M20C-FKS, M20D-FKS ENGINE MECHANICAL ENGINE UNIT REASSEMBLY
CAUTION / NOTICE / HINT
- NOTICE:
-
This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.
PROCEDURE
1.INSTALL STRAIGHT PIN
- NOTICE:
-
It is not necessary to remove the straight pins unless they are being replaced.
Using a plastic hammer, tap in 4 new straight pins to the No. 2 timing chain cover assembly.
| *a | Protrusion Height | - | - |
- Standard Protrusion Height:
- Straight Pin (A):
3.0 to 5.0 mm (0.118 to 0.197 in.)
- Straight Pin (B):
5.0 to 7.0 mm (0.197 to 0.276 in.)
2.INSTALL RING PIN
- NOTICE:
-
It is not necessary to remove the ring pins unless they are being replaced.
| *a | Protrusion Height |
Using a plastic hammer, tap in 6 new ring pins to the stiffening crankcase assembly.
- Standard Protrusion Height:
- Ring Pin (A):
3.5 to 4.5 mm (0.138 to 0.177 in.)
- Ring Pin (B):
4.3 to 5.3 mm (0.169 to 0.209 in.)
3.INSTALL STUD BOLT
- NOTICE:
-
If a stud bolt is deformed or its threads are damaged, replace it.
| *a | 9 mm (0.354 in.) |
| *b | 19 mm (0.748 in.) |
Using an E6 "TORX" socket wrench, install the 2 stud bolts to the stiffening crankcase assembly.
- Torque:
- 4.0 N*m (41 kgf*cm, 35 in.*lbf)
| *a | 21 mm (0.827 in.) |
| *b | 9 mm (0.354 in.) |
| *c | 34 mm (1.34 in.) |
Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.
- Torque:
- 4.0 N*m (41 kgf*cm, 35 in.*lbf)
4.INSTALL WIRE HARNESS CLAMP BRACKET
Install the wire harness clamp bracket to the stiffening crankcase assembly with the bolt.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
5.INSTALL STRAIGHT SCREW PLUG
Using a 10 mm hexagon socket wrench, install the straight screw plug and a new gasket to the stiffening crankcase assembly.
- Torque:
- 44 N*m (449 kgf*cm, 32 ft.*lbf)
13620B
6.INSTALL ENGINE BALANCER ASSEMBLY
Install the engine balancer assembly to the stiffening crankcase assembly with the 2 bolts.
- Torque:
- 24 N*m (245 kgf*cm, 18 ft.*lbf)
11420
7.INSTALL STIFFENING CRANKCASE ASSEMBLY
| *a | 270° |
| *b | Crankshaft Timing Gear Key Groove |
Rotate the crankshaft clockwise so that the crankshaft timing gear key groove is at the position 270° from the bottom as shown in the illustration.
| *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
- Standard Seal Packing Dimension:
Area Specified Condition Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.)
- NOTICE:
- ·
Remove any oil from the contact surfaces.
·Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
·Do not add engine oil for at least 2 hours after the installation.
·Make sure that the diameter at the start and end of each line of seal packing is 3 to 7 mm (0.118 to 0.276 in.).
·After installation, if the seal packing has seeped out, wipe it off.
·Do not start the engine for at least 2 hours after installation.
| *a | Cutout |
Check that the rear cutouts are as shown in the illustration.
Clean the bolts and bolt holes.
| *a | Bolt Type |
Temporarily install the stiffening crankcase assembly with the 11 bolts.
- Bolt Length:
Item Length Bolt (A) 40 mm (1.57 in.) Bolt (B) 90 mm (3.54 in.) Bolt (C) 170 mm (6.69 in.)
| *a | Tightening Order |
Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.
- Torque:
- 43 N*m (438 kgf*cm, 32 ft.*lbf)
15100
8.INSTALL OIL PUMP ASSEMBLY
15520B
9.INSTALL CRANKCASE CAP ASSEMBLY
Install the crankcase cap assembly to the stiffening crankcase assembly.
Install a new clip to the crankcase cap assembly.
15104
10.INSTALL OIL STRAINER SUB-ASSEMBLY
Apply a light coat of engine oil to a new oil strainer gasket.
