7GR-FKS ENGINE MECHANICAL  ENGINE UNIT  REASSEMBLY  

Using a plastic-faced hammer, tap in new ring pins to the camshaft housing.

Standard protrusion height:

2.7 to 3.3 mm (0.106 to 0.130 in.)

0.188,0.083 0.479,0.344 0.292,0.26 10 false *a 2.906,0.052 3.198,0.313 0.292,0.26 10 false *b 6.781,1.229 7.073,1.49 0.292,0.26 10 false *c

*a	LH	*b	RH
*c	Protrusion Height	-	-

Using a plastic-faced hammer, tap in new straight pins to the camshaft housing.

Standard protrusion height:

7.7 to 8.3 mm (0.303 to 0.327 in.)

0.177,0.073 0.49,0.313 0.313,0.24 10 false *a 2.854,0.052 3.167,0.292 0.313,0.24 10 false *b 6.531,0.948 6.844,1.188 0.313,0.24 10 false *c

*a	LH	*b	RH
*c	Protrusion Height	-	-

0.312,0.637 0.626,0.784 0.313,0.147 10 SST 1.063,1.537 0.679,0.781 0.679,0.781 1.206,0.912 false

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

SST

09223-15030  
09950-70010  (09951-07100)

NOTICE:

·

Keep the lip free of foreign matter.

·

Do not tap on the oil seal at an angle.

0.304,0.285 0.645,0.543 0.341,0.258 10 *a 0.999,0.648 0.774,0.397 false 0.774,0.397 0.504,0.397 false

*a	Seal Packing

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 0.157 in.)

NOTICE:

·

Remove any oil from the contact surface.

·

Install the rear engine oil seal retainer within 3 minutes after applying seal packing.

·

Do not start the engine for at least 2 hours after installation.

0.615,1.313 0.781,1.51 0.167,0.198 10 true A 3.063,0.177 3.208,0.375 0.146,0.198 10 true A

Install the rear engine oil seal retainer with the 6 bolts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

NOTICE:

Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

0,0 0,0 false

Front Side

Install the 2 cylinder block water jacket spacers as shown in the illustration.

Install the No. 1 water outlet pipe with the 2 bolts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

Attach the 2 clamps and install the No. 5 engine wire.

2.667,1.667 2.552,1.875 2.552,1.875 2.146,1.875 false 1.958,1.792 2.229,1.99 0.271,0.198 10 false *a

*a	Camshaft Installation Surface

Install the oil control valve filter LH to the camshaft bearing cap.

NOTICE:

Make sure the oil control valve filter does not protrude past the camshaft installation surface shown in the illustration.

0.875,0.292 1.323,0.292 false 2.219,0.417 2.302,0.188 2.302,0.188 2.438,0.188 false 2.802,1.229 2.802,1.552 false 0.646,2.167 0.49,1.406 0.49,1.406 0.406,1.406 false 0.656,0.208 0.969,0.406 0.313,0.198 10 false *1 2.521,0.094 2.833,0.292 0.313,0.198 10 false *2 2.729,1.594 3.042,1.792 0.313,0.198 10 false *3 0.229,1.323 0.542,1.521 0.313,0.198 10 false *4

*1	No. 1 Idle Gear Shaft
*2	Idle Sprocket
*3	No. 2 Idle Gear Shaft
*4	Knock Pin
	Apply Engine Oil

Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

Check that the camshaft timing gear position on the RH bank and the timing marks on the LH bank and crankshaft are positioned as shown in the illustration.

0.781,1.208 0.323,1.323 false 0.885,0.979 1.208,0.344 1.208,0.344 1.417,0.344 false 5.396,2.094 5.073,2.323 false 5.385,1.594 4.927,1.177 false 6.469,1.573 6.74,1.094 false 6.5,1.896 6.781,2.25 false 0.115,1.271 0.333,1.51 0.219,0.24 10 true *a 1.49,0.26 1.781,0.5 0.292,0.24 10 false *b 0.479,0.469 0.771,0.708 0.292,0.24 10 false *c 4.875,2.292 5.208,2.563 0.333,0.271 10 false *a 4.75,1.031 5.083,1.302 0.333,0.271 10 false *a 6.781,0.854 7.021,1.125 0.24,0.271 10 true *a 6.802,2.25 7.042,2.521 0.24,0.271 10 false *a

