Part 1
2UR-GSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the new O-ring to the oil drain pipe sub-assembly.
(c) Install the oil drain pipe sub-assembly with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL ENGINE REAR OIL SEAL RETAINER
(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:
2.0 to 3.0 mm (0.0787 to 0.118 in.)
Application position from inside edge of retainer:
3.5 mm (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 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil seal retainer.
* When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is not damaged.
* When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is folded correctly.
(b) Install the engine rear oil seal retainer with the 6 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the new O-ring to the oil strainer sub-assembly.
(c) Install the oil strainer sub-assembly with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
Make sure that the O-ring is not twisted or damaged.
4. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) Install the No. 1 oil pan baffle plate with the 8 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL 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
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
Application position from inside edge of oil pan:
6.0 mm (0.236 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.
(b) Install the oil pan sub-assembly with the 14 bolts and 2 nuts.
Bolt A - Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
Bolt B - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Nut - Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
6. 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
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.
(b) Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
7. INSTALL VENTILATION PIPE GASKET
(a) Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.
SST : 09950-60010
09951-00360
SST : 09950-70010
09951-07100
HINT
* Do not tap the ventilation pipe gasket at an angle.
* Do not tap the ventilation pipe gasket excessively.
8. INSTALL HEAT EXCHANGER ASSEMBLY
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTICE:
Remove any oil from the contact surface.
(b) Install the heat exchanger assembly with the 11 bolts and 2 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
* Install the No. 1 heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the cover.
(c) Install the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
9. INSTALL CYLINDER BLOCK WATER JACKET SPACER
(a) Install the 2 cylinder block water jacket spacers as shown in the illustration.
HINT
* Face the cutouts away from the center of the engine.
* Face each "Up" mark as shown in the illustration.
10. INSTALL NO. 2 CYLINDER HEAD GASKET (for Bank 1) Installation
11. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1) Installation
12. INSTALL CYLINDER HEAD GASKET (for Bank 2) Installation
13. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2) Installation
14. INSTALL VALVE ROCKER ARM PIVOT
(a) Install the 32 valve rocker arm pivots to the cylinder head assembly.
Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)
15. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Apply engine oil to the valve rocker arm pivot and valve adjusting shim.
(b) Install the 32 No. 1 valve rocker arm sub-assembly on the cylinder heads.
(c) Make sure that the 32 No. 1 valve rocker arm sub-assembly are installed as shown in the illustration.
16. INSTALL NO. 3 CAMSHAFT Installation
17. INSTALL NO. 4 CAMSHAFT Installation
18. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation
19. INSTALL CAMSHAFT Installation
20. INSTALL NO. 2 CAMSHAFT Installation
21. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation
22. INSTALL CRANKSHAFT TIMING GEAR KEY
(a) Install the crankshaft timing gear key.
(b) Temporarily install the crankshaft pulley set bolt, and set the crankshaft timing gear key in the position as shown in the illustration.
(c) Remove the crankshaft pulley set bolt.
23. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 2)
(a) Install the No. 2 chain tensioner assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) While raising the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) pin into the hole to fix it in place.
24. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)
HINT
The crankshaft timing gear, camshaft timing gear assembly and camshaft timing exhaust gear assembly will be installed with the No. 1 chain sub-assembly and No. 2 chain sub-assembly connected to the gears.
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.
(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.
(c) Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.
(d) Install the crankshaft timing gear to the crankshaft.
(e) Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly.
(f) Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
(g) Remove the pin from the No. 2 chain tensioner assembly.
25. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)
(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
26. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)
(a) Install the chain tensioner slipper.
HINT
If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.
27. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)
(a) Move the stopper plate upward to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly.
(b) Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the hole of the stopper plate.
(c) Install the No. 1 chain tensioner assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the No. 3 chain tensioner assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) While raising the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) pin into the hole to fix it in place.
29. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)
HINT
The crankshaft timing sprocket, camshaft timing gear assembly and camshaft timing exhaust gear assembly will be installed with the No. 1 chain sub-assembly and No. 2 chain sub-assembly connected to the gears.
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.
(b) Align the No. 1 chain's orange mark plate with the crankshaft timing sprocket's timing mark, and attach the chain to the gear as shown in the illustration.
(c) Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.
(d) Install the crankshaft timing sprocket to the crankshaft.
(e) Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly.
(f) Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
NOTICE:
Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.
(g) Remove the pin from the No. 3 chain tensioner.
30. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)
(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
31. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)
(a) Install the chain tensioner slipper.
HINT
If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner slipper.
32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)
(a) Move the stopper plate upward to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly.
(b) Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the hole of the stopper plate.
(c) Install the No. 1 chain tensioner assembly and gasket with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
33. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY
(a) for Bank 1:
(1) Using a wrench, hold the hexagonal portion of the No. 3 camshaft.
(2) Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.
Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)
(3) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
(b) for Bank 2:
(1) Using a wrench, hold the hexagonal portion of the No. 1 camshaft.
(2) Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.
Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)
(3) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
34. INSPECT NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Temporarily install the crankshaft pulley bolt.
(b) Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.
(c) Remove the crankshaft pulley bolt.
