PROCEDURE
INSTALL OIL PAN SUB-ASSEMBLY
Apply seal packing to the oil pan sub-assembly in a continuous line as shown in the illustration.
*1 | φ 2.0 to 3.0 (0.0787 to 0.118) |
*2 | Min. 7.0 (0.276) |
*3 | Min. 3.0 (0.118) |
*4 | mm (in.) |
Standard Seal Packing Diameter | ||||||
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Seal packing |
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Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Remove any oil from the contact surfaces.
Install the oil pan within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.
Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.
Using several steps, temporarily tighten the 12 bolts, and then tighten them to the specified torque in the order shown in the illustration.
Bolt Length | ||||||||
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INSTALL ENGINE REAR OIL SEAL
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INSTALL ENGINE OIL LEVEL SENSOR
Install a new gasket to the engine oil level sensor.
*1 | Gasket |
*2 | Engine Oil level Sensor |
*a | Engine Oil level Sensor Side |
*b | Float Side |
*c | Groove |
Securely install the gasket to the engine oil level sensor groove.
Temporarily tighten the engine oil level sensor with the 5 bolts.
Do not deform the engine oil level sensor float or allow it to come in contact with other parts.
Fully tighten the 4 bolts (A) first, and then the bolt (B).
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
Apply seal packing (diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.)) to the No. 2 oil pan sub-assembly in a continuous line as shown in the illustration.
*a | Seal Packing |
Seal packing |
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Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
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 the seal packing.
Do not start the engine for at least 2 hours after installing the No. 2 oil pan sub-assembly.
Temporarily tighten the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.
Fully tighten the 10 bolts and 2 nuts, as shown in the illustration.
Install a new gasket and oil pan drain plug.
INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
Check and clean the oil filter bracket sub-assembly installation surface.
Install a new gasket to the oil pan sub-assembly.
Install the oil filter bracket sub-assembly with the 2 bolts.
INSTALL OIL COOLER ASSEMBLY
Check and clean the oil cooler assembly installation surface.
Install 2 new O-rings and a new gasket to the oil filter bracket sub-assembly.
Install the oil cooler assembly with the 2 bolts and 2 nuts.
INSTALL OIL FILTER ELEMENT
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INSTALL CYLINDER BLOCK WATER JACKET SPACER
Install the cylinder block water jacket spacer to the cylinder block sub-assembly.
INSTALL CYLINDER HEAD GASKET
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INSTALL CYLINDER HEAD SUB-ASSEMBLY
Apply a light coat of engine oil to the threads of the 10 cylinder head set bolts.
Using several steps, install and uniformly tighten the 10 cylinder head set bolts and 10 plate washers in the order shown in the illustration. (*1)
*a | Paint Mark |
Front |
Mark the front of the 10 cylinder head set bolts with paint.
Using the same order as step (*1), tighten the 10 cylinder head set bolts an additional 90°.
Repeat the step above 2 more times as shown in the illustration.
Check that each paint mark is now 270° from the front.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
Apply engine oil to the valve stem end caps, No. 1 valve rocker arm sub-assembly pivot top surfaces and No. 1 valve rocker arm sub-assembly roller portions.
Install the 8 No. 1 valve rocker arm sub-assemblies.
INSTALL CAMSHAFT
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INSTALL CHAIN DAMPER SPRING
Install the chain damper spring to the chain tensioner plate.
INSTALL NO. 2 CHAIN SUB-ASSEMBLY
Align the crankshaft key with the TDC mark on the cylinder block sub-assembly.
*1 | Key |
*a | TDC Mark |
*b | Oil Pump Shaft |
*c | Flat Side |
Rotate the oil pump shaft so that the flat side faces left when viewing the cylinder block sub-assembly from the front.
Align the orange mark plates with the timing mark of each gear as shown in the illustration.
*1 | Oil Pump Drive Gear |
*2 | Oil Pump Drive Shaft Gear |
*a | Timing Mark |
*b | Orange Mark Plate |
Install the sprockets onto the crankshaft and oil pump shaft with the No. 2 chain sub-assembly wrapped around the gears.
Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
Install the chain tensioner plate with the chain damper spring to the pin.
*1 | Chain Tensioner Plate |
*2 | Chain Damper Spring |
*a | Pin |
*b | Pivot Hole |
Push the chain tensioner plate so that the area around the pivot hole reaches the base of the pin.
The end of the chain damper spring should contact the side of the oil pan sub-assembly so that tension is applied to the No. 2 chain sub-assembly.
Check that the mark plates and timing marks are in the positions shown in the illustration.
*1 | Key |
*a | Timing Mark |
*b | Mark Plate |
*c | TDC Mark |
INSTALL CHAIN SUB-ASSEMBLY
Turn the camshaft to set the straight pin in the position shown in the illustration.
*a | Straight Pin |
Turn the crankshaft to set the key in the position shown in the illustration.
*1 | Key |
*a | Turn |
*b | TDC Mark |
Align the 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.
