Part 1

2GR-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL REAR ENGINE OIL SEAL

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

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

SST : 09223-15030

SST : 09950-70010

09951-07100

Oil seal tap in depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196)

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the rear engine oil seal at an angle.
2. INSTALL REAR ENGINE 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 rear engine 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 rear engine 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 INLET WATER PIPE

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

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

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

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.

Text in 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 TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge.

SST : 09223-22010

SST : 09506-35010

Oil seal tap in depth:

-1.0 to 1.0 mm (-0.0393 to 0.0393)

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.
* Make sure that the oil seal edge does not stick out of the timing chain case.
32. 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.

33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove any old packing material remaining on the sealing surfaces before applying seal packing.

(b) Clean and degrease the contact surfaces of the timing chain cover, cylinder head and cylinder block, and confirm that no oil, moisture, or other foreign matter remains on the surfaces.

(d) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing:

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

Seal diameter:

3.0 mm (0.118 in.)

NOTICE:
* When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
* Do not add engine oil for at least 2 hours after installing the chain cover.
* Do not start the engine for at least 2 hours after installing the chain cover.
(e) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Seal packing:

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

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

NOTICE:
* If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

Seal Packing Application Chart

(f) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Text in Illustration

(g) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Bolt Length

NOTICE:
Make sure that there is no oil on the bolt and nut threads.

(h) Fully tighten the 2 bolts.

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

(i) Fully tighten the 2 bolts.

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

(j) Fully tighten the 7 bolts and 2 nuts.

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

HINT
First tighten the upper bolts and nuts followed by lower bolts and nuts as shown in the illustration.

(k) Fully tighten the 12 bolts.

Bolt A - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

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

HINT
Tighten the bolts in the order of lower to upper as shown in the illustration.

(l) Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.

Torque : 9.1 Nm (93 kgf-cm, 81 in-lbf)