Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - (Continued)

26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the chain tensioner with the bolt.

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

(b) While pushing in the tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.

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

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

(b) Apply a small amount 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. Install the camshaft timing gear and camshaft timing exhaust gear with the No. 2 chain installed.

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

SST : 09922-10010

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

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

28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the chain tensioner with the bolt.

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

(b) While pushing in the tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.

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

(a) Align the mark plate (yellow) with the timing marks (2 dot mark) of the camshaft timing gears as shown in the illustration.

SST : 09922-10010

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

(e) Remove the pin from the No. 3 chain tensioner.

30. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Install the timing gear set keys and timing gear as shown in the illustration.

31. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the chain vibration damper with the 2 bolts.

Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)

32. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 chain vibration dampers.

33. INSTALL IDLE SPROCKET ASSEMBLY

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

(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 direction.

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

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

34. INSTALL CHAIN SUB-ASSEMBLY

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

NOTICE:
Do not pass the chain over the crankshaft. Rest the chain on top of the crankshaft.

HINT
The chain mark plate is orange.

(b) Turn the camshaft timing gear of bank 1 counterclockwise to tighten the chain between the banks.

NOTICE:
When reusing the idle sprocket, align the inner and outer chain plates with the inner and outer chain plate marks of the sprocket as shown in the illustration and install the chain.

(c) Temporarily install the crankshaft pulley set bolt to the crankshaft.

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

HINT
The chain mark plate is yellow.

(e) Turn the crankshaft clockwise to set it to the bank 1 block bore center line (TDC / compression).

35. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

36. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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

(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 chain tensioner with the 2 bolts.

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

37. INSPECT VALVE TIMING

(a) Remove the lock pin of the chain tensioner. 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.

38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/ Oil Pump) Installation

39. INSTALL WATER PUMP ASSEMBLY Installation

40. 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 Block, Three Bond 1207B or equivalent

Standard seal diameter:

2.0 to 3.0 mm (0.079 to 0.118 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the crankcase within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after the installation.

(b) Install the oil seal retainer with the 6 bolts.

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

NOTICE:
Apply adhesive 1324 to the 2 bolts labeled A.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

41. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(b) Using SST, install the pulley bolt.

SST : 09213-70011

SST : 09330-00021

Torque : 250 Nm (2549 kgf-cm, 184 ft-lbf)

42. INSTALL OIL PAN BAFFLE PLATE NO.1

(a) Temporarily install the 7 bolts.

(b) Tighten the 7 bolts in the order shown in the illustration.

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

43. INSTALL OIL PAN SUB-ASSEMBLY Installation

44. INSTALL OIL STRAINER SUB-ASSEMBLY Installation

45. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Installation

46. INSTALL OIL FILTER ELEMENT Replacement

47. INSTALL OIL FILTER CAP SUB-ASSEMBLY Replacement

48. INSTALL WATER INLET HOUSING Installation

49. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET

(a) Install the engine mounting bracket 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 the installation.

50. POUR ENGINE OIL

HINT
Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.

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

(a) Apply seal packing as shown in the illustration.

Seal packing:

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

NOTICE:
* Remove any oil from the contact surface.
* Install the crankcase within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after the installation.

(b) Install a new gasket to the head cover.

(c) Install the head cover with the 12 bolts in the order shown in the illustration.

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for except bolt A

HINT
Make sure the tightening torque of bolt 1and 11 in correct.

52. INSTALL OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter.

(b) Install the oil control valve filter to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the head cover side) with the oil pipe union.

NOTICE:
Remove any oil from the contact surface.

(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.

NOTICE:
Remove any oil from the contact surface.

(d) Install bolt A to the cylinder head.

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

(e) Tighten the 2 oil pipe union bolts.

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

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

(a) Apply seal packing as shown in the illustration.

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for except bolt A

HINT
Make sure the tightening torque of bolts 1 and 10 is correct.

54. INSTALL NO. 1 OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter.

(b) Install the oil control valve filter to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the head cover side) with the oil pipe union.

(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe union.

NOTICE:
Remove any oil from the contract surface.

(d) Tighten the 2 oil pipe union bolts.

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

55. INSTALL WATER OUTLET

(a) Install 2 new gaskets and a new O-ring.

(b) Apply soapy water to the O-ring.

(c) Install the water outlet with the 2 bolts and 4 nuts.

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

56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Install the 4 camshaft timing oil control valves with the 4 bolts.

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

57. INSTALL VVT SENSOR

(a) Install the 4 VVT sensors with the 4 bolts.

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

58. INSTALL SPARK PLUG

(a) Install the 6 spark plugs.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)