Part 2

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY (Continued)

35. INSTALL NO. 1 IDLE GEAR
(a) Apply a light coat of engine oil to the rotating surface of idle gear shaft No. 1.

(b) Temporarily install idle gear shaft No. 1 together with idle gear shaft No. 2 while aligning the knock pin of idle gear shaft No. 1 with the knock pin groove of the cylinder block.
NOTE: Install the idle gear in the correct direction.

(c) Using a 10 mm hexagon wrench, tighten idle gear shaft No. 2.
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
(d) Remove the bar from the chain tensioner.
36. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Remove any old packing material and oil from the contact surfaces of the timing chain cover, cylinder head and cylinder block.

(b) Install a new O-ring onto the cylinder head LH as shown in the illustration.

(c) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the timing chain cover as shown in the illustration.
Seal packing:
Water pump part
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or the equivalent
Other parts
Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent

NOTICE :
- Install the timing chain cover within 3 minutes of applying the seal packing. After installation, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.
- Do not apply seal packing to A as shown in the illustration.

(d) Keep the seal surface between the cylinder block and the cylinder head shown in the illustration free of oil before installing the chain cover.

(e) Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.

(f) Install the timing chain cover with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)

NOTICE :
- Do not wrap the chain and slipper beyond the timing chain cover seal line.
- After installing the timing chain cover, install the water pump within 15 minutes.
HINT: Each bolt length is as follows:

(g) Install the timing chain cover plate with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

37. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 17 bolts.
Bolt A - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Bolt B - Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
38. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and oil from the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

(b) Install the 4 stud bolts.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

(d) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent
NOTE: Install the oil pan within 3 minutes of applying the seal packing. After installation, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(e) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
10 mm (0.39 in.) head - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
12 mm (0.47 in.) head - Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)
HINT: Each bolt length is as follows:

39. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Install a new gasket, then install the oil strainer with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
40. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the No. 2 contact surfaces of the oil pan and oil pan.

(b) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent
NOTE: Install the No. 2 oil pan within 3 minutes of applying the seal packing. After installation, the No. 2 oil pan bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(c) Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Bolt - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Nut - Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
41. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)

42. INSTALL CRANKSHAFT PULLEY
(a) Using SST, fix the pulley and tighten the bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 185 ft-lbf)
43. SET NO. 1 CYLINDER TO TDC/COMPRESSION
44. INSPECT VALVE CLEARANCE
45. ADJUST VALVE CLEARANCE
46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material and oil from the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
(b) Install the gasket onto the cylinder head cover.

(c) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent
NOTE: Install the cylinder head cover within 3 minutes of applying the seal packing. After installation, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

(d) Install the seal washers onto the bolts.

(e) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Bolt A - Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
Bolt B - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Nut - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
HINT: Each bolt length is as follows:

47. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove any old packing material and oil from the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
(b) Apply adhesive to the threads of the ventilation valve.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or the equivalent
(c) Install the ventilation valve onto the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
(d) Install the gasket onto the cylinder head cover.

(e) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent
NOTE: Install the cylinder head cover of 3 minutes of applying the seal packing. After installation, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(f) Install the seal washers onto the bolts.

(g) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Bolt A - Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
Bolt B - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Nut - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
HINT: Each bolt length is as follows:

48. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign objects on the mesh part of the 2 filters.
(b) Install a new gasket onto each new plug.
(c) Insert the filters into the plugs.
(d) Apply adhesive to 2 or 3 threads of the plugs.
Adhesive:
Part No. 08833-00080, THREE BOND 1344 LOCTITE 242 or the equivalent
(e) Install the plugs onto each cylinder head.
Torque: 62 Nm (632 kgf-cm, 46 ft-lbf)

49. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)

50. INSTALL VVT SENSOR
(a) Apply a light coat of engine oil to the O-ring of each VVT sensor.
(b) Install the 2 VVT sensors with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
51. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the drain cock ends.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or the equivalent

(b) Tighten the drain cocks to the specified torque, and rotate them clockwise as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE :
- Do not rotate the drain cocks more than 1 complete revolution (360°) after tightening the drain cocks to the specified torque.
- Do not loosen the drain cocks after setting them correctly.

52. INSTALL OIL LEVEL GAUGE GUIDE
(a) Install a new O-ring onto the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push the oil level gauge guide end into the guide hole of the oil pan.
(d) Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
53. INSTALL SPARK PLUG
(a) Using a spark plug wrench, install the 6 spark plugs.
Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)
54. INSTALL WATER INLET

(a) Install a new gasket onto the timing chain cover.
(b) Install a new O-ring onto the water by-pass outlet pipe.

(c) Install the water inlet with the 5 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
55. INSTALL WATER BY-PASS HOSE
(a) Install the water by-pass hose with the 2 clamps.
56. INSTALL NO. 2 WATER BY-PASS HOSE
(a) Install the No. 2 water by-pass hose with the 2 clamps.
57. INSTALL NO. 3 WATER BY-PASS HOSE
(a) Install the No. 3 water by-pass hose with the 2 clamps.

58. INSTALL WITH THERMOSTAT WATER INLET SUB-ASSEMBLY
(a) Install a new O-ring and the water inlet with thermostat with the 3 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
59. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

(a) Install the 2 stud bolts.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
(b) Install a new gasket.

60. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or the equivalent.
(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
61. INSTALL OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)

62. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Clean the oil filter contact surface on the oil filter bracket.
(b) Apply clean engine oil to the rubber gasket of a new oil filter.
(c) Tighten the oil filter by hand until the rubber gasket comes into contact with the seat of the filter bracket.
(d) Using SST, tighten it an additional 3/4 turn to set the oil filter.
SST: 09228-07501
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)

63. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2)
(a) Install the camshaft timing oil control valve bank 2 with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

64. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1)
(a) Install the camshaft timing oil control valve bank 1 with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
65. INSTALL WATER BY-PASS JOINT RR

(a) Install a new O-ring onto the water outlet pipe.
(b) Install the 2 gaskets onto the bank 1 and bank 2 cylinder heads.

66. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install the engine coolant temperature sensor with a new gasket.
Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)

67. INSTALL ENGINE HANGERS
(a) Install engine hanger No. 1 with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
(b) Install engine hanger No. 2 with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)