Part 2

1NZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY (Continued)

30. INSTALL CHAIN SUB-ASSEMBLY

(a) Make sure that all the timing marks are in the positions (TDC) shown in the illustration.
HINT: The positions of the timing marks may differ from the predetermined positions due to the force of the valve spring.

(b) Set the timing mark of the crankshaft in a position between 40 and 140°ATDC, as illustrated.

(c) Set the camshaft timing gear and the camshaft timing sprocket in the positions (20°ATDC) shown in the illustration.
(d) Set the crankshaft in the position (20°ATDC) shown in the illustration.

(e) Install chain vibration damper No. 1 with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

(f) Align the timing marks of the camshaft with the mark plates of the timing chain and install the timing chain.
HINT: Align the timing marks with the mark plates while turning the hexagonal service portion of the camshaft using a wrench.

31. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.

32. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
(a) Install chain tensioner assembly No. 1 with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(b) Remove the bar from chain tensioner assembly No. 1.

33. INSTALL OIL PUMP SEAL
(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST: 09950-60010
09951-00250
09951-00380
09952-06010
SST: 09950-70010
09951-07100
NOTICE:
- Do not tap the oil seal at an angle.
- Keep the seal lip free of foreign matter.

(b) Apply MP grease to the oil seal lip.
34. INSTALL OIL PUMP ASSEMBLY

(a) Install 2 new O-rings in the 2 locations shown in the illustration.
(b) Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration.

Seal packing:
Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B 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 assembly within 3 minutes and tighten the bolts and nut within 15 minutes of applying the the seal packing.
- Do not expose the seal to engine oil for at least 2 hours after the installation.

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

(d) Install the oil pump assembly with the 15 bolts and nut. Tighten the bolts and nut uniformly 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)
NOTE: Install the mounting bracket and water pump within 15 minutes of installing the oil pump assembly.
HINT: Each bolt length is as follows.
A: 30 mm (1.181 in.)
B: 35 mm (1.378 in.)
C: 20 mm (0.787 in.)
E: 20 to 14 mm (0.787 to 0.551 in.) Double ended bolt

35. INSTALL WATER PUMP ASSEMBLY
(a) Install the water pump and a new gasket with the 3 bolts and 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8.1 ft-lbf)

36. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the transverse engine mounting bracket with the 4 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
37. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
(a) Align the pin hole in the crankshaft damper with the pin position and install the crankshaft damper sub-assembly.
(b) Provisionally install the bolt.

(c) Using 2 SSTs, tighten the bolt while holding the crankshaft damper sub-assembly.
SST: 09213-14010
91651-60865
SST: 09330-00021
Torque: 128 Nm (1305 kgf-cm, 95 ft-lbf)
NOTE: Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.

38. INSTALL WATER PUMP PULLEY
(a) Using SST, install the pump pulley with the 3 bolts.
SST: 09960-10010
09962-01000
09963-00700
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
39. INSPECT VALVE CLEARANCE

(a) Set the No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump.

(2) Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward, as shown in the illustration.
HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

(b) Check the valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (cold):
for intake
0.15 to 0.25 mm (0.006 to 0.010 in.)
for exhaust
0.25 to 0.35 mm (0.010 to 0.014 in.)
(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
(c) Turn the crankshaft 1 complete revolution (360°) and align its timing notch with timing mark "0" of the oil pump.

(d) Check the valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (cold):
for Intake
0.15 to 0.25 mm (0.006 to 0.010 in.)
for Exhaust
0.25 to 0.35 mm (0.010 to 0.014 in.)
(2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
40. ADJUST VALVE CLEARANCE

NOTE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with the matchmark of the timing chain cover to prevent the pistons from coming into contact with the valves.

(a) Set the No. 1 cylinder to TDC/compression.

(1) Turn the crankshaft damper, and align its timing notch with timing mark "0" of the oil pump.

(2) Check that the timing marks on the camshaft timing sprocket and camshaft timing gear are all facing upward as shown in the illustration.
HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

(b) Put paint marks on the chain in the places where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located.

(d) Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.

(e) Using a wrench, rotate the No. 2 camshaft clockwise to push in the plunger of the chain tensioner.

(f) Remove the screwdriver from the service hole, then align the hole in the stopper plate with the service hole and insert a 3 mm (0.12 in.) diameter bar into the holes to hold the stopper plate.
HINT:
- Fix the stopper plate using the bar while rotating the camshaft right and left slightly.
- Hold the bar with tape so that it does not come out.

(g) Using a wrench, hold the hexagonal lobe of No. 2 camshaft and remove the flange bolt.

