Reassembly

1NZ-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL CYLINDER BLOCK WATER DRAIN COCK

(a) Apply adhesive to 2 or 3 threads of the drain cock, and install it within 3 minutes.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Tighten the drain cock to the specified torque. Then rotate the drain cock clockwise until its drain port faces downward.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)

NOTICE:
- Install the water drain cock within 3 minutes of applying adhesive.
- Do not add coolant for at least 1 hour after installation.
- Do not rotate the drain cock more than 360° in this step, and never loosen it after setting the drain cock correctly.
- The pipe of the drain cock should be within 40° of the vertical position.

2. INSTALL TIGHT PLUG

(a) Apply adhesive to new tight plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using SST, tap in the tight plugs as shown in the illustration.

SST: 09950-60010
09951-00180
SST: 09950-70010
09951-07100
Standard depth:
0.2 to 1.2 mm (0.008 to 0.047 in.)

3. INSTALL STRAIGHT PIN

(a) Using a plastic-faced hammer, tap in a new end plate straight pin.
Standard protrusion:
11.5 to 12.5 mm (0.453 to 0.492 in.)
- Pin height: 20 mm (0.787 in.)
- Pin diameter: 8 mm (0.315 in.)

(b) Using a plastic-faced hammer, tap in a new oil pan straight pin.
Standard protrusion:
8.5 to 9.5 mm (0.335 to 0.374 in.)
- Pin height: 18 mm (0.709 in.)
- Pin diameter: 8 mm (0.315 in.)

(c) Using a plastic-faced hammer, tap in a new cylinder head straight pin.
Standard protrusion:
8.5 to 9.5 mm (0.335 to 0.374 in.)
HINT:
- Pin height: 18 mm (0.709 in.)
- Pin diameter: 8 mm (0.315 in.)

(d) Using a plastic-faced hammer, tap in a new chain tensioner straight pin.
Standard protrusion:
18.5 to 19.5 mm (0.728 to 0.768 in.)
HINT:
- Pin height: 36 mm (1.417 in.)
- Pin diameter: 10 mm (0.394 in.)

4. INSTALL RING PIN

(a) Using a plastic-faced hammer, tap in a new oil pump ring pin.
Standard protrusion:
3.5 to 4.5 mm (0.134 to 0.177 in.)
HINT:
- Pin height: 8 mm (0.315 in.)
- Pin diameter: 8 mm (0.315 in.)

5. INSTALL STUD BOLT
(a) Using an E5 "TORX" socket, install the 6 stud bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)

NOTE: Make sure that the bottom of the stud bolt contacts the cylinder block, as shown in the illustration.

(b) Install the stud bolt for the knock sensor to the cylinder block.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
6. INSTALL OIL JET

(a) Align the concave of the cylinder block with the bracket of the oil jet, then tap in the oil jet (the service part).
NOTE: Do not tap the tip of the oil jet.

7. INSTALL CRANKSHAFT

(a) Install the upper bearing with the oil groove onto the cylinder block, and the lower bearing onto the bearing cap.
NOTE: Do not apply engine oil to the contact surface of the cylinder block or the backside of the bearing.
HINT: Mass production parts do not have claws as marks. If reusing the mass production parts, measure the clearance of both sides with the bearing in the center of the bearing cap.

Standard clearance:
A - B = within 0.8 mm (0.032 in.)

(b) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.
(c) Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.

(d) Check the front marks and numbers and install the bearing caps onto the cylinder block.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(f) Using SST, tighten the bolts in several steps by the specified torque in the sequence shown in the illustration.
SST: 09011-38121
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
NOTE: Check that the crankshaft turns smoothly.

(g) Mark the front of the bearing cap bolts with paint.
(h) Retighten the bearing cap bolts by 90° in the same sequence.
(i) Check that the painted mark is now at a 90° angle to the front.
8. INSTALL PISTON PIN

(a) Apply engine oil to the piston pin and the inside surface of the connecting rod.
(b) Align the front marks of the piston and connecting rod.

(c) Using SST, push in the piston pin.
SST: 09221-25026
09221-00021
09221-00030
09221-00190
09221-00141
09221-00150
NOTE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembling.

(d) Check the piston pin position.
Specified clearance:
A - B = -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
9. INSTALL CONNECTING ROD BEARING

(a) Align the bearing claw with the grooves of the connecting rod and connecting rod cap.
NOTE: Do not apply engine oil to the contact surface of the connecting rod and connecting rod cap and the backside of the bearing.

10. INSTALL PISTON RING SET

HINT: If reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly.

(a) Install the 2 compression rings and oil ring.
Code mark:

(b) Position the piston rings so that the ring ends are as shown in the illustration.
11. INSTALL PISTON WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and the surfaces of the connecting rod bearings.
(b) Check the position of the piston ring ends.

(c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark on the piston facing forward.
NOTICE:
- Do not apply engine oil to the contact surface of the connecting rod cap and the backside of the bearing.
- Match the numbered connecting rod cap with the correct connecting rod.

(d) Match the connecting rod and cap together in the correct combination. Then install the cap onto the connecting rod, making sure that the front mark on the cap is correctly oriented.
(e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

(f) Using SST, tighten the bolts in several steps by the specified torque.
SST: 09205-16010
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)

(g) Mark the front of the connecting cap bolts with paint.
(h) Retighten the cap bolts by 90° as shown.
(i) Check that the crankshaft turns smoothly.
12. INSTALL OIL PAN
(a) Using an E5 "TORX" socket, install the 4 stud bolts.

Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)

(b) Apply a continuous line of seal packing to the oil pan mating surface as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
2.0 to 3.0 mm (0.079 to 0.118 in.)
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not expose the seal to engine oil for at least 2 hours after installation.

(d) Using several steps, install and uniformly tighten the 13 bolts in the sequence shown in the illustration.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
HINT: Each bolt length is as follows:
49 mm (1.93 in.) for bolt A
88 mm (3.47 in.) for bolt B
144 mm (5.67 in.) for bolt C

13. INSTALL ENGINE REAR OIL SEAL Replacement
14. INSTALL OIL STRAINER

(a) Install a new gasket and the oil strainer with the 2 nuts and bolt.
Torque: 11 Nm (112 kgf-cm, 8.1 ft-lbf)
15. INSTALL NO. 2 OIL PAN

(a) Apply a continuous line of seal packing to the oil pan mating surface 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 (0.098 to 0.14 in.)
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes of applying seal packing.
- Do not expose the seal to engine oil for at least 2 hours after installation.
- Do not start the engine within 2 hours of installation.

(b) Install the No. 2 oil pan with the 9 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Install the drain plug with a new gasket.
Torque: 37.5 Nm (382 kgf-cm, 28 ft-lbf)
16. INSTALL OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
17. INSTALL OIL FILTER
(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 comes into contact with the seat.

(d) Using SST, tighten it an additional 3/4 turn.
SST: 09228-06501
If using a torque wrench, tighten to the specified torque.
Torque: 17.5 Nm (178 kgf-cm, 13 ft-lbf)
18. INSTALL CYLINDER HEAD GASKET

(a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
NOTICE:
- Remove any oil from the contact surface.
- Pay attention to the mounting orientation of the cylinder head gasket.
- Place the cylinder head on the cylinder block gently in order not to damage the gasket at the bottom part of the head.

19. INSTALL CYLINDER HEAD
HINT: The cylinder head bolts are tightened in 2 successive steps.

(a) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.5 to 4.5 mm (0.177 to 0.217 in.)
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes of applying seal packing.

(b) Apply a light coat of engine oil to the threads of the cylinder head bolts.

(c) Using several steps, install and uniformly tighten the 10 cylinder head bolts and plate washers with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)

(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by an additional 90° and then another 90°, as shown in the illustration.
(f) Check that the painted mark is now at a 180° angle to the front.
20. INSTALL CAMSHAFT TIMING GEAR

(a) Put the camshaft timing gear and camshaft together so that the straight pin and key groove are offset, as shown in the illustration.
(b) Turn the camshaft timing gear assembly clockwise while pushing it lightly towards the camshaft. Push further at the position where the pin fits into the groove.
NOTE: Be careful not to turn the camshaft timing gear to the retard angle (to the right).

(c) Check that there is no clearance between the gear fringe and the camshaft.
(d) Tighten the flange bolt with the camshaft timing gear fixed in place.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
(e) Check that the camshaft timing gear can move to the retard angle (to the right) and is locked in the most retarded position.
21. INSTALL CAMSHAFT

(a) Turn the crankshaft by 40° counterclockwise from TDC/compression.

(b) Apply a light coat of engine oil to the camshaft journals.
(c) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
(d) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9 ft-lbf)
NOTE: Tighten each bolt uniformly, keeping the camshaft level.

22. INSTALL CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise.
(b) Align the knock pin hole of the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
NOTE: Be careful not to damage the camshaft.

23. INSTALL NO. 2 CAMSHAFT

(a) Apply a light coat of engine oil to the camshaft journals.
(b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.
(c) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (133 kgf-cm, 9 ft-lbf)
NOTE: Tighten each bolt uniformly, keeping the camshaft level.

(d) Install the No. 1 bearing cap.
Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
24. INSTALL CHAIN Installation
25. INSTALL OIL PUMP SEAL Replacement
26. INSTALL TIMING CHAIN COVER

(a) Remove any old packing material from the contact surface.
(b) Install 2 new O-rings onto the 2 locations as shown in the illustration.
(c) Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration below.

Seal packing:
Water pump part: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Other part: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pump within 3 minutes of applying seal packing.
- Do not expose the seal to engine oil for at least 2 hours after installation.
- Do not start the engine for at least 2 hours after installation.

(d) Align the keyway of the oil pump drive rotor with the rectangular portion of the crankshaft, and slide the oil pump into place.

(e) Install the oil pump assembly with the 15 bolts and nut. Uniformly tighten the bolts and nut in several steps.
Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
Torque: 11 Nm (112 kgf-cm, 8.1 ft-lbf)
Torque: 11 Nm (112 kgf-cm, 8.1 ft-lbf)
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
NOTICE:
- Be careful not to disturb the seal packing.
- After installing the timing chain case, install the mounting bracket and water pump within 15 minutes.
HINT: Each bolt length is as follows:
30 mm (1.18 in.) for bolt A
35 mm (1.38 in.) for bolt B
20 mm (0.79 in.) for bolt C
20 to 14 mm (0.79 to 0.55 in.) for bolt E

27. INSTALL CRANKSHAFT PULLEY

(a) Install the crankshaft straight pin to the crankshaft.
(b) Align the hole of the crankshaft pulley with the straight pin, then install the crankshaft pulley.
(c) Using SST, hold the crankshaft pulley and tighten the crankshaft bolt.
SST: 09213-58013
91111-50845
SST: 09330-00021
Torque: 128 Nm (1,305 kgf-cm, 95 ft-lbf)
NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.

28. INSTALL WATER PUMP

(a) Install a new gasket and the water pump with the 3 bolts and 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
29. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 4 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
30. INSPECT VALVE CLEARANCE Adjustments
31. ADJUST VALVE CLEARANCE Adjustments
32. INSTALL FUEL INJECTOR

(a) Install new insulators onto each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to new O-rings and install them onto each fuel injector.
(c) Apply a light coat of spindle oil or gasoline to the place where a delivery pipe comes into contact with the O-ring.

(d) While turning the injector clockwise and counterclockwise, install it to the delivery pipe.
NOTICE:
- Be careful not to twist the O-ring.
- After installing the fuel injectors, check that they turn smoothly. If not, reinstall it with a new O-ring.

33. INSTALL FUEL DELIVERY PIPE
(a) Install the 2 spacers onto the cylinder head.

(b) Install the fuel delivery pipe and 4 fuel injectors together.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE:
- Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
- Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.

34. INSTALL CYLINDER HEAD COVER

(a) Install the gasket onto the cylinder head cover.
(b) Apply seal packing to the 2 locations shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes of applying seal packing.
- Do not start the engine for at least 2 hours after installation.

(c) Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts.
(d) Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
35. INSTALL VENTILATION VALVE

(a) Install the ventilation valve onto the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
36. INSTALL OIL FILLER CAP
(a) Install a new gasket and the oil filler cap.
37. INSTALL WATER PUMP PULLEY

(a) Temporarily install the water pump pulley with the 3 bolts.
(b) Using SST, tighten the 3 bolts.
SST: 09960-10010
09962-01000
09963-00600
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
38. INSTALL CRANKSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring on the sensor.
NOTE: If the O-ring is damaged, replace the sensor.

(b) Install the sensor with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
39. INSTALL THERMOSTAT

(a) Install a new gasket onto the thermostat.
(b) Install the thermostat with the jiggle valve facing upward.
HINT: The jiggle valve may be set within 10° on either side as shown in the illustration.

(c) Install the water inlet with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
40. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Apply a light coat of engine oil to a new O-ring, and install it onto the oil control valve.
(b) Install the oil control valve with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
NOTE: Be careful not to twist the O-ring.

41. INSTALL CAMSHAFT POSITION SENSOR

(a) Apply engine oil to the O-ring.
NOTE: If the O-ring is damaged, replace the sensor.

(b) Install the sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
42. INSTALL SPARK PLUG
(a) Using a 16 mm plug wrench, install the 4 spark plugs.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)