Part 3

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

Part 3 of 3

55. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) For 2WD:
(1) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.

Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

(2) Install the baffle plate with the 8 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
HINT:
Temporarily tighten the 8 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.

(3) Install a new gasket and the oil strainer with the 3 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) For 4WD:
(1) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.

Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

(2) Install the baffle plate with the 7 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
HINT:
Temporarily tighten the 7 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.

(3) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)

(c) Install 2 new O-rings.
56. INSTALL OIL PAN SUB-ASSEMBLY
(a) When replacing a stud bolt, install it by using an E6 "TORX" socket wrench.

Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

(b) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing.

(c) Install the oil pan with the 16 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
57. INSTALL OIL WITH STRAINER PIPE SUB-ASSEMBLY (for 4WD)

(a) Install a new gasket and the oil with strainer pipe with the 3 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
58. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
- Remove any oil from the contact surface.
- Install the oil pan No. 2 within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing.

(b) For 2WD:

(1) Install the oil pan with the 15 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) For 4WD:

(1) Install the oil pan with the 14 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
59. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and the drain plug.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
60. INSTALL SPARK PLUG TUBE GASKET

(a) Using a cutter, cut off the sealing part of the removed plug tube gasket.

(b) Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.
HINT:
If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

(c) Return the claws of the ventilation baffle plate to their original positions.
61. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

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

(b) Install 3 new gaskets as shown in the illustration.
(c) Install a new gasket to the head cover.

(d) Install the head cover with the 14 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
62. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(b) Install 3 new gaskets as shown in the illustration.
(c) Install a new gasket to the head cover.

(d) Install the head cover with the 12 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(e) For 4WD:
(1) Install the engine hanger with the 2 bolts.
Torque: 33 Nm (337 kgf-cm, 24 ft-lbf)
63. INSTALL REAR WATER BY-PASS JOINT

(a) Install 2 new gaskets and a new O-ring.
HINT:
Apply soapy water to the O-ring.

(b) Install the water by-pass joint with the 2 bolts and 4 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTE:
Be careful that the O-ring does not get caught between the parts.

64. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

(a) Install a new gasket and water inlet with thermostat with the 3 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
65. INSTALL WATER INLET SUB-ASSEMBLY

(a) Install the 3 water by-pass hoses.

(b) Install 2 new O-rings.
HINT:
Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installing it.

(c) Install the water inlet with the 4 bolts and nut.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTE:
Be careful that the O-ring does not get caught between the parts.

(d) Install the 3 water by-pass hoses.
66. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(b) Using SST, install the pulley bolt.
SST: 09213-70011
09213-70020
SST: 09330-00021
Torque: 250 Nm (2,550 kgf-cm, 184 ft-lbf)
67. INSTALL OIL FILTER ELEMENT (for 2WD)

(a) Clean the inside of the oil filter cap, the threads and O-ring groove.
(b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
(c) Set a new oil filter element to the oil filter cap.
(d) Remove any dirt or foreign matter from the installation surface of the engine.
(e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap.
NOTE:
Be careful that the O-ring does not get caught between the parts.

(f) Using SST, tighten the oil filter cap.
SST: 09228-06501
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTE:
Make sure that the oil filter is installed securely as shown in the illustration.

68. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD)

(a) Install a new gasket and the oil filter bracket with the bolt and 2 nuts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
69. INSTALL OIL FILTER ELEMENT (for 4WD)

(f) Using SST, tighten the oil filter cap.
SST: 09228-06501
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
- Make sure that the oil filter is installed securely as shown in the illustration.
- Be careful that the O-ring does not get caught between the parts.

(g) Apply a light coat of engine oil to a new drain plug O-ring, and install it to the oil filter cap.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
- Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.
- Be careful that the O-ring does not get caught between the parts.

70. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cocks.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the water drain cocks as shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTE:
Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.
Torque: 13 Nm (130 kgf-cm, 9 ft-lbf)
71. INSTALL NO. 1 OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
NOTE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
(d) Tighten the oil pipe union (on the head cover side).
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
(e) Tighten the oil check valve bolt (on the cylinder head side).
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
NOTE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

72. INSTALL NO. 2 OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
NOTE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
(d) Tighten the oil pipe union (on the head cover side).
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
(e) Tighten the oil check valve bolt (on the cylinder head side).
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
NOTE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

73. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
74. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Install the 4 oil control valves with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
75. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the 4 sensors with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
76. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive around the ventilation valve.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
77. INSTALL SPARK PLUG
(a) Install the spark plugs.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
78. INSTALL RADIATOR CAP SUB-ASSEMBLY
(a) Install the radiator cap.
79. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install a new gasket.
(b) Install the oil filler cap.