Reassembly (from 07/2011)

1NZ-FE ENGINE MECHANICAL: ENGINE UNIT (for Hatchback): REASSEMBLY

1. INSTALL STUD BOLT

(a) Using "TORX" socket wrench E5, install the 4 stud bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

2. INSTALL OIL PAN SUB-ASSEMBLY

(a) Remove any old packing material from the contact surface.

(b) Apply a continuous bead of seal packing (Diameter 2.0 to 3.0 mm (0.079 to 0.118 in.)) to the oil pan mating surface as shown in the illustration.

Text in Illustration

Seal packing:

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

NOTICE:
* Install the oil pan within 3 minutes of applying seal packing.
* Do not expose the seal to engine oil for at least 2 hours after the installation.

(c) Install 2 new O-rings onto the cylinder block.

(d) Using several steps, install and tighten the 13 bolts uniformly in the sequence shown in the illustration.

Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)

HINT

Each bolt length is as follows:

* Bolt A 49 mm (1.93 in.)
* Bolt B 88 mm (3.47 in.)
* Bolt C 144 mm (5.67 in.)

3. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Install a new gasket and the oil strainer with the 2 nuts and the bolt.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove any old packing material from the contact surface.

(b) Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan mating surface as shown in the illustration.

Text in Illustration

Seal packing:

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

NOTICE:
* Install the oil pan within 3 minutes of applying seal packing.
* Do not expose the seal to engine oil for at least 2 hours after the installation.

(c) Install the No. 2 oil pan with the 9 bolts and the 2 nuts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(d) Install the drain plug with a new gasket.

Torque : 38 Nm (382 kgf-cm, 28 ft-lbf)

5. INSTALL OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, install the oil filter union.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

6. INSTALL OIL FILTER SUB-ASSEMBLY

(a) Check and clean the oil filter installation surface.

(b) Apply clean engine oil to the gasket of a new oil filter.

(c) Gently screw the oil filter into place, and tighten it until the gasket comes into contact with the seat.

(d) Using SST, tighten it an additional 3/4 turn.

SST : 09228-06501

HINT
When using a torque wrench, tighten it to the specified torque.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

7. INSTALL CYLINDER HEAD GASKET

(a) Clean the sealing surfaces of the cylinder head gasket, cylinder head and cylinder block.

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

Text in Illustration

NOTICE:
* Pay attention to the mounting orientation of the cylinder head gasket.
* Do not damage the cylinder gasket when installing the cylinder head onto the cylinder block.

8. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE:
The cylinder head bolts are tightened in 2 successive steps.

HINT
Perform "Inspection After Repairs" after replacing the cylinder head Programming and Relearning.

(a) Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the plate washer.

(b) Temporarily install the cylinder head with the 10 cylinder head bolts and 10 plate washers.

NOTICE:
Do not drop the plate washers into the cylinder head.

(c) Using several steps, tighten the 10 cylinder head bolts and 10 plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

(d) Mark the front side of the cylinder head bolts with paint.

Text in Illustration

(e) Retighten the cylinder head bolts an additional 90°, and then once more 90° as shown in the illustration.

(f) Check that the paint mark is now at a 180° angle to the front.

9. INSTALL REAR ENGINE OIL SEAL

(a) Apply MP grease to the lip of a new rear engine oil seal.

NOTICE:
Keep the lip free of foreign matter.

(b) Using SST and a hammer, tap in the rear engine oil seal until its surface is flush with the cylinder block and oil pan.

SST : 09223-56010

NOTICE:
* Do not tap the oil seal at an angle.
* Wipe any extra grease off the crankshaft.

10. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

NOTICE:
Install the camshaft timing gear assembly onto the camshaft with the lock pin of the camshaft timing gear assembly released.

HINT
Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly Programming and Relearning.

(a) Clamp the camshaft in a vise, and confirm that it is locked.

NOTICE:
Do not damage the camshaft.

(b) Put the camshaft timing gear assembly and camshaft together with the straight pin of the groove.

Text in Illustration

(c) Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits into the groove, push to ensure a good fit.

NOTICE:
Do not turn the camshaft timing gear in the retard direction (to the right).

(d) Check that there is no clearance between the gear flange and the camshaft.

