Reassembly [02/2017 - 10/2017]: Procedure

INSTALL STIFFENING CRANKCASE RING PIN

NOTE:

It is not necessary to remove ring pins unless they are being replaced.

Using a plastic hammer, tap 2 new stiffening crankcase ring pins into the stiffening crankcase assembly.

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*a	Protrusion Height
*b	11 mm (0.433 in.)
*c	8 mm (0.315 in.)

Standard Ring Pin

Item	Protrusion Height	Height	Width
Ring pin	4.0 mm (0.157 in.)	8.0 mm (0.315 in.)	11 mm (0.433 in.)

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.)

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*a	Protrusion Height
*b	11 mm (0.433 in.)
*c	8 mm (0.315 in.)

INSTALL STUD BOLT

NOTE:

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

Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

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

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*1	Stud Bolt
*a	8.5 mm (0.335 in.)
*b	8.0 mm (0.315 in.)
*c	18 mm (0.709 in.)

Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

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

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*a	15 mm (0.591 in.)
*b	12 mm (0.472 in.)
*c	34 mm (1.339 in.)

Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration.

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

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*a	12 mm (0.472 in.)
*b	9.0 mm (0.354 in.)
*c	23 mm (0.906 in.)

Using an E7 "TORX" socket wrench, install the camshaft housing stud bolts.

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

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*a	12 mm (0.472 in.)
*b	18 mm (0.709 in.)
*c	48.5 mm (1.909 in.)

INSTALL STIFFENING CRANKCASE ASSEMBLY

Apply seal packing in a continuous line as shown in the illustration.

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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.

Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.

Fig 1: Stiffening Crankcase Assembly Bolts Tightening Sequence

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

Bolt Length

Item	Specified Condition
Bolt (A)	143.7 mm (5.43 in.)
Bolt (B)	35 mm (1.38 in.)
Bolt (C)	70 mm (2.76 in.)

Recheck the torque for the bolts (1) and (2).
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
Wipe off any excess seal packing with a clean piece of cloth.

INSTALL OIL PUMP ASSEMBLY
Refer to PROCEDURE - Step 1
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
Refer to PROCEDURE - Step 2

INSTALL OIL PAN DRAIN PLUG

Install a new gasket and oil pan drain plug to the No. 2 oil pan sub-assembly.

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

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INSTALL REAR ENGINE OIL SEAL
Refer to PROCEDURE - Step 1

INSTALL NO. 1 TAPER SCREW PLUG

Apply adhesive to 2 or 3 threads of the No. 1 taper screw plug, and install the No. 1 taper screw plug (A).

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*a	5.0 mm (0.197 in.)
*b	11 mm (0.433 in.)
*c	18 mm (0.709 in.)
*d	8.0 mm (0.315 in.)
*e	12.5 mm (0.492 in.)
*f	22 mm (0.866 in.)

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

Adhesive

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTE:

Install the No. 1 taper screw 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.

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 No. 1 taper screw 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.

INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)
Refer to PROCEDURE - Step 1
INSTALL CYLINDER HEAD GASKET
Refer to PROCEDURE - Step 1
INSTALL CYLINDER HEAD SUB-ASSEMBLY
Refer to PROCEDURE - Step 2
INSTALL VALVE STEM CAP
1. Apply a light coat of engine oil to the valve stem ends.
2. Install the 16 valve stem caps to the valve stems.
  HINT:
  
  Do not drop the valve stem caps into the cylinder head sub-assembly.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
1. Inspect each valve lash adjuster assembly before installing it.
  See step 2
2. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.
  NOTE:
  Install the valve lash adjuster assembly to the same place it was removed from.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Apply engine oil to the valve lash adjuster assembly tips and valve stem cap ends.

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*1	Valve Lash Adjuster Assembly
*2	No. 1 Valve Rocker Arm Sub-assembly
*3	Valve Stem
*4	Valve Stem Cap

Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

INSTALL CAMSHAFT HOUSING STRAIGHT PIN

NOTE:

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

Using a plastic 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.)

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*a	Protrusion Height
*b	14 mm (0.551 in.)
*c	6.0 mm (0.236 in.)

INSTALL CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY
Refer to PROCEDURE - Step 1
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
Refer to PROCEDURE - Step 3
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
Refer to PROCEDURE - Step 5
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
Refer to PROCEDURE - Step 4

INSTALL CRANKSHAFT TIMING GEAR KEY

Using a plastic hammer, tap in the 2 crankshaft timing gear keys.

HINT:

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

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INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.

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INSTALL NO. 2 CHAIN SUB-ASSEMBLY
Refer to PROCEDURE - Step 3
INSTALL CRANKSHAFT TIMING SPROCKET
Refer to PROCEDURE - Step 4

INSTALL NO. 1 CHAIN VIBRATION DAMPER

Install the No. 1 chain vibration damper with the 2 bolts.

