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Reassembly [08/2017 - ]: Procedure

  1. INSTALL STIFFENING CRANKCASE RING PIN 
    NOTE:

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

    GTY367697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Protrusion Height
    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.)

  2. INSTALL STIFFENING CRANKCASE STUD BOLT 
    NOTE:

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

    GTY368281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Front Side *b Lower Side
    *c 20 mm (0.787 in.) *d 35 mm (1.38 in.)
    *e 13 mm (0.512 in.) *f 8.5 mm (0.335 in.)
    *g 18 mm (0.709 in.) *h 8.0 mm (0.315 in.)
    1. Using an E5 and E8 "TORX" socket wrench, install the stud bolts.

      for stud bolt A 

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

      for stud bolt B 

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

  3. INSTALL ENGINE BALANCER ASSEMBLY 
    1. Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.
      GTY370297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Alignment Mark

      If the alignment marks are not aligned, realign them.

      1. Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place.
        GTY372493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Driven Gear
        *2 Damper Cover
        *3 Alignment Mark
      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.
    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) 

      Fig 1: Engine Balancer Bolts Tightening Sequence
      GTY382607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL STIFFENING CRANKCASE ASSEMBLY 
    1. Rotate the crankshaft clockwise so that the crankshaft key is at the position 270° from the bottom as shown in the illustration.
      GTY368316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Key
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY369862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Packing
      *a 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *b 7.0 to 9.0 mm (0.276 to 0.354 in.)
      Stiffening Crankcase
      Cylinder Block

      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 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.
      • Do not start the engine for at least 4 hours after the installation.
    3. Check that the rear cutouts are as shown in the illustration.
      GTY369040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cutout
    4. Clean the bolts and their installation holes.
    5. Apply adhesive to 3 threads or more at the end of bolt A.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Temporarily install the stiffening crankcase with the 11 bolts.
      GTY361767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt Length

      Item Specified Condition
      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 bolt A before installing it.

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

      for 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
      GTY361768Courtesy 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) 

      Fig 3: No. 1 Engine Oil Pan Baffle Plate Tightening Sequence
      GTY373747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new gasket.
      Fig 4: Engine Oil Strainer Bolts Tightening Sequence
      GTY368359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Protrusion
    2. Align the protrusion of the gasket with the cutout of the oil strainer 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 sequence shown in the illustration.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  7. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY379533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Packing

      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.)

      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.
      • Do not start the engine for at least 4 hours after the installation.
    2. Install the oil pan sub-assembly with 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 are tightened twice.

      Fig 5: Engine Oil Pan Bolts And Nuts Tightening Sequence
      GTY365390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL OIL FILTER ELEMENT 

    Refer to PROCEDURE - Step 3

  9. INSTALL REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 1

  10. INSTALL CYLINDER BLOCK WATER JACKET SPACER 
    1. Install the cylinder block water jacket spacer to the cylinder block.
  11. INSTALL CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 1

  12. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  13. SET CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

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

    GTY367973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Protrusion Height
    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.

    GTY374598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Protrusion Height
    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 its threads are damaged, replace it.

    1. Using an E8 "TORX" socket wrench, install the stud bolt.
      GTY383836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 20 mm (0.787 in.)
      *b 35 mm (1.38 in.)
      *c 13 mm (0.512 in.)

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

  17. INSTALL NO. 1 CAMSHAFT BEARING 
    1. Clean the No. 1 camshaft bearing.
      GTY374669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Vernier Caliper
    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. INSTALL NO. 2 CAMSHAFT BEARING 
    1. Clean the No. 2 camshaft bearing.
      GTY365788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Vernier Caliper
    2. Install the camshaft bearing to the camshaft housing.
    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.)

  19. 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
  20. INSTALL CAMSHAFT 

    Refer to PROCEDURE - Step 10

  21. INSTALL CAMSHAFT BEARING CAP 

    Refer to PROCEDURE - Step 11

  22. INSTALL VALVE STEM CAP 

    Refer to PROCEDURE - Step 3

  23. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 5

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

    Refer to PROCEDURE - Step 6

  25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12

  26. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 13

  27. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 14

  28. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket to the crankshaft.
  29. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 15

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 16

  31. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 17

  32. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 18

  33. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 19

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 20

  35. INSTALL TIMING CHAIN GUIDE 

    Refer to PROCEDURE - Step 21

  36. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 22

  37. INSTALL TIMING CHAIN COVER PLATE 

    Refer to PROCEDURE - Step 14

  38. INSTALL TIMING CHAIN COVER TIGHT PLUG 
    1. Using a 14 mm hexagon wrench, install a new gasket and timing chain cover tight plug.

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

  39. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  40. INSTALL ENGINE MOUNTING BRACKET RH 

    Refer to PROCEDURE - Step 2

  41. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1

  42. INSTALL SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 7

  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  44. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the crankshaft pulley.
      GTY362219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    2. Using SST, hold the crankshaft pulley and install the pulley bolt.
      • SST: 09213-54015 
      • SST: 09330-00021 

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

      HINT: 

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

  45. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  46. 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) 

  47. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) 

    Refer to PROCEDURE - Step 1

  48. INSTALL ENGINE WATER PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  49. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  50. INSTALL THERMOSTAT 

    Refer to PROCEDURE - Step 1

  51. INSTALL WATER INLET 

    Refer to PROCEDURE - Step 2

  52. 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) 

  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) 

  54. INSTALL PCV CASE 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY367082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Packing

      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.)

      NOTE:
      • Remove any oil from the contact surface.
      • Install the PCV case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
    2. Install the PCV case, and then install the 8 bolts and 2 nuts in the order shown in the illustration.
      Fig 6: PCV Case Bolts And Nuts Tightening Sequence
      GTY377040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      Bolt A is tightened twice.

  55. INSTALL PCV VALVE 

    Refer to PROCEDURE - Step 1

  56. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side) 

    Refer to PROCEDURE - Step 2

  57. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side) 

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 1

  60. 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.
  61. INSTALL SPARK PLUG 

    Refer to PROCEDURE - Step 1

  62. INSTALL ENGINE COVER JOINT 
    1. Install the 3 engine cover joints.

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

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