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Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Mechanical (2ZR-FAE) - Service Information (2 Of 2) (Model Code: ZRE172)) >> Engine Unit >> Reassembly [08/2013 - 04/2014] >> Procedure

Reassembly [08/2013 - 04/2014]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL STIFFENING CRANKCASE RING PIN 
    NOTE:

    It is not necessary to remove a stiffening crankcase ring pin unless it is being replaced.

    GTY434622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Protrusion Height
    *b Width
    *c Height
    1. Using a plastic hammer, tap in 2 new stiffening crankcase ring pins until they are seated.

      Standard Ring Pin

      Item Protrusion Height Height Width
      Stiffening crankcase ring pin 3.0 mm (0.118 in.) 8 mm (0.315 in.) 11 mm (0.433 in.)
  2. INSTALL STIFFENING CRANKCASE STUD BOLT 
    NOTE:

    If a stiffening crankcase stud bolt is deformed or the threads are damaged, replace it.

    GTY433312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using an E6 "TORX" socket wrench, install the stiffening crankcase stud bolts as shown in the illustration.

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

  3. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY430644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Diameter

      Area Specified Condition
      Continuous Line 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      A 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Application Length A

      56 mm (2.20 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.
    2. Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.

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

      Fig 1: Stiffening Crankcase Bolts Tightening Sequence
      GTY442428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Bolt Length
      Bolt A 143.7 mm (5.43 in.)
      Bolt B 35 mm (1.38 in.)
      Bolt C 70 mm (2.76 in.)
    3. Recheck the torque for the bolts (1) and (2).

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

    4. Wipe off any excess seal packing with a clean piece of cloth.
  4. INSTALL OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove any remaining seal packing and be careful not to drop any oil on the contact surfaces of the cylinder block and No. 2 oil pan sub-assembly.
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY446046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing Black

      Application Specification

      Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing
      A - A 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.)
      B - B -

      Seal Packing

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

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installing the No. 2 oil pan sub-assembly.
    3. Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.

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

  6. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug.
      GTY449115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 1

  8. INSTALL NO. 1 TAPER SCREW PLUG 
    1. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).
      GTY448781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      NOTE:
      • Install the plug within 3 minutes of applying adhesive.
      • Do not start the engine for at least 1 hour after installing the No. 1 taper screw plug.
    2. Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (B).

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

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:
      • Install the plug within 3 minutes of applying adhesive.
      • Do not start the engine for at least 1 hour after installing the No. 1 taper screw plug.
  9. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 1

  10. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 6

  11. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  12. INSTALL CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE:

    It is not necessary to remove a camshaft housing straight pin unless it is being replaced.

    GTY448012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Protrusion Height
    *b Height
    *c Width
    1. Using a plastic-faced hammer, tap in a new camshaft housing straight pin to the specified protrusion height.

      Standard Straight Pin

      Item Protrusion Height Height Width
      Camshaft housing straight pin 6.5 to 7.5 mm (0.256 to 0.295 in.) 14 mm (0.551 in.) 6.0 mm (0.236 in.)
  13. INSTALL CAMSHAFT HOUSING STUD BOLT 
    NOTE:

    If a camshaft housing stud bolt is deformed or the threads are damaged, replace it.

    GTY433307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.

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

  14. INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  15. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  17. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 5

  18. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Using a plastic hammer, tap in the 2 crankshaft timing gear keys.
      GTY161232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  19. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
    1. Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.
      GTY449127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL NO. 2 CHAIN SUB-ASSEMBLY 
    1. Temporarily install the crankshaft pulley bolt.
      GTY429634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Set the crankshaft timing gear key as shown in the illustration.
    3. Turn the oil pump drive shaft so that the cutout faces upward.
    4. Remove the crankshaft pulley bolt.
    5. Align the yellow mark plates with the timing mark of the oil pump drive gear and oil pump drive shaft gear as shown in the illustration.
      GTY453134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *a Yellow Mark Plate
      *b Timing Mark
      Engine Front
    6. Install the oil pump drive gear onto the crankshaft and oil pump drive shaft gear with the No. 2 chain sub-assembly on the oil pump drive gear and oil pump drive shaft gear.
    7. Temporarily install the oil pump drive shaft gear with the nut.
    8. Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.
      GTY455886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    9. Temporarily install the crankshaft pulley with the crankshaft pulley bolt.
      GTY439315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using SST, hold the crankshaft. Then tighten the oil pump drive shaft gear nut.

