RM3090E _51 Engine / Hybrid System _008396 2AR-FE ENGINE MECHANICAL _0046880 ENGINE UNIT A

2AR-FE ENGINE MECHANICAL ENGINE UNIT REASSEMBLY

PROCEDURE

Hide Display 1.INSTALL STIFFENING CRANKCASE RING PIN

NOTICE:: It is not necessary to remove the ring pin unless it is being replaced.

2.375,2.427 2.604,2.594 0.229,0.167 10 *1

*1	Protrusion Height

Using a plastic-faced hammer, tap in 2 new ring pins until they stop.

Standard protrusion height:: 4.3 to 5.3 mm (0.169 to 0.209 in.)

Hide Display 2.INSTALL STIFFENING CRANKCASE STUD BOLT

NOTICE:: If a stud bolt is deformed or its threads are damaged, replace it.

4.76,0.74 5.156,0.271 5.156,0.271 5.313,0.271 false 4.75,1.115 5.135,1.5 5.135,1.5 5.302,1.5 false 4.75,2.104 5.115,1.781 5.115,1.781 5.302,1.781 false 4.75,2.365 5.135,2.635 5.135,2.635 5.333,2.635 false 2.24,1.135 2.385,1.302 0.146,0.167 10 A 0.99,1.708 1.135,1.875 0.146,0.167 10 B 5.375,0.802 5.573,0.969 0.198,0.167 10 *d 5.344,0.146 5.542,0.313 0.198,0.167 10 *c 5.354,1.385 5.552,1.552 0.198,0.167 10 *e 5.344,1.677 5.542,1.844 0.198,0.167 10 *f 5.375,2.146 5.573,2.313 0.198,0.167 10 *g 5.375,2.531 5.573,2.698 0.198,0.167 10 *h 2.146,2.51 2.292,2.677 0.146,0.167 10 B 0.677,0.052 0.927,0.219 0.25,0.167 10 *a 0.688,1.469 0.938,1.635 0.25,0.167 10 *b 4.104,0.135 4.25,0.302 0.146,0.167 10 A 4.104,1.646 4.25,1.813 0.146,0.167 10 B

*a	Front Side	*b	Lower Side
*c	20 mm (0.787 in.)	*d	35 mm (1.38 in.)
*e	13 mm (0.512 in.)	*f	8.5 mm (0.335 in.)
*g	18 mm (0.709 in.)	*h	8.0 mm (0.315 in.)

Using an E5 and E8 "TORX" socket wrench, install the stud bolts.

Torque:: for stud bolt A : 5.0 N*m (51 kgf*cm, 44 in.*lbf); for stud bolt B : 9.5 N*m (97 kgf*cm, 84 in.*lbf)

Hide Display 13620B 3.INSTALL ENGINE BALANCER ASSEMBLY

2.188,0.99 0.74,0.521 0.74,0.521 2.188,1.104 true 0.521,0.396 0.75,0.563 0.229,0.167 10 *1

*1	Alignment Mark

Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.

If the alignment marks are not aligned, realign them.

0.635,0.76 0.865,0.76 0.865,0.76 1.583,1.25 true 2.229,1.292 2.865,2.042 2.865,2.042 2.313,1.167 true 1.208,1.74 1.688,1.563 true 0.406,0.677 0.594,0.833 0.188,0.156 10 *1 1,1.677 1.188,1.854 0.188,0.177 10 *2 2.917,1.958 3.115,2.135 0.198,0.177 10 *3

*1	Driven Gear
*2	Damper Cover
*3	Alignment Mark

Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place.

ii.

Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.

2.76,1.667 2.885,1.854 0.125,0.188 10 3 0.958,1.344 1.115,1.542 0.156,0.198 10 1 2.677,0.229 2.833,0.427 0.156,0.198 10 2

Install the engine balancer to the stiffening crankcase with the 3 bolts and tighten the bolts in the sequence shown in the illustration.

Torque:: 24 N*m (245 kgf*cm, 18 ft.*lbf)

Hide Display 11420 4.INSTALL STIFFENING CRANKCASE ASSEMBLY

1.927,1.063 2.375,0.615 2.375,0.615 2.563,0.615 true 2.594,0.51 2.802,0.688 0.208,0.177 10 *1 0.833,1.354 1.188,1.542 0.354,0.188 10 270°

Key

Rotate the crankshaft clockwise so that the crankshaft key is at the position 270° from the bottom as shown in the illustration.

