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Reassembly [12/2013 - 11/2015]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL REAR ENGINE OIL SEAL 
    1. Install the rear engine oil seal from the cylinder block sub-assembly.
  2. INSTALL STIFFENING CRANKCASE RING PIN 
    NOTE:

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

    1. Using a plastic hammer, tap in 2 new stiffening crankcase ring pins until they stop.
      GTY455008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard Protrusion Height

      4.3 to 5.3 mm (0.169 to 0.209 in.)

  3. INSTALL ENGINE BALANCER ASSEMBLY 
    1. Check that the alignment marks of the balance shaft damper cover and No. 1 balance shaft driven gear are aligned.
      GTY452546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark

      If the alignment marks are not aligned, align them.

      1. Place a wrench on the rear cutout part of the No. 2 balance shaft and secure the No. 2 balance shaft in place.
        GTY434307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 No. 1 Balance Shaft Driven Gear
        *2 Balance Shaft Damper Cover
        *a Alignment Mark
      2. Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the No. 1 balance shaft driven gear with the alignment mark of the balance shaft damper cover.
    2. Install the engine balancer assembly to the stiffening crankcase assembly with the 3 bolts, and tighten the bolts in the order shown in the illustration.

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

      Fig 1: Engine Balancer Bolts Tightening Sequence
      GTY437495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL STIFFENING CRANKCASE STUD BOLT 
    NOTE:

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

    1. Using E5 and E8 "TORX" socket wrenches, install the stiffening crankcase stud bolts.
      GTY428040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Side *b Lower Side

      Stud Bolt (A) 

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

      Stud Bolt (B) 

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

  5. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Rotate the crankshaft clockwise so that the crankshaft pulley key is at the position 90° from the bottom as shown in the illustration.
      GTY434114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Key
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY445904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Stiffening Crankcase Assembly
      Cylinder Block Sub-assembly

      Seal Packing

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

      Standard Seal Dimension

      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 surfaces.
      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
      • Do not apply oil for at least 2 hours after the installation.
    3. Check that the rear cutouts are as shown in the illustration.
      GTY433341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cutout
    4. Clean the bolts and the bolt holes.
    5. Apply adhesive to 3 or more threads at the tip of the bolts (A).
      GTY429516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Temporarily install the stiffening crankcase assembly with the 11 bolts.
      GTY426242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt Length

      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.)

      HINT: 

      Apply adhesive to the bolts (A) before installation.

    7. Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.

      Bolt (A) 

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

      except Bolt (A) 

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

      Fig 2: Stiffening Crankcase Bolts Tightening Sequence
      GTY426243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 OIL PAN BAFFLE PLATE 
    1. Install the No. 1 oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the order shown in the illustration.

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

      Fig 3: No. 1 Engine Oil Pan Baffle Plate Bolts Tightening Sequence
      GTY429883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new gasket.
    2. Align the protrusion of the gasket with the cutout of the oil strainer sub-assembly, and install the gasket to the oil strainer sub-assembly.
    3. Install the oil strainer sub-assembly with the 3 bolts in several steps, in the order shown in the illustration.

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

      Fig 4: Engine Oil Strainer Bolts Tightening Sequence
      GTY426575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
  8. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY167807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Packing Diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
    2. Install the oil pan sub-assembly with the 11 bolts and 2 nuts in several steps, in the order shown in the illustration.

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

      HINT: 

      The bolt (A) and nut (A) are tightened twice.

      Fig 5: Engine Oil Pan Bolts And Nuts Tightening Sequence
      GTY441054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
  9. INSTALL OIL PAN DRAIN PLUG 
    1. Install a new gasket and the oil pan drain plug to the oil pan sub-assembly.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  10. INSTALL OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. INSTALL REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 1

  12. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the cylinder block water jacket spacer to the cylinder block sub-assembly.
      GTY312332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 3

  14. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  15. SET CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 6

  16. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

    It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.

    1. Using a plastic hammer, tap in 10 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.
      GTY439477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard Protrusion Height

      2.7 to 3.3 mm (0.106 to 0.130 in.)

  17. INSTALL CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE:

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

    1. Using a plastic hammer, tap in 2 new camshaft housing straight pins to the camshaft housing sub-assembly.
      GTY441434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard Protrusion Height

      5.0 to 7.0 mm (0.197 to 0.276 in.)

  18. INSTALL CAMSHAFT HOUSING STUD BOLT 
    NOTE:

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

    1. Using an E8 "TORX" socket wrench, install the camshaft housing stud bolt.
      GTY447531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

  19. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean the No. 1 camshaft bearing.
      GTY426684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper
    2. Install the No. 1 camshaft bearing to the No. 1 camshaft bearing cap.
    3. Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Difference Between (A) and (B)

      0 to 0.7 mm (0 to 0.0276 in.)

