Part 1
1AR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL ENGINE BALANCER ASSEMBLY
(a) Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.
If the alignment marks are not aligned, realign them.
(1) Place a wrench on the rear cutout part of the No. 2 balance shaft and hold the shaft in place.
(2) Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.
(b) Install the engine balancer to the stiffening crankcase with the 3 bolts, and tighten the bolts in the sequence shown in the illustration.
Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)
2. INSTALL STIFFENING CRANKCASE STUD BOLT
NOTICE:
If a stud bolt is deformed or the threads are damaged, replace it.
(a) Using E5 and E8 "TORX" socket wrenches, install the stud bolts.
for stud bolt A - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
for stud bolt B - Torque : 9.5 Nm (97 kgf-cm, 84 in-lbf)
3. INSTALL STIFFENING CRANKCASE RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in 2 new ring pins until they stop.
Standard protrusion height:
4.3 to 5.3 mm (0.169 to 0.209 in.)
4. INSTALL STIFFENING CRANKCASE ASSEMBLY
(a) Rotate the crankshaft clockwise so that the crankshaft key is at the position 90° from the bottom as shown in the illustration.
(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
Standard Seal Dimension:
Application Length A:
28 mm (1.10 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
* Do not apply oil for at least 4 hours after the installation.
(c) Check that the rear cutouts are as shown in the illustration.
(d) Clean the bolts and their installation holes.
(e) Apply adhesive to 3 threads or more of the end of bolt A.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(f) Temporarily install the stiffening crankcase with the 11 bolts.
Bolt Length:
HINT
Apply adhesive to bolt A before installing it.
(g) Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase.
for Bolt A - Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)
except Bolt A - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
5. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps, in the sequence shown in the illustration.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
6. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new gasket.
(b) Align the protrusion of the gasket with the cutout of the oil strainer, and install the gasket to the oil strainer.
(c) Install the oil strainer by tightening the 3 bolts in several steps, in the sequence shown in the illustration.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
7. INSTALL OIL PAN SUB-ASSEMBLY
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
2.5 to 3.5 mm (0.0984 to 0.138 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
* Do not apply oil for at least 4 hours after the installation.
(b) Install the oil pan by tightening the 11 bolts and 2 nuts in several steps, in the sequence shown in the illustration.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
HINT
Bolt A and nut A should be tightened twice.
8. INSTALL OIL FILTER CAP ASSEMBLY Replacement
9. INSTALL REAR ENGINE OIL SEAL Installation
10. INSTALL CYLINDER BLOCK WATER JACKET SPACER
(a) Install the water jacket spacer to the cylinder block.
11. INSTALL CYLINDER HEAD GASKET Installation
12. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation
13. SET CAMSHAFT TIMING GEAR ASSEMBLY Installation
14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.
Standard protrusion height:
2.7 to 3.3 mm (0.106 to 0.130 in.)
15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing.
Standard protrusion height:
5.0 to 7.0 mm (0.197 to 0.276 in.)
16. INSTALL CAMSHAFT HOUSING STUD BOLT
NOTICE:
If a stud bolt is deformed or the threads are damaged, replace it.
(a) Using an E8 "TORX" socket wrench, install the stud bolt.
Torque : 9.5 Nm (97 kgf-cm, 84 in-lbf)
17. INSTALL NO. 1 CAMSHAFT BEARING
(a) Clean the No. 1 camshaft bearing.
(b) Install the camshaft bearing to the No. 1 camshaft bearing cap.
(c) Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.
Dimension A - B or B - A:
0 to 0.7 mm (0 to 0.0276 in.)
18. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean the No. 2 camshaft bearing.
(b) Install the camshaft bearing to the camshaft housing.
(c) Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.
Standard distance:
1.15 to 1.85 mm (0.0453 to 0.0728 in.)
19. INSTALL OIL CONTROL VALVE FILTER
(a) Install the oil control valve filter to the No. 1 camshaft bearing cap.
20. INSTALL CAMSHAFT Installation
21. INSTALL CAMSHAFT BEARING CAP Installation
22. INSTALL VALVE STEM CAP Installation
23. INSTALL VALVE LASH ADJUSTER ASSEMBLY Installation
24. INSTALL VALVE ROCKER ARM SUB-ASSEMBLY Installation
25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY Installation
26. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation
27. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Installation
28. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the crankshaft timing sprocket to the crankshaft.
29. ADD ENGINE OIL Installation
30. SET NO. 1 CYLINDER TO TDC/COMPRESSION Installation
31. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation