Part 3

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY (Continued)

49. INSTALL WATER INLET HOUSING

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

(b) Install the stud bolts.
Torque: 4.0 Nm (41 kgf-cm, 35in-lbf)

(c) Install the water inlet with the 2 bolts and nut.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
NOTICE:
Be careful that the O-ring does not get caught between the parts.

(d) Connect the No. 1 water by-pass hose.
(e) Apply adhesive around the drain cock.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(f) Install the drain cock to the water inlet housing.
Torque: 30 Nm (306 kgf-cm, 22ft-lbf)
(g) Install the drain cock plug to the water drain cock.
Torque: 13 Nm (132 kgf-cm, 10ft-lbf)
(h) Install a new gasket to the thermostat.

(i) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.
HINT: The jiggle valve may be set within 10° of either side of the prescribed positions.

(j) Install the water inlet with the 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
50. INSTALL FRONT ENGINE MOUNTING BRACKET NO. 1 LH

(a) Install the engine mounting bracket with the 6 bolts.
Torque: 54 Nm (550 kgf-cm, 40ft-lbf)
- Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
- Do not start the engine for at least 2 hours after installation.

(b) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
51. INSTALL OIL PAN BAFFLE PLATE NO.1

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

52. INSTALL OIL PAN SUB-ASSEMBLY
(a) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench (w/o oil cooler).

Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
(b) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench (w/ oil cooler).

Torque: 10 Nm (102 kgf-cm, 7ft-lbf)

(d) 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.

(e) Install the oil pan with the 16 bolts and 2 nuts.
Bolt A - Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
Except Bolt A - Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
53. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm, 35in-lbf)

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

(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm, 35in-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 No. 2 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, 7ft-lbf)
55. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and the drain plug.
Torque: 40 Nm (408 kgf-cm, 30ft-lbf)
56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for RH Side)

(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 a head cover with the 12 bolts and a new washer.
Bolt A - Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
Except Bolt A - Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
HINT: After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

57. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for LH Side)

(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 and a new washer.
Bolt A - Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
Except Bolt A - Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
HINT: After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

58. INSTALL WATER OUTLET

(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, 7ft-lbf)
NOTICE:
Be careful that the O-ring does not get caught between the parts.

59. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)

(a) Using an E8 "TORX" socket, install the stud bolts as shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)

(b) Install a new gasket to the No. 1 oil cooler bracket.
(c) Install the oil cooler pipe with the bolt and 2 nuts.
Torque: 21 Nm (214 kgf-cm, 16ft-lbf)

(d) Install a new gasket to the No. 1 oil pan.
(e) Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.
Torque: 21 Nm (214 kgf-cm, 16ft-lbf)
60. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)

(a) Install a new O-ring.
(b) Install the oil cooler assembly with the union bolt.
Torque: 68 Nm (693 kgf-cm, 50ft-lbf)

(c) Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
61. 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 (2550 kgf-cm, 184ft-lbf)
62. INSTALL OIL FILTER ELEMENT

(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 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.
NOTICE:
- Be careful that the O-ring does not get caught between the parts.
- The O-ring must not be twisted on the groove.

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

(g) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
NOTICE:
Remove all dirt and foreign matter from the installation surface.

(h) Install the oil filter drain plug to the oil filter cap.
Torque: 13 Nm (132 kgf-cm, 10ft-lbf)
NOTICE:
Make sure that the O-ring does not get caught between the parts.

63. 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: 25 Nm (255 kgf-cm, 18ft-lbf)
NOTICE:
Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.
Torque: 13 Nm (132 kgf-cm, 10ft-lbf)
64. INSTALL NO. 1 OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
NOTICE:
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: 65 Nm (663 kgf-cm, 48ft-lbf)
(e) Tighten the oil pipe union (on the cylinder head side).
Torque: 65 Nm (663 kgf-cm, 48ft-lbf)
NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

65. INSTALL OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
NOTICE:
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) Install the bolt (A) to the cylinder head.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
(e) Tighten the oil pipe union (on the head cover side).
Torque: 65 Nm (663 kgf-cm, 48ft-lbf)
(f) Tighten the oil pipe union (on the cylinder head side).
Torque: 65 Nm (663 kgf-cm, 48ft-lbf)
NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

66. INSTALL CRANKSHAFT POSITION SENSOR

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

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

(a) Install the 4 sensors with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
69. 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, 20ft-lbf)
70. INSTALL SPARK PLUG
(a) Install the 6 spark plugs.
Torque: 18 Nm (184 kgf-cm, 13ft-lbf)
71. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install a new gasket.
(b) Install the oil filler cap.