2.115,0.969 1.771,0.271 1.771,0.271 1.667,0.271 false 1.813,3.771 1.885,3.479 1.885,3.479 2.052,3.479 false 1.427,0.156 1.625,0.344 0.198,0.188 10 *1 3.01,0.49 3.146,0.656 0.135,0.167 10 A 1.146,3.521 1.281,3.688 0.135,0.167 10 A 1.01,4.094 1.219,4.26 0.208,0.167 10 *a 2.104,3.375 2.323,3.552 0.219,0.177 10 *b

*1	Seal Packing
*a	2.5 to 3.5 mm (0.0984 to 0.138 in.)
*b	7.0 to 9.0 mm (0.276 to 0.354 in.)
	Stiffening Crankcase
	Cylinder Block

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 Dimension:

Area	Specified Condition
Continuous Line	2.5 to 3.5 mm (0.0984 to 0.138 in.)
Dashed Line	7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick

Application length A:: 28 mm (1.10 in.)

NOTICE:: ·

Remove any oil from the contact surface.

·

Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

·

Do not apply oil for at least 4 hours after the installation.

·

Do not start the engine for at least 4 hours after the installation.

1.417,0.979 1.208,0.302 1.208,0.302 1.99,0.99 false 1.083,0.125 1.396,0.281 0.313,0.156 10 *1

Cutout

Check that the rear cutouts are as shown in the illustration.

Clean the bolts and their installation holes.

Apply adhesive to 3 threads or more at the end of bolt A.

Adhesive:: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

2.719,0 2.875,0.198 0.156,0.198 10 B 0.885,1.938 1.042,2.135 0.156,0.198 10 A 2.969,1.885 3.125,2.083 0.156,0.198 10 B 2.531,1.969 2.688,2.167 0.156,0.198 10 C 2.802,1.083 2.958,1.281 0.156,0.198 10 C 2.802,0.865 2.958,1.063 0.156,0.198 10 C 2.333,0.031 2.49,0.229 0.156,0.198 10 D 1.26,0.021 1.417,0.219 0.156,0.198 10 D 0.656,0.271 0.813,0.469 0.156,0.198 10 A 1.292,1.979 1.448,2.177 0.156,0.198 10 D 2.208,1 2.365,1.198 0.156,0.198 10 D

Temporarily install the stiffening crankcase with the 11 bolts.

Bolt Length :

Item	Specified Condition
Bolt A	65 mm (2.56 in.)
Bolt B	35 mm (1.38 in.)
Bolt C	125 mm (4.92 in.)
Bolt D	165 mm (6.50 in.)

HINT:: Apply adhesive to bolt A before installing it.

2.542,1.958 2.698,2.156 0.156,0.198 10 1 2.333,0.01 2.49,0.208 0.156,0.198 10 2 2.219,1 2.375,1.198 0.156,0.198 10 3 2.729,0.01 2.885,0.208 0.156,0.198 10 4 2.979,1.885 3.135,2.083 0.156,0.198 10 5 1.271,0.021 1.427,0.219 0.156,0.198 10 6 1.292,1.979 1.448,2.177 0.156,0.198 10 7 2.802,0.844 2.958,1.042 0.156,0.198 10 8 2.802,1.073 2.958,1.271 0.156,0.198 10 9 0.615,0.271 0.813,0.469 0.198,0.198 10 10 0.844,1.969 1.042,2.167 0.198,0.198 10 11

Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase.

Torque:: for bolt A : 24 N*m (245 kgf*cm, 18 ft.*lbf); except bolt A : 43 N*m (438 kgf*cm, 32 ft.*lbf)

Hide Display 12121 5.INSTALL NO. 1 OIL PAN BAFFLE PLATE

1.115,0.604 1.271,0.802 0.156,0.198 10 1 2.063,1.979 2.219,2.177 0.156,0.198 10 2 0.635,0.833 0.792,1.031 0.156,0.198 10 3 1.5,1.927 1.656,2.125 0.156,0.198 10 4 1.167,0.24 1.323,0.438 0.156,0.198 10 5

Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the sequence shown in the illustration.

