Engine Unit (For Sedan) Reassembly

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

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Remove any old packing material from the contact surface.

Apply a continuous bead of seal packing to the oil pan mating surface 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 oil pan within 3 minutes of applying seal packing.
   
3. Do not expose the seal to engine oil for at least 2 hours after the installation.
   

Install 2 new O-rings onto the cylinder block.

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

Torque:

24 N*m{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.)

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

Torque:

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

Remove any old packing material from the contact surface.

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.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan within 3 minutes of applying seal packing.
   
3. Do not expose the seal to engine oil within 2 hours of installation.
   
4. Do not start the engine for at least 2 hours after the installation.
   

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

Torque:

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

Install the drain plug with a new gasket.

Torque:

38 N*m{382 kgf*cm, 28 ft.*lbf}

Using a 12 mm (0.47 in.) hexagon wrench, install the oil filter union.

Torque:

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

Check and clean the oil filter installation surface.

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

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

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 N*m{133 kgf*cm, 10 ft.*lbf}

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Pay attention to the mounting orientation of the cylinder head gasket.
   
3. Do not damage the cylinder gasket when installing the cylinder head onto the cylinder block.
   

Apply a light coat of engine oil to the threads of the cylinder head bolts.

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

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Mark the front of the cylinder head bolt with paint.

Further tighten the cylinder head bolts by an additional 90° and one more additional 90° as shown in the illustration.

Check that the paint mark is now at a 180° angle from the front.

Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 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 surface.
   
2. Install the oil pump assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
   

Apply MP grease to a new oil seal lip.

NOTICE:

Keep the lip free of foreign matter.

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

SST

09223-56010

NOTICE:

1. Do not tap the oil seal at an angle.
   
2. Wipe any extra grease off the crankshaft.
   

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

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).

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

Tighten the fringe bolt with the camshaft timing gear fixed.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

NOTICE:

1. Do not lock the camshaft timing gear assembly when tightening the bolt.
   
2. 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.
   
3. Tightening the bolts with the lock pin locked could cause breakage of the lock pin.
   

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

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

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

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

Torque:

13 N*m{129 kgf*cm, 9 ft.*lbf}

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

Clamp the camshaft in a vise.

Align the knock pin hole the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket with the fringe bolt.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

NOTICE:

Do not damage the camshaft.

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

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

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.

Torque:

13 N*m{129 kgf*cm, 9 ft.*lbf} for No. 2 bearing cap

23 N*m{235 kgf*cm, 17 ft.*lbf} for No. 1 bearing cap

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

Apply engine oil to the O-ring.

NOTICE:

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

Install the camshaft position sensor with the bolt.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

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

HINT:

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

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

Set the camshaft timing gear and the camshaft timing sprocket in the positions (20° ATDC) shown in the illustration.

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

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

Torque:

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

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

HINT:

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

Install the chain tensioner slipper.

Install the No. 1 chain tensioner assembly with the 2 bolts.

Torque:

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

Remove the bar from the No. 1 chain tensioner assembly.

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

SST

09950-60010(09951-00250,09951-00380,09952-06010)
09950-70010(09951-07100)

NOTICE:

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

Apply MP grease to the oil seal lip.

Install 2 new O-rings onto the 2 locations shown in the illustration.

Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the 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:

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

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

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

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf}for bolt A

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

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

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

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

NOTICE:

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

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

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

Torque:

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

Install the transverse engine engine mounting bracket with the 4 bolts.

Torque:

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

Align the pin hole in the crankshaft damper with the pin position and install the crankshaft damper sub-assembly.

Provisionally install the bolt.

Using 2 SSTs, tighten the bolt while holding the crankshaft damper sub-assembly.

SST

09213-14010(91651-60865)
09330-00021

Torque:

128 N*m{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 assembly.

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

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

SST

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

Set the No. 1 cylinder to TDC/compression.

1. Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.
   





2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration.
   

   HINT:

   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

Check the valves indicated in the illustration.

