Reassembly
1UR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
(a) Install the timing chain cover stud bolts.
(1) Using an E10 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
(b) Install the No. 1 oil pan stud bolts.
(1) Using E6 and E7 "TORX" socket wrenches, install the 3 stud bolts as shown in the illustration.
for stud bolt A - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
for stud bolt B - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
2. INSTALL RING PIN
NOTICE:
It is not necessary to remove a ring pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in new ring pins to the timing chain cover.
Standard Protrusion:
3. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the O-ring to the oil drain pipe.
(c) Install the oil drain pipe with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL REAR CRANKSHAFT OIL SEAL
(a) Apply MP grease to the lip of a new rear crankshaft oil seal.
NOTICE:
* Do not allow foreign matter to contact the lip of the oil seal.
* Do not allow MP grease to contact the dust seal.
(b) Using SST, tap in a rear crankshaft oil seal until its surface is flush with the rear engine oil seal retainer edge.
SST : 09223-15030
SST : 09950-70010
09951-07100
Standard depth:
0 to 1.0 mm (0 to 0.0394 in.)
NOTICE:
* Keep the lip free from foreign matter.
* Do not tap the rear crankshaft oil seal at an angle.
5. INSTALL REAR ENGINE OIL SEAL RETAINER
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
2.0 to 3.0 mm (0.0787 to 0.118 in.)
Application position from inside edge of retainer:
3.5 mm (0.138 in.)
Text in Illustration
NOTICE:
* Remove any oil from the contact surface.
* Install the rear engine oil seal retainer within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
(b) Install the rear engine oil seal retainer with the 6 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
* Do not start the engine for at least 2 hours after installing the rear engine oil seal retainer.
* When installing the rear engine oil seal retainer, make sure the lip of the rear crankshaft oil seal is not damaged.
* When installing the rear engine oil seal retainer, make sure the lip of the rear crankshaft oil seal is not folded incorrectly.
6. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the O-ring to the oil strainer.
(c) Install the oil strainer with the 2 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
NOTICE:
Make sure the O-ring is not twisted or damaged.
7. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) Install the No. 1 oil pan baffle plate with the 7 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
8. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
Text in Illustration
NOTICE:
* Remove any oil from the contact surface.
* Install the No. 1 oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
(b) Install the No. 1 oil pan with the 14 bolts and 2 nuts.
for bolt A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for bolt B and nut - Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
Text in Illustration
NOTICE:
Do not start the engine for at least 2 hours after installing the oil pan.
9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
Text in Illustration
NOTICE:
* Remove any oil from the contact surface.
* Install the No. 2 oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
(b) Install the No. 2 oil pan with the 12 bolts and 2 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Text in Illustration
NOTICE:
Do not start the engine for at least 2 hours after installing the oil pan.
10. INSTALL NO. 1 HEAT EXCHANGER COVER
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
Text in Illustration
NOTICE:
* Remove any oil from the contact surface.
* Install the No. 1 heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
(b) Install the No. 1 heat exchanger cover with the 12 bolts and 2 nuts.
for bolt C - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for bolt A, bolt B and nut - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Standard Bolt:
Text in Illustration
NOTICE:
Do not start the engine for at least 2 hours after installing the heat exchanger cover.
11. INSTALL VENTILATION PIPE GASKET
(a) Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.
SST : 09950-60010
09951-00360
SST : 09950-70010
09951-07100
NOTICE:
* Do not tap the ventilation pipe gasket at an angle.
* Do not tap the ventilation pipe gasket excessively.
12. INSTALL OIL RETURN PIPE GASKET
(a) Install a new oil return pipe gasket.
13. INSTALL CYLINDER BLOCK WATER JACKET SPACER
(a) Install the 2 cylinder block water jacket spacers as shown in the illustration.
Text in Illustration
NOTICE:
* Make sure that the cutouts indicated by the arrows in the illustration face away from the engine.
* Make sure that the "up" marks are oriented as shown in the illustration.
