Part 2

2GR-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

HINT
The jiggle valve may be set within 10° of either side of the prescribed position.

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

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

35. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) 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 inlet water and mounting bracket within 15 minutes after installing the chain cover.
* Do not start the engine for at least 2 hours after installation.

(b) Using an E8 "TORX" socket wrench, install the 2 stud bolts.

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

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 the 2 bolts (A) shown in the illustration before tightening the other bolts.

37. INSTALL OIL PAN SUB-ASSEMBLY

(a) Using an E8 "TORX" socket wrench, install the 2 stud bolts.

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 surfaces.
* 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 2 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 2 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 surfaces.
* 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)

40. INSTALL OIL PAN DRAIN PLUG

(a) Install a new oil pan drain plug gasket and the oil pan drain plug.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Install 3 new gaskets as shown in the illustration.

(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

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

Seal packing:

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

NOTICE:
* Remove any oil from the contact surfaces.
* Install the head cover within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

(d) Install the head cover with the 12 bolts and a new seal washer.

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

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

HINT
After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Install 3 new gaskets as shown in the illustration.

(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH.

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

Seal packing:

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

NOTICE:
* Remove any oil from the contact surfaces.
* Install the cylinder head cover sub-assembly LH within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

(d) Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.

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

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

HINT
After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

43. INSTALL OUTLET WATER

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

HINT
Apply soapy water to the O-ring.

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

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.

44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

(b) w/ oil cooler

(1) Install the engine oil level dipstick guide.

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

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

(a) Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration.

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

(b) Install a new gasket to the No. 1 oil cooler bracket.

Text in Illustration

(c) Install the oil cooler pipe with the bolt and 2 nuts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

(d) Install a new gasket to the No. 1 oil pan.

(e) Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

46. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)

(a) Install a new O-ring.

(b) Install the oil cooler assembly with the union bolt.

Torque : 68 Nm (693 kgf-cm, 50 ft-lbf)

(c) Install the No. 4 water by-pass hose with the bolt, hose clamp and 2 clamps.

Text in Illustration

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

HINT
Make sure to install the hose to the upper part of the hose clamp as shown in the illustration.

(d) Install the water pipe sub-assembly and gasket with the 2 nuts and clamp.

Text in Illustration

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

47. INSTALL CRANKSHAFT PULLEY Installation

48. INSTALL OIL FILTER ELEMENT

(a) Clean the inside of the oil filter cap sub-assembly, threads and O-ring groove.

Text in Illustration

(b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap sub-assembly.

(c) Set a new oil filter element to the oil filter cap sub-assembly.

(d) Remove dirt and foreign matter from the installation surface of the engine.

(e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap sub-assembly.

NOTICE:
* Be careful that the O-ring does not get caught between any parts.
* The O-ring must not be twisted on the groove.

(f) Using SST, tighten the oil filter cap sub-assembly.

SST : 09228-06501

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Make sure that the oil filter is installed securely as shown in the illustration.

(g) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

Text in Illustration

NOTICE:
Remove all dirt and foreign matter from the installation surfaces.

(h) Install the oil filter drain plug to the oil filter cap sub-assembly.

Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)

NOTICE:
Make sure that the O-ring does not get caught between the parts.

49. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cock sub-assembly.

Text in Illustration

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the water drain cocks as shown in the illustration.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

50. INSTALL NO. 1 OIL PIPE

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

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

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

Text in Illustration

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

(d) Tighten the oil pipe union (on the head cover side).

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

(e) Tighten the oil pipe union (on the cylinder head side).

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

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

51. INSTALL OIL PIPE

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

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

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

Text in Illustration

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

(d) Install the bolt (A) to the cylinder head.

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

(e) Tighten the oil pipe union (on the head cover side).

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

(f) Tighten the oil pipe union (on the cylinder head side).

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

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

52. INSTALL CRANK POSITION SENSOR Installation

53. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) Installation

54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) Installation

55. INSTALL VVT SENSOR (for Bank 1) Installation

56. INSTALL VVT SENSOR (for Bank 2) Installation

57. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive around the ventilation valve sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve sub-assembly.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

58. INSTALL SPARK PLUG Installation

59. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install a new oil filler gasket.

(b) Install the oil filler cap sub-assembly.