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

Hide Display 15104 6.INSTALL OIL STRAINER SUB-ASSEMBLY

1.49,0.448 1.635,0.448 1.635,0.448 2.115,0.625 false 1.281,0.344 1.594,0.5 0.313,0.156 10 *1 0.635,1.917 0.792,2.115 0.156,0.198 10 1 2.146,3 2.302,3.198 0.156,0.198 10 3 0.656,3.083 0.813,3.281 0.156,0.198 10 2

*1	Protrusion

Apply a light coat of engine oil to a new gasket.

Align the protrusion of the gasket with the cutout of the oil strainer and install the gasket to the oil strainer sub-assembly.

Install the oil strainer sub-assembly with the 3 bolts in several steps in the sequence shown in the illustration.

Torque:: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

Hide Display 12101 7.INSTALL OIL PAN SUB-ASSEMBLY

1.51,1.5 1.625,1.5 1.625,1.5 1.885,1.25 true 1.281,1.406 1.458,1.573 0.177,0.167 10 *1

*1	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 diameter:: 2.5 to 3.5 mm (0.0984 to 0.138 in.)

NOTICE:: ·

Remove any oil from the contact surface.

·

Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

·

Do not apply oil for at least 4 hours after the installation.

·

Do not start the engine for at least 4 hours after the installation.

2.313,0.229 2.542,0.385 0.229,0.156 10 10 1.208,1.385 1.583,1.563 0.375,0.177 10 2, 15 2.625,0.74 2.854,0.896 0.229,0.156 10 11 2.615,1.156 2.844,1.313 0.229,0.156 10 12 2.396,1.802 2.625,1.958 0.229,0.156 10 13 2,1.99 2.229,2.146 0.229,0.156 10 14 1.438,1.927 1.573,2.073 0.135,0.146 10 A 1.729,0.052 1.865,0.198 0.135,0.146 10 A 0.698,1.896 0.833,2.042 0.135,0.146 10 3 0.385,1.615 0.521,1.76 0.135,0.146 10 4 0.365,1.021 0.5,1.167 0.135,0.146 10 5 0.958,0.396 1.094,0.542 0.135,0.146 10 7 0.667,0.615 0.802,0.76 0.135,0.146 10 6 1.094,0.083 1.229,0.229 0.135,0.146 10 8 1.458,0.573 1.75,0.75 0.292,0.177 10 1, 9

Install the oil pan sub-assembly with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration.

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

HINT:: Bolt A and nut A are tightened twice.

Hide Display 8.INSTALL OIL FILTER ELEMENT

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Hide Display 11401L 9.INSTALL REAR ENGINE OIL SEAL

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Hide Display 11445 10.INSTALL CYLINDER BLOCK WATER JACKET SPACER

Install the cylinder block water jacket spacer to the cylinder block.

Hide Display 11115 11.INSTALL CYLINDER HEAD GASKET

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Hide Display 11101 12.INSTALL CYLINDER HEAD SUB-ASSEMBLY

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Hide Display 13050 13.SET CAMSHAFT TIMING GEAR ASSEMBLY

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Hide Display 11151A 14.INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

NOTICE:: It is not necessary to remove the ring pin unless it is being replaced.

2.427,1.604 2.604,1.76 0.177,0.156 10 *1

*1	Protrusion Height

Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.

Standard protrusion height:: 2.7 to 3.3 mm (0.106 to 0.130 in.)

Hide Display 11114A 15.INSTALL CAMSHAFT HOUSING STRAIGHT PIN

NOTICE:: It is not necessary to remove the straight pin unless it is being replaced.

2.067,1.558 2.242,1.73 0.175,0.171 10 *1

*1	Protrusion Height

Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing.

Standard protrusion height:: 5.0 to 7.0 mm (0.197 to 0.276 in.)

Hide Display 16.INSTALL CAMSHAFT HOUSING STUD BOLT

NOTICE:: If a stud bolt is deformed or its threads are damaged, replace it.

1.885,1.542 1.76,1.542 1.76,1.542 1.542,2.125 false 1.531,2.823 1.833,3.219 1.833,3.219 1.99,3.219 false 2.052,3.083 2.229,3.26 0.177,0.177 10 *c 1.948,1.458 2.156,1.646 0.208,0.188 10 *a 2.24,2.406 2.438,2.583 0.198,0.177 10 *b

*a	20 mm (0.787 in.)
*b	35 mm (1.38 in.)
*c	13 mm (0.512 in.)

