Part 2

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

REASSEMBLY(continued)

21. INSTALL NO. 2 WITH HEAD STRAIGHT SCREW PLUG
(a) Using a 19 mm hexagon wrench, install a new gasket and the straight screw plug.
Torque: 90 Nm (918 kgf-cm, 66 ft. lbs.)

22. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign matter is on the mesh part of the filter.
If foreign objects are present, clean the part thoroughly.
(b) Using a 8 mm hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
23. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.

24. INSTALL VALVE STEM OIL SEAL
(a) Apply a light coat of engine oil to new oil seals.

NOTICE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

HINT: The intake valve oil seals are white and the exhaust valve oil seals are black.

(b) Using SST, push in the oil seals.
SST 09201-41020

NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated.

25. INSTALL INTAKE VALVE
(a) Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

(b) Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to the original locations.

(d) Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the valve stem tip.

26. INSTALL EXHAUST VALVE
(a) Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

(b) Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to the original locations.

(d) Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the valve stem tip.

27. INSTALL VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
^ Keep the lash adjuster free from dirt and foreign objects.
^ Only use clean engine oil.

(a) Place the lash adjuster into a container full of engine oil.
(b) Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.
SST 09276-75010
(c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed the air.
OK: Plunger moves up and down.

NOTICE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

(e) After bleeding the air, remove the SST. Then quickly and firmly press the plunger with a finger.
OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.

(f) Install the lash adjusters.

NOTICE: Install the lash adjuster to the original position.

28. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the valve stem caps to the cylinder head.

29. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY
(a) Install the 2 pulley keys to the crankshaft.

30. INSTALL NO. 4 CHAIN VIBRATION DAMPER
(a) Install the vibration damper No.4 with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

31. INSTALL NO.2 CHAIN SUB-ASSEMBLY
(a) Install the timing sprocket No.2 as shown in the illustration.

NOTICE: Check that the No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side.

HINT: Install the sensor plate with the front mark facing forward.

(b) As shown in the illustration, install the chain on the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.

(c) Fit the other mark link of the crankshaft timing sprocket behind the large timing mark of the balance shaft drive gear.
(d) Insert the balance shaft drive gear shaft through the balance shaft drive gear so that it fits into the thrust plate hole.

(e) Align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear.
(f) Install the bolt to the balance shaft drive gear and tighten it.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

(g) Check that each timing mark is matched with the corresponding mark link.

NOTICE: Check that the No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side.

32. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner assembly No.2 with the nut.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

NOTICE: Assemble the chain tensioner with the pin installed, then remove the pin after assembly. When doing this, avoid pushing the vibration damper against the chain.

(b) Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.
(c) Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

33. INSTALL NO. 3 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper No.3 with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

34. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper No.2 with the bolt.
Torque: 27 Nm (270 kgf-cm, 20 ft. lbs.)
(b) Remove a pin from the chain tensioner assembly No.2 and release the plunger.

35. INSTALL NO. 1 WITH HEAD TAPER SCREW PLUG
(a) Install the screw plug No.1 to the cylinder block.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

36. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
(a) Using a hexagon wrench, install the oil filter bracket union.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

(b) Install a new oil filter bracket gasket to the oil filter bracket.
(c) Install a new O-ring to the oil filter bracket union.

NOTICE: Apply a light coat of engine oil to the new O-ring and oil filter bracket.

(d) Install 2 new gaskets and the 2 screw plugs to the oil filter bracket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

(e) Install the oil filter bracket with the 2 bolts and nut.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

(f) Using a 27 mm socket wrench, install the oil filter union.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)

37. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten the oil filter.
SST 09228-07501
(1) When using a torque wrench: Using a torque wrench, tighten the oil filter.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
(2) When not using a torque wrench: Tighten it an additional 3/4 turn.

38. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width: 2 to 3 mm (0.079 to 0.118 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 4 hours after installing.

(b) Install the oil seal retainer with the 6 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)

39. INSTALL CYLINDER HEAD GASKET
(a) Apply a continuous bead (seal width: 4 to 7 mm (0.15 to 0.28 inch)) of seal packing to the cylinder block upper side and cylinder head gasket upper side as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Seal width: 4 to 7 mm (0.15 to 0.28 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head gasket within 3 minutes after applying the seal packing.
^ Install the cylinder head bolt within 15 minutes after applying the seal packing.
^ Do not put into engine oil within 4 hours of installation.

(b) Install a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

NOTICE:
^ Make sure that the installation direction is correct.
^ Place the cylinder head gently to avoid damaging the gasket with the bottom part of the head.

40. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT: The cylinder head bolts are tightened in 3 progressive steps.

(a) Place the cylinder head on the cylinder block.
(b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(c) Step 1
(1) Install and uniformly tighten the 10 cylinder head bolts with the plate washers, in several steps, in the sequence shown.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)

(d) Step 2
(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Retighten the cylinder head bolts by 90°.
(e) Step 3
(1) Retighten the cylinder head bolts by an additional 90°.
(2) Check that the painted mark is now facing rearward.

(f) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.