Engine Unit Reassembly

Using a small screwdriver, install a new snap ring onto one end of the piston pin hole.

УКАЗАНИЕ:

Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

Gradually heat the piston up to 80 to 90°C (176 to 194°F).

Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin comes into contact with the snap pin hole.

УКАЗАНИЕ:

Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

Install the expander and oil ring by hand.

УКАЗАНИЕ:

1. Install the expander and oil ring so that their ring ends are at opposite sides.
   
2. Securely install the expander to the oil ring's inner groove.
   

Using a piston ring expander, install the 2 compression rings with the paint mark as shown in the illustration.

ПРИМЕЧАНИЕ:

Install the No. 2 compression ring with the cord mark (2N) facing upward.

Position the piston rings so that the ring ends are as shown in the illustration.

Install the 4 oil nozzles with the 4 bolts.

Момент затяжки:

7.0 Н*м{71 кгс*см, 62 фунт-сила-дюймов}

Install the upper bearing with an oil groove onto the cylinder block.

ПРИМЕЧАНИЕ:

Do not apply engine oil to the bearing its contact surface.

Install the lower bearing onto the bearing cap.

ПРИМЕЧАНИЕ:

Do not apply engine oil to the bearing its contact surface.

Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil groove facing outward.

Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block.

Examine the front marks and numbers, and install the bearing caps onto the cylinder block in the order shown in the illustration.

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

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

Момент затяжки:

40 Н*м{408 кгс*см, 30 фунт-сила-футов}

Mark the front of the bearing cap bolts with paint.

Retighten the 10 bearing cap bolts by 90° in the same sequence.

Check that the paint marks are now at a 90° angle to the front.

Check that the crankshaft turns smoothly.

Align the bearing claw with the oil groove of the connecting rod or connecting rod cap.

ПРИМЕЧАНИЕ:

Do not apply engine oil to the bearing or its contact surface.

Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.

Check the position of the piston ring ends.

Using a hammer handle and piston ring compressor, press a piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

Check that the front mark of the connecting rod cap is facing in the correct direction.

ПРИМЕЧАНИЕ:

Match the numbered connecting rod cap with the connecting rod.

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

Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque.

Момент затяжки:

24.5 Н*м{250 кгс*см, 18 фунт-сила-футов}

Mark the front of the connecting rod bolts with paint.

Retighten the cap bolts 90°as shown in the illustration.

Check that the crankshaft turns smoothly.

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

ПРИМЕЧАНИЕ:

Do not apply engine oil to the bearing its contact surface.

Apply a light coat of engine oil in the bearings.

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

Confirm that the timing marks on the No. 1 and No. 2 driven gears are aligned.

Align the timing marks of the No. 1 and No. 2 balance shafts as shown in the illustration.

Place the No. 1 and No. 2 balance shafts 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.

Момент затяжки:

21.6 Н*м{220 кгс*см, 16 фунт-сила-футов}

Mark the front of the bolts with paint.

Retighten the bolts 90°as shown in the illustration.

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

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

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 6 o'clock position, install the No. 1 and No. 2 balance shafts 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:

Tayota Genuine Seal Packing Black, Three bond 1207B or Equivalent

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   

1. Install the crankcase within 3 minutes of applying seal packing.
   

1. 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.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Confirm that the timing marks of the balance shafts are aligned when the key groove is placed at the 6 o'clock position, as shown in the illustration.

Apply multi-purpose grease to the lip of a new oil seal.

ПРИМЕЧАНИЕ:

Keep the lip of foreign objects.

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

Специальный инструмент (SST):

09223-15030
09950-70010(09951-07100)

ПРИМЕЧАНИЕ:

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

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

Момент затяжки:

26 Н*м{265 кгс*см, 19 фунт-сила-футов}

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

ПРИМЕЧАНИЕ:

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 are no foreign objects on the mesh part of the oil control valve filter.

Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the plug.

Момент затяжки:

30 Н*м{306 кгс*см, 22 фунт-сила-футов}

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

After tightening the drain cock to the specified torque, turn the drain cock clockwise as shown in the illustration.

