Part 3

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6) (RH Side):

COMPONENTS (Part 7) (LH Side):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

REASSEMBLY Continued

40. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.

41. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

(d) Remove the lock pin of the chain tensioner assembly No. 1. Check that each timing mark is aligned with the crankshaft at the TDC / compression.
(e) Remove the pulley set bolt.

42. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 8 bolts.
Torque: 9.1 N*m (93 kgf/cm, 81 in. lbs.)

NOTICE: Be sure to replace the bolts indicated by B with new ones or reuse them after applying adhesive 1344.

43. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Install a new gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 N*m (93 kgf/cm, 81 in. lbs.)
(b) Apply seal packing in a continuous bead to the engine unit as shown in the following illustration.

Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width: 3.0 mm or more (0.118 in.)

NOTICE:
^ Be sure to clean and degrease the contact surfaces, especially the areas indicated by C in the illustration.
^ When the contact surfaces are wet, degrease with cleaning agent and wipe off with an oil-free cloth before applying seal packing.
^ Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installation.

(c) Apply seal packing in a continuous bead to the timing chain cover as shown in the following illustration.

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

NOTICE:
^ When the contact surfaces are wet, degrease with cleaning agent and wipe off with an oil-free cloth before applying seal packing.
^ Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installation.

HINT: Apply seal packing referring to the table and illustration below.

(d) Install a new gasket.

(e) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.
(f) Loosely install the timing chain cover with the 23 bolts and 2 nuts, but do not tighten the bolts and 2 nuts yet.

NOTICE: Make sure that there is no oil on the bolt threads.

HINT: Bolt length

(g) Fully tighten the bolts in this order: Area 1 and Area 2.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
(h) Fully tighten the bolts and nuts in this order: Area 3.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
(i) Fully tighten the bolts in this order: Area 4.
Torque:
Bolt A 43 N*m (438 kgf/cm, 32 ft. lbs.)
Bolts except A 21 N*m (214 kgf/cm, 15 ft. lbs.)

44. INSTALL WATER INLET HOUSING

(a) Install 2 new O-rings.
(b) Apply soapy water to the O-ring.

(d) Apply adhesive around the drain cock.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(e) Install the water drain cock to the water inlet housing.
Torque: 30 N*m (306 kgf/cm, 22 ft. lbs.)
(f) Install the water drain cock plug to the water drain cock.
Torque: 13 N*m (130 kgf/cm, 9 ft. lbs.)
(g) Install a new gasket to the thermostat.

(h) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

HINT: The jiggle valve may be set within 10° of either side of the prescribed position.

(i) Install the water inlet with the 2 nuts.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)

45. INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 LH
(a) Install the engine mounting bracket front No. 1 LH with the 6 bolts.
Torque: 54 N*m (551 kgf/cm, 40 ft. lbs.)

NOTICE:
^ Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
^ Do not start the engine for at least 2 hours after installation.

46. INSTALL OIL PAN BAFFLE PLATE
(a) Install the oil pan baffle plate with the 7 bolts.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)

47. INSTALL OIL PAN SUB-ASSEMBLY

(a) Install the stud bolt.
(1) Using an E8 "TORX" socket wrench, install the stud bolts as shown in the illustration.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)

(b) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installation.

(d) Install the oil pan with the 16 bolts and 2 nuts.
Torque:
Bolt A 10 N*m (102 kgf/cm, 7 ft. lbs.)
Bolts except A 21 N*m (214 kgf/cm, 15 ft. lbs.)

48. INSTALL OIL STRAINER SUB-ASSEMBLY

Timing Chain Cover:

(a) Install the stud bolt.
(1) Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.
Torque: 4.0 N*m (41 kgf/cm, 35 in. lbs.)

(b) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)

49. INSTALL OIL PAN SUB-ASSEMBLY NO. 2

(a) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installation.

(b) Install the stud bolt.
(1) Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.
Torque: 4.0 N*m (41 kgf/cm, 35 in. lbs.)

50. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and the drain plug.
Torque: 40 N*m (408 kgf/cm, 30 ft. lbs.)

51. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Apply seal packing 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.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installation.

(b) Install the gasket to the head cover.