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

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SET NO. 1 CYLINDER TO TDC/COMPRESSION

Temporarily install the crankshaft pulley bolt.

Turn the crankshaft counterclockwise to position the timing gear key to the top.

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*1	Timing Gear Key

Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are aligned as shown in the illustration.

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*a	Timing Mark

Remove the crankshaft pulley bolt.

INSTALL CHAIN SUB-ASSEMBLY

Align the mark plates (orange) with the timing marks as shown in the illustration and install the chain sub-assembly.

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Mark Plate (Orange)

Timing Mark

HINT:

Be sure to position the mark plate at the front of the engine.
The mark plate on the camshaft side is colored orange.
Do not pass the chain sub-assembly around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
Pass the chain sub-assembly through the No. 1 chain vibration damper.

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark, and then install the chain sub-assembly.
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.
HINT:

To tension the chain sub-assembly, slowly turn the camshaft timing gear assembly clockwise to prevent the chain sub-assembly from being misaligned.

Align the mark plates (pink) and timing marks and install the chain to the crankshaft timing gear.

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*a	Timing Mark
*b	Mark Plate (Pink)

HINT:

The mark plates on the crankshaft side are colored pink.

INSTALL CHAIN TENSIONER SLIPPER

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1. Install the chain tensioner slipper to the cylinder block sub-assembly.

CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

Check each timing mark at TDC/compression.

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*a	Timing Mark	*b	Mark Plate (Orange)
*c	Mark Plate (Pink)	-	-

INSTALL NO. 1 GENERATOR BRACKET

Install the No. 1 generator bracket with the 4 bolts.

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

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INSTALL WATER INLET HOUSING

Install a new gasket and the water inlet housing with the 3 bolts.

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

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
Refer to PROCEDURE - Step 10
INSTALL TIMING CHAIN COVER OIL SEAL
Refer to PROCEDURE - Step 11
INSTALL CRANKSHAFT PULLEY
Refer to PROCEDURE - Step 2

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Raise the cam, then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

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*a	Cam
*b	Hook
*c	Plunger
*d	Pin
*e	Correct
*f	Incorrect
*g	Push
*h	Raise

NOTE:

Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

Install a new gasket, the bracket and No. 1 chain tensioner assembly with the 2 nuts.

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

NOTE:

If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, set the hook again.

Rotate the crankshaft counterclockwise slightly and check that the hook is released.

*a	Hook
*b	Disconnect

Turn the crankshaft clockwise and check that the plunger is extended.

*a	Plunger
*b	Plunger Extended

INSTALL OIL FILTER BRACKET CLIP (for Oil Filter Element Kit Type)

Install the oil filter bracket clip to the oil filter bracket.

INSTALL OIL FILTER UNION (for Oil Filter Sub-assembly Type)

Courtesy 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)
INSTALL OIL FILTER
Refer to PROCEDURE - Step 4

INSTALL SPARK PLUG TUBE GASKET

Using a cutter knife, cut off the seal part of the removed spark plug tube gasket.

*a	Part to Cut Off

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.

*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.

Return the claws of the ventilation baffle plate to their original positions.

INSTALL CYLINDER HEAD COVER GASKET

Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

NOTE:

Remove any oil from the contact surfaces.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Install 3 new gaskets to the camshaft bearing cap.

Apply seal packing as shown the illustration.

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.

Install the cylinder head cover sub-assembly with a new seal washer and the 13 bolts.

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

INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
Refer to PROCEDURE - Step 1
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Refer to PROCEDURE - Step 1
INSTALL KNOCK SENSOR
Refer to PROCEDURE - Step 1
INSTALL CRANKSHAFT POSITION SENSOR
Refer to PROCEDURE - Step 1
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
- for Intake Side:
  Refer to PROCEDURE - Step 2
- for Exhaust Side:
  Refer to PROCEDURE - Step 1
INSTALL VALVEMATIC SHAFT SENSOR (CAMSHAFT POSITION SENSOR)
Refer to PROCEDURE - Step 1
INSTALL CAMSHAFT POSITION SENSOR
- for Intake Side:
  Refer to PROCEDURE - Step 1
- for Exhaust Side:
  Refer to PROCEDURE - Step 2
INSTALL SPARK PLUG
Refer to PROCEDURE - Step 1

INSTALL ENGINE COVER JOINT

Install the 2 engine cover joints.

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

INSTALL OIL FILLER CAP GASKET

Install the oil filler cap gasket to the oil filler cap sub-assembly.

INSTALL OIL FILLER CAP SUB-ASSEMBLY

Install the oil filler cap sub-assembly.