Part 2

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

REASSEMBLY(continued)

31. INSTALL KEYS
(a) Install the 2 keys.
32. INSTALL NO. 2 CHAIN SUB-ASSEMBLY
33. INSTALL CRANKSHAFT TIMING SPROCKET
34. INSTALL NO. 1 CHAIN VIBRATION DAMPER
35. INSTALL CHAIN SUB-ASSEMBLY
36. INSTALL CHAIN TENSIONER SLIPPER
37. INSTALL TIMING CHAIN GUIDE
38. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

39. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223-22010
(b) Apply a light coat of MP grease to the lip of the oil seal.

NOTICE:
^ Keep the lip free of foreign matter.
^ Do not tap on the oil seal at an angle.
^ Make sure that the oil seal edge does not stick out of the timing chain cover.

40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
41. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
42. INSTALL OIL PAN SUB-ASSEMBLY

43. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and oil pan drain plug.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
44. INSTALL WATER PUMP ASSEMBLY
(a) Remove any old seal packing material from the contact surface.

(b) Apply a continuous line of seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent
Standard seal diameter: 2.2 to 2.5 mm (0.09 to 0.10 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ The parts must be set within 3 minutes after applying seal packing. Otherwise, the material must be removed and reapplied.

(c) Install the water pump and bracket with the 4 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: Tighten the outside bolts and nuts with the clamp.

45. INSTALL WATER PUMP PULLEY
(a) Using SST, install the water pump pulley with the 4 bolts.
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)

46. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring of the sensor.

(b) Confirm that the wire harness of the sensor is placed as shown in the illustration.

(d) Install the clamp of the crankshaft position sensor onto the water pump.
47. INSTALL CRANKSHAFT PULLEY
48. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
49. INSPECT VALVE CLEARANCE
50. ADJUST VALVE CLEARANCE

51. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring of the sensor.

(b) Install the sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

52. INSTALL CYLINDER HEAD COVER GASKET
(a) Install the cylinder head cover gasket to the cylinder head cover.

NOTICE: Remove any oil from the contact surface.

53. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.

(b) Apply seal packing to the 2 locations shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes of applying seal packing.
^ Do not add engine oil for at least 2 hours after installing the cylinder head cover.

(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
Bolt A 11 Nm (112 kgf-cm, 8 ft. lbs.)
Bolt B 14 Nm (143 kgf-cm, 10 ft. lbs.)
Nut 11 Nm (112 kgf-cm, 8 ft. lbs.)

54. INSTALL OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
55. 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) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.

(d) When using a torque wrench:
(1) Using SST, tighten the oil filter.
SST 09228-06501
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)

(e) When not using a torque wrench:
(1) Using SST, tighten it an additional 3/4 turn.
SST 09228-06501

56. INSTALL SPARK PLUG
(a) Install the spark plugs.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

57. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive on the threads of the ventilation valve.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

(b) Install the ventilation valve.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

58. INSTALL OIL FILLER CAP GASKET
(a) Install the gasket to the cap.

59. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install the oil filler cap.