Engine Unit: Reassembly

INSTALL NO. 1 BALANCESHAFT BEARING
1. Align the bearing claw with the claw groove, and push in the 8 bearings.
  NOTE: Do not apply engine oil to the contact surfaces of the balanceshaft bearing and balanceshaft housing.
2. Apply a light coat of the engine oil to the bearings.
Fig 1: Removing/Installing No. 1 Balanceshaft Bearings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 AND NO. 2 BALANCESHAFTS
1. Rotate the No. 1 driven gear of the No. 1 balanceshaft in the rotating direction until it hits the stopper.
  NOTE: Confirm that the matchmarks on the No. 1 and No. 2 driven gears are matched.
  
  Fig 2: Aligning Matchmarks On No. 1 And No. 2 Driven Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Confirm that the alignment marks on the No. 1 and No. 2 balanceshafts are aligned.
  
  Fig 3: Aligning Marks On No. 1 And No. 2 Balanceshafts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the alignment marks on the No. 1 and No. 2 balanceshafts as shown in the illustration.
4. Place the No. 1 and No. 2 balancshafts onto the crankcase.
5. Apply a light coat of engine oil to the threads and under the heads of the bolts.
  
  Fig 4: Aligning Marks On No. 1 And No. 2 Balanceshafts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
  Torque: 22 N*m (220 kgf*cm, 16 ft.*lbf)
  
  Fig 5: Tightening Bolts Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Mark the front of the bolts with paint.
  
  Fig 6: [Identifying Paint Mark On Bolt]
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Further tighten the bolts 90° as shown in the illustration.
9. Check that the paint mark is now at a 90° angle to the front.
  
  Fig 7: Identifying Bolt Tightening Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL STIFFENING CRANKCASE ASSEMBLY

Place a new O-ring on the cylinder block as shown in the illustration.

Fig 8: Identifying O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
With the No. 1 crank pin of the crankshaft placed at the TDC position, install the No. 1 and No. 2 balanceshafts and align the adjusting holes as shown in the illustration.

Fig 9: Aligning Adjusting Holes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
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 of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the crankcase.
  
  Fig 10: Identifying Seal Packing Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily install the crankcase with the 11 bolts.

BOLT LENGTH SPECIFICATION

Item	Bolt Length
A	125 mm (4.92 in.)
B	45 mm (1.77 in.)

Fig 11: Identifying Crankcase With Bolts

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

Fig 12: Identifying Crankcase Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Confirm that the timing marks on the balanceshafts are aligned when the key groove is placed at the TDC position, as shown in the illustration.

Fig 13: Identifying Timing Mark Location
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OIL PUMP ASSEMBLY (See INSTALLATION )
INSTALL REAR CRANKSHAFT OIL SEAL (See INSTALLATION )
INSTALL NO. 1 TAPER HEAD SCREW PLUG
1. Apply adhesive to 2 or 3 threads of the plug, and install it.
  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.
  Fig 14: Identifying No. 1 Taper Head Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL CONTROL VALVE FILTER
1. Check that there are no foreign objects on the mesh part of the oil control valve filter.
2. Using an 8 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the plug.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  Fig 15: Identifying Gasket And Oil Control Valve Filter With Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Apply adhesive to 2 or 3 threads of the drain cock.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  Fig 16: Identifying Adhesive Applying Area To Drain Cock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water drain cock within the range shown in the illustration.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cock to the specified torque.
3. Install the water drain cock plug to the water drain cock.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  Fig 17: Tightening Drain Cock To Specified Torque
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BLOCK WATER JACKET SPACER
1. Install the water jacket spacer as shown in the illustration.
  HINT:
  
  Be sure to face the slope to the front of the engine.
INSTALL CYLINDER HEAD GASKET (See INSTALLATION )
INSTALL CYLINDER HEAD SUB-ASSEMBLY (See INSTALLATION )

Fig 18: Identifying Water Jacket Spacer In Illustration
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Apply a light coat of engine oil onto a new O-ring.
2. Install the O-ring to the camshaft timing oil control valve.
  
  Fig 19: Identifying Camshaft Timing Oil Control Valve O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the camshaft timing oil control valve with the bolt.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY (See INSTALLATION )

Fig 20: Locating Camshaft Timing Oil Control Valve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
1. Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.
  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.
  
  Fig 21: Removing/Installing Camshaft Timing Gear With Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the claws and install the No. 1 camshaft bearing onto the No. 1 camshaft bearing cap.
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.
  