      for 86 mm (3.39 in.) Bolt Pitch Type:

      • SST: 09330-0002109213-58014 
        1. 91551-80840

      for 64 mm (2.52 in.) Bolt Pitch Type:

      • SST: 09213-5401509330-00021 

      HINT: 

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

    11. Remove SST, the crankshaft pulley bolt and crankshaft pulley.
  21. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket as shown in the illustration.
      GTY447302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Engine Front
  22. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 6

  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 7

  24. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  25. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 10

  26. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 9

  27. INSTALL NO. 1 GENERATOR BRACKET 
    1. Install the No. 1 generator bracket with the 4 bolts.
      GTY449224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  28. INSTALL WATER INLET HOUSING 
    1. Install a new gasket and the water inlet housing with the 3 bolts.
      GTY455906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  29. INSTALL WATER INLET HOUSING STUD BOLT 
    NOTE:

    If a water inlet housing stud bolt is deformed or the threads are damaged, replace it.

    GTY454516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using an E5 "TORX" socket wrench, install the water inlet housing stud bolts as shown in the illustration.

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

  30. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Install a new gasket.
      NOTE:

      Remove any oil from the contact surface.

    2. Install the engine water pump assembly with the 3 bolts.

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

    3. Remove any remaining packing (FIPG) material.
      NOTE:

      Be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head sub-assembly, camshaft housing sub-assembly, stiffening crankcase assembly and cylinder block sub-assembly.

      GTY438220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Side *b Timing Chain Cover Side
      Surface to be cleaned - -
    4. Install 3 new O-rings.
    5. Apply seal packing as shown in the illustration.
      GTY424106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Diameter

      5.0 mm (0.197 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installing the timing chain cover sub-assembly.
    6. Apply seal packing to the timing chain cover sub-assembly in a continuous line as shown in the following illustration.
      GTY481552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Application Specification

      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.0 mm (0.0984 to 0.118 in.) Center of seal packing
      2.5 mm (0.0984 in.)      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.) Center of seal packing
      3.0 mm (0.118 in.)      		 - -
      A - A 2.5 to 3.0 mm (0.0984 to 0.118 in.) Center of seal packing
      2.5 mm (0.0984 in.)      		 - -
      B - B 4.5 to 5.5 mm (0.177 to 0.217 in.) Opposite edge of seal packing
      5.0 mm (0.197 in.)      		 - -
      C - C 7.0 to 8.0 mm (0.276 to 0.315 in.) Opposite edge of seal packing
      7.5 mm (0.295 in.)      		 - -
      F 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.5 mm (0.610 in.) 50.4 mm (1.98 in.)
      G 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 143.1 mm (5.63 in.)
      H 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 153.4 mm (6.04 in.)
      I 4.5 to 5.5 mm (0.177 to 0.217 in.) - 16.0 mm (0.630 in.) 385.8 mm (1.27 ft.)
      J 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      K 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 121.9 mm (4.80 in.)
      L 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 147.2 mm (5.80 in.)
      M 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.1 mm (0.201 in.) 173.0 mm (6.81 in.)
      N 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 385.8 mm (1.27 ft.)
      O 4.0 mm (0.157 in.) Center of seal packing
      3.0 mm (0.118 in.)      		 - -
      NOTE:
      • If there is oil on the contact surfaces, wipe them with oil-free cloth before applying seal packing.
      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH and oil filter bracket within 10 minutes.
      • Do not add engine oil for at least 2 hours after installation.
    7. Clean the bolts and their installation holes.
    8. Install the timing chain cover sub-assembly.
    9. Temporarily install the engine mounting bracket RH with the 3 bolts.
      NOTE:
      • Install the engine mounting bracket RH within 10 minutes of installing the timing chain cover sub-assembly.
      • Do not add engine oil for at least 2 hours after installation.
    10. Install 2 new O-rings.
    11. Temporarily tighten the oil filter bracket with the 4 bolts.
      NOTE:
      • Install the oil filter bracket within 10 minutes of installing the timing chain cover sub-assembly.
      • Do not add engine oil for at least 2 hours after installation.
    12. Apply adhesive to 5 and a half threads or more of the end of the bolt (E).
      GTY423433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the timing chain cover sub-assembly with the 26 bolts and seal washer in the order shown in the illustration.
      Fig 2: Timing Chain Cover Bolts Tightening Sequence
      GTY451369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque *b Bolt Tightening Order
      *1 Seal Washer - -