*a | Timing Mark |
*b | Orange Mark Plate |
*c | Yellow Mark Plate |
Install the chain sub-assembly, camshaft timing sprocket and crankshaft timing sprocket together onto the engine.
*a | Timing Mark |
*b | Orange Mark Plate |
*c | Yellow Mark Plate |
w/o Stop And Start System
Using SST, secure the camshaft timing sprocket, and install the camshaft timing sprocket with the 3 bolts.
w/ Stop And Start System
Install the 3 bolts while holding the hexagonal portion of the camshaft, and then install the camshaft timing sprocket and sensor plate.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
Install the No. 1 chain vibration damper with the 2 bolts.
INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper to the cylinder block sub-assembly.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
Push in the plunger until the groove is aligned with the hole, and then insert a 1.1 mm (0.0433 in.) diameter bar.
*a | Push |
*b | Plunger |
*c | Groove |
*d | Hole |
Install the No. 1 chain tensioner assembly with the 2 bolts.
Remove the 1.1 mm (0.0433 in.) diameter bar from the No. 1 chain tensioner assembly.
Check that the mark plates and timing marks are in the positions shown in the illustration.
*a | Timing Mark |
*b | Orange Mark Plate |
*c | Yellow Mark Plate |
INSTALL INLET WATER HOUSING
Install a new No. 2 water inlet housing gasket to the inlet water housing.
Install the inlet water housing to the timing chain cover sub-assembly with the 3 bolts.
INSTALL OIL CHECK VALVE SUB-ASSEMBLY
Using a 6 mm hexagon socket wrench, install the oil check valve sub-assembly with the bolt.
INSTALL TIMING CHAIN COVER OIL SEAL
Apply MP grease to a new timing chain cover oil seal lip.
Keep the lip free from foreign matter.
Using SST and a hammer, tap in the new timing chain cover oil seal until its surface is flush with the timing chain cover sub-assembly edge.
Oil seal tap in depth |
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-1.0 to 0 mm (-0.0394 to 0 in.) |
Do not tap in the timing chain cover oil seal at an angle.
Wipe off extra grease from the crankshaft.
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
Install the new oil pump gasket.
Apply seal packing to the engine body and oil pump as shown in the illustration below.
*a | Seal Width (Toyota Genuine Seal Packing Black, Three Bond 1207B) | *b | Seal Width (Toyota Genuine Seal Packing 1282B, Three Bond 1282B) |
*c | Width | *d | Height |
*e | Double Line Area | - | - |
Remove any oil from the contact surfaces.
Install the timing chain cover sub-assembly within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.
Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.
Seal packing |
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Engine water pump assembly: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent |
Other: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Install the timing chain cover sub-assembly with the 20 bolts and 2 nuts, as shown in the illustration.
*1 | Nut | - | - |
Bolt Length | ||||||||
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Make sure that the chain sub-assembly and No. 2 chain sub-assembly do not come into contact with the seal packing when installing the timing chain cover sub-assembly.
Install the engine mounting bracket RH within 10 minutes of installing the timing chain cover sub-assembly.
INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
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INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY
Apply a light coat of engine oil to the O-ring of the oil pressure switching valve assembly.
*a | O-ring |
Install the oil pressure switching valve assembly with the bolt.
Make sure that the O-ring is not torn or pinched when installing.
INSTALL NO. 2 TIMING CHAIN COVER
Install the No. 2 timing chain cover with the harness bracket and bolt.
INSTALL ENGINE MOUNTING BRACKET RH
Temporarily tighten the engine mounting bracket RH with the 4 bolts.
Fully tighten the 4 bolts, as shown in the illustration.
INSTALL OIL PRESSURE SENDER GAGE ASSEMBLY
Apply adhesive to 2 or 3 threads of the oil pressure sender gage assembly.
*a | Adhesive |
Adhesive |
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Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
Using a 27 mm deep socket wrench, install the oil pressure sender gage assembly.
INSTALL WATER INLET
Install a new No. 1 water inlet housing gasket to the water inlet.
Install the water inlet with the 3 bolts.
INSTALL OUTLET WATER SUB-ASSEMBLY
Install a new water outlet gasket to the cylinder head sub-assembly.
Install the outlet water sub-assembly with the 2 bolts and 2 nuts.
INSTALL WATER TEMPERATURE SENSOR
Install a new gasket to the water temperature sensor.
Using a 19 mm deep socket wrench, install the water temperature sensor.
CHECK VALVE CLEARANCE
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ADJUST VALVE CLEARANCE
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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Install the cylinder head gasket to the cylinder head cover sub-assembly.
Apply seal packing to the 4 locations shown in the illustration, and then install the cylinder head cover sub-assembly.
Seal Packing |
Seal packing |
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Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
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 the seal packing.
Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly.
Temporarily tighten the cylinder head cover sub-assembly with the 12 bolts.
Fully tighten the 12 bolts in the order shown in the illustration.
INSTALL OIL FILLER CAP SUB-ASSEMBLY
Install the oil filler cap gasket to the oil filler cap sub-assembly.
Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.