*a	Timing Mark	*b	Center Line
*c	Approximately 10°	-	-

2.49,0.771 2.229,1.01 false 0.927,3.917 0.594,4.146 false 2.625,0.938 2.885,1.021 false 1.031,4.104 1.25,4.188 false 2.042,0.938 2.281,1.167 0.24,0.229 10 false *a 0.427,4.104 0.667,4.333 0.24,0.229 10 false *a 2.906,0.969 3.146,1.198 0.24,0.229 10 false *b 1.292,4.156 1.531,4.385 0.24,0.229 10 false *b

*a	Mark Plate (Yellow)
*b	Timing Mark

Align the mark plates and timing marks as shown in the illustration and install the chain sub-assembly.

HINT:

The camshaft mark plates are yellow.

Rest the chain sub-assembly on top of the crankshaft.

2.729,3.667 2.979,3.667 false 1.771,3.74 0.615,3.74 false 1.781,3.844 2.042,4.094 2.042,4.094 2.333,3.948 false 3.031,3.573 3.281,3.875 0.25,0.302 10 false *d 0.25,2.771 0.573,3.042 0.323,0.271 10 false *a 0.427,3.656 0.729,3.927 0.302,0.271 10 false *b 1.958,4.156 2.198,4.406 0.24,0.25 10 false *c

*a	When idle sprocket is reused
*b	Mark
*c	Align
*d	Chain Plate
	Turn

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.

2.677,1.406 2.417,1.563 false 2.417,1.563 2.625,1.594 false 2.844,1.385 2.927,0.708 false 2.844,0.521 3.052,0.719 0.208,0.198 10 false *a 2.219,1.458 2.417,1.656 0.198,0.198 10 true *b

*a	Mark Plate (Pink)
*b	Timing Mark

Align the mark plate and timing mark as shown in the illustration and install the chain sub-assembly onto the crankshaft timing gear or sprocket.

HINT:

The crankshaft mark plate is pink.

0.938,1.354 0.521,1.615 false 1.729,0.833 1.25,1.198 false 0.292,1.552 0.521,1.792 0.229,0.24 10 true *a 1.781,0.667 2.031,0.938 0.25,0.271 10 true *b 0.802,0.781 1.135,1.021 0.333,0.24 10 false 10°

*a	Timing Mark
*b	Center Line
	Turn

Turn the crankshaft clockwise 10° to set it to the RH block bore center line (TDC/compression).

1.49,1.833 1.313,1.969 1.313,1.969 0.875,1.969 false 3.177,0.615 3.063,0.615 3.063,0.615 2.969,1.49 false 0.99,1.094 0.667,0.281 0.667,0.281 2.427,1.125 false 0.438,0.188 0.615,0.354 0.177,0.167 10 false *a 0.667,1.885 0.844,2.052 0.177,0.167 10 false *b 3.229,0.521 3.417,0.74 0.188,0.219 10 false *b

*a	Stopper Plate
*b	Plunger

Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

Check that each camshaft timing mark is positioned as shown in the illustration.

2.094,2.052 2.75,2.323 2.75,2.323 2.104,2.719 false 5.719,2.292 6.49,2.469 6.49,2.469 5.74,2.573 true 1.438,0.5 0.688,0.594 0.688,0.594 1.458,0.833 true 4.365,0.479 3.635,0.708 3.635,0.708 4.333,1.094 true 0.438,4.406 0.708,4.615 0.271,0.208 10 false *b 1.26,3.865 1.531,4.073 0.271,0.208 10 false *b 3.938,3.615 4.208,3.823 0.271,0.208 10 false *b 4.813,3.948 5.083,4.156 0.271,0.208 10 false *b 2.854,2.219 3.115,2.469 0.26,0.25 10 true *a 0.458,0.49 0.688,0.75 0.229,0.26 10 true *a 6.563,2.365 6.896,2.615 0.333,0.25 10 true *a 3.385,0.573 3.583,0.802 0.198,0.229 10 true *a