Using an 8 mm socket wrench, install the oil strainer sub-assembly and oil strainer gasket with the bolt.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
12101
11.INSTALL OIL PAN SUB-ASSEMBLY
| *a | Seal Packing |
| *b | 4.5 mm (0.177 in.) |
| *c | 2.5 to 3.5 mm (0.0984 to 0.138 in.) |
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 Packing Diameter:
2.5 to 3.5 mm (0.0984 to 0.138 in.)
- NOTICE:
- ·
Remove any oil from the contact surfaces.
·Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.
·Do not add engine oil for at least 2 hours after the installation.
·Do not start the engine for at least 2 hours after installation.
·Make sure that the diameter at the start and end of each line of seal packing is 3 to 7 mm (0.118 to 0.276 in.).
| *a | Nut |
Install the oil pan sub-assembly with the 12 bolts and 2 nuts in several steps in the order shown in the illustration.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
12101A
12.INSTALL OIL PAN DRAIN PLUG
Install a new gasket and the oil pan drain plug to the oil pan sub-assembly.
- Torque:
- 40 N*m (408 kgf*cm, 30 ft.*lbf)
15600A
13.INSTALL OIL FILTER UNION
Using a 12 mm straight hexagon wrench, install the oil filter union to the stiffening crankcase assembly.
- Torque:
- 29.5 N*m (301 kgf*cm, 22 ft.*lbf)
15601
14.INSTALL OIL FILTER SUB-ASSEMBLY
11401L
15.INSTALL REAR ENGINE OIL SEAL
11445
16.INSTALL CYLINDER BLOCK WATER JACKET SPACER
Install the cylinder block water jacket spacer to the exhaust side of the cylinder block sub-assembly.
11115
17.INSTALL CYLINDER HEAD GASKET
11101
18.INSTALL CYLINDER HEAD SUB-ASSEMBLY
- HINT:
-
The cylinder head set bolts are tightened in 3 progressive steps.
Place the cylinder head sub-assembly on the cylinder block sub-assembly.
- NOTICE:
- ·
Ensure that the contact surface of the cylinder head sub-assembly is free of oil.
·Place the cylinder head sub-assembly on the cylinder block sub-assembly gently in order not to damage the cylinder head gasket with the bottom of the cylinder head sub-assembly.
·Do not allow oil to adhere to the bottom of the cylinder head sub-assembly.
·Clean the bolt and bolt hole.
Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
| *a | Plate Washer |
|
Front of Engine |
Install the 6 plate washers to the 10 cylinder head set bolts.
- Bolt Length:
Item Length Bolt (A) 129.1 to 130.9 mm (5.08 to 5.15 in.) Bolt (B) 139.1 to 140.9 mm (5.48 to 5.55 in.)
Step 1:
|
|
Front of Engine |
Using a 12 mm socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.
- Torque:
- 50 N*m (510 kgf*cm, 37 ft.*lbf)
- NOTICE:
-
Be careful not to drop the plate washers into the cylinder head sub-assembly.
Step 2:
| *a | Paint Mark |
|
|
Front of Engine |
Mark each cylinder head set bolt head with paint as shown in the illustration.
Tighten the cylinder head set bolts 90° in the order shown in step 1.
Step 3:
Tighten the cylinder head set bolts another 90° in the order shown in step 1.
Check that the paint marks are now facing rearward.
- HINT:
-
Perform "Inspection After Repair" after replacing the cylinder head sub-assembly.
16268L
19.INSTALL NO. 1 WATER BY-PASS PIPE
Using an 8 mm socket wrench, install the No. 1 water by-pass pipe and a new gasket to the cylinder head sub-assembly with the 2 bolts.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
13716
20.INSTALL VALVE STEM CAP
Apply a light coat of engine oil to the valve stem cap ends.
Install the 16 valve stem caps to the cylinder head sub-assembly.
- NOTICE:
- ·
Install the same parts in the same combination to their original locations.
·Do not drop the valve stem caps into the cylinder head sub-assembly.
13750
21.INSTALL VALVE LASH ADJUSTER ASSEMBLY
Inspect the 16 valve lash adjuster assemblies before installing them.
Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.
- NOTICE:
-
Install the same parts in the same combination to their original locations.
