ENGINE UNIT > REASSEMBLY

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1. INSTALL OIL PAN SUB-ASSEMBLY



A198493E01

  1. Apply a continuous bead of seal packing to the oil pan as illustrated.

    Standard Seal Diameter:
    Area
    		Bead Size
    mm (in.)
    A - A
    		2.0 to 3.0
    (0.079 to 0.118)
    B - B
    		Min. Width: 7.0 (0.2756)
    Min. Height: 3.0 (0.1181)

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

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the oil pan within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.



    A198496E01

  1. Using several steps, temporarily tighten the 12 bolts in the sequence shown in the illustration, and then tighten the bolts to the specified torque.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

    Bolt Length:
    Bolt
    		Length
    mm (in.)
    A
    		35 (1.378)
    B
    		143.7 (5.657)
    C
    		119 (4.685)



2. INSTALL ENGINE REAR OIL SEAL


    A198492E01

  1. Apply MP grease to a new oil seal lip.

    NOTICE:
    Keep the lip free of foreign matter.

  1. Using SST and a hammer, tap in the new oil seal until its surface is flush the cylinder block edge.

    SST
    09223-15030  
    09950-70010   (09951-07100)

    NOTICE:
    1. Tap the oil seal from the vertical position.
    2. Wipe any extra grease off the crankshaft.



3. INSTALL ENGINE OIL LEVEL SENSOR


A198338E01

  1. Temporarily tighten the oil level sensor with the 5 bolts.

  1. Fully tighten the A bolts first, and then tighten bolt B.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    A198494E02

  1. Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.098 to 0.138 in.)) to the No. 2 oil pan as illustrated.
    Text in Illustration 
    *1
    		Seal Packing

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

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the oil pan within 3 minutes, and tighten the bolts within 10 minutes of applying the seal packing.

  1. Temporarily tighten the No. 2 oil pan with the 10 bolts and 2 nuts.



    A198497E01

  1. Fully tighten the 10 bolts and 2 nuts, as shown in the illustration.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Install a new gasket and oil pan drain plug.

    Torque:
    38 N*m{ 387 kgf*cm , 28 ft.*lbf }



5. INSTALL OIL PAN COVER SILENCER


A198406

  1. Install the oil pan cover silencer with the 3 clips.



6. SET OIL FILTER BRACKET SUB-ASSEMBLY

  1. Check and clean the oil filter bracket installation surface.



    A198426

  1. Install 2 new O-rings to the oil pan.



    A198424

  1. Set the oil filter bracket to the oil pan.



7. INSTALL OIL COOLER ASSEMBLY

  1. Check and clean the oil cooler installation surface.



    A198422

  1. Install 2 new O-rings and a new gasket to the oil filter bracket.



    A198420

  1. Temporarily tighten the oil cooler bracket and oil cooler with the spacer and 2 bolts and 2 nuts.

  1. Fully tighten the 2 bolts and 2 nuts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



8. INSTALL OIL FILTER ELEMENT


A194555E02

  1. Clean the inside of oil filter cap, threads, and O-ring groove.

  1. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

  1. Install a new oil filter element into the oil filter cap.

  1. Remove any dirt or foreign matter from the contact surfaces of the oil filter cap (with oil filter element) and oil filter bracket.

  1. Install the oil filter cap (with oil filter element) to the oil filter bracket.



9. INSTALL OIL FILTER CAP ASSEMBLY WITH ELEMENT


A204109E01

  1. Using SST, tighten the oil filter cap.

    SST
    09228-06501  

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }



10. INSTALL CYLINDER BLOCK WATER JACKET SPACER


A198503

  1. Install the cylinder block water jacket spacer to cylinder block.



11. INSTALL CYLINDER HEAD GASKET


A198505E01

  1. Inspect the protrusion height of the piston heads.

    1. Place a dial indicator on the cylinder block as shown in the illustration.

      NOTICE:
      Make sure that the dial indicator is at right angles to the cylinder block top surface.

    2. Measure the protrusion height of the piston head of each cylinder at 2 places as shown in the illustration.



    A198506E01

  1. Select a new cylinder head gasket.

    1. Select the highest protrusion height among the 8 measurements records. It is used to select a new cylinder head gasket.