*a

Timing Mark

*b

Viewpoint

HINT:

1.719,0.375 2.781,0.24 true 1.74,0.573 2.771,0.583 true 1.698,0.969 2.771,0.896 true 1.719,1.354 2.792,1.677 true 2.833,0.156 3.052,0.375 0.219,0.219 10 true A 2.844,0.51 3.063,0.729 0.219,0.219 10 true B 2.823,0.813 3.042,1.031 0.219,0.219 10 true C 2.844,1.646 3.063,1.865 0.219,0.219 10 true D

For the intake camshaft:

Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

1.583,0.188 1.74,0.385 0.156,0.198 10 false 1 2.125,0.198 2.281,0.396 0.156,0.198 10 false 2 2.135,1.833 2.292,2.031 0.156,0.198 10 true 3 0.5,1.146 0.656,1.344 0.156,0.198 10 true 4 0.708,0.135 1.094,0.344 0.385,0.208 10 false 5 (A) 3.104,0.406 3.26,0.604 0.156,0.198 10 false 6 2.99,1.729 3.375,1.917 0.385,0.188 10 false 7 (A) 1.573,1.833 1.729,2.031 0.156,0.198 10 false 8

Install the No. 1 oil pan baffle plate with the 8 bolts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

HINT:

Temporarily install the 8 bolts. Tighten the 2 bolts A shown in the illustration before tightening the other bolts.

When replacing a stud bolt, install it by using an E6 and E8 "TORX" socket wrench.

4.781,0.896 5.323,1.031 5.323,1.031 5.052,0.677 true 2.083,1.073 2.542,1.74 2.542,1.74 2.333,1.094 true 2.802,0.99 3.396,0.729 3.396,0.729 2.792,0.438 true 2.323,0.688 2.656,0.26 2.656,0.26 2.49,0.771 true 2.24,2.25 2.417,2.448 0.177,0.198 10 false *a 2.458,2.375 2.646,2.563 0.188,0.188 10 false *b 3.813,2.135 3.99,2.333 0.177,0.198 10 false *c 4.042,2.323 4.229,2.51 0.188,0.188 10 false *d 5.594,2.073 5.792,2.281 0.198,0.208 10 false *e 2.24,2.5 2.417,2.698 0.177,0.198 10 false *a 3.813,2.521 3.99,2.719 0.177,0.198 10 false *a 5.365,1.781 5.552,1.969 0.188,0.188 10 false *b 5.375,2.417 5.563,2.615 0.188,0.198 10 false *c 5.365,0.979 5.521,1.177 0.156,0.198 10 false C 2.531,1.781 2.688,1.979 0.156,0.198 10 false A 3.448,0.656 3.604,0.854 0.156,0.198 10 false A 2.667,0.094 2.823,0.292 0.156,0.198 10 false B 4.99,1.198 5.146,1.396 0.156,0.198 10 false C 3.458,1.698 3.615,1.896 0.156,0.198 10 false B 1.885,1.885 2.042,2.083 0.156,0.198 10 false A

*a	9.0 mm (0.354 in.)	*b	19 mm (0.748 in.)
*c	16 mm (0.630 in.)	*d	27 mm (1.06 in.)
*e	44 mm (1.73 in.)	-	-

Torque:

for stud bolt A and B : 4.0 N*m (41 kgf*cm, 35 in.*lbf)

for stud bolt C : 10 N*m (102 kgf*cm, 7 ft.*lbf)

Install 3 new O-rings to the timing chain cover assembly.

0.99,0.594 0.698,0.208 0.698,0.208 0.552,0.208 true 0.375,0.094 0.573,0.302 0.198,0.208 10 false *a

*a	Seal Packing

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 sub-assembly within 3 minutes after applying seal packing.

·

Do not start the engine for at least 2 hours after installation.