13801
22.INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
| *1 | No. 1 Valve Rocker Arm Sub-assembly |
| *2 | Valve Lash Adjuster Assembly |
| *3 | Valve Stem Cap |
Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.
Install the 16 No. 1 valve rocker arm sub-assemblies as shown in the illustration.
- NOTICE:
-
Install the same parts in the same combination to their original locations.
11155B
23.INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
- NOTICE:
-
It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.
| *a | Protrusion Height |
Using a plastic hammer, tap in 10 new camshaft bearing cap setting ring pins to the camshaft housing sub-assembly.
- Standard Protrusion Height:
3.2 to 4.3 mm (0.126 to 0.169 in.)
13502B
24.INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY
- HINT:
-
Perform "Inspection After Repair" after replacing the exhaust camshaft sub-assembly.
Clean the camshaft journals and camshaft housing sub-assembly.
Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.
Install the exhaust camshaft sub-assembly to the camshaft housing sub-assembly.
13501A
25.INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY
- HINT:
-
Perform "Inspection After Repair" after replacing the intake camshaft sub-assembly.
Clean the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.
Install the intake camshaft sub-assembly to the camshaft housing sub-assembly.
26.INSTALL CAMSHAFT BEARING CAP
Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap in their correct locations.
Uniformly tighten the 9 bolts in the order shown in the illustration.
- Torque:
- 16 N*m (163 kgf*cm, 12 ft.*lbf)
11103
27.INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
| *1 | No. 1 Valve Rocker Arm Sub-assembly |
| *2 | Valve Stem Cap |
| *3 | Valve Lash Adjuster Assembly |
| *a | Incorrect |
| *b | Correct |
Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.
| *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
- Standard Seal Packing Diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
- NOTICE:
- ·
Remove any oil from the contact surfaces.
·Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
·Make sure that the diameter at the start and end of each line of seal packing is 3 to 7 mm (0.118 to 0.276 in.).
·After installation, if the seal packing has seeped out, wipe it off.
| *a | 17° to 47° |
| *b | 42° to 72° |
| *c | No. 1 Cylinder Cam Nose |
Position the intake camshaft sub-assembly and exhaust camshaft sub-assembly as shown in the illustration.
Temporarily install the camshaft housing sub-assembly with the 17 bolts.
- Bolt Length:
Item Length Bolt (A) 40 mm (1.57 in.) Bolt (B) 65 mm (2.56 in.)
- NOTICE:
-
If the bolts are loosened during installation, reapply seal packing to the camshaft housing sub-assembly.
Tighten the 17 bolts in several steps in the order shown in the illustration.
- Torque:
- 28.5 N*m (291 kgf*cm, 21 ft.*lbf)
- NOTICE:
- ·
Do not add engine oil for at least 2 hours after installation.
·Do not start the engine for at least 2 hours after installation.
23477
28.INSTALL FUEL PUMP LIFTER GUIDE
Using an 8 mm socket wrench, install the fuel pump lifter guide to the No. 4 camshaft bearing cap with the 2 bolts.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
13471A
29.INSTALL CRANKSHAFT TIMING GEAR KEY
Using a plastic hammer, tap in the 2 crankshaft timing gear keys.
- HINT:
-
Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.
15703A
30.INSTALL OIL NOZZLE VALVE SUB-ASSEMBLY
Install the oil nozzle valve sub-assembly to the cylinder block sub-assembly.
11310
31.INSTALL TIMING CHAIN COVER ASSEMBLY
Clean the contact surfaces of the timing chain cover assembly, cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
| *a | Timing Chain Cover Assembly Side | *b | Engine Assembly Side |
Apply seal packing to the timing chain cover assembly as shown in the illustration.
| *a | 2.5 to 3.5 mm (0.0984 to 0.138 in.) | *b | 2.0 to 6.0 mm (0.0787 to 0.236 in.) |
| *c | 10 mm (0.394 in.) | *d | 20 mm (0.787 in.) |
| *e | 344.2 mm (1.13 ft.) | *f | 4.0 to 6.0 mm (0.157 to 0.236 in.) |
| *g | 3.0 to 4.0 mm (0.118 to 0.157 in.) | - | - |
|
Seal Packing | - | - |
- Seal Packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- NOTICE:
- ·
Clean the surfaces with non-residue solvent before applying seal packing.
·Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
·Do not add engine oil for at least 2 hours after installation.
·Do not start the engine for at least 2 hours after installation.
·Make sure that the diameter at the start and end of each line of seal packing is 3 to 7 mm (0.118 to 0.276 in.).
Temporarily install the timing chain cover assembly with the 20 bolts.
- Bolt Length:
Bolt Length Bolt (A) 30 mm (1.18 in.) Bolt (B) 45 mm (1.77 in.)
- NOTICE:
-
Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.
Tighten the 20 bolts in the order shown in the illustration.
- Torque:
- 27 N*m (275 kgf*cm, 20 ft.*lbf)
13070A
32.INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
- HINT:
-
Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.
| *a | Knock Pin Hole |
| *b | Knock Pin |
Align and fit the knock pin of the exhaust camshaft sub-assembly to the knock pin hole of the camshaft timing exhaust gear assembly.
Apply a light coat of engine oil to the O-ring of the camshaft timing valve assembly.
- NOTICE:
-
If reusing the camshaft timing valve assembly, be sure to inspect the O-ring.
Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.
- NOTICE:
-
Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly or spark plug tube with the wrench.
Using a 5 mm hexagon socket wrench, install the camshaft timing exhaust gear assembly and camshaft timing valve assembly with the 3 bolts.
- Torque:
- 19 N*m (194 kgf*cm, 14 ft.*lbf)
33.SET NO. 1 CYLINDER TO TDC (COMPRESSION)
Temporarily install the crankshaft pulley bolt.
| *1 | Crankshaft Timing Gear Key |
| *a | 44.2° |
Rotate the crankshaft 44.2° counterclockwise to position the crankshaft timing gear key as shown in the illustration.
| *a | Timing Mark |
| *b | Knock Pin |
Check that the timing marks of the camshaft timing exhaust gear assembly and knock pin are as shown in the illustration.
13561
34.INSTALL NO. 1 CHAIN VIBRATION DAMPER
Install the No. 1 chain vibration damper with the 2 bolts.
- Torque:
- 24 N*m (245 kgf*cm, 18 ft.*lbf)
13559
35.INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper with the bolt.
- Torque:
- 24 N*m (245 kgf*cm, 18 ft.*lbf)
13540
36.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
- HINT:
-
After replacing or removing and installing the No. 1 chain tensioner assembly, an abnormal noise may occur at start up until the oil in the line has had time to replenish.
| *1 | Chain Tensioner Slipper |
| *a | End of the Plunger |
| *b | Groove |
| *c | Oil Hole |
| *d | Plunger |
While slightly pushing in the plunger of the No. 1 chain tensioner assembly, install the chain tensioner slipper.
- HINT:
- ·
Make sure that the end of the plunger is correctly seated in the groove of the chain tensioner slipper.
·Make sure that the oil hole of the plunger is facing up.
Using an 8 mm socket wrench, install the bolt.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
Install the nut.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
13506
37.INSTALL CHAIN SUB-ASSEMBLY
| *1 | Crankshaft Timing Gear Key |
Set the crankshaft timing gear key as shown in the illustration.
Remove the crankshaft pulley bolt.
Install the crankshaft timing sprocket and chain sub-assembly.
| *a | Paint Mark (Yellow) |
| *b | Timing Mark |
Align the paint mark (yellow) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.
| *a | Paint Mark (Orange) |
| *b | Timing Mark |
|
Turn |
Using the hexagonal portion of the exhaust camshaft sub-assembly, rotate the exhaust camshaft sub-assembly counterclockwise with a wrench, align the timing mark of the camshaft timing exhaust gear assembly with the paint mark (orange) of the chain sub-assembly, and install the chain sub-assembly to the camshaft timing exhaust gear assembly.
- NOTICE:
-
Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly or spark plug tube with the wrench.
13050
38.INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
- HINT:
-
Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.
| *a | Loosen |
Hold the hexagonal portion of the exhaust camshaft sub-assembly with a wrench and turn the camshaft timing exhaust gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and crankshaft timing sprocket as shown in the illustration.
- NOTICE:
-
Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly or spark plug tube with the wrench.
| *a | Paint Mark (Orange) |
| *b | Timing Mark |
Align the paint mark (orange) of the chain sub-assembly with the timing mark of the camshaft timing gear assembly and install the chain sub-assembly to the camshaft timing gear assembly.
| *a | Knock Pin Hole |
| *b | Knock Pin |
Align and fit the knock pin of the intake camshaft sub-assembly to the knock pin hole of the camshaft timing gear assembly.
| *a | Hold |
|
|
Turn |
Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.
- NOTICE:
- ·
Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.
·Do not disassemble the camshaft timing gear assembly.
Using a 10 mm bi-hexagon socket wrench, install the camshaft timing gear assembly with the bolt.
- Torque:
- 86 N*m (877 kgf*cm, 63 ft.*lbf)
13507A
39.INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY
Set the crankshaft timing gear key as shown in the illustration.
| *1 | Oil Pump Drive Sprocket | *2 | Oil Pump Drive Shaft Sprocket |
| *3 | Crankshaft Timing Gear Key | *4 | Oil Pump Assembly |
| *a | Mark Plate (Yellow) | *b | Timing Mark |
| *c | Mark Plate (Orange) | - | - |
Turn the oil pump drive shaft so that the flat face is facing upward.
Align the mark plates with the timing marks of the oil pump drive sprocket and oil pump drive shaft sprocket as shown in the illustration.
- HINT:
-
Make sure the mark plates of the oil pump drive chain sub-assembly are facing away from the engine assembly.
With the oil pump drive chain sub-assembly placed around the oil pump drive sprocket and oil pump drive shaft sprocket, install the oil pump drive sprocket to the crankshaft and temporarily install the oil pump drive shaft sprocket to the oil pump drive shaft.
| *1 | Chain Tensioner Plate |
| *2 | Chain Damper Spring |
Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate.
Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
Using SST, hold the crankshaft pulley assembly and install the bolt.
- SST
- 09213-54015
09330-00021
- Torque:
- 50 N*m (510 kgf*cm, 37 ft.*lbf)
Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.
40.SET NO. 1 CYLINDER TO TDC (COMPRESSION)
11320B
41.INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY
Clean the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
| *a | No. 2 Timing Chain Cover Assembly Side | *b | Timing Chain Cover Assembly Side |
|
|
Seal Packing |
Apply seal packing to the No. 2 timing chain cover assembly as shown in the illustration.
- Seal Packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Standard Seal Packing Diameter:
2.5 to 3.5 mm (0.0984 to 0.138 in.)
- NOTICE:
- ·
Clean the surfaces with non-residue solvent before applying seal packing.
·Install the No. 2 timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
·Do not add engine oil for at least 2 hours after installation.
·Do not start the engine for at least 2 hours after installation.
·Make sure that the diameter at the start and end of each line of seal packing is 3 to 7 mm (0.118 to 0.276 in.).
Temporarily install the No. 2 timing chain cover assembly to the timing chain cover assembly with the 20 bolts.
- NOTICE:
-
Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.
Tighten the 20 bolts in the order shown in the illustration.
- Torque:
- 24 N*m (245 kgf*cm, 18 ft.*lbf)
Install the engine mounting bracket RH with the 3 bolts.
- Torque:
- 43 N*m (438 kgf*cm, 32 ft.*lbf)
- NOTICE:
-
After applying seal packing to the No. 2 timing chain cover assembly, install the engine mounting bracket RH within 10 minutes.
42.INSTALL STRAIGHT SCREW PLUG
Apply adhesive to the straight screw plug.
- Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Using a 10 mm hexagon socket wrench, install the straight screw plug.
- Torque:
- 40 N*m (408 kgf*cm, 30 ft.*lbf)
- NOTICE:
- ·
Install the straight screw plug within 3 minutes of applying adhesive.
·Do not add engine oil for at least 1 hour after installation.
11301C
43.INSTALL TIMING CHAIN COVER OIL SEAL
11193
44.INSTALL SPARK PLUG TUBE GASKET
Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.
11201
45.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Install a new camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.
Install 7 new cylinder head cover gaskets to the cylinder head cover sub-assembly.
| *a | Seal Packing Diameter: 3.0 to 6.0 mm |
| *b | Mark |
|
Seal Packing |
Apply seal packing as shown in the illustration.
- Seal Packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Standard Seal Packing Diameter:
3.0 to 6.0 mm (0.118 to 0.236 in.)
- NOTICE:
- ·
Remove any oil from the contact surfaces.
·Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
| *a | O-ring Groove |
| *b | Camshaft Position Sensor Tip |
Perform this procedure only when reusing the 2 camshaft position sensors (for Exhaust Side and for Intake Side).
Clean each O-ring groove of the 2 camshaft position sensors (for Exhaust Side and for Intake Side).
- NOTICE:
-
Make sure the O-ring groove is free of foreign matter.
Install 2 new O-rings to the 2 camshaft position sensors (for Exhaust Side and for Intake Side).
- NOTICE:
-
Set each O-ring on the tip of the 2 camshaft position sensors (for Exhaust Side and for Intake Side) and roll it into the O-ring groove with bare hands to install it.
| *1 | O-ring |
| *a | OK |
| *b | NG |
| *c | Seam |
Check if each O-ring is twisted.
- HINT:
-
Check the entire circumference of the seam of the O-ring for twisting.
Apply a light coat of engine oil to the O-ring of the camshaft position sensor.
Using an 8 mm socket wrench, install the 2 camshaft position sensors (for Exhaust Side and for Intake Side) with 2 new bolts (B) and cylinder head cover sub-assembly with 4 new bolts (C) and the 12 bolts (A) in the order shown in the illustration.
- Bolt Length:
Bolt Length Width Across Flats Bolt (A) 23.5 mm (0.925 in.) 10 mm (0.394 in.) Bolt (B), (C) 30 mm (1.18 in.) 8 mm (0.315 in.)
- Torque:
- 7.5 N*m (76 kgf*cm, 66 in.*lbf)
- NOTICE:
- ·
Do not add engine oil for at least 2 hours after the installation.
·Do not start the engine for at least 2 hours after installation.
16305E
46.INSTALL WATER BY-PASS OUTLET SUB-ASSEMBLY
Using an 8 mm socket wrench, install the water by-pass outlet sub-assembly and a new water pipe outlet gasket to the cylinder head sub-assembly with the 3 bolts.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
16331
47.INSTALL WATER OUTLET
Using an 8 mm socket wrench, install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 2 bolts.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
13470
48.INSTALL CRANKSHAFT PULLEY ASSEMBLY
Align the crankshaft timing gear key with the key groove of the crankshaft pulley assembly.
| *a | Hold |
| *b | Turn |
Using SST, hold the crankshaft pulley assembly and install the crankshaft pulley bolt.
- SST
- 09213-54015
09330-00021
- Torque:
- 260 N*m (2651 kgf*cm, 192 ft.*lbf)
29300
49.INSTALL VACUUM PUMP ASSEMBLY
for M20 Series Engine, BOSCH Made:
for M20 Series Engine, except BOSCH Made:
12204C
50.INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)
11401G
51.INSTALL CRANKSHAFT POSITION SENSOR
12108A
52.INSTALL OIL FILLER CAP GASKET
Install a new oil filler cap gasket to the oil filler cap assembly.
12180E
53.INSTALL OIL FILLER CAP ASSEMBLY
Install the oil filler cap assembly to the cylinder head cover sub-assembly.
16264
54.INSTALL NO. 2 WATER BY-PASS HOSE
Install the No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
16261Z
55.INSTALL NO. 1 WATER BY-PASS HOSE
Install the No. 1 water by-pass hose to the cylinder block sub-assembly and slide the clip to secure it.
15710
56.INSTALL OIL COOLER ASSEMBLY
13090E
57.INSTALL CAM TIMING CONTROL MOTOR O-RING
13090D
58.INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY
59.INSTALL O-RING
15370
60.INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY
15250
61.INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY
89448D
62.INSTALL OIL PRESSURE AND TEMPERATURE SENSOR
89615
63.INSTALL KNOCK CONTROL SENSOR
19100P
64.INSTALL SPARK PLUG