      Bolt A, E 

      Torque: 25.5 N*m (260 kgf*cm, 19 ft.*lbf) 

      Bolt B 

      Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf) 

      Bolt C 

      Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf) 

      Bolt D 

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

      NOTE:
      • If there is oil on the contact surfaces, wipe them with oil-free cloth before applying seal packing.
      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installation.
      Item Bolt Length Thread Diameter
      Bolt A, E 35 mm (1.38 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt C 80 mm (3.15 in.) 10 mm (0.394 in.)
      Bolt D 40 mm (1.57 in.) 6 mm (0.236 in.)

      HINT: 

      Apply adhesive to the bolt (E) before installing it.

  31. INSTALL STUD BOLT 
    1. Install the stud bolt to the engine mounting bracket RH.

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

  32. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1

  33. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 2

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 15

  35. INSTALL OIL FILTER UNION (for Oil Filter Sub-assembly Type) 
    GTY718990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 12 mm hexagon socket wrench, install the oil filter union to the oil filter bracket.

      Torque: 29.5 N*m (301 kgf*cm, 22 ft.*lbf) 

  36. INSTALL OIL FILTER 

    Refer to PROCEDURE - Step 3

  37. INSTALL SPARK PLUG TUBE GASKET 
    1. Using a cutter knife, cut off the seal part of the removed spark plug tube gasket.
      GTY439306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Part to Cut Off
    2. Using a hammer and the spark plug tube gasket which has had the sealing part cut off, uniformly tap in a new spark plug tube gasket all the way.
      GTY430390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
      *1 Spark Plug Tube Gasket without Seal Part
      *2 New Spark Plug Tube Gasket
      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap the spark plug tube gasket.

      HINT: 

      If a spark plug tube gasket that will be used to install the spark plug tube gasket is deformed, and cannot be positioned on the spark plug tube gasket, correct the deformation using pliers.

    3. Return the claws of the ventilation baffle plate to their original positions.
  38. INSTALL CYLINDER HEAD COVER GASKET 
    1. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
      GTY434674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Remove any oil from the contact surfaces.

  39. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install 3 new gaskets to the camshaft bearing cap.
      GTY429204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing as shown the illustration.
      GTY429202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Diameter

      4.0 mm (0.157 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    3. Install the cylinder head cover sub-assembly with a new seal washer and the 13 bolts.
      GTY452313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  40. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  41. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  42. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  43. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  44. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side) 

    Refer to PROCEDURE - Step 1

  45. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side) 

    Refer to PROCEDURE - Step 2

  46. INSTALL VALVEMATIC SHAFT SENSOR (NO. 1 CRANK POSITION SENSOR) 

    Refer to PROCEDURE - Step 1

  47. INSTALL CAMSHAFT POSITION SENSOR (NO. 1 CRANK POSITION SENSOR) 

    Refer to PROCEDURE - Step 1

  48. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  49. INSTALL ENGINE COVER JOINT 
    1. Install the 2 engine cover joints.
      GTY432584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  50. INSTALL OIL FILLER CAP GASKET 
    1. Install the oil filler cap gasket to the oil filler cap.
      GTY288028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap sub-assembly.
      GTY432583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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