Блок Двигателя Повторная Сборка. Corolla Auris

Apply seal packing in a continuous bead (diameter: 2.5 mm (0.098 in.)) to the places shown in the illustration.

Seal packing:

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

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   
2. Install the crankcase within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing the stiffening crankcase.
   

Install the stiffening crankcase with the 11 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

Bolt length:

Item	Length
Bolt A	138 mm (5.43 in.)
Bolt B	35 mm (1.38 in.)
Bolt C	70 mm (2.76 in.)

Recheck the torque for bolts 1 and 2.

Момент затяжки:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

Wipe off any excess seal packing with a clean piece of cloth.

Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge.

SST

09223-15030
09950-70010(09951-07100)

ПРИМЕЧАНИЕ:

1. Keep the lip free from foreign materials.
   
2. Do not tap on the oil seal at an angle.
   

Apply MP grease to a new oil seal lip.

ПРИМЕЧАНИЕ:

Wipe off extra grease on the crankshaft.

Install the oil pump with the 3 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

Apply a continuous bead of seal packing (Diameter 4.0 mm (0.157 in.)) as shown in the illustration.

Seal packing:

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

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surfaces.
   
2. Install the oil pan within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing the oil pan.
   

Install the No. 2 oil pan with the 10 bolts and 2 nuts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Install a new gasket and oil pan drain plug.

Момент затяжки:

37 Н*м{377 кгс*см, 27 фунт-сила-футов}

Apply adhesive to the threads of the drain cock.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the water drain cocks as shown in the illustration.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. Do not rotate the drain cock more than 1 revolution (360°) after tightening it to the specified torque.
   
2. Install the water drain cock within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing the water drain cock.
   

Install the water drain cock plug to the water drain cock.

Момент затяжки:

13 Н*м{130 кгс*см, 9 фунт-сила-футов}

Apply adhesive to the threads of the ventilation valve.

Install the ventilation valve.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

ПРИМЕЧАНИЕ:

1. Install the crankcase within 3 minutes after applying seal packing.
   
2. Do not start the engine for at least 2 hours after installing the ventilation valve.
   

Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   
2. Make sure that the gasket is installed in the correct direction.
   

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

Install the bolts and plate washers to the cylinder head.

ПРИМЕЧАНИЕ:

Do not drop the washers into the cylinder head.

Using several passes, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.

Момент затяжки:

49 Н*м{500 кгс*см, 36 фунт-сила-футов}

Mark the front side of the cylinder head bolt with paint.

Retighten the cylinder head bolts by additional 90° and one more additional 45° as shown in the illustration.

Check that the paint mark is now at a 135° angle to the front.

Place the lash adjuster into a container filled with engine oil.

Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

SST

09276-75010

Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.

Check the movement of the plunger and bleed it.

OK:

Plunger moves up and down.

ПРИМЕЧАНИЕ:

When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.

After bleeding, remove SST. Then, try to press the plunger quickly and firmly with a finger.

OK:

Plunger is very difficult to move.

Install the lash adjusters.

ПРИМЕЧАНИЕ:

Install the lash adjuster to the same place it was removed from.

Apply engine oil to the lash adjuster tip and valve stem cap end.

Make sure that the valve rocker arms are installed as shown in the illustration.

Clean the both surfaces of the bearing.

Install the 2 No. 1 camshaft bearings.

Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.

Dimension (A - B):

0.7 mm (0.0276 in.) or less

ПРИМЕЧАНИЕ:

Position the bearing to the center of the bearing cap by measuring dimension A - B.

Check that no foreign matter is on the mesh part of the filter.

Install the oil control valve filter.

ПРИМЕЧАНИЕ:

Do not touch the mesh when installing the oil control valve filter.

Clean the both surfaces of the bearing.

Install the 2 No. 2 camshaft bearings.

Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.

Dimension (A):

1.05 to 1.75 mm (0.041 to 0.069 in.)

ПРИМЕЧАНИЕ:

Position the bearing to the center of the bearing cap by measuring dimension A.

Clean the camshaft journals.

Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

Install the No. 2 camshaft to the camshaft housing.

Clean the camshaft journals.

Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

Install the camshaft to the camshaft housing.

Apply engine oil to the camshaft journals, camshaft housing and bearing caps.

Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

УКАЗАНИЕ:

Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Tighten the 10 bolts in the order shown in the illustration.