      Piston Protrusion:
      Piston Protrusion mm (in.)
      		Gasket Cutout
      		Gasket Size
      0.525 to 0.575
      (0.020 to 0.023)
      		1
      		A
      0.576 to 0.625
      (0.023 to 0.025)
      		2
      		B
      0.626 to 0.675
      (0.025 to 0.027)
      		3
      		C
      0.676 to 0.725
      (0.027 to 0.029)
      		4
      		D
      0.726 to 0.775
      (0.029 to 0.031)
      		5
      		E



  1. Install the cylinder head gasket.

    1. Apply seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.)) to the cylinder block side as shown in the illustration.

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

      NOTICE:
      Remove any oil from the contact surface.

    2. Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.



    3. Apply seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.)) to the top surface of the cylinder head again as shown in the illustration.


      A198507E01

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



      4. A198504

    4. Install the cylinder head gasket onto the cylinder block.

      NOTICE:
      1. Remove any oil from the contact surface.
      2. Install the cylinder head within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.



12. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT:
The cylinder head bolts are tightened in multiple steps.

  1. Apply a light coat of engine oil to the threads of the cylinder head bolts.



    A200012E02

  1. Using several passes, uniformly install and tighten the 10 cylinder head bolts and plate washers in the sequence shown in the illustration. (*1)
    Text in Illustration 
    *1
    		Paint Mark

    Torque:
    50 N*m{ 510 kgf*cm , 37 ft.*lbf }

  1. Mark the front of the cylinder head bolts with paint.

  1. Using the same sequence as step (*1), retighten the cylinder head bolts by an additional 90° and one more additional 90°.

  1. Repeat the step above 2 more times as shown in the illustration.

  1. Check that each paint mark is now 270° from the front.



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


    G035835

  1. Apply engine oil to the stem end caps, valve rocker arm pivot top surfaces and valve rocker arm roller portions.

  1. Install the 8 valve rocker arms.



14. INSTALL CAMSHAFT


    A198508E02

  1. Turn the crankshaft to set the key in the 70° BTDC position.
    Text in Illustration 
    *1
    		TDC Mark
    *2
    		Key

  1. Apply engine oil to the camshaft journal portion and cam portion.



    A198511E01

  1. Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then, temporarily tighten the camshaft with the camshaft bearing caps and bolts.

    NOTICE:
    Do not tilt the valve rocker arm when installing the camshaft onto the cylinder head.



    A200011E01

  1. Using several steps, temporarily tighten the bolts in the sequence shown in the illustration, and then tighten the bolts to the specified torque.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



15. INSTALL CHAIN DAMPER SPRING


A198518

  1. Install the chain damper spring to the chain tensioner plate.



16. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


A198512E02
Text in Illustration 
*1
TDC Mark
*2
Key
*3
Oil Pump Shaft
*4
Flat Faces

  1. Align the crankshaft key with the TDC mark on the cylinder block.

  1. Rotate the oil pump shaft so that the flat faces left when viewing the cylinder block from the front.



    A198513E02

  1. Align the orange mark links with the timing marks of each gear as shown in the illustration.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Mark Link
    *3
    		Oil Pump Drive Gear
    *4
    		Oil Pump Drive Shaft Gear



    A198514

  1. Install the sprockets onto the crankshaft and oil pump shaft with the chain wrapped on the gears.



    A198516

  1. Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole on the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

    Torque:
    30 N*m{ 306 kgf*cm , 22 ft.*lbf }



    A198517E02

  1. Install the chain tensioner plate with the chain damper spring to the pin.
    Text in Illustration 
    *1
    		Tensioner Plate
    *2
    		Damper Spring
    *3
    		Pin
    *4
    		Pivot Hole

    NOTICE:
    1. Push the chain tensioner plate so that the area around the pivot hole reaches the base of the pin.
    2. The end of the spring should contact the side of the oil pan so that tension is applied to the chain.



    A198519E02

  1. Check that the mark plate and timing mark are in the positions shown in the illustration.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Mark Link
    *3
    		TDC Mark
    *4
    		Key



17. INSTALL CHAIN SUB-ASSEMBLY


    G035839E02

  1. Turn the camshaft to set the straight pin in the position shown in the illustration.
    Text in Illustration 
    *1
    		Straight Pin



    A198509E02

  1. Turn the crankshaft to set the key in the position shown in the illustration.
    Text in Illustration 
    *1
    		TDC Mark
    *2
    		Key



    A198520E02

  1. Align the chain's 2 orange mark plates with the timing mark on the camshaft timing sprocket, and the yellow mark plate with the timing mark on the crankshaft timing sprocket.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Orange Mark Plate
    *3
    		Yellow Mark Plate



    A198521E02

  1. Install the chain, camshaft timing sprocket and crankshaft sprocket together onto the engine.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Orange Mark Plate
    *3
    		Yellow Mark Plate



    A198523E01

  1. Using SST, fix the camshaft timing sprocket, and install the camshaft timing sprocket with the 3 bolts.

    SST
    09960-10010   (09962-01000, 09963-01000)

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



18. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    A198524

  1. Install the chain vibration damper with the 2 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



19. INSTALL CHAIN TENSIONER SLIPPER


    A198525

  1. Install the chain tensioner slipper onto the cylinder block.



20. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    A200013E01

  1. Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.



