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Engine Unit: Reassembly

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  1. INSTALL ENGINE BALANCER ASSEMBLY 
    1. Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned. If the alignment marks are not aligned, realign them.
      Fig 1: Identifying Alignment Marks Of Balance Shaft Damper Cover And Balance Shaft Driven Gear
      G05998002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place a wrench on the rear cutout part of the No. 2 balance shaft and hold the shaft in place.
      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.
      Fig 2: Rotating Balance Shaft Driven Gear Of No. 1 Balance Shaft
      G05998003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine balancer to the stiffening crankcase with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.

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

  2. INSTALL STIFFENING CRANKCASE STUD BOLT 
    NOTE: If a stud bolt is deformed or the threads are damaged, replace it.
    Fig 3: Identifying Engine Balancer Bolts Tightening Sequence
    G05998004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Locating Stud Bolts
    G06112272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using E5 and E8 "TORX" socket wrenches, install the stud bolts.

      Torque: for stud bolt A 

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

      for stud bolt B 

      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.
    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.) 

    Fig 5: Locating Ring Pins With Protrusion Height
    G05998006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Rotate the crankshaft clockwise so that the crankshaft key is at the position 90° from the bottom as shown in the illustration.
      Fig 6: Rotating Crankshaft
      G05998007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing in a continuous line as shown in the illustration.

      Seal packing: 

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

      Standard Seal Dimension 

      SEAL DIMENSION SPECIFICATION

      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.) 

      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.
      Fig 7: Applying Seal Packing In Continuous Line
      G05998008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the rear cutouts are as shown in the illustration.
    4. Clean the bolts and their installation holes.
      Fig 8: Checking Rear Cutouts
      G05998009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply adhesive to 3 threads or more of the end of bolt A.

      Adhesive: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 9: Applying Adhesive To Threads Of End Of Bolt
      G06030305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Temporarily install the stiffening crankcase with the 11 bolts.

      Bolt Length 

      BOLT LENGTH REFERENCE

      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.)
      Fig 10: Locating Stiffening Crankcase Bolts
      G05998011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

      Torque: for Bolt A 

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

      except Bolt A 

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

      Fig 11: Identifying Stiffening Crankcase Bolts Tightening Sequence
      G05998012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.

      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: Identifying No. 1 Oil Pan Baffle Plate Bolts Tightening Sequence
      G05998013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 by tightening the 3 bolts in several steps, in the sequence shown in the illustration.

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

    Fig 13: Aligning Protrusion Of Gasket With Cutout Of Oil Strainer
    G05998014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.

      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.) 

      Fig 14: Applying Seal Packing In Continuous Line
      G05998015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. Install the oil pan by tightening the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

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

      HINT:

      Bolt A and nut A should be tightened twice.

  8. INSTALL OIL FILTER CAP ASSEMBLY  (See REPLACEMENT )
  9. INSTALL REAR ENGINE OIL SEAL  (See REMOVAL )
    Fig 15: Identifying Oil Pan Bolts And Nuts Tightening Sequence
    G05998016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the water jacket spacer to the cylinder block.
  11. INSTALL CYLINDER HEAD GASKET  (See CYLINDER HEAD )
  12. INSTALL CYLINDER HEAD SUB-ASSEMBLY  (See CYLINDER HEAD )
  13. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY  (See INSTALLATION )
    Fig 16: Identifying Cylinder Block Water Jacket Spacer And Cylinder Block
    G05997967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE: It is not necessary to remove the ring pin unless it is being replaced.
    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.) 

  15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE: It is not necessary to remove the straight pin unless it is being replaced.
    Fig 17: Locating Camshaft Housing Ring Pins With Protrusion Height
    G05998018Courtesy 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.) 

  16. INSTALL CAMSHAFT HOUSING STUD BOLT 
    NOTE: If a stud bolt is deformed or the threads are damaged, replace it.
    Fig 18: Locating Camshaft Housing Straight Pins With Protrusion Height
    G05998019Courtesy 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) 

    Fig 19: Locating Stud Bolt
    G05998020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean the No. 1 camshaft bearing.
    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. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Clean the No. 2 camshaft bearing.
    2. Install the camshaft bearing to the camshaft housing.
      Fig 20: Measuring Distance Between Camshaft Bearing Cap Edge And Camshaft Bearing Edge
      G05998021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.) 

    Fig 21: Measuring Distance Between Camshaft Housing Edge And Camshaft Bearing Edge
    G05998022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL OIL CONTROL VALVE FILTER 
    1. Install the oil control valve filter to the No. 1 camshaft bearing cap.
  20. INSTALL CAMSHAFT  (See CYLINDER HEAD GASKET )
  21. INSTALL CAMSHAFT BEARING CAP  (See CYLINDER HEAD GASKET )
  22. INSTALL VALVE STEM CAP  (See CYLINDER HEAD )
    Fig 22: Identifying Oil Control Valve Filter
    G05997964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY  (See CYLINDER HEAD GASKET )
  24. INSTALL VALVE ROCKER ARM SUB-ASSEMBLY  (See CYLINDER HEAD GASKET )
  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY  (See CYLINDER HEAD GASKET )
  26. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY  (See CYLINDER HEAD GASKET )
  27. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket to the crankshaft.
  28. ADD ENGINE OIL  (See CYLINDER HEAD GASKET )
  29. SET NO. 1 CYLINDER TO TDC/COMPRESSION  (See CYLINDER HEAD GASKET )
  30. INSTALL NO. 1 CHAIN VIBRATION DAMPER  (See CYLINDER HEAD GASKET )
    Fig 23: Identifying Crankshaft Timing Sprocket And Crankshaft
    G05997963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL CHAIN SUB-ASSEMBLY 
  32. INSTALL CHAIN TENSIONER SLIPPER  (See CYLINDER HEAD GASKET )
  33. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  (See CYLINDER HEAD GASKET )
  34. INSTALL TIMING CHAIN GUIDE  (See CYLINDER HEAD GASKET )
  35. CHECK NO. 1 CYLINDER TDC/COMPRESSION  (See CYLINDER HEAD GASKET )
  36. 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) 