(h) Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2.
NOTE: Loosen each bolt uniformly while keeping the camshaft level.

(i) Remove the flange bolt and remove the camshaft timing sprocket.

(j) Remove the No. 2 camshaft.

(k) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove camshaft bearing cap No. 2.
NOTE: Loosen the bolts uniformly while keeping the camshaft level.

(l) Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly.

(m) Tie the chain with a piece of string as shown in the illustration.
(n) Remove the valve lifters.

(o) Using a micrometer, measure the thickness of the removed lifter.
(p) Calculate the thickness of the new lifter so that the valve clearance comes to within the specified values.

Valve clearance:
Intake A = B + (C - 0.20 mm (0.008 in.))
Exhaust A = B + (C - 0.30 mm (0.012 in.))
(q) Select a new lifter with a thickness as close to the calculated values as possible.
HINT: Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

Intake valve clearance (cold):
0.15 to 0.25 mm (0.006 to 0.010 in.)
EXAMPLE:
A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.
New Shim Thickness:

Exhaust valve clearance (cold):
0.25 to 0.35 mm (0.010 to 0.014 in.)
EXAMPLE:
A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.
New Shim Thickness:

(r) Install the selected valve lifter.
(s) Apply a light coat of engine oil to the camshaft and camshaft journals.

(t) Install the chain onto the camshaft timing gear with the paint mark and the timing mark aligned, as shown in the illustration.

(u) Examine the front marks and the numbers on camshaft bearing cap 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)
NOTE: Tighten the bolts uniformly while keeping the camshaft level.

(v) Install camshaft No. 2.

(w) Hold the chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the chain.
(x) Align the alignment pin hole in the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket onto the camshaft.

(y) Provisionally install the flange bolt.

(z) Examine the front marks and the numbers of camshaft bearing cap No. 1 and camshaft bearing cap 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 the bolts uniformly while keeping the camshaft level.

(aa) Using a wrench, hold the hexagonal lobe of camshaft No. 2, and install the flange bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
(ab) Remove the bar from the timing chain tensioner.

(ac) Turn the crankshaft damper, and align its timing notch with the timing mark "0" of the oil pump.

(ad) Check that all the pairs of timing marks are aligned.
(ae) Apply adhesive to the end 2 or 3 threads of the screw plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

(af) Using an 8 mm hexagon wrench, install the screw plug.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)

41. 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 camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
NOTE: Do not twist the O-ring.

42. INSTALL FUEL INJECTOR ASSEMBLY

(a) Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each fuel injector.
(b) Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the O-ring of the fuel injector.

(c) While turning the fuel injector left and right, install it onto the fuel delivery pipe.
NOTICE:
- Do not twist the O-ring.
- After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring with a new one.

43. INSTALL INJECTOR VIBRATION INSULATOR
(a) Install 4 new injector vibration insulators onto the cylinder head.

44. INSTALL DELIVERY PIPE NO. 1 SPACER
(a) Install the 2 delivery pipe No. 1 spacers onto the cylinder head.
NOTE: Install delivery pipe No. 1 spacer in the correct direction.

45. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Provisionally install the fuel delivery pipe sub-assembly and 4 fuel injectors with the 3 bolts.
NOTICE:
- Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
- Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe sub-assembly.

(b) Tighten the 3 bolts to the specified torque.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Install the gasket onto the cylinder head cover.
(b) Apply seal packing to the cylinder head, 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 cylinder head cover sub-assembly within 3 minutes of applying the seal packing.
- Do not start engine for at least 2 hours after the installation.

(c) Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.

(d) Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7.0 ft-lbf)

47. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Install the ventilation valve onto the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
48. INSTALL OIL LEVEL GAUGE GUIDE
(a) Apply engine oil to a new O-ring.
(b) Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
49. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.
NOTE: If the O-ring is damaged, replace the crankshaft position sensor.

(b) Install the crankshaft position sensor with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
50. INSTALL OIL FILLER CAP GASKET
(a) Install the oil filler cap gasket onto the oil filler cap.
51. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install the oil filler cap onto the cylinder head cover.
52. 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°either side as shown in the illustration.

53. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
54. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Provisionally install the engine coolant temperature sensor through a new gasket.

(b) Using SST, tighten the engine coolant temperature sensor.
SST: 09817-33190
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
55. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Apply adhesive to the end 2 or 3 threads of the oil pressure switch.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)

56. INSTALL KNOCK SENSOR
(a) Install the knock sensor with the nut as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)

57. INSTALL SPARK PLUG
(a) Using a spark plug wrench, install the spark plugs.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)