plugs.

      SST 09950-60010 (09951-00200), 09950-70010 (09951-07100) 

      Standard depth 

      STANDARD DEPTH

      Item Specified Condition
      A 1.7 to 2.7 mm (0.067 to 0.106 in.)
      B 2.2 to 3.2 mm (0.087 to 0.126 in.)
      Fig 9: Identifying Front And Rear Side Of Cylinder Block & Tight Plug Placement
      G04484978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REPLACE RING PIN (for Cylinder Block) 
    NOTE: It is not necessary to remove with head pin unless it is being replaced.
    1. Remove the 12 ring pins.
    2. Using a plastic-faced hammer, install 12 new ring pins.

      Standard protrusion height 

      PROTRUSION HEIGHT (STANDARD)

      Item Specified Condition
      A 6.0 mm (0.236 in.)
      B 5.0 mm (0.197 in.)
      Fig 10: Identifying Upper And Lower Side Of Cylinder Block & Ring Pin Placement
      G04484979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REPLACE STRAIGHT PIN (for Cylinder Block) 
    NOTE: It is not necessary to remove with straight pin unless it is being replaced.
    1. Remove the 8 straight pins.
    2. Using a plastic-faced hammer, install 8 new straight pins.

      Standard protrusion height 

      PROTRUSION HEIGHT (STANDARD)

      Item Specified Condition
      A 8.0 mm (0.315 in.)
      B 7.5 mm (0.295 in.)
      C 12.0 mm (0.472 in.)
      D 5.0 mm (0.197 in.)
      Fig 11: Identifying Front And Rear Side Of Cylinder Block & Straight Pin Placement
      G04484980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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