    Fig 24: Locating Timing Chain Cover Plate Bolts
    G05997962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL TIMING CHAIN COVER TIGHT PLUG 
    1. Using a 14 mm hexagon wrench, install a new gasket and the plug.

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

  38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY  (See INSTALLATION )
  39. INSTALL ENGINE MOUNTING BRACKET RH  (See INSTALLATION )
    Fig 25: Identifying Timing Chain Cover Tight Plug And Gasket
    G05997961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL TIMING CHAIN COVER OIL SEAL  (See INSTALLATION )
  41. INSTALL SPARK PLUG TUBE GASKET 
    1. Visually check the spark plug tube gasket.

      OK 

      SPECIFIED CONDITION REFERENCE

      Area Specified Condition
      Upper surface No scratches or deformation
      Outer lip No scratches or deformation
      Inner lip No scratches

      If the result is not as specified, replace the spark plug tube gasket.

      Fig 26: Checking Spark Plug Tube Gasket
      G05999057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 plug tube gaskets to the cylinder head cover.
    NOTE: After pressing in the spark plug tube gasket, make sure the gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover.
    Fig 27: Locating Spark Plug Tube Gaskets
    G05999058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to 3 new gaskets.
    2. Install the 3 gaskets to the camshaft bearing caps.
    3. Install a new gasket to the cylinder head cover.
      NOTE: Remove any oil from the contact surface.
      Fig 28: Locating Camshaft Bearing Caps Gaskets
      G05999044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply seal packing as shown in the illustration.

      Seal packing: 

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

      Standard seal diameter: 

      3.0 to 6.0 mm (0.118 to 0.236 in.) 

      Application width A: 

      5.0 mm (0.197 in.) 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      Fig 29: Identifying Seal Packing Applying Area
      G05999060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.
    6. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      NOTE: Do not apply oil for at least 4 hours after the installation.
      Fig 30: Identifying Cylinder Head Cover Bolts Tightening Sequence
      G05999061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the crankshaft pulley.
    2. Using SST, hold the crankshaft pulley and install the pulley bolt.

      SST 09213-54015, 09330-00021, 91551 -80650 

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

  44. INSTALL CRANKSHAFT POSITION SENSOR  (See REMOVAL )
    Fig 31: Loosening Crankshaft Pulley Bolts
    G06112223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL INLET WATER HOUSING 
    1. Install a new gasket and the inlet water housing with the 4 bolts and nut.

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

  46. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)  (See INSPECTION )
  47. INSTALL WATER PUMP ASSEMBLY  (See REMOVAL )
    Fig 32: Locating Inlet Water Housing Bolts And Nut
    G05997958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Install the V-ribbed belt tensioner with the bolt.

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

  49. INSTALL THERMOSTAT  (See INSTALLATION )
  50. INSTALL INLET WATER  (See INSTALLATION )
    Fig 33: Locating V-Ribbed Belt Tensioner Bolt
    G05998871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL WATER DRAIN COCK 
    1. Apply adhesive to 2 or 3 threads of the drain cock.

      Adhesive: 

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 34: Applying Adhesive To Threads Of Drain Cock
      G05998029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 the drain cock to the specified torque.
      • Do not loosen the drain cock to adjust it. If an adjustment is necessary, remove the drain cock and reinstall it.
      Fig 35: Identifying Water Drain Cock Installation Position
      G05998030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the water drain cock plug to the water drain cock.

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

  52. 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) 

    Fig 36: Locating Water By-Pass Pipe Bolt And Nuts
    G05997956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. 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) 

    Fig 37: Identifying Separator Case Bolts And Gasket
    G06030246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL VENTILATION CASE SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.

      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.) 

      Fig 38: Identifying Seal Packing Applying Area
      G06030334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
    2. Install the ventilation case, and install the 8 bolts and 2 nuts in the order shown in the illustration.

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

      HINT:

      Bolt A should be tightened twice.

  55. INSTALL VENTILATION VALVE SUB-ASSEMBLY  (See INSPECTION )
  56. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)  (See REMOVAL )
    Fig 39: Identifying Ventilation Case Bolts And Nuts Tightening Sequence
    G06112307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)  (See REMOVAL )
  58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)  (See INSTALLATION )
  59. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)  (See INSTALLATION )
  60. 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.
  61. INSTALL SPARK PLUG  (See REMOVAL )
  62. INSTALL ENGINE COVER JOINT 
    1. Install the 3 joints.

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

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