Part 1

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. REASSEMBLY CYLINDER HEAD SUB-ASSEMBLY
Refer to the procedures up to "REASSEMBLY CYLINDER HEAD" Reassembly.
2. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Stud bolt A - Torque: 11 Nm (112 kgf-cm, 8.1 ft-lbf)
Stud bolt B - Torque: 4.5 Nm (46 kgf-cm, 40 in-lbf)
Stud bolt C - Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
Stud bolt D - Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

3. INSTALL STRAIGHT PIN
(a) Using a plastic-faced hammer, tap in a new straight pin.
Standard protrusion:
Pin A
22.5 to 23.5 mm (0.886 to 0.925 in.)
Pin B
10.5 to 11.5 mm (0.413 to 0.453 in.)
Pin C
8.5 to 9.5 mm (0.335 to 0.374 in.)
Pin D
5.5 to 6.5 mm (0.217 to 0.256 in.)

4. INSTALL TIGHT PLUG
(a) Apply adhesive around new tight plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or the equivalent
(b) Using SST, install the tight plugs as shown in the illustration.
SST: 09550-60010
09951-00350
SST: 09950-70010
09951-07150
Standard depth:
0.2 to 1.2 mm (0.008 to 0.047 in.)

5. INSTALL OIL JET
(a) Using a screw driver and hammer, tap in the oil jet.

6. INSTALL NO. 1 SUB-ASSEMBLY OIL NOZZLE
(a) Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

7. INSTALL HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring onto the side of the piston pin hole.
HINT: Check that the end gap of the snap ring does not overlap with the pin hole cutout portion of the piston.

8. INSTALL WITH PIN PISTON SUB-ASSEMBLY

(a) Gradually heat the piston to about 80°C (176°F).

(b) Coat the piston pin with engine oil.
(c) Align the front marks of the piston and connecting rod, and push in the piston pin with a thumb.

9. INSTALL HOLE SNAP RING
(a) Using a small screwdriver, install a new snap ring onto the other side of the piston pin hole.
HINT: Make sure that the gap in the snap ring does not overlap with the pin hole cutout portion of the piston.

10. INSTALL PISTON RING SET

(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression rings.
NOTE: Install compression ring No. 2 with the painted mark facing upward.

11. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
NOTE: Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oil.

12. INSTALL CRANKSHAFT BEARING

HINT: There are 2 types of main bearings with different widths (19.0 mm (0.748 in.) and 22.4 mm (0.882 in.)) for use in the inspection. Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.

(a) Clean each main journal and bearing.

(b) Install the 4 upper bearings.
(1) Install the upper bearings near the center of the cylinder block.
NOTICE:
- The widths of the No. 1 and No. 4 journal bearings are different from those of the No. 2 and No. 3 journal bearings. Therefore, confirm the identity of each journal bearing prior to installation.
- Do not apply engine oil to the bearing installation surfaces of the cylinder block and the back side of the bearings.
- Check that the oil groove on the cylinder block can be seen through the oil supply holes of the upper bearing.

(c) Install the 4 lower bearings.
(1) Install the lower bearings near the center of the cylinder block.
NOTE: Do not apply engine oil to the bearing or its contact surface.
HINT: The number marked on each main bearing cap indicates the installation position.

13. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.

(b) Install the 2 upper thrust washers onto the No. 2 journal position of the cylinder block.
(1) Push the crankshaft toward the front (rear) side.
(2) Install the 2 upper thrust washers with the oil grooves facing outward.

(d) Examine the front marks and numbers, check the sequence number is as shown in the illustration and install the bearing caps on the cylinder block.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.
(f) Temporarily install the 8 main bearing cap bolts in the inside positions.

(g) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block is under 6 mm (0.23 in.).

(h) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(i) Apply a light coat of engine oil to the threads of the main bearing cap bolts.

(j) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft-lbf)

(k) Mark the front side of the bearing cap bolts with paint.
(l) Retighten the bearing cap bolts 90° in the sequence as shown.
(m) Check that the painted marks are now at a 90° angle from the front.
(n) Check that the crankshaft turns smoothly.

(o) Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
14. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correct number piston and connecting rod into each cylinder with the front mark of the piston facing forward.
NOTICE:
- Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oil.
- Match the numbered connecting rod cap with the connecting rod.

(d) Check that the protrusion of the connecting rod cap is facing in the correct direction.
(e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

(f) Tighten the bolts alternately to the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)

(g) Mark the front side of the each connecting cap bolt with paint.
(h) Retighten the cap bolts 90° as shown.
(i) Check that the crankshaft turns smoothly.
15. INSTALL REAR ENGINE OIL SEAL RETAINER
(a) Remove any old packing material and oil from the contact surfaces of the oil seal retainer and cylinder block.

(b) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent
NOTE: Parts must be assembled within 3 minutes of application. Otherwise, the seal packing must be removed and reapplied.

(c) Install the oil seal retainer with the 5 bolts and 2 nuts.
Nut - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Bolt - Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)

16. INSTALL KNOCK SENSOR
(a) Install the 2 knock sensors with the 2 bolts as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
(b) Connect the knock sensor connectors.
(c) Install the knock sensor wire.

17. INSTALL NO. 1 WATER OUTLET PIPE
(a) Install the water outlet pipe with the 3 bolts.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
18. INSTALL CYLINDER HEAD GASKET
(a) Remove any old packing material and oil from the contact surfaces of the cylinder head and cylinder block.

(b) Apply a continuous bead of seal packing (diameter 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent
NOTE: Install the cylinder head within 3 minutes of applying the seal packing. After installation, cylinder head bolts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE :
- Install the cylinder head gasket in the correct direction.
- Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

19. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Place the cylinder head RH on the cylinder head gasket.
(b) Install the 8 cylinder head bolts.
HINT:
- The cylinder head bolts are tightened in 2 successive steps (steps (*1), (*2) and (*3)).
- If any cylinder head bolts are broken or deformed, replace them.
(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(2) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft-lbf)
If any cylinder head bolts do not meet the torque specification, replace them.
NOTE: Do not drop the washers into the cylinder head.

(3) Mark the front of the cylinder head bolt with paint. (*1)
(4) Retighten the cylinder head bolts by 180° as shown. (*2)
(5) Check that the painted marks are now at 180° from the engine front. (*3)
20. INSTALL NO. 2 CYLINDER HEAD GASKET
(a) Remove any old packing material and oil from the contact surfaces of the cylinder head and cylinder block.

(b) Apply a continuous bead of seal packing (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent
NOTE: Install the cylinder head within 3 minutes of applying the seal packing. After installation, cylinder head bolts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE :
- Be careful of the installation direction.
- Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

21. INSTALL CYLINDER HEAD LH
(a) Place the cylinder head LH on the cylinder head gasket.
(b) Install the 8 cylinder head bolts.
HINT:
- The cylinder head bolts are tightened in 2 successive steps (steps (*4), (*5) and (*6)).
- If any cylinder head bolts are broken or deformed, replace them.
(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(2) Using several steps, uniformly install and tighten the 8 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft-lbf)
If any cylinder head bolts do not meet the torque specification, replace them.
NOTE: Do not drop the washers into the cylinder head.

(3) Mark the front of the cylinder head bolt with paint. (*4)
(4) Retighten the cylinder head bolts by 180° as shown. (*5)
(5) Check that the painted marks are now at 180° from the engine front. (*6)

(c) Install the 2 cylinder head bolts.
(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(2) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)

22. INSTALL NO. 1 CAMSHAFT BEARING
(a) Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.
NOTICE:
- Install the bearing while aligning it with the oil hole in the bearing cap.
- Clean the back side of the bearing and the surface of the bearing cap and keep them free of oil.

23. INSTALL NO. 2 CAMSHAFT BEARING
(a) Install the No. 2 camshaft bearing onto the cylinder head.
NOTE: Clean the back side of the bearing and the bearing surface of the cylinder head and keep them free of oil.

24. INSTALL CAMSHAFTS
NOTE: Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust force. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.

(a) Set the crankshaft position.
(1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key in the left horizontal position as indicated.
NOTE: Setting the crankshaft at the wrong angle could cause the piston head and valve head to come into contact with each other when the camshaft is installed. This could cause damage, so always set the camshaft at the correct angle.

(b) Apply new engine oil to the thrust portion and journal of the camshafts.
(c) Install the camshafts of bank 1.

(1) Place the 2 camshafts on the cylinder head RH with the No. 1 cam lobes facing as shown the illustration.

(2) Install the 8 bearing caps in their correct locations.
(3) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(4) Using several steps, uniformly tighten the 16 bearing cap bolts in the sequence shown in the illustration.
10 mm (0.39 in.) head - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
12 mm (0.47 in.) head - Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)

(5) Using a wrench, turn the camshafts clockwise until each camshaft knock pin comes to a position 90° to the cylinder head.
(d) Install the camshafts of bank 2.

(1) Place the 2 camshafts on the cylinder head LH with the No.1 cam lobes facing as shown the illustration.

(2) Install the 8 bearing caps in the correct locations as shown.
(3) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(a) While pushing in the tensioner, insert a pin of dia 1.0 mm (0.039 in.) into the hole to fix it.

(b) Install chain tensioner No. 2 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
26. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) Align the yellow mark links with the timing marks (1 dot mark) of camshaft timing gears as shown in the illustration.

(b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain onto the bank 1 camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.
NOTE: Do not push the camshaft timing gear assembly onto the camshaft forcibly when installing it.

(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(e) Remove the pin from chain tensioner No. 2.
27. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) While pushing in the tensioner, insert a pin of dia 1.0 mm (0.039 in.) into the hole to hold it.

(b) Install chain tensioner No. 3 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
28. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) Align the yellow mark links with the timing marks (1 dot mark and 2 dot marks) on the camshaft timing gears as shown in the illustration.

(b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain onto the bank 2 camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.
NOTE: Do not push the camshaft timing gear assembly onto the camshaft forcibly when installing it.

(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(e) Remove the pin from chain tensioner No. 3.

29. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install chain vibration damper No. 1 with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)

30. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Align the timing gear set key with the key groove of the timing gear.
(b) Install the timing gear onto the crankshaft with the gear side facing inward.
31. INSTALL CHAIN TENSIONER SLIPPER

32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of dia 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
33. INSTALL CHAIN SUB-ASSEMBLY

(a) Set the No. 1 cylinder to TDC/ compression.
(1) Align the timing marks of the camshaft timing gears and bearing caps.

(2) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

(b) Align the yellow mark link with the timing mark of the crankshaft timing gear.

34. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Instal the 2 No. 2 chain vibration dampers.