Момент затяжки:

16 Н*м{163 кгс*см, 12 фунт-сила-футов}

Make sure that the valve rocker arm is installed as shown in the illustration.

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:

3.5 to 4.0 mm (0.138 to 0.158 in.)

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   
2. Install the camshaft housing sub-assembly RH within 3 minutes.
   
3. Do not start the engine for at least 2 hours after installing.
   

Set the camshaft and No. 2 camshaft as shown in the illustration.

Install the camshaft housing and tighten the 17 bolts in the order shown in the illustration.

Момент затяжки:

27 Н*м{275 кгс*см, 20 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
   
2. If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
   
3. If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
   
4. After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.
   

Check that the knock pin is installed on the camshaft.

Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.

ПРИМЕЧАНИЕ:

Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear assembly.

Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

ПРИМЕЧАНИЕ:

Do not turn the camshaft timing gear in the retard direction (the right angle).

Check that there is no clearance between the gear and camshaft.

Tighten the flange bolt with the camshaft timing gear fixed in place.

Момент затяжки:

54 Н*м{551 кгс*см, 40 фунт-сила-футов}

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

Check that the knock pin is installed on the camshaft.

Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.

Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.

ПРИМЕЧАНИЕ:

Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle).

Check that there is no clearance between the gear's flange and the camshaft.

Tighten the flange bolt with the camshaft timing exhaust gear fixed.

Момент затяжки:

54 Н*м{551 кгс*см, 40 фунт-сила-футов}

Check the camshaft timing exhaust gear lock.

1. Make sure that the camshaft timing exhaust gear is locked.
   

Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

УКАЗАНИЕ:

Tap in the crankshaft timing gear keys until they become in contact with the crankshaft.

Install the sensor plate with the "F" mark facing forward.

Set the crankshaft key as shown in the illustration.

Turn the drive shaft so that the cutout faces right horizontal position.

Align the yellow mark links with the timing marks of each gear as shown in the illustration.

Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.

Temporarily tighten the oil pump drive shaft sprocket with the nut.

Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.

Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

Момент затяжки:

28 Н*м{286 кгс*см, 21 фунт-сила-футов}

Install the crankshaft timing sprocket.

Install the No. 1 chain vibration damper with the 2 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

Install the No. 2 chain vibration damper with the 2 bolts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Check the No. 1 cylinder TDC/compression.

1. Temporarily tighten the crankshaft pulley bolt.
   





2. Turn the crankshaft counterclockwise to position the timing gear key to the top.
   

3. Remove the crankshaft pulley bolt.
   





4. Check the timing marks on each camshaft timing gear.
   

Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

УКАЗАНИЕ:

1. Be sure to position the mark plate at the front of the engine.
   
2. The mark plate on the camshaft side is colored orange.
   
3. Do not pass the chain around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
   
4. Pass the chain through the No. 1 vibration damper.
   

Place the chain on the crankshaft without passing it around the shaft.

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark.

УКАЗАНИЕ:

1. Be sure to position the mark plate at the front of the engine.
   
2. The mark plate on the camshaft side is colored orange.
   

Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

УКАЗАНИЕ:

To tension the chain, slowly turn the camshaft timing gear assembly clockwise to prevent the chain from being misaligned.

Align the mark plate (yellow) and timing mark and install the chain to the crankshaft timing gear.

УКАЗАНИЕ:

The mark plate on the crankshaft side is colored yellow.

Recheck each timing mark at TDC/compression.

Install the chain tensioner slipper.

Install the No. 1 generator bracket with the 4 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

Install the water inlet housing with the 3 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

SST

09223-22010

Apply a light coat of MP grease to the lip of the oil seal.

ПРИМЕЧАНИЕ:

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

Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, and cylinder block.

Install 3 new O-rings.

Apply seal packing as shown in the illustration.

Seal packing:

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

Seal diameter:

3.0 mm (0.118 in.)

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   
2. Install the chain cover within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.
   

Apply seal packing to the timing chain cover in a continuous line as shown in the following illustration.

ПРИМЕЧАНИЕ:

1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
   
2. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing.
   

Apply seal packing as follows:

Area	Seal Packing Diameter	Application Position from Inside Seal Line	Seal packing
Continuous Line Area	3.0 mm (0.118 in.)	2.5 mm (0.098 in.)	Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Dashed Line Area	4.0 mm (0.156 in.)	3.0 mm (0.118 in.)	Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent

Install the timing chain cover.