  20. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean the No. 2 camshaft bearing.
    2. Install the No. 2 camshaft bearing to the camshaft housing sub-assembly.
    3. Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.
      GTY453665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Vernier Caliper

      Standard Distance

      1.15 to 1.85 mm (0.0453 to 0.0728 in.)

  21. INSTALL OIL CONTROL VALVE FILTER 
    1. Install the oil control valve filter to the No. 1 camshaft bearing cap.
      GTY384553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL CAMSHAFT 

    Refer to PROCEDURE - Step 12

  23. INSTALL CAMSHAFT BEARING CAP 

    Refer to PROCEDURE - Step 13

  24. INSTALL VALVE STEM CAP 

    Refer to PROCEDURE - Step 5

  25. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 7

  26. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  28. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 15

  29. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 16

  30. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket to the crankshaft.
      GTY314227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 17

  32. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 18

  33. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 19

  34. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 20

  35. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 21

  36. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 22

  37. INSTALL TIMING CHAIN GUIDE 

    Refer to PROCEDURE - Step 23

  38. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 18

  39. INSTALL TIMING CHAIN COVER PLATE 
    1. Install a new gasket and the timing chain cover plate with the 4 bolts.
      GTY312183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  40. INSTALL TIMING CHAIN COVER TIGHT PLUG 
    1. Using a 14 mm hexagon wrench, install a new gasket and the timing chain cover tight plug.
      GTY312189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

  41. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  42. INSTALL ENGINE MOUNTING BRACKET RH 

    Refer to PROCEDURE - Step 2

  43. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1

  44. INSTALL SPARK PLUG TUBE GASKET 
    1. Tap in 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.
      GTY184248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After tapping in the spark plug tube gaskets, make sure each gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover sub-assembly.

  45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to 3 new camshaft bearing cap oil hole gaskets.
      GTY314686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the camshaft bearing cap oil hole gaskets.
    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
      NOTE:

      Remove any oil from the contact surface.

    4. Apply seal packing as shown in the illustration.
      GTY442016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Timing Chain Cover Sub-assembly
      *2 Camshaft Housing Sub-assembly
      *a Application Width 5.0 mm (0.197 in.)
      Seal Packing

      Seal Packing

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

      Standard Seal Packing Diameter

      3.0 to 6.0 mm (0.118 to 0.236 in.)

      Application Width

      5.0 mm (0.197 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
    5. Align the cylinder head cover sub-assembly with the pin (A). Then align the cylinder head cover sub-assembly with the pin (B) and install the cylinder head cover sub-assembly.
    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) 

      Fig 6: Cylinder Head Cover Bolts Tightening Sequence
      GTY434351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Washer
      NOTE:

      Do not start the engine for at least 2 hours after installation.

  46. INSTALL CRANKSHAFT PULLEY 
    1. Align the crankshaft pulley key with the key groove of the crankshaft pulley.
      GTY428068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    2. Using SST, hold the crankshaft pulley and install the crankshaft pulley bolt.
      • SST: 09213-54015 
      • SST: 09330-00021 

      HINT: 

      SST (crankshaft pulley holding tool) fixing bolt part No.: 91551-80650 (2 pcs)

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

  47. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  48. INSTALL WATER INLET HOUSING 
    1. Install a new gasket and the water inlet housing with the 4 bolts and nut.

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

  49. INSTALL ENGINE WATER PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  50. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Install the V-ribbed belt tensioner assembly with the bolt.
      GTY314503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  51. INSTALL THERMOSTAT 

    Refer to PROCEDURE - Step 1

  52. INSTALL WATER INLET 

    Refer to PROCEDURE - Step 2

  53. INSTALL NO. 1 WATER BY-PASS PIPE 
    1. Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.

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

  54. INSTALL SEPARATOR CASE 
    1. Apply a light coat of engine oil to a new gasket.
      GTY430039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the gasket to the separator case.
    3. Install the separator case to the ventilation case sub-assembly with the 2 bolts.

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

  55. INSTALL VENTILATION CASE SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY186229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Packing Diameter

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the ventilation case sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes of applying seal packing.
    2. Install the ventilation case sub-assembly, 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: 

      The bolt (A) is tightened twice.

      Fig 7: Ventilation Case Bolts And Nuts Tightening Sequence
      GTY428785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 1

  57. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side) 

    Refer to PROCEDURE - Step 1

  58. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side) 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 2

  61. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install a new gasket to the oil filler cap sub-assembly.
    2. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
  62. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  63. INSTALL ENGINE COVER JOINT 
    1. Install the 3 engine cover joints.
      GTY312223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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