Engine Unit Reassembly

Align the bearing claw with the claw groove, and push in the 8 bearings.

NOTICE:

Do not apply engine oil to the contact surfaces of the balanceshaft bearing and balanceshaft housing.

Apply a light coat of the engine oil to the bearings.

Rotate the No. 1 driven gear of the No. 1 balanceshaft in the rotating direction until it hits the stopper.

NOTICE:

Confirm that the matchmarks on the No. 1 and No. 2 driven gears are matched.

Confirm that the alignment marks on the No. 1 and No. 2 balanceshafts are aligned.

Align the alignment marks on the No. 1 and No. 2 balanceshafts as shown in the illustration.

Place the No. 1 and No. 2 balanceshafts onto the crankcase.

Apply a light coat of engine oil to the threads and under the heads of the bolts.

Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Torque:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Mark the front of the bolts with paint.

Further tighten the bolts 90° as shown in the illustration.

Check that the paint mark is now at a 90° angle to the front.

Place a new O-ring on the cylinder block as shown in the illustration.

With the No. 1 crank pin of the crankshaft placed at the TDC position, install the No. 1 and No. 2 balanceshafts and align the adjusting holes as shown in the illustration.

Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.098 to 0.118 in.)) as shown in the illustration.

Seal Packing:

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

NOTICE:

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

Temporarily install the crankcase with the 11 bolts.

Uniformly tighten the bolts.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Confirm that the timing marks on the balanceshafts are aligned when the key groove is placed at the TDC position, as shown in the illustration.

Install a new gasket and the oil pump with the 3 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Apply MP grease to the lip of a new rear crankshaft oil seal.

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

SST

09223-15030
09950-70010(09951-07100)

NOTICE:

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

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

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

1. Install the plug within 3 minutes of applying adhesive.
   
2. Do not add coolant for at least an hour after installing the plug.
   

Check that there is no foreign matter on the mesh part of the oil control valve filter.

Using a 8 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the plug.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Apply adhesive to 2 or 3 threads of the drain cock.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the water drain cock within the range shown in the illustration.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

NOTICE:

Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cock to the specified torque.

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

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Install the water jacket spacer as shown in the illustration.

HINT:

Be sure to face the slope to the front of the engine.

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Be careful of the installation direction.
   

Place the cylinder head on the cylinder head gasket.

NOTICE:

Place the cylinder head gently in order to avoid damaging the cylinder head gasket.

Install the cylinder head bolts.

NOTICE:

The cylinder head bolts are tightened in 2 successive steps.

1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
   

2. Using several steps, 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.
   

   Torque:

   70 N*m{714 kgf*cm, 52 ft.*lbf}

Mark the front of the cylinder head bolts with paint.

Further tighten the cylinder head bolts 90° as shown in the illustration.

Check that the paint mark is now at a 90° angle to the front.

Apply a light coat of engine oil onto a new O-ring.

Install the O-ring to the camshaft timing oil control valve.

Install the camshaft timing oil control valve with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

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

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.

NOTICE:

Be sure not to turn the camshaft timing gear to the retard direction (clockwise).

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

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

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

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

Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

Clean the installation surfaces and the inner and outer surfaces of the bearing.

NOTICE:

Keep the installation surfaces and the back surfaces of the bearing free of engine oil.

Align the claws and install No. 1 camshaft bearing onto No. 1 camshaft bearing cap.

Clean the installation surfaces and the inner and outer surfaces of the bearing.

NOTICE:

Keep the installation surfaces and the back surfaces of the bearing free of engine oil.

Install the No. 2 camshaft bearing onto the cylinder head.

Apply a light coat of engine oil to the journal portion.

Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque:

No. 1 Bearing cap:

30 N*m{301 kgf*cm, 22 ft.*lbf}

No. 3 Bearing cap:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

Torque:

No. 2 Bearing cap:

30 N*m{301 kgf*cm, 22 ft.*lbf}

No. 3 Bearing cap:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the 2 keys.

Set the crankshaft key in the left horizontal position.

Turn the cutout of the drive shaft so that it faces upward.