Install a new gasket.

ПРИМЕЧАНИЕ:

Remove any oil from the contact surface.

Install the water pump with the 3 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

Install the engine mounting bracket with the 3 bolts.

ПРИМЕЧАНИЕ:

1. Install the mounting bracket within 10 minutes after installing the chain cover.
   
2. Do not start the engine for at least 2 hours after installation.
   

Bolt length:

Item	Length
Bolt	80 mm (3.15 in.)

Install 2 new O-rings.

Temporarily tighten the oil filter bracket with the 4 bolts.

ПРИМЕЧАНИЕ:

1. Install the oil filter bracket within 10 minutes after installing the chain cover.
   
2. Do not start the engine for at least 2 hours after installation.
   

Bolt length:

Item	Length
Bolt	35 mm (1.38 in.)

Apply adhesive to the threads of the bolt E.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the timing chain cover with the 26 bolts as shown in the illustration.

Момент затяжки:

Bolt A, E:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

Bolt B:

43 Н*м{439 кгс*см, 32 фунт-сила-футов}

Bolt C:

43 Н*м{439 кгс*см, 32 фунт-сила-футов}

Bolt D:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
   
2. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying the seal packing.
   
3. Do not start the engine for at least 2 hours after installing.
   

Bolt length:

Item	Length
Bolt A, E	35 mm (1.38 in.)
Bolt B	55 mm (2.16 in.)
Bolt C	80 mm (3.15 in.)
Bolt D	40 mm (1.57 in.)

Align the pulley set key with the key groove of the pulley.

Using SST, hold the pulley in place and tighten the bolt.

SST

09213-54015(91651-60855)
09330-00021

Момент затяжки:

190 Н*м{1940 кгс*см, 140 фунт-сила-футов}

Apply adhesive to 2 or 3 threads of the oil pressure switch.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a 24 mm deep socket wrench, install the oil pressure switch.

Момент затяжки:

15 Н*м{153 кгс*см, 11 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. Install the oil pressure switch within 3 minutes.
   
2. Do not start the engine within 1 hour after installation.
   

Install a new gasket to the engine water temperature sensor.

Install the engine water temperature sensor.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

Install the knock control sensor with the bolt.

Момент затяжки:

21 Н*м{214 кгс*см, 16 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Make sure that the knock control sensor is in the correct position.

Apply adhesive to 2 or 3 threads of the plug, and install the plug.

Момент затяжки:

43 Н*м{439 кгс*см, 32 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. Install the plug within 3 minutes.
   
2. Do not start the engine within 1 hour after installation.
   

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Install the crankshaft position sensor with the bolt.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Release the ratchet pawl, then fully push in the plunger and hook the hook to the pin so that the plunger is in the position shown in the illustration.

ПРИМЕЧАНИЕ:

Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

Install a new gasket, bracket and the No. 1 chain tensioner with the 2 nuts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

ПРИМЕЧАНИЕ:

If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.

Turn the crankshaft clockwise, then check that the plunger is extended.

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

Момент затяжки:

30 Н*м{301 кгс*см, 22 фунт-сила-футов}

Check and clean the oil filter installation surface.

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

Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.

When using a torque wrench:

1. Using SST, tighten the oil filter.
   

   SST

   09228-06501
   

   Момент затяжки:

   25 Н*м{255 кгс*см, 18 фунт-сила-футов}

When not using a torque wrench:

1. Using SST, tighten it an additional 3/4 turn.
   

   SST

   09228-06501
   

Install the gasket to the cylinder head cover.

ПРИМЕЧАНИЕ:

Remove any oil from the contact surface.

Install 3 new gaskets to the No. 1 camshaft bearing cap.

Apply seal packing as shown the illustration.

Seal packing:

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

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after the installation.
   

Install the cylinder head cover with a new seal washer and the 13 bolts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

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

Install the 2 camshaft timing oil control valves and bracket with the 2 bolts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

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

Install the 2 sensors with the 2 bolts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Using a 14 mm spark plug wrench, install the 4 spark plugs.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

Install the 2 engine cover joints.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Install the gasket to the cap.

Install the oil filler cap.

Install the 2 engine hangers with the 2 bolts.

Момент затяжки:

43 Н*м{439 кгс*см, 32 фунт-сила-футов}