    A198527

  1. Install the chain tensioner with the 2 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Remove the 1.1 mm (0.043 in.) diameter bar from the chain tensioner.



    A198522E02

  1. Check that the mark plate and timing mark are in the positions shown in the illustration.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Orange Mark Plate
    *3
    		Yellow Mark Plate



21. INSTALL WATER INLET HOUSING


A204120

  1. Install a new gasket to the water inlet housing.

  1. Install the water inlet housing to the timing chain cover with the 3 bolts.

    Torque:
    9.1 N*m{ 93 kgf*cm , 81 in.*lbf }



22. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY



A198337E01

  1. Apply seal packing to the engine body and oil pump as shown in the illustration below.

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the timing chain cover within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    Seal packing:
    Water pump: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
    Other: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent



  1. Install the timing chain cover with the 20 bolts and 2 nuts, as shown in the illustration.


    A198333E01

    Torque:
    Bolt A, B, Nut:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }
    Bolt C:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }

    Bolt Length:
    Bolt
    		Length
    mm (in.)
    A
    		25 (0.984)
    B
    		35 (1.378)
    C
    		40 (1.575)

    NOTICE:
    1. Make sure that the chain does not come into contact with the seal packing when installing the timing chain cover.
    2. Install the engine mounting bracket RH and water pump within 10 minutes of installing the timing chain cover.



23. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

  1. Align the key with the key groove of the crankshaft damper, and slide the crankshaft damper to the crankshaft.



    A204631E01

  1. Using SST, secure the crankshaft damper.

    SST
    09213-58014  
    09330-00021  

  1. Tighten the bolt to the specified torque.

    Torque:
    210 N*m{ 2141 kgf*cm , 155 ft.*lbf }



24. INSTALL NO. 2 TIMING CHAIN COVER


    A198405

  1. Install the No. 2 timing chain cover with the clip.



25. INSTALL ENGINE MOUNTING BRACKET RH

  1. Temporarily tighten the engine mounting bracket with the 4 bolts.



    A198404E01

  1. Fully tighten the 4 bolts, as shown in the illustration.

    Torque:
    55 N*m{ 561 kgf*cm , 41 ft.*lbf }



26. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


P013638E09
Text in Illustration 
*1
Adhesive

  1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

    Adhesive:
    TOYOTA Genuine Adhesive 1344, Three Bond 1344 or equivalent



    A198414E01

  1. Using a 24 mm deep socket wrench, install the oil pressure switch.
    Text in Illustration 
    *1
    		24 mm Deep Socket Wrench

    Torque:
    15 N*m{ 153 kgf*cm , 11 ft.*lbf }



27. INSTALL THERMOSTAT


    A204608E01

  1. Install a new gasket onto the thermostat.

  1. Install the thermostat with the jiggle valve facing upward.

    HINT:
    The jiggle valve should be set within 10° of the vertical position as illustrated.



    A202789

  1. Install the water inlet with the 3 bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



28. INSTALL WATER OUTLET SUB-ASSEMBLY


A202788

  1. Install a new gasket to the cylinder head.

  1. Install the water outlet with the 2 bolts and 2 nuts.

    Torque:
    11 N*m{ 112 kgf*cm , 8 in.*lbf }



29. INSTALL WATER TEMPERATURE SENSOR


A202787E01
Text in Illustration 
*1
19 mm Deep Socket Wrench

  1. Install a new gasket to the water temperature sensor.

  1. Using a 19 mm deep socket wrench, install the water temperature sensor.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



30. CHECK VALVE CLEARANCE


    A198346E01

  1. Set the No. 1 cylinder to TDC/Compression.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		TDC Mark

    1. Turn the crankshaft pulley until the grooves of the crankshaft damper and oil pump are aligned.

    2. Check that the timing mark of the camshaft timing sprocket is in the position shown in the illustration.

      HINT:
      If not, turn the crankshaft damper 1 revolution (360°) to align the timing mark and sprocket as above.