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

   Valve clearance (cold):

   for intake:

   0.15 to 0.25 mm (0.006 to 0.010 in.)
   

   for exhaust:

   0.25 to 0.35 mm (0.010 to 0.014 in.)
   

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

Turn the crankshaft 1 complete revolution (360°) and align its timing notch with the timing mark "0" of the oil pump.

Check the valves indicated in the illustration.

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

   Valve clearance (cold):

   for intake:

   0.15 to 0.25 mm (0.006 to 0.010 in.)
   

   for exhaust:

   0.25 to0.35 mm (0.010 to 0.014 in.)
   

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

Remove the fan and generator V belt (YARIS_NCP93 RM000001DCJ016X_01_0002.html).

Remove the engine mounting insulator sub-assembly RH (YARIS_NCP93 RM000001DDZ00QX_01_0037.html).

Set the No. 1 cylinder to TDC/compression.

1. Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.
   





2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration.
   

   HINT:

   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

Place paint marks on the chain in the places where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.

Using an 8 mm hexagon wrench, remove the screw plug.

Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.

Using a wrench, rotate No. 2 camshaft clockwise to push in the plunger of the chain tensioner.

Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and insert a 3 mm (0.12 in.) diameter bar into the holes to hold the stopper plate.

HINT:

1. Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
   
2. Hold the bar with tape so that the bar does not come off.
   

Using a wrench, hold the hexagonal lobe of No. 2 camshaft and remove the fringe bolt.

Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.

Remove the fringe bolt and remove the camshaft timing sprocket.

Remove No. 2 camshaft.

Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove No. 2 camshaft bearing cap.

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.

Hold the chain by hand and remove the camshaft and the camshaft timing gear assembly.

Tie the chain with a piece of string as shown in the illustration.

Remove the 16 valve lifters.

Using a micrometer, measure the thickness of the removed lifter.

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

Valve clearance:

Intake A = B + (C - 0.20 mm (0.008 in.))

Exhaust A = B + (C - 0.30 mm (0.012 in.))

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

HINT:

Lifters are available in 35 sizes in increments of 0.020mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

Intake valve clearance (cold):

0.15 to 0.25 mm (0.006 to 0.010 in.)

EXAMPLE:

A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.

New Shim Thickness:

Shim No.	Thickness	Shim No.	Thickness	Shim No.	Thickness
06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)
08	5.080 (0.2000)	32	5.320 (0.2094)	56	5.560 (0.2189)
10	5.100 (0.2008)	34	5.340 (0.2102)	58	5.580 (0.2197)
12	5.120 (0.2016)	36	5.360 (0.2110)	60	5.600 (0.2205)
14	5.140 (0.2024)	38	5.380 (0.2118)	62	5.620 (0.2213)
16	5.160 (0.2031)	40	5.400 (0.2126)	64	5.640 (0.2220)
18	5.180 (0.2039)	42	5.420 (0.2134)	66	5.660 (0.2228)
20	5.200 (0.2047)	44	5.440 (0.2142)	68	5.680 (0.2236)
22	5.220 (0.2055)	46	5.460 (0.2150)	70	5.700(0.2244)
24	5.240 (0.2063)	48	5.480 (0.2157)	72	5.720 (0.2252)
26	5.260 (0.2071)	50	5.500 (0.2165)	74	5.740 (0.2260)
28	5.280 (0.2079)	52	5.520 (0.2173)

Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.010 to 0.014 in.)

EXAMPLE:

A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.