Using an E8 "TORX" socket wrench, install the stud bolt.

Torque:: 9.5 N*m (97 kgf*cm, 84 in.*lbf)

Hide Display 11811 17.INSTALL NO. 1 CAMSHAFT BEARING

0.137,2.355 0.27,2.525 0.133,0.17 10 A 1.628,2.355 1.761,2.525 0.133,0.17 10 B 2.099,2.478 2.276,2.641 0.177,0.163 10 *1 1.832,2.234 1.964,2.566 1.964,2.566 2.061,2.566 false

*1	Vernier Caliper

Clean the No. 1 camshaft bearing.

Install the camshaft bearing to the No. 1 camshaft bearing cap.

Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.

Dimension A - B or B - A:: 0 to 0.7 mm (0 to 0.0276 in.)

Hide Display 11821 18.INSTALL NO. 2 CAMSHAFT BEARING

0.851,2.324 0.984,2.489 0.133,0.166 10 A 0.97,1.284 1.154,1.468 0.184,0.184 10 *1 0.915,1.379 0.818,1.379 0.818,1.379 0.743,2.589 false

*1	Vernier Caliper

Clean the No. 2 camshaft bearing.

Install the camshaft bearing to the camshaft housing.

Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.

Standard distance:: 1.15 to 1.85 mm (0.0453 to 0.0728 in.)

Hide Display 15678A 19.INSTALL OIL CONTROL VALVE FILTER

Install the oil control valve filter to the No. 1 camshaft bearing cap.

Hide Display 13511 20.INSTALL CAMSHAFT

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Hide Display 21.INSTALL CAMSHAFT BEARING CAP

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Hide Display 13716 22.INSTALL VALVE STEM CAP

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Hide Display 13750 23.INSTALL VALVE LASH ADJUSTER ASSEMBLY

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Hide Display 13801 24.INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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Hide Display 11103 25.INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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Hide Display 13050 26.INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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Hide Display 13070A 27.INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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Hide Display 13521 28.INSTALL CRANKSHAFT TIMING SPROCKET

Install the crankshaft timing sprocket to the crankshaft.

Hide Display 29.ADD ENGINE OIL

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Hide Display 30.SET NO. 1 CYLINDER TO TDC/COMPRESSION

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Hide Display 13561 31.INSTALL NO. 1 CHAIN VIBRATION DAMPER

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Hide Display 13506 32.INSTALL CHAIN SUB-ASSEMBLY

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Hide Display 13559 33.INSTALL CHAIN TENSIONER SLIPPER

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Hide Display 13540 34.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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Hide Display 13566B 35.INSTALL TIMING CHAIN GUIDE

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Hide Display 36.CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

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Hide Display 11324 37.INSTALL TIMING CHAIN COVER PLATE

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Hide Display 38.INSTALL TIMING CHAIN COVER TIGHT PLUG

Using a 14 mm hexagon wrench, install a new gasket and timing chain cover tight plug.

Torque:: 30 N*m (306 kgf*cm, 22 ft.*lbf)

Hide Display 11310 39.INSTALL TIMING CHAIN COVER ASSEMBLY

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Hide Display 12315A 40.INSTALL ENGINE MOUNTING BRACKET RH

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Hide Display 11301C 41.INSTALL TIMING CHAIN COVER OIL SEAL

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Hide Display 11193 42.INSTALL SPARK PLUG TUBE GASKET

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Hide Display 11201 43.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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Hide Display 13471 44.INSTALL CRANKSHAFT PULLEY

1.354,0.99 0.792,0.927 0.792,0.927 1.292,0.656 false 0.802,0.927 1.375,0.885 false 0.531,0.271 0.74,0.469 0.208,0.198 10 *a 2.292,1.698 2.5,1.896 0.208,0.198 10 *b 0.469,0.833 0.792,1 0.323,0.167 10 SST

*a	Hold
*b	Turn

Align the pulley set key with the key groove of the crankshaft pulley.

Using SST, hold the crankshaft pulley and install the pulley bolt.