    A125843E03

  1. Check the valve clearance of the No. 1 cylinder exhaust valve and the No. 2 cylinder intake valve.
    Text in Illustration 
    *1
    		No. 1 Exhaust
    *2
    		No. 2 Intake
    *3
    		Camshaft
    *4
    		Feeler Gauge

    1. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm.

      Valve clearance (cold):
      0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
      0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

      NOTICE:
      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
      1. Do not apply excessive force to the valve adjusting screw when using adjusting tools such as SST and a screwdriver.

      HINT:
      If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.



    A125846E02

  1. Check the valve clearance of the No. 1 cylinder intake valve and the No. 3 cylinder exhaust valve.
    Text in Illustration 
    *1
    		No. 1 Intake
    *2
    		No. 3 Exhaust
    *3
    		Camshaft
    *4
    		Feeler Gauge

    1. Turn the crankshaft by a further 180° clockwise.

    2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm as shown in the illustration.

      Valve clearance (cold):
      0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
      0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

      NOTICE:
      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

      HINT:
      If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.



    A125845E02

  1. Check the valve clearances of the No. 3 cylinder intake valve and No. 4 cylinder exhaust valve.
    Text in Illustration 
    *1
    		No. 3 Intake
    *2
    		No. 4 Exhaust
    *3
    		Camshaft
    *4
    		Feeler Gauge

    1. Turn the crankshaft clockwise by a further 180°.

    2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm as shown in the illustration.

      Valve clearance (cold):
      0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
      0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

      NOTICE:
      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

      HINT:
      If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.



    A125850E02

  1. Check the valve clearances of the No. 2 cylinder intake valve and No. 4 cylinder intake valve.
    Text in Illustration 
    *1
    		No. 2 Exhaust
    *2
    		No. 4 Intake
    *3
    		Camshaft
    *4
    		Feeler Gauge

    1. Turn the crankshaft clockwise by a further 180°.

    2. Using a feeler gauge, measure the clearance between the camshaft and No. 1 valve rocker arm.

      Valve clearance (cold):
      0.11 to 0.17 mm (0.004 to 0.007 in.) for intake
      0.14 to 0.20 mm (0.006 to 0.008 in.) for exhaust

      NOTICE:
      1. Insert the feeler gauge into the center of the roller surface, parallel to the No. 1 valve rocker arm.
      2. Do not apply excessive force to the valve adjusting screw with adjusting tools when measuring or adjusting.

      HINT:
      If the clearance is not as specified, record the out-of-specification measurement, and then adjust the valve clearance.



31. ADJUST VALVE CLEARANCE


    A200014E02

  1. Using SST and a screwdriver, loosen the valve adjusting nut while keeping the valve adjusting screw in position.
    Text in Illustration 
    *1
    		Adjusting Screw
    *2
    		Lock Nut

    SST
    09248-56010  



    A200015E02

  1. Adjust valve clearance (intake side).
    Text in Illustration 
    *1
    		Adjusting Screw
    *2
    		Lock Nut
    *3
    		Feeler Gauge

    1. Insert a feeler gauge (0.14 mm (0.006 in.)) between the camshaft and No. 1 valve rocker arm, and turn the valve adjusting screw to adjust it.

      Valve clearance (cold):
      0.14 mm (0.006 in.)



      2. A200016E02

    2. Using SST and a screwdriver, tighten the valve adjusting nut while keeping the valve adjusting screw in position.
      Text in Illustration 
      *1
      		Adjusting Screw
      *2
      		Lock Nut

      Torque:
      With SST:
      13 N*m{ 133 kgf*cm , 10 ft.*lbf }
      Without SST:
      20 N*m{ 204 kgf*cm , 15 ft.*lbf }

      HINT:
      1. This torque wrench value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.81 in.) and SST with a fulcrum length of 150 mm (5.91 in.) (Click here).
      2. This torque value is effective when SST is parallel to a torque wrench.

  1. Adjust the valve clearance (exhaust side).

    Valve clearance (cold):
    0.17 mm (0.007 in.)

    HINT:
    Perform the same procedure as for the intake valve clearance adjustment.



32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

  1. Install the cylinder head gasket onto the cylinder head cover.



    A198334E01

  1. Apply seal packing to the 4 locations shown in the illustration, and then install the cylinder head cover.

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

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.



    A198344E01

  1. Temporarily tighten the cylinder head cover with the 12 bolts.

  1. Fully tighten the 12 bolts, as shown in the illustration.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }



33. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  1. Install the oil filler cap gasket onto the oil filler cap.

  1. Install the oil filler cap onto the cylinder head cover.