Part 3

ENGINE UNIT

COMPONENTS (Part 1) (RH Side):

COMPONENTS (Part 2) (LH Side):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7) (RH Side):

COMPONENTS (Part 8) (LH Side):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

REASSEMBLY Continued

41. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
(b) Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.

NOTICE: Be sure to install the idle gear shaft in the correct direction.

HINT: Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.

(c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)

HINT: After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.

42. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the mark plate and timing marks as shown in the illustration and install the chain.

HINT: The color of the camshaft mark plate is orange.

(b) Do not pass the chain over the crankshaft, just put it on it.

(c) Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.

NOTICE: When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

(d) Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.

HINT: The color of the crankshaft mark plate is yellow.

(e) Temporarily tighten the pulley set bolt.

(f) Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).

43. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.

44. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

(d) Remove the hexagon wrench of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression.
(e) Remove the pulley set bolt.

45. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST 09223-22010, 09506-35010

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 case.

46. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 8 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)

NOTICE: Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

47. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 3.0 mm (0.118 in.)

NOTICE:
^ Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
^ When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
^ Install the chain cover within 3 minutes.
^ Do not start the engine for at least 2 hours after installing.

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

Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent

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

Apply seal packing as follows:

(d) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.
(e) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Bolt length:

NOTICE: Make sure that there is no oil on the bolt and nut threads.

(f) Fully tighten the bolts in this order: Area 1 and Area 2.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(g) Fully tighten the bolts in Area 3.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

HINT: Tighten the bolts and nuts in the order of upper to lower as shown in the illustration.

(h) Fully tighten the bolts in Area 4.
Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except bolt A

HINT: Tighten the bolts in the order of lower to upper as shown in the illustration.

(i) Install a new gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)

48. INSTALL WATER INLET HOUSING
(a) Install 2 new O-rings.

HINT: Apply a small amount of water or soapy water to O-ring (A) in the illustration before installing it.

(b) Install the stud bolts.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

(c) Install the water inlet with the 2 bolts and nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

NOTICE: Be careful that the O-ring does not get caught between the parts.

(d) Connect the No. 1 water by-pass hose.
(e) Apply adhesive around the drain cock.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(f) Install the drain cock to the water inlet housing.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
(g) Install the drain cock plug to the water drain cock.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
(h) Install a new gasket to the thermostat.

(i) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

HINT: The jiggle valve may be set within 10° of either side of the prescribed positions.

(j) Install the water inlet with the 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

49. INSTALL FRONT ENGINE MOUNTING BRACKET NO. 1 LH
(a) Install the engine mounting bracket with the 6 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)

NOTICE:
^ Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
^ Do not start the engine for at least 2 hours after installation.

(b) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

50. INSTALL OIL PAN BAFFLE PLATE
(a) Install the oil pan baffle plate with the 7 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

HINT: Temporarily tighten the 7 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.

51. INSTALL OIL PAN SUB-ASSEMBLY
(a) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Install 2 new O-rings.

Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.)

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

(d) Install the oil pan with the 16 bolts and 2 nuts.
Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A

Timing Chain Cover:

52. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

(b) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

53. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

(b) 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: 3.0 to 4.0 mm (0.118 to 0.156 in.)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan No. 2 within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

54. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and the drain plug.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)