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 placed 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.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

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

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

Torque:

30 N*m{301 kgf*cm, 22 ft.*lbf}

Install the crankshaft timing gear or sprocket to the crankshaft.

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

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Set the No. 1 cylinder to TDC/compression.

1. Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks on the camshaft timing gear with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.
   





2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
   

Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

Using SST and a hammer, tap in the crankshaft timing sprocket.

SST

09309-37010

Align the gold or yellow links with the timing marks located on the camshaft timing gear and sprocket, then install the chain.

Install the chain tensioner slipper with the bolt.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the timing chain guide with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

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

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

SST

09223-22010

NOTICE:

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

Apply MP grease to the lip of the oil seal.

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

Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the illustration.

Seal packing:

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

NOTICE:

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

Apply a continuous bead of seal packing as shown in the illustration.

Seal packing:

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

NOTICE:

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

Apply adhesive to the threads of the bolt A.

Seal packing:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Temporarily install the timing chain cover with the 12 bolts and 2 nuts.

Bolt length:

Item	Length
Bolt A	30 mm (1.18 in.) length for 10 mm head
Bolt B	30 mm (1.18 in.) length for 12 mm head
Bolt C	40 mm (1.57 in.) length for 14 mm head

Temporarily install the engine transverse engine engine mounting bracket with the 3 bolts.

Fully tighten the timing chain cover with the 15 bolts and 2 nuts as shown in the illustration.

Torque:

Bolt A:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Bolt B:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Bolt C:

55 N*m{561 kgf*cm, 41 ft.*lbf}

Nut:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.

Torque:

22 N*m{220 kgf*cm, 16 ft.*lbf}

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

Install a new gasket and the chain tensioner with the 2 nuts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

NOTICE:

When installing the chain tensioner, set the hook again if the hook releases the plunger.

Temporarily install the V-ribbed belt tensioner assembly with the nut.

Slightly push down on the V-ribbed belt tensioner assembly at part (A) to align the holes of the engine and tensioner as shown in the illustration, and temporarily install the bolt .

Tighten the bolt and nut to install the V-ribbed belt tensioner.

Torque:

60 N*m{612 kgf*cm, 44 ft.*lbf}

NOTICE:

1. When replacing the V-ribbed belt tensioner with a new one, do not pull out the pin.
   
2. The pin will be removed in a later step.
   

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

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

Install the sensor with the 2 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the clamp of the crankshaft position sensor onto the water pump.

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 to 4.5 mm (0.158 to 0.177 in.)) as shown in the illustration.

Seal packing:

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

NOTICE:

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

Install the oil pan onto the cylinder block.

Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Place a wooden block between a floor jack and the engine, then support the engine using the floor jack.

Remove the chain block and sling device.

Remove the 2 bolts and engine hangers.

Install the oil drain plug with a new gasket.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Remove any old seal packing material from the contact surface.

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 (0.0866 to 0.0984 in.)

NOTICE:

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

Install the water pump and clamp bracket with the 4 bolts and 2 nuts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Confirm that the wire harness of the crankshaft position sensor is secured to the wire harness clamp bracket through the back of the rib of the timing chain cover.

Install the wire harness clamp.

Using SST, install the water pump pulley with the 4 bolts.

SST

09960-10010(09962-01000,09963-00700)

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

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

SST

09213-54015(91651-60855)
09330-00021

Torque:

180 N*m{1835 kgf*cm, 133 ft.*lbf}

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

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

Check only the valves indicated in the illustration.

1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   

   Standard Valve Clearance (Cold):

   Item	Specified Condition
   Intake	0.19 to 0.29 mm (0.00748 to 0.0114 in.)
   Exhaust	0.38 to 0.48 mm (0.0150 to 0.0189 in.)

2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve clearance lifters.
   

Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to TDC/compression.

Check only the valves indicated in the illustration.

1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
   

   Standard Valve Clearance (Cold):

   Item	Specified Condition
   Intake	0.19 to 0.29 mm (0.00748 to 0.0114 in.)
   Exhaust	0.38 to 0.48 mm (0.0150 to 0.0189 in.)

2. Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
   

Set No. 1 cylinder to TDC/compression (COROLLA_ZRE142 RM0000032Z3011X_01_0006.html).

Remove the No. 1 chain tensioner (COROLLA_ZRE142 RM0000032Z3011X_01_0013.html).

Loosen the camshaft timing sprocket (COROLLA_ZRE142 RM0000032Z3011X_01_0007.html).

Remove the No. 2 camshaft (COROLLA_ZRE142 RM0000032Z3011X_01_0008.html).

Remove the camshaft (COROLLA_ZRE142 RM0000032Z3011X_01_0009.html).

Remove the valve lifters.

Using a micrometer, measure the thickness of the removed valve lifters.

Calculate the thickness of a new lifter so that the valve clearance comes within the specified values.

New Lifter Thickness:

Item	Specification
Intake	A = B + (C - 0.24 mm (0.00945 in.))
Exhaust	A = B + (C - 0.43 mm (0.0169 in.))

1. Measured intake valve clearance = 0.40 mm (0.0157 in.)
   (Measured - Specification = Excess clearance)
   
1. 0.40 mm (0.0157 in.) - 0.24 mm (0.00945 in.) = 0.16 mm (0.00630 in.)
   
2. Measured used lifter thickness = 5.250 mm (0.2067 in.)
   
3. New lifter thickness = 5.410 mm (0.2130 in.)
   (Excess clearance + Used lifter thickness = Ideal new lifter)
   
1. 0.16 mm (0.00630 in.) + 5.250 mm (0.2067 in.) = 5.410 mm (0.2130 in.)
   
4. Closest new lifter = 5.420 mm (0.2134 in.)
   
1. Select No. 42 lifter
   

Select a new lifter with a thickness as close as possible to the calculated values.

HINT:

1. Lifters are available in 35 sizes in increments of 0.020 mm (0.000787 in.), from 5.060 to 5.740 mm (0.1992 to 0.2260 in.).
   


2. The identification number inside the valve lifters shows the value to 2 decimal places. (The illustration shows 5.420 mm (0.2134 in.)
   

Valve lifter selection chart (intake).

Standard intake valve clearance (cold):

0.19 to 0.29 mm (0.00748 to 0.0114 in.)

Valve lifter selection chart (exhaust).

Standard exhaust valve clearance (cold):

0.38 to 0.48 mm (0.0150 to 0.0189 in.)

Install the selected valve lifter.

Install the camshaft (COROLLA_ZRE142 RM0000032Z4011X_01_0001.html).

Install the No. 2 camshaft (COROLLA_ZRE142 RM0000032Z4011X_01_0002.html).

Install the No. 1 chain tensioner (COROLLA_ZRE142 RM0000032Z4011X_01_0012.html).

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

Install the camshaft position sensor with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the cylinder head cover gasket onto the cylinder head cover.

Remove any old packing material from the contact surface.

Apply seal packing to the 2 locations shown in the illustration.

Seal Packing:

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

NOTICE:

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

Install the cylinder head cover with the 8 bolts and 2 nuts.

Torque:

Bolt A:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Bolt B:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Nut:

11 N*m{112 kgf*cm, 8 ft.*lbf}

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

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Clean the oil filter installation surface.

Apply engine oil to a new oil filter gasket.

Lightly screw the oil filter into the engine until the oil filter does not turn.

Using SST, tighten the oil filter.

SST

09228-06501

1. Depending on the work space available, choose from the following:
   1. If enough space is available, use a torque wrench to tighten the oil filter.
   

   Torque:

   18 N*m{179 kgf*cm, 13 ft.*lbf}

   2. If enough space is not available to use a torque wrench, tighten the oil filter a 3/4 turn by hand or use a common wrench.
   

Install the 4 spark plugs.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Apply adhesive to the threads of the ventilation valve.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using a 22 mm deep socket wrench, install the ventilation valve onto the cylinder head cover.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the oil filler cap gasket onto the oil filler cap.

Install the oil filler cap onto the cylinder head cover.