SST: 09213-54015
09330-00021

Torque:: 260 N*m (2651 kgf*cm, 192 ft.*lbf)

HINT:: Part number of installation bolt for SST (crankshaft pulley holdingtool): 91551-80650 (quantity: 2)

Hide Display 11301K 45.INSTALL CRANKSHAFT POSITION SENSOR

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Hide Display 16323 46.INSTALL WATER INLET HOUSING

Install a new gasket and the water inlet housing with the 4 bolts and nut.

Torque:: 43 N*m (438 kgf*cm, 32 ft.*lbf)

Hide Display 15710 47.INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)

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Hide Display 16100 48.INSTALL ENGINE WATER PUMP ASSEMBLY

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Hide Display 16620 49.INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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Hide Display 16331A 50.INSTALL THERMOSTAT

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Hide Display 16321 51.INSTALL WATER INLET

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Hide Display 16268 52.INSTALL NO. 1 WATER BY-PASS PIPE

Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.

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

Hide Display 12215 53.INSTALL SEPARATOR CASE

Apply a light coat of engine oil to a new gasket.

Install the gasket to the separator case.

Install the separator case with the 2 bolts.

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

Hide Display 12205 54.INSTALL PCV CASE

2.031,1.313 2.344,1.729 false 2.344,1.74 2.344,1.854 false 2.26,1.865 2.469,2.031 0.208,0.167 10 *1

*1	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 diameter:: 2.5 to 3.5 mm (0.0984 to 0.138 in.)

NOTICE:: ·

Remove any oil from the contact surface.

·

Install the PCV case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

2.521,0.563 2.656,0.563 false 0.656,1.354 0.74,1.354 0.74,1.354 0.792,1.448 false 0.177,1.635 0.792,1.833 0.615,0.198 10 1, 8 2.938,0.156 3.323,0.365 0.385,0.208 10 2, 12 3.094,0.906 3.25,1.104 0.156,0.198 10 3 3.063,1.667 3.219,1.865 0.156,0.198 10 4 2.135,1.823 2.292,2.021 0.156,0.198 10 5 1.521,1.844 1.677,2.042 0.156,0.198 10 6 0.979,1.708 1.135,1.906 0.156,0.198 10 7 0.302,0.406 0.458,0.604 0.156,0.198 10 9 0.802,0.146 1.115,0.344 0.313,0.198 10 10 1.521,0.125 1.833,0.323 0.313,0.198 10 11 2.719,0.49 2.875,0.688 0.156,0.198 10 A 0.531,1.271 0.688,1.469 0.156,0.198 10 A

Install the PCV case, and then install the 8 bolts and 2 nuts in the order shown in the illustration.

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

HINT:: Bolt A is tightened twice.

Hide Display 12204 55.INSTALL PCV VALVE

Click hereEngine / Hybrid System>2AR-FE EMISSION CONTROL>PCV VALVE>INSTALLATION201212,999999,_51,_008398,_0046893,RM1000000003UNL_01_0001,

Hide Display 11102A 56.INSTALL CAMSHAFT POSITION SENSOR (for Intake Side)

Click hereEngine / Hybrid System>2AR-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>INSTALLATION201212,999999,_51,_008378,_0046925,RM1000000003UQM_01_0009,

Hide Display 57.INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side)

Click hereEngine / Hybrid System>2AR-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>INSTALLATION201212,999999,_51,_008378,_0046925,RM1000000003UQM_01_0001,

Hide Display 11101J 58.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

Click hereEngine / Hybrid System>2AR-FE ENGINE CONTROL>CAMSHAFT OIL CONTROL VALVE>INSTALLATION201212,999999,_51,_008378,_0046920,RM1000000003UQ0_01_0009,

Hide Display 59.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

Click hereEngine / Hybrid System>2AR-FE ENGINE CONTROL>CAMSHAFT OIL CONTROL VALVE>INSTALLATION201212,999999,_51,_008378,_0046920,RM1000000003UQ0_01_0001,

Hide Display 12108 60.INSTALL OIL FILLER CAP SUB-ASSEMBLY

Install the gasket to the oil filler cap sub-assembly.

Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

Hide Display 19100P 61.INSTALL SPARK PLUG

Click hereEngine / Hybrid System>2AR-FE ENGINE CONTROL>IGNITION COIL AND SPARK PLUG>INSTALLATION201212,999999,_51,_008378,_0046927,RM1000000003UQT_01_0006,

Hide Display 62.INSTALL ENGINE COVER JOINT

Install the 3 engine cover joints.

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

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