Part 1

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

COMPONENTS (Part 13):

REASSEMBLY

1. INSTALL REAR CRANKSHAFT OIL SEAL
(a) Place the oil seal retainer on wooden blocks.
(b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-56010
(c) Apply MP grease to the lip of the oil seal.

2. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter: 3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:
^ Install the oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
^ Do not expose the seal to engine oil for at least an hour after installing it.

(b) Install a new O-ring to the cylinder block.
(c) Install the oil seal retainer with the 7 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

3. INSTALL FRONT CRANKSHAFT OIL SEAL
(a) Place the oil pump on a wooden block.
(b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09316-60011
(c) Apply MP grease to the lip of the oil seal.
4. INSTALL OIL PUMP ASSEMBLY
5. INSTALL OIL STRAINER SUB-ASSEMBLY
6. INSTALL NO. 3 OIL PAN BAFFLE PLATE
(a) Install the baffle plate with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
7. INSTALL NO. 2 OIL PAN BAFFLE PLATE
(a) Install the baffle plate with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
8. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) Install the baffle plate with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
9. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY
10. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
11. INSTALL OIL FILTER ASSEMBLY
12. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
13. INSTALL WATER PUMP ASSEMBLY

14. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply seal packing to 2 or 3 threads of the drain cock.
Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

(b) Install the 2 drain cocks as shown in the illustration.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)

NOTICE:
^ Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.
^ Do not loosen the drain cocks to adjust them. If an adjustment is necessary, remove the drain cocks and reinstall them.

15. INSTALL CYLINDER HEAD GASKET LH
16. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
17. INSTALL CYLINDER HEAD GASKET RH
18. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
19. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil to the valve lifters and shims.
(b) Install the valve lifters and shims.
(c) Check that the valve lifter rotates smoothly by hand.

20. INSTALL CAMSHAFT SETTING OIL SEAL
(a) Insert 2 new oil seals into the camshaft timing tube until they reach the stopper.

NOTICE:
^ Be careful of the installation direction.
^ Do not turn over the lip of the oil seal.

21. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY
(a) Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
(b) Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several steps.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
SST 09960-10010 (09962-01000, 09963-00500)

NOTICE: Be careful not to damage the timing tube.

(d) Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
(e) Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
(f) Install the seal washer and screw plug.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

22. INSTALL CAMSHAFT SUB-GEAR
(a) Install the gear spring [1], sub-gear [2] and wave washer [3].

HINT: Attach the pins on the gears to the gear spring ends.

(b) Using snap ring pliers, install the snap ring.

(d) Using SST, align the holes of the driven main gear and sub-gear by turning the sub-gear clockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)

Recommended service bolt:

(e) Align the gear teeth of the driven main gear and sub-gear, and tighten the service bolt.
23. INSTALL CAMSHAFT SUB-ASSEMBLY (for Bank 2)
24. INSTALL CAMSHAFT SUB-ASSEMBLY (for Bank 1)