Момент затяжки:

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

ПРИМЕЧАНИЕ:

1. Install the drain cock within 3 minutes of applying adhesive.
   

1. Do not add coolant for at least an hour after installing the drain cock.
   

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

1. Do not loosen the drain cock after setting it correctly.
   

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

ПРИМЕЧАНИЕ:

1. Remove any oil from contact surface.
   

1. Be careful of the installation direction.
   

Place the cylinder head on the head gasket.

ПРИМЕЧАНИЕ:

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

Install the cylinder head bolts.

ПРИМЕЧАНИЕ:

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.
   

   Момент затяжки:

   78.5 Н*м{800 кгс*см, 58 фунт-сила-футов}

Mark the front of the cylinder head bolts with paint.

Retighten the cylinder head bolts by 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 to a new O-ring, then install it onto the camshaft timing oil control valve.

Install the camshaft timing oil control valve with the bolt.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

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.

ПРИМЕЧАНИЕ:

Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).

Check that there is no clearance between the gear fringe 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.

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

Момент затяжки:

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

ПРИМЕЧАНИЕ:

Do not damage the camshaft.

Clean the contact surface of the bearing and the cylinder head.

ПРИМЕЧАНИЕ:

Do not apply engine oil to the bearing its contact surface.

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

Clean the contact surface of the bearing and the bearing cap.

ПРИМЕЧАНИЕ:

Do not apply engine oil to the bearing its contact surface.

Align the bearing claw with the claw groove of No. 1 and No. 2 bearing cap, and push in the No. 1 camshaft bearing.

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

Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.

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 20 bearing cap bolts in the sequence shown in the illustration.

Момент затяжки:

29.5 Н*м{301 кгс*см, 22 фунт-сила-футов} for No. 1 and No. 2 bearing cap

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов} for No. 3 bearing cap

ПРИМЕЧАНИЕ:

1. Tighten the bolts after deciding the position in the thrust direction of the camshaft by the No. 1 and No. 2 bearing caps.
   

1. Install the camshaft with the timing mark of the camshaft timing gear on top.
   

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

Момент затяжки:

19 Н*м{194 кгс*см, 14 фунт-сила-футов}

Set the No. 1 cylinder to TDC/compression.

1. Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks of the camshaft timing gear with each timing mark 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.

Специальный инструмент (SST):

09309-37010

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

Install the chain vibration damper with the 2 bolts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Set the No. 1 cylinder to TDC/compression.

1. Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks of the camshaft timing gear with each timing mark 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.

Специальный инструмент (SST):

09309-37010

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

Install the chain tensioner slipper with the bolt.

Момент затяжки:

19 Н*м{194 кгс*см, 14 фунт-сила-футов}

Install the timing chain guide with the bolt.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

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

If the timing chain cover is removed from the cylinder block:

1. Using a screwdriver and hammer, tap out the oil seal.
   

2. Apply multi-purpose grease to the lip of a new oil seal.
   

   ПРИМЕЧАНИЕ:

   Keep the lip free of foreign objects.





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

   Специальный инструмент (SST):

   09223-22010
   

   ПРИМЕЧАНИЕ:

   Do not tap the oil seal at an angle.

If the timing chain cover oil seal is installed to the cylinder block:

1. Remove fan and generator V belt (see page RAV4_ACA30 RM000001R3F001X.html).
   

2. Remove the crankshaft pulley (see page RAV4_ACA30 RM000001R3L001X_01_0018.html).
   





3. Using a knife, cut off the lip of the oil seal.
   

4. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.
   

   ПРИМЕЧАНИЕ:

   After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

5. Apply multi-purpose grease to the lip of a new oil seal.
   

   ПРИМЕЧАНИЕ:

   Keep the lip free of foreign objects.





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

   Специальный инструмент (SST):

   09223-22010
   

   ПРИМЕЧАНИЕ:

   Do not tap the oil seal at an angle.

