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Installation





2GR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 1): INSTALLATION

1. INSTALL CAMSHAFT BEARING CAP

(a) Apply engine oil to the camshaft journals, camshaft housing sub-assembly RH and camshaft bearing caps.

(b) Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly RH.

(c) Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.





(d) Temporarily tighten the 8 bearing cap bolts in the order shown in the illustration.





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

2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.





(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:

3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing sub-assembly RH within 3 minutes.
* Do not start the engine for at least 2 hours after installing.
(c) Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.





Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

NOTICE:
* When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration.
* Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
* If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing sub-assembly is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
(d) Tighten the 8 bolts in the order shown in the illustration.





Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

3. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 2 chain tensioner assembly with the bolt.





Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(b) While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to fix it.

4. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.





(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH with the No. 2 chain subassembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.





SST : 09922-10010

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the No. 2 chain tensioner assembly.

5. INSTALL IDLE SPROCKET ASSEMBLY Reassembly

6. INSTALL CHAIN SUB-ASSEMBLY Reassembly

7. INSTALL CHAIN TENSIONER SLIPPER Reassembly

8. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly

9. INSTALL TIMING CHAIN CASE OIL SEAL Reassembly

10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Reassembly

11. INSTALL OIL PAN SUB-ASSEMBLY Reassembly

12. INSTALL OIL STRAINER SUB-ASSEMBLY Reassembly

13. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Reassembly

14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) Reassembly

15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) Reassembly

16. INSTALL WATER OUTLET Reassembly

17. INSTALL WATER INLET HOUSING Reassembly

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

19. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) Reassembly

20. INSTALL CRANKSHAFT PULLEY Reassembly

21. INSTALL OIL PIPE Reassembly

22. INSTALL NO. 1 OIL PIPE Reassembly

23. INSTALL CRANKSHAFT POSITION SENSOR Reassembly

24. INSTALL KNOCK CONTROL SENSOR Installation

25. INSTALL KNOCK CONTROL SENSOR WIRE Installation

26. INSTALL NO. 1 VACUUM SWITCHING VALVE Installation

27. INSTALL RADIO SETTING CONDENSER Installation

28. INSTALL NO. 1 ENGINE FRONT MOUNTING BRACKET LH

(a) Install the No. 1 front engine mounting bracket LH with the 6 bolts.





Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

NOTICE:
* 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.
29. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Installation

30. INSTALL NO. 2 TIMING GEAR COVER Installation

31. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation

32. INSTALL GENERATOR ASSEMBLY Installation

33. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET Installation

34. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

35. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

36. INSTALL NO. 2 MANIFOLD STAY Installation

37. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Installation

38. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

39. INSTALL INTAKE MANIFOLD Installation

40. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation

41. INSTALL IGNITION COIL ASSEMBLY Installation

42. REMOVE ENGINE STAND

43. INSTALL ENGINE ASSEMBLY

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