(c) Install the head cover with the 12 bolts.
Torque:
Bolt A 21 N*m (214 kgf/cm, 15 ft. lbs.)
Bolts except A 10 N*m (102 kgf/cm, 7 ft. lbs.)

HINT: Make sure the tightening torque of bolt 1.

52. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(c) Install the head cover with the 14 bolts.
Torque:
Bolt A 21 N*m (214 kgf/cm, 15 ft. lbs.)
Bolts except A 10 N*m (102 kgf/cm, 7 ft. lbs.)

HINT: Make sure the tightening torque of bolts 1 and 10.

53. INSTALL WATER OUTLET

(a) Install 2 new gaskets and a new O-ring.
(b) Apply soapy water to the O-ring.

(c) Install the water outlet with the 2 bolts and 4 nuts.
Torque:
Bolts 10 N*m (102 kgf/cm, 7 ft. lbs.)
Nuts 10 N*m (102 kgf/cm, 7 ft. lbs.)

54. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 250 N*m (2,550 kgf/cm, 184 ft. lbs.)

55. INSTALL OIL FILTER ELEMENT

(a) Clean the inside of the oil filter cap, the threads and O-ring groove.
(b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.
(c) Set a new oil filter element to the oil filter cap.
(d) Remove dirt or foreign matter from the installation surface and inside of the engine.
(e) Apply a small amount of engine oil to the O-ring again and install the oil filter cap.

NOTICE:
^ Be careful that the O-ring does not get caught between the parts.
^ The O-ring must not be twisted on the groove.

(f) Using SST, install the oil filter cap.
SST 09228-06501
Torque: 25 N*m (255 kgf/cm, 18 ft. lbs.)

NOTICE: Make sure that the oil filter is installed securely as shown in the illustration.

(g) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

NOTICE: Remove all dirt and foreign matter from the installation surface.

(h) Install the oil filter drain plug to the oil filter cap.
Torque: 13 N*m (130 kgf/cm, 9 ft. lbs.)

NOTICE: Make sure that the O-ring does not get caught between the parts.

56. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cocks.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the cylinder block water drain cocks as shown in the illustration.
Torque: 25 N*m (255 kgf/cm, 18 ft. lbs.)

NOTICE:
^ Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
^ Do not loosen the drain cocks after setting correctly.

(c) Install the water drain cock plug to the water drain cocks.
Torque: 13 N*m (130 kgf/cm, 9 ft. lbs.)

57. INSTALL OIL PIPE NO. 1
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
(b) Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install oil pipe No. 1 (on the head cover side) with the oil pipe union.
(c) Install a new gasket and temporarily install oil pipe No. 1 (on the cylinder head side) with the oil pipe union.

NOTICE: Remove any oil from the contract surface.

(d) Tighten the oil pipe union (on the head cover side).
Torque: 57 N*m (581 kgf/cm, 42 ft. lbs.)
(e) Tighten the oil check valve bolt (on the cylinder head side).
Torque: 57 N*m (581 kgf/cm, 42 ft. lbs.)

58. INSTALL OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
(b) Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the head cover side) with the oil pipe union.

NOTICE: Remove any oil from the contact surface.

(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.

NOTICE: Remove any oil from the contact surface.

(d) Install the bolt (A) to the cylinder head.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)
(e) Tighten the oil pipe union (on the head cover side).
Torque: 57 N*m (581 kgf/cm, 42 ft. lbs.)
(f) Tighten the oil pipe union (on the cylinder head side).
Torque: 57 N*m (581 kgf/cm, 42 ft. lbs.)

59. INSTALL CRANK POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)

60. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Install the 4 camshaft timing oil control valves with the 4 bolts.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)

61. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the 4 camshaft position sensors with the 4 bolts.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)

62. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive around the ventilation valve.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the ventilation valve sub-assembly.
Torque: 27 N*m (275 kgf/cm, 20 ft. lbs.)

63. INSTALL SPARK PLUG
(a) Install the 6 spark plugs.
Torque: 18 N*m (184 kgf/cm, 13 ft. lbs.)

64. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install the oil filter cap sub-assembly.