14. INSTALL CYLINDER HEAD GASKET Installation
15. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation
16. INSTALL NO. 2 CYLINDER HEAD GASKET Installation
17. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH Installation
18. INSTALL VALVE STEM CAP Installation
19. INSTALL VALVE LASH ADJUSTER ASSEMBLY Installation
20. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Installation
21. INSTALL CAMSHAFT BEARING CAP RH Installation
22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Installation
23. INSTALL CAMSHAFT BEARING CAP LH Installation
24. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Installation
25. INSTALL CRANKSHAFT TIMING GEAR KEY
(a) Install the crankshaft timing gear key.
HINT
The other crankshaft timing gear key will be installed in a later step.
26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Installation
27. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH Installation
28. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH Installation
29. INSTALL CHAIN TENSIONER SLIPPER RH Installation
30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH Installation
31. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Installation
32. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH Installation
33. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH Installation
34. INSTALL CHAIN TENSIONER SLIPPER LH Installation
35. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH Installation
36. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY Installation
37. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Temporarily install the pulley set bolt.
(b) Rotate the crankshaft clockwise and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.
(c) Remove the crankshaft pulley set bolt.
Text in Illustration
38. INSTALL WATER INLET PIPE Installation
39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
40. INSTALL WATER PUMP ASSEMBLY Installation
41. INSTALL FRONT CRANKSHAFT OIL SEAL Installation
42. INSTALL CRANKSHAFT TIMING GEAR KEY Installation
43. INSTALL SPARK PLUG TUBE GASKET
(a) Using a cutter knife, cut off the seal part of the removed spark plug tube gasket.
Text in Illustration
(b) Using the removed spark plug tube gasket and a hammer, tap in a new spark plug tube gasket until it stops.
Text in Illustration
HINT
If the removed spark plug tube gasket does not fit on the new one, correct the removed one with pliers.
(c) Apply a light coat of MP grease to the spark plug tube gasket lip.
(d) Return the 4 ventilation baffle plate claws to their original positions.
44. INSTALL OIL CONTROL VALVE FILTER
(a) for Bank 1:
(1) Install the oil control valve filter to the cylinder head cover.
Text in Illustration
(2) Install a new gasket and the cylinder head cover spacer with the 3 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for Bank 2:
(1) Install the oil control valve filter to the cylinder head cover.
Text in Illustration
(2) Install a new gasket and the cylinder head cover spacer with the 3 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH Installation
46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Installation
47. INSTALL FRONT WATER BY-PASS JOINT Installation
48. INSTALL WATER INLET HOUSING Installation
49. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the cylinder block water drain cocks.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the cylinder block water drain cocks.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
Text in Illustration
(c) Tighten the cylinder block water drain cocks up to an additional 360° so that the cylinder block water drain cock pipes are within the range shown in the illustration.
NOTICE:
* Do not rotate the cylinder block water drain cocks more than 1 revolution (360°) after tightening the cylinder block water drain cocks to the specified torque.
* Do not loosen the cylinder block water drain cocks to adjust them. If an adjustment is necessary, remove the cylinder block water drain cocks and reinstall them.
(d) Install the water drain cock plugs to the water drain cocks.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
50. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) for Bank 1:
(1) Apply a light coat of engine oil to 2 new O-rings.
(2) Install the 2 O-rings to the 2 camshaft timing oil control valves.
(3) Install the 2 camshaft timing oil control valves with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for Bank 2:
(1) Apply a light coat of engine oil to 2 new O-rings.
(2) Install the 2 O-rings to the 2 camshaft timing oil control valves.
(3) Install the 2 camshaft timing oil control valves with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
51. INSTALL CRANKSHAFT POSITION SENSOR Installation
52. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR Installation
53. INSTALL CAMSHAFT POSITION SENSOR Installation
54. INSTALL VVT SENSOR Installation
55. INSTALL KNOCK SENSOR Installation
56. INSTALL SPARK PLUG Installation
57. INSTALL OIL FILLER CAP HOUSING
(a) Align the protrusion of a new gasket with the cutout of the oil filler cap housing and install the gasket to the oil filler cap housing.
Text in Illustration
(b) Install the oil filler cap housing with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
58. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install the gasket to the oil filler cap.
(b) Install the oil filler cap.
59. INSTALL CRANKSHAFT PULLEY Installation
60. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY Installation
61. INSTALL OIL FILTER ELEMENT Replacement