7. Install the crankshaft pulley (see page RAV4_ACA30 RM000001AA9002X_01_0011.html).
   

8. Install the fan and generator V belt (see page RAV4_ACA30 RM000001R3D001X.html).
   

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

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   

1. Install the chain cover within 3 minutes of applying seal packing.
   

1. 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

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   

1. Install the chain cover within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the chain cover.
   
   
   
   
   
   

Install the timing chain cover with the 12 bolts and 2 nuts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов} for bolt A

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

55 Н*м{561 кгс*см, 41 фунт-сила-футов} for bolt C

11 Н*м{112 кгс*см, 8 фунт-сила-футов} for nut

УКАЗАНИЕ:

Bolt length:

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

Момент затяжки:

21.5 Н*м{219 кгс*см, 16 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.

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

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

ПРИМЕЧАНИЕ:

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

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

Специальный инструмент (SST):

09213-54015(91651-60855)
09330-00021

Момент затяжки:

180 Н*м{1,835 кгс*см, 133 фунт-сила-футов}

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

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

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 3.0 to 4.0 mm (0.118 to 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 surface.
   

1. Install the oil pan within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the oil pan to the cylinder block.

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

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Place a transmission jack underneath the engine, then put a wooden block on the jack.

Remove the chain block and sling device.

Remove the No. 1 and No. 2 engine hangers.

Place a new gasket on the oil pan drain plug, then install it onto the oil pan.

Момент затяжки:

40 Н*м{408 кгс*см, 30 фунт-сила-футов}

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 (0.09 to 0.10 in.)

ПРИМЕЧАНИЕ:

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.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Install the wire of the crankshaft position sensor onto the clamp bracket.

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

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

Специальный инструмент (SST):

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

Момент затяжки:

26 Н*м{265 кгс*см, 19 фунт-сила-футов}

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

Install the sensor with the bolt.

Момент затяжки:

9.0 Н*м{90 кгс*см, 80 фунт-сила-дюймов}

Connect the sensor connector.

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

Момент затяжки:

29.5 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 by hand. Tighten it until the gasket contacts the seat.

Using SST, tighten the oil filter.

Специальный инструмент (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.
   

   Момент затяжки:

   17.2 Н*м{175 кгс*см, 13 фунт-сила-футов}

   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.
   

Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.

Check that each timing mark of the camshaft timing gear and sprocket is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.

Check only the valves indicated.

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

   Standard valve clearance (cold):

   Item	Standard Condition
   Intake	0.21 to 0.27 mm (0.0083 to 0.0106 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 the TDC/compression.

Check only the valves indicated.

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

   Standard valve clearance (cold):

   Item	Standard Condition
   Intake	0.21 to 0.27 mm (0.0083 to 0.0106 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.
   

Remove the No. 2 camshaft (see page RAV4_ACA30 RM000001AN8002X_01_0057.html).

Remove the camshaft (see page RAV4_ACA30 RM000001AN8002X_01_0058.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 (0.0095 in.))
Exhaust	A = B + (C - 0.35 mm (0.0138 in.))

1. Measured intake valve clearance = 0.16 mm (0.0063 in.)
   (Measured - Specification = Excess clearance)
   
1. 0.40 mm (0.0158 in.) - 0.24 mm (0.0095 in.) = 0.16 mm (0.0063 in.)
   
2. Measured used lifter measurement = 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 (0.0063 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.

УКАЗАНИЕ:

1. Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 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):

0.21 to 0.27 mm (0.0083 to 0.0106 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.

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

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

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 on 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.

Момент затяжки:

29.5 Н*м{301 кгс*см, 22 фунт-сила-футов} for No. 1 bearing cap

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов} for No. 3 bearing cap

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

Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket.

While holding the No. 2 camshaft by hand, temporarily tighten the camshaft timing sprocket set bolt.

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.

Момент затяжки:

29.5 Н*м{301 кгс*см, 22 фунт-сила-футов} for No. 2 bearing cap

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов} for No. 3 bearing cap

While holding the camshaft with a wrench, tighten the camshaft timing sprocket set bolt.