  Fig 22: Locating No. 2 Camshaft Bearing Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 2 camshaft bearing onto the cylinder head.
INSTALL CAMSHAFT
1. Apply a light coat of engine oil to the journal portion.
  
  Fig 23: Identifying No. 2 Camshaft Bearing Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.
3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
  
  Fig 24: Identifying Bearing Caps Installing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
  Torque: No. 1 bearing cap
  
  30 N*m (301 kgf*cm, 22 ft.*lbf)
  
  No. 3 bearing cap
  
  9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 25: Identifying Bearing Caps Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CAMSHAFT
1. Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.
2. 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.
3. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
  
  Fig 26: Identifying No. 2 Camshaft Bearing Caps Installing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
  Torque: No. 2 bearing cap
  
  30 N*m (301 kgf*cm, 22 ft.*lbf)
  
  No. 3 bearing cap
  
  9.0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 27: Identifying No. 2 Camshaft Bearing Caps Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL KEYS
1. Install the 2 keys.
  
  Fig 28: Identifying Pulley Set Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 CHAIN SUB-ASSEMBLY (See INSTALLATION )
INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET (See INSTALLATION )
INSTALL NO. 1 CHAIN VIBRATION DAMPER (See INSTALLATION )
INSTALL CHAIN SUB-ASSEMBLY (See INSTALLATION )
INSTALL CHAIN TENSIONER SLIPPER (See INSTALLATION )
INSTALL TIMING CHAIN GUIDE (See INSTALLATION )
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (See INSTALLATION )
INSTALL FRONT CRANKSHAFT OIL SEAL (See INSTALLATION )
INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (See INSTALLATION )
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See INSTALLATION )
INSTALL CRANKSHAFT POSITION SENSOR
1. Apply a light coat of engine oil to the O-ring of the sensor.
  
  Fig 29: Identifying Crankshaft Position Sensor O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Confirm that the wire harness of the sensor is placed as shown in the illustration.
  
  Fig 30: Identifying Wire Harness With Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the sensor with the 2 bolts.
  Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
4. Install the clamp of the crankshaft position sensor onto the water pump.
INSTALL OIL PAN SUB-ASSEMBLY (See INSTALLATION )

Fig 31: Locating Crankshaft Position Sensor And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN DRAIN PLUG
1. Install the oil pan drain plug with a new gasket.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
  
  Fig 32: Locating Oil Pan Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER PUMP ASSEMBLY (See INSTALLATION )
INSTALL WATER PUMP PULLEY (See INSTALLATION )
INSTALL CRANKSHAFT PULLEY (See INSTALLATION )
INSPECT VALVE CLEARANCE (See VALVE CLEARANCE )
ADJUST VALVE CLEARANCE (See VALVE CLEARANCE )
INSTALL CAMSHAFT POSITION SENSOR
1. Apply a light coat of engine oil onto the O-ring of the sensor.
  
  Fig 33: Identifying Camshaft Position Sensor O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the camshaft position sensor with the bolt.
  Torque: 9 0 N*m (92 kgf*cm, 80 in.*lbf)
  
  Fig 34: Locating Camshaft Position Sensor And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER GASKET
1. Install the cylinder head cover gasket onto the cylinder head cover.
  
  Fig 35: Identifying Cylinder Head Cover Gasket
  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.
  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 of applying seal packing.
  - Do not start the engine for at least 2 hours after installing the cylinder head cover.
  Fig 36: Identifying Seal Packing Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cylinder head cover with the 8 bolts and 2 nuts.
  Torque: Bolt A
  
  11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Bolt B
  
  14 N*m (143 kgf*cm, 10 ft.*lbf)
  
  Nut
  
  11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 37: Locating Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER UNION
1. Using a 12 mm socket hexagon wrench, install the oil filter union.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
INSTALL OIL FILTER SUB-ASSEMBLY (See REPLACEMENT )
INSTALL SPARK PLUG (See INSTALLATION )

Fig 38: Locating Oil Filter Union
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VENTILATION VALVE SUB-ASSEMBLY
1. Apply adhesive to the threads of the ventilation valve.
  Adhesive:
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  
  Fig 39: Applying Adhesive To Threads Of Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 22 mm deep socket wrench, install the ventilation valve onto the cylinder head cover.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Fig 40: Locating Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILLER CAP GASKET
1. Install the oil filler cap gasket onto the oil filler cap.
Fig 41: Locating 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 42: Locating Oil Filler Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002