New Shim Thickness:

Shim No.	Thickness	Shim No.	Thickness	Shim No.	Thickness
06	5.060 (0.1992)	30	5.300 (0.2087)	54	5.540 (0.2181)
08	5.080 (0.2000)	32	5.320 (0.2094)	56	5.560 (0.2189)
10	5.100 (0.2008)	34	5.340 (0.2102)	58	5.580 (0.2197)
12	5.120 (0.2016)	36	5.360 (0.2110)	60	5.600 (0.2205)
14	5.140 (0.2024)	38	5.380 (0.2118)	62	5.620 (0.2213)
16	5.160 (0.2031)	40	5.400 (0.2126)	64	5.640 (0.2220)
18	5.180 (0.2039)	42	5.420 (0.2134)	66	5.660 (0.2228)
20	5.200 (0.2047)	44	5.440 (0.2142)	68	5.680 (0.2236)
22	5.220 (0.2055)	46	5.460 (0.2150)	70	5.700 (0.2244)
24	5.240 (0.2063)	48	5.480 (0.2157)	72	5.720 (0.2252)
26	5.260 (0.2071)	50	5.500 (0.2165)	74	5.740 (0.2260)
28	5.280 (0.2079)	52	5.520 (0.2173)

Install the selected valve lifter.

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

Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration.

Examine the front marks and the numbers on No. 2 camshaft bearing cap and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps in the sequence shown in the illustration.

Torque:

13 N*m{129 kgf*cm, 9 ft.*lbf}

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

Install No. 2 camshaft.

Hold the chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the chain.

Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft.

Provisionally install the flange bolt.

Examine the front marks and the numbers of No. 1 camshaft bearing cap and No. 2 camshaft bearing cap and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts in several steps, in the sequence shown in the illustration.

Torque:

for No. 2 bearing cap:

13 N*m{129 kgf*cm, 9 ft.*lbf}

for No. 1 bearing cap:

23 N*m{235 kgf*cm, 17 ft.*lbf}

NOTICE:

Tighten each bolt uniformly while keeping the camshaft level.

Using a wrench, hold the hexagonal lobe of No. 2 camshaft and install the flange bolt.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Remove the bar from the timing chain tensioner.

Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump.

Check that all the pairs of timing marks are aligned.

Apply adhesive to the 2 or 3 threads of the screw plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

Using an 8 mm hexagon wrench, install the screw plug.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Install the engine mounting insulator sub-assembly RH (YARIS_NCP93 RM000001DDV00RX_01_0047.html).

Install the fan and generator V belt (YARIS_NCP93 RM000001DCG017X_01_0001.html).

Adjust the fan and generator V belt (YARIS_NCP93 RM000001DCG017X_01_0002.html).

Inspect the fan and generator V belt (YARIS_NCP93 RM000001DCH00ZX_01_0001.html).

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

Install the camshaft timing oil control valve with the bolt.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

NOTICE:

Do not twist the O-ring.

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

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.

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

NOTICE:

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

Install 4 new injector vibration insulators onto the cylinder head.

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

NOTICE:

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

Provisionally install the fuel delivery pipe sub-assembly with the 4 fuel injectors using the 3 bolts.

NOTICE:

1. Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
   
2. Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub-assembly.
   

Tighten the 3 bolts to the specified torque.

Torque:

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

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

Install a new gasket onto the cylinder head cover.

Apply seal packing to the cylinder head, 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 cylinder head cover sub-assembly within 3 minutes of applying seal packing.
   
3. Do not start engine for at least 2 hours after the installation.
   

Provisionally install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.

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

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the ventilation valve onto the cylinder head cover.

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

Apply engine oil to a new O-ring.

Install the oil level dipstick guide with the bolt.

Torque:

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

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

NOTICE:

If the O-ring is damaged, replace the crankshaft position sensor.

Install the crankshaft position sensor with the bolt.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

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

Install the oil filler cap onto the cylinder head cover.

Install a new gasket onto the thermostat.

Install the thermostat with the jiggle valve facing upward.

HINT:

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

Install the water inlet with radiator hose using the 2 nuts.

Torque:

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

Provisionally install the engine coolant temperature sensor using a new gasket.

Using SST, tighten the engine coolant temperature sensor.

SST

09817-33190

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

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

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

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Install the knock sensor with the nut as shown in the illustration.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Using a spark plug wrench, install the spark plugs.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}