Момент затяжки:

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

ПРИМЕЧАНИЕ:

Be careful not to damage the valve lifter.

Check that the paint marks on the chain are aligned with the timing marks on the camshaft timing gear and camshaft timing sprocket. Also, check that the crankshaft pulley groove is aligned with the timing mark "0" of the timing chain cover.

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.

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

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

ПРИМЕЧАНИЕ:

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

Install the 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

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surface.
   

1. Install the oil pan within 3 minutes of applying seal packing.
   

1. Do not add engine oil for at least 2 hours after installing the oil pan.
   

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

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов} for bolt A

14 Н*м{143 кгс*см, 10 фунт-сила-футов} for bolt B

11 Н*м{112 кгс*см, 8 фунт-сила-футов} for nut

Install the 2 engine wires with the 2 bolts.

Момент затяжки:

8.4 Н*м{86 кгс*см, 74 фунт-сила-дюймов}

Connect the clamp of the engine wire (labeled B).

Connect the 2 ventilation hoses to the cylinder head cover.

Install the gasket to the cap.

Install the oil filler cap.

Момент затяжки:

3.0 Н*м{31 кгс*см, 26 фунт-сила-дюймов}

Install the 4 ignition coils with the 4 bolts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Connect the 4 ignition coil connectors.

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.

Момент затяжки:

19 Н*м{194 кгс*см, 14 фунт-сила-футов}

Apply a light coat of engine oil to a new O-ring and install it onto the guide.

Install the guide with the bolt.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Install the sensor with the bolt.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Using SST, install a new gasket and the ECT sensor.

Момент затяжки:

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

Специальный инструмент (SST):

09817-33190

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:

13 Н*м{133 кгс*см, 10 фунт-сила-футов}

Install the condenser with the bolt.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Install the sensor with the nut.

Момент затяжки:

20 Н*м{205 кгс*см, 15 фунт-сила-футов}

ПРИМЕЧАНИЕ:

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

Connect the sensor connector.

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

Install the oil control valve with the bolt.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

ПРИМЕЧАНИЕ:

Make sure that the O-ring is not cracked or jammed.

Connect the oil control valve connector.

Clean the oil cooler contact surface on the cooler mounting.

Install a new O-ring to the oil cooler.

Apply a light coat of engine oil on the threads and under the head of the union bolt.

Install the oil cooler with the plate washer, union bolt and nut.

Момент затяжки:

29.5 Н*м{301 кгс*см, 22 фунт-сила-футов} for union bolt

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов} for nut

Connect the 2 oil cooler hoses.

Install the V-ribbed belt tensioner with the bolt and nut.

Момент затяжки:

59.5 Н*м{607 кгс*см, 44 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Do not lift the engine more than necessary.

Apply adhesive to the threads of the union bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

Install the union bolt.

Момент затяжки:

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

Install a new gasket and the pipe with the bolt and 2 nuts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Connect the No. 3 and No. 4 water by-pass hose to the oil cooler.

Install a new gasket and the pipe with the bolt and 2 nuts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Install a new gasket onto the thermostat.

Install the thermostat with the jiggle valve upward.

УКАЗАНИЕ:

The jiggle valve may be set to within 10° on either side of the prescribed position.

Install the water inlet with the 2 nuts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Install a new gasket onto the cylinder head.

Temporarily tighten the exhaust manifold converter with the 5 nuts.

Tighten the 5 nuts in the sequence shown in the illustration.

Момент затяжки:

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

Install the exhaust manifold heat insulator with the 4 bolts.

Момент затяжки:

12 Н*м{122 кгс*см, 9 фунт-сила-футов}

Connect the air-fuel ratio sensor connector.

Install the stay with the bolt and nut.

Момент затяжки:

44 Н*м{449 кгс*см, 32 фунт-сила-футов}

Install the stay with the bolt and nut.

Момент затяжки:

44 Н*м{449 кгс*см, 32 фунт-сила-футов}

Install the idler bracket with the 2 bolts.

Момент затяжки:

60 Н*м{612 кгс*см, 44 фунт-сила-футов}