Part 1

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.

(b) Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge.

SST : 09223-15030

SST : 09950-70010

09951-07100

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the engine rear oil seal at an angle.
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.)

NOTICE:
* Remove any oil from the contact surfaces.
* Install the oil seal retainer within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installation.
(b) Install the engine rear oil seal retainer with the 6 bolts.

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

NOTICE:
Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

3. INSTALL WATER INLET PIPE

(a) Install the water inlet pipe with the 2 bolts.

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

(b) Install the No. 1 water by-pass hose.

4. INSTALL CYLINDER HEAD GASKET RH Installation

5. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH Installation

6. INSTALL CYLINDER HEAD GASKET LH Installation

7. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH Installation

8. INSTALL VALVE STEM CAP Installation

9. INSTALL VALVE LASH ADJUSTER ASSEMBLY Installation

10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Installation

11. INSTALL NO. 3 CAMSHAFT Installation

12. INSTALL NO. 4 CAMSHAFT Installation

13. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation

14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Installation

15. INSTALL CAMSHAFT Installation

16. INSTALL NO. 2 CAMSHAFT Installation

17. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation

18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Installation

19. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Installation

20. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) Installation

21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Installation

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

23. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.

Torque : 23 Nm (230 kgf-cm, 17 ft-lbf)

24. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 No. 2 chain vibration dampers.

25. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the 2 keys and crankshaft timing sprocket as shown in the illustration.

26. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

Text in Illustration:

(b) Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

NOTICE:
Be careful of the idle gear installation position.

HINT
Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.

(c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

HINT
After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.

27. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plates and timing marks as shown in the illustration and install the chain.

Text in Illustration:

HINT
The camshaft mark plates are orange.

(b) Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.

NOTICE:
When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

(d) Align the mark plate and timing marks as shown in the illustration and install the chain onto the crankshaft timing sprocket.

Text in Illustration:

HINT
The crankshaft mark plate is yellow.

(e) Temporarily tighten the pulley set bolt.

(f) Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

Text in Illustration:

28. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

Text in Illustration:

(b) Move the stopper plate downward to set the lock, and insert a 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.

30. INSPECT VALVE TIMING

(a) Check the camshaft timing marks.

NOTICE:
* Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.
* If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
(b) Check that each camshaft timing mark is positioned as shown in the illustration.

HINT
For the intake camshaft:

Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

(c) If the valve timing is misaligned, reinstall the timing chain.

(d) Remove the pulley set bolt.

31. INSTALL WATER PUMP ASSEMBLY

(a) Install a new water pump gasket and the water pump assembly with the 8 bolts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

NOTICE:
Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

32. INSTALL TIMING CHAIN CASE OIL SEAL Installation

33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

34. INSTALL WATER INLET HOUSING

(a) Install 2 new O-rings.

HINT
Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.

(b) Install the 2 stud bolts.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(c) Install the water inlet housing with the 2 bolts and nut.

Text in Illustration:

Torque : 10 Nm (102 kgf-cm, 7 ft-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 assembly to the water inlet housing.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

(g) Install the drain cock plug to the drain cock assembly.

Torque : 13 Nm (130 kgf-cm, 9 ft-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 position.

(j) Install the water inlet with the 2 nuts.

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

35. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) When replacing 2 stud bolts, install them by using an E8 "TORX" socket wrench.

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

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

Torque : 54 Nm (550 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.
36. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate with the 7 bolts.

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

HINT
Temporarily tighten the 7 bolts. Fully tighten 2 bolts (A) shown in the illustration before tightening the other bolts.

37. INSTALL OIL PAN SUB-ASSEMBLY

(a) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.

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

Bolt B - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Install 2 new O-rings.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:
* 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.
(d) Install the oil pan with the 16 bolts and 2 nuts.

Text in Illustration:

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

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

38. 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, 35 in-lbf)

(b) Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

Text in Illustration:

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

39. 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, 35 in-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 0.157 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(c) Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

Text in Illustration:

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