(e) Tighten the bolt with the camshaft timing gear fixed.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

NOTICE:
* Do not lock the camshaft timing gear assembly when tightening the bolt.
* Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position.
* Tightening the bolts with the lock pin locked could cause breakage of the lock pin.

(f) Check that the camshaft timing gear assembly can move in the retard direction (to the right) and is locked in the most retarded position.

11. INSTALL CAMSHAFT

HINT
Perform "Inspection After Repairs" after replacing the camshaft Programming and Relearning.

(a) Apply a light coat of engine oil to the camshaft journals.

(b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.

(c) Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.

Torque : 13 Nm (129 kgf-cm, 9 ft-lbf)

NOTICE:
Tighten each bolt uniformly while keeping the camshaft level.

12. INSTALL CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise, and confirm that it is locked.

NOTICE:
Do not damage the camshaft.

(b) Align the knock pin hole the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket with the bolt.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

13. INSTALL NO. 2 CAMSHAFT

HINT
Perform "Inspection After Repairs" after replacing the camshaft Programming and Relearning.

(a) Apply a light coat of engine oil to the camshaft journals.

(b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.

(c) Examine the front marks and numbers on the No. 1 and No. 2 camshaft bearing caps and check that the order is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.

Text in Illustration

No. 2 bearing cap - Torque : 13 Nm (129 kgf-cm, 9 ft-lbf)

No. 1 bearing cap - Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)

NOTICE:
Tighten each bolt uniformly while keeping the camshaft level.

14. INSTALL CAMSHAFT POSITION SENSOR

(a) Apply engine oil to the O-ring.

NOTICE:
If the O-ring is damaged, replace the camshaft position sensor.

(b) Install the camshaft position sensor with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

15. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

16. INSTALL CHAIN SUB-ASSEMBLY

(a) Make sure that all the timing marks are in the positions (TDC) shown in the illustration.

Text in Illustration

HINT
The positions of the timing marks may differ the predetermined positions due to the force of the valve spring.

(b) Set the timing mark of the crankshaft in a position between 40 and 140° ATDC, as illustrated.

Text in Illustration

(d) Set the crankshaft in the position (20° ATDC) shown in the illustration.

(e) Align the timing marks of the camshaft with the mark plates of the timing chain and install the timing chain.

Text in Illustration

HINT
Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench.

17. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

18. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 1 chain tensioner assembly with the 2 bolts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Remove the bar from the No. 1 chain tensioner assembly.

19. INSTALL OIL PUMP SEAL

(a) Using SST and a hammer, tap in a new oil pump seal until its surface is flush with the timing chain cover.

SST : 09950-60010

09951-00250

09951-00410

09952-06010

SST : 09950-70010

09951-07100

NOTICE:
* Do not tap the oil seal at an angle.
* Keep the seal lip free of foreign matter.

(b) Apply a light coat of MP grease to the oil pump seal lip.

20. INSTALL OIL PUMP ASSEMBLY

(a) Install 2 new O-rings.

(b) Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration.

Text in Illustration

Seal packing:

Water pump part
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

Other part
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pump assembly within 3 minutes and tighten the bolts and nut within 15 minutes of applying the seal packing.
* Do not expose the seal to engine oil for at least 2 hours after the installation.

(c) Align the keyway of the oil pump rotor with the rectangular portion of the crankshaft, and slide the oil pump into place.

(d) Install the oil pump assembly with the 15 bolts and nut. Tighten the bolts and nut uniformly in several steps.

Bolt A - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

Bolt B, C - Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

Bolt D, E - Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)

NOTICE:
Install the mounting bracket and water pump within 15 minutes of installing the oil pump.

HINT

Each bolt length is as follows.

* A: 30 mm (1.181 in.)
* B: 35 mm (1.378 in.)
* C: 20 mm (0.787 in.)
* E: 20 to 14 mm (0.787 to 0.551 in.) Double ended bolt

21. INSTALL ENGINE WATER PUMP ASSEMBLY

(a) Install the engine water pump and a new gasket with the 3 bolts and 2 nuts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

22. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

(a) Install the transverse engine engine mounting bracket with the 4 bolts.

Torque : 55 Nm (561 kgf-cm, 41 ft-lbf)

23. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

(a) Align the pin hole in the crankshaft damper with the pin position and install the crankshaft damper.

(b) Temporarily install the bolt.

(c) Using SST, tighten the bolt while holding the crankshaft damper.

SST : 09213-14010

91651-60865

SST : 09330-00021

Torque : 128 Nm (1305 kgf-cm, 95 ft-lbf)

NOTICE:
Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump.

24. INSTALL WATER PUMP PULLEY

(a) Using SST, install the water pump pulley with the 3 bolts.

Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)

SST : 09960-10010

09962-01000

09963-00700

25. INSPECT VALVE CLEARANCE Adjustments

26. ADJUST VALVE CLEARANCE Adjustments

27. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Apply a light coat of engine oil to a new O-ring, and install it onto the camshaft timing oil control valve.

(b) Install the camshaft timing oil control valve with the bolt.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

NOTICE:
Do not twist the O-ring.

28. INSTALL FUEL INJECTOR ASSEMBLY

(a) Apply a light coat of gasoline or spindle oil to a new O-ring, then install one onto each fuel injector.

Text in Illustration

(b) Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the O-ring of the fuel injector.

(c) While turning the fuel injector left and right, install it onto the fuel delivery pipe.

Text in Illustration

NOTICE:
* Do not twist the O-ring.
* After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring with a new one.

29. INSTALL INJECTOR VIBRATION INSULATOR

(a) Install 4 new injector vibration insulators onto the cylinder head.

30. INSTALL NO. 1 DELIVERY PIPE SPACER

(a) Install the 2 No. 1 delivery pipe spacers onto the cylinder head.

NOTICE:
Install the delivery pipe No. 1 spacer in the correct direction.

31. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Temporarily install the fuel delivery pipe with the 4 fuel injectors using the 3 bolts.

NOTICE:
* Do not drop the fuel injectors when installing the fuel delivery pipe.
* Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.

(b) Tighten the 3 bolts to the specified torque.

Bolt A - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

Bolt B - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Install a new gasket onto the cylinder head cover.

(b) Apply seal packing to the cylinder head, as shown in the illustration.

Text in Illustration

Seal Packing:

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

NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head cover sub-assembly within 3 minutes of applying seal packing.
* Do not start engine for at least 2 hours after the installation.

(c) Temporarily install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.

(d) Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

33. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Install the ventilation valve onto the cylinder head cover.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

34. INSTALL OIL LEVEL DIPSTICK GUIDE

(a) Apply engine oil to a new O-ring.

(b) Install the O-ring onto the oil level dipstick guide.

(c) Install the oil level dipstick guide with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

35. INSTALL CRANKSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring.

NOTICE:
If reusing the camshaft position sensor, be sure to inspect the O-ring.

(b) Install the crankshaft position sensor with the bolt.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

36. INSTALL OIL FILLER CAP GASKET

(a) Install the oil filler cap gasket onto the oil filler cap.

37. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler cap onto the cylinder head cover.

38. INSTALL THERMOSTAT

(a) Install a new gasket onto the thermostat.

(b) Install the thermostat with the jiggle valve facing upward.

Text in Illustration

HINT
The jiggle valve may be set within 10° on either side as shown in the illustration.

39. INSTALL WATER INLET

(a) Install the water inlet with the 2 nuts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

40. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

(a) Install a new gasket onto the engine coolant temperature sensor.

(b) Using a 19 mm socket wrench, install the engine coolant temperature sensor.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

HINT
Perform "Inspection After Repairs" after replacing the engine coolant temperature sensor Programming and Relearning.

41. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Apply adhesive to the end 2 or 3 threads of the engine oil pressure switch.

Text in Illustration

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:
Do not start the engine for at least 1 hour after the installation.

(b) Using a 24 mm deep socket wrench, install the engine oil pressure switch.

Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)

42. INSTALL KNOCK SENSOR

(a) Install the knock sensor with the nut as shown in the illustration.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

43. INSTALL SPARK PLUG

(a) Using a 16 mm spark plug wrench, install the 4 spark plugs.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

HINT
Perform "Inspection After Repairs" after replacing the spark plug Programming and Relearning.