0.063,0.031 0.26,0.24 0.198,0.208 10 false *a 0.063,2.375 0.26,2.583 0.198,0.208 10 false *b 3.125,0.927 3.281,1.125 0.156,0.198 10 false A 2.906,1.969 3.063,2.167 0.156,0.198 10 true B 2.271,0.125 2.427,0.323 0.156,0.198 10 false C 0.344,0.396 0.5,0.594 0.156,0.198 10 true D 3.125,1.344 3.281,1.542 0.156,0.198 10 false A 2.313,2.146 2.469,2.344 0.156,0.198 10 true B 1.979,2.104 2.135,2.302 0.156,0.198 11 true B 1.563,2.146 1.719,2.344 0.156,0.198 10 true B 0.823,2.135 0.979,2.333 0.156,0.198 10 true B 2.906,0.281 3.063,0.479 0.156,0.198 10 false B 1.917,0.115 2.073,0.313 0.156,0.198 10 false C 1.542,0.104 1.698,0.302 0.156,0.198 10 false C 0.719,0.156 0.875,0.354 0.156,0.198 10 false B 0.281,0.938 0.438,1.135 0.156,0.198 10 true D 0.281,1.302 0.438,1.5 0.156,0.198 10 true D 0.458,1.917 0.615,2.115 0.156,0.198 10 true D 3.104,3.573 3.313,3.76 0.208,0.188 10 false 10 3.104,3.135 3.313,3.323 0.208,0.188 10 false 11 0.24,3.521 0.448,3.708 0.208,0.188 10 true 12 2.833,4.26 3.042,4.448 0.208,0.188 10 true 13 2.938,2.5 3.146,2.688 0.208,0.188 10 false 14 0.313,2.604 0.521,2.792 0.208,0.188 10 true 15 0.792,4.365 1,4.552 0.208,0.188 10 true 16 0.406,4.135 0.615,4.323 0.208,0.188 10 true 17 0.656,2.385 0.865,2.573 0.208,0.188 10 false 18 0.313,3.156 0.448,3.354 0.135,0.198 10 true 9 2.271,2.344 2.406,2.542 0.135,0.198 10 false 8 1.271,4.385 1.406,4.583 0.135,0.198 10 true 7 2.333,4.375 2.469,4.573 0.135,0.198 10 true 6 1.229,2.323 1.365,2.521 0.135,0.198 10 false 5 1.938,2.333 2.073,2.531 0.135,0.198 10 false 4 1.573,4.385 1.708,4.583 0.135,0.198 10 true 3 1.979,4.344 2.115,4.542 0.135,0.198 10 true 2 1.542,2.344 1.677,2.542 0.135,0.198 10 false 1

*a	Types of Nut and Bolt
*b	Tightening Order

Install the oil pan sub-assembly with the 16 bolts and 2 nuts.

Torque:

for bolt A : 10 N*m (102 kgf*cm, 7 ft.*lbf)

for bolt B, C, D and nut : 21 N*m (214 kgf*cm, 15 ft.*lbf)

Standard Bolt:

Item	Length
Bolt A	16 mm (0.630 in.)
Bolt B	45 mm (1.77 in.)
Bolt C	25 mm (0.984 in.)
Bolt D	70 mm (2.76 in.)

0,0 0,0 false

Wipe off the Seal Packing

After tightening the oil pan bolts and nuts wipe off the seal packing material that has seeped out from between the contact surfaces of the cylinder block sub-assembly and oil pan sub-assembly.

Install a new O-ring to the No. 1 water outlet pipe.

HINT:

Apply water to the O-ring.

Install 2 new O-rings to the rear water by-pass joint.

Install the water by-pass joint with the 4 bolts and 2 nuts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

NOTICE:

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

Attach the 2 clamps and connect the No. 5 engine wire.

Install a new O-ring to the No 1 water outlet pipe.

Install the water outlet with the 2 bolts.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

NOTICE:

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

1.5,1.583 1.958,1.781 0.458,0.198 10 false 80°

Install the cylinder block water drain cock sub-assembly as shown in the illustration.

Torque:

25 N*m (255 kgf*cm, 18 ft.*lbf)

NOTICE:

Do not rotate the cylinder block drain cock sub-assembly more than 1 revolution (360°) after tightening the cylinder block water drain cock sub-assembly to the specified torque.

Install the No. 1 engine cover sub-assembly to the cylinder head cover sub-assembly with the 2 clips.