Part 1

1NZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to the end 2 or 3 threads of the drain union and install the water drain cock within 3 minutes of applying the adhesive.





(b) After applying the specified torque, rotate the drain union clockwise until its drain port faces downward.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
NOTICE:
- Do not add coolant within 1 hour of installation.
- Do not rotate the drain union more than 360° in step (b), and never loosen it after setting the union correctly.

2. INSTALL STRAIGHT PIN





(a) Using a plastic-faced hammer, tap in the straight pin.
Standard protrusion:
Pin A
8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin B
8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin C
18.5 to 19.5 mm (0.728 to 0.768 in.)
Pin D
11.5 to 12.5 mm (0.453 to 0.492 in.)





3. INSTALL OIL PUMP SET RING PIN
(a) Using a plastic-faced hammer, tap in a new ring pin.
Standard protrusion:
3.5 to 4.5 mm (0.138 to 0.177 in.)
4. INSTALL STUD BOLT





(a) Using "Torx" socket wrench E5, install the 7 stud bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)(for Stud bolt A, B and D)
Torque: 11 Nm (112 kgf-cm, 8.1 ft-lbf)(for Stud bolt C)
NOTE: The lower threads of the bolt are installed into the cylinder block.

5. INSTALL CRANKSHAFT BEARING





(a) Align the crankshaft bearing (upper) with the oil hole of the cylinder block and install the bearing.
NOTE: Do not apply engine oil to the bearing or its contact surface.





(b) Align the crankshaft bearing (lower) with the bearing cap and install the crankshaft bearing cap.
NOTICE:
- Install the bearing cap so that the gap between A and B is less than 0.7 mm (0.028 in.).
- Do not apply engine oil to the bearing or its contact surface.





6. INSTALL CRANKSHAFT THRUST WASHER UPPER
(a) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.
(b) Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.
7. INSTALL CRANKSHAFT





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





(c) Using a 12 mm socket wrench, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration (*1).
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
NOTE: Check that the crankshaft turns smoothly.





(d) Mark the front of the bearing cap bolts with paint.
(e) Retighten the bearing cap bolts by 90° in the same sequence as step (*1).
(f) Check that the painted mark is now at a 90° angle from the front.
8. INSPECT CRANKSHAFT THRUST CLEARANCE Engine Unit
9. INSPECT CRANKSHAFT OIL CLEARANCE Engine Unit
10. INSTALL WITH PIN PISTON SUB-ASSEMBLY





(a) Coat the piston pin and pin holes in the piston with engine oil.
(b) Align the cavity of the piston with the protruding portion on the connecting rod.





(c) Using SST, press in the piston pin.
SST: 09221-25026
09221-00021
09221-00030
09221-00090
09221-00150
09221-00100
NOTE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to the original locations when reassembled.





11. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
NOTE: Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oil.

12. INSTALL PISTON RING SET




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

(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression rings.





(c) Position the piston rings so that the ring ends are as shown.
13. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the 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:
- Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oil.
- Match the numbered connecting rod cap with the connecting rod.





(d) Make sure that the connecting rod and its cap are in the correct combination and that the front mark of the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod.
(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 to the specified torque.
SST: 09205-16011
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.
14. INSPECT CONNECTING ROD THRUST CLEARANCE Engine Unit
15. INSPECT CONNECTING ROD OIL CLEARANCE Engine Unit
16. INSTALL STUD BOLT
(a) Using "Torx" socket wrench E5, install the 4 stud bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)





17. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.





(b) Apply a continuous bead of seal packing (Diameter 2.0 mm to 3.0 mm (0.079 to 0.118 in.)) to the oil pan mating surface as 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 oil pan within 3 minutes of applying the seal packing.
- Do not expose the seal to engine oil for at least within 2 hours after the installation.

(c) Install 2 new O-rings onto the cylinder block.





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

18. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the 2 nuts and the bolt.
Torque: 11 Nm (112 kgf-cm, 8.1 ft-lbf)
19. INSTALL OIL PAN SUB-ASSEMBLY NO. 2
(a) Remove any old packing material from the contact surface.





(b) Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.)) to the oil pan mating surface as 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 oil pan within 3 minutes of applying the seal packing.
- Do not expose the seal to engine oil for at least 2 hours after the installation.
- Do not start the engine for at least 2 hours after the installation.

(c) Install oil pan No. 2 with the 9 bolts and the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(d) Install the drain plug with a new gasket.
Torque: 38 Nm (382 kgf-cm, 28 ft-lbf)





20. 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)
21. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Gently 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
HINT: When using a torque wrench, tighten it to the specified torque.

Torque: 13 Nm (133 kgf-cm, 9.5 ft-lbf)





22. 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 head gently in order not to damage the gasket.

23. INSTALL CYLINDER HEAD SUB-ASSEMBLY
HINT: The cylinder head bolts are tightened in 2 successive steps.





(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
(c) Mark the front of the cylinder head bolt with paint.





(d) Retighten the cylinder head bolts by 90° and then an additional 90° as shown in the illustration.
(e) Check that the paint mark is now at a 180° angle from the front.





(f) Apply a continuous bead of seal packing (Diameter 4.5 to 5.5 mm (0.177 to 0.217 in.)) as 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 oil pump assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

24. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTE: Keep the seal lip free of foreign matter.





(b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST: 09223-56010
NOTICE:
- Do not tap the oil seal at an angle.
- Wipe any extra grease off the crankshaft.

25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
NOTE: Install the camshaft timing gear assembly onto the camshaft with the lock pin of the camshaft timing gear assembly released.





(a) Put the camshaft timing gear assembly and camshaft together with the straight pin of the groove.
(b) Turn the camshaft timing gear assembly clockwise while pushing it gently toward the camshaft. When the pin fits into the groove, push to ensure a good fit.
NOTE: Do not turn the camshaft timing gear in the retard direction (clockwise).

(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.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
NOTICE:
- Do not lock the camshaft timing gear assembly when tightening the bolt.
- Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position.
- Tightening the bolts with the lock pin locked could cause breakage of the lock pin.

(e) Check that the camshaft timing gear assembly moves smoothly in the retard direction (clockwise) and is locked in the most retarded position.
26. INSTALL 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 (129 kgf-cm, 9.4 ft-lbf)
NOTE: Tighten each bolt uniformly while keeping the camshaft level.





27. INSTALL CAMSHAFT TIMING SPROCKET
(a) Clamp the camshaft in a vice.
(b) Align the knock pin hole in 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: Do not damage the camshaft.

28. 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 on camshaft bearing caps No. 1 and No. 2 and check that the sequence is as shown in the illustration. Then uniformly tighten the bolts, in several steps, in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9.4 ft-lbf)
Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
NOTE: Tighten each bolt uniformly while keeping the camshaft level.





29. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply engine oil to the O-ring.
NOTE: If the O-ring is damaged, replace the camshaft position sensor.

(b) Install the camshaft position sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)