Part 2

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

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

(a) Check the piston protrusions for each cylinder.

(1) Clean the cylinder block with solvent.

(2) Set the piston of the cylinder to be measured to slightly before TDC.

(b) Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.5 to 3.0 mm (0.098 to 0.118 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head gasket within 3 minutes after applying the seal packing.
* Do not apply engine oil within 2 hours of installation.

(c) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

Bank 1:

NOTICE:
* Be careful of the installation direction.
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder head.

(d) Place the cylinder head on the cylinder block.

NOTICE:
Ensure that no oil is on the mounting surface of the cylinder head.

HINT
The cylinder head bolts are tightened in 3 progressive steps.

(e) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(f) Step 1:

(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps, in the sequence shown in the illustration.

Bank 1:

Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

(g) Step 2:

(1) Mark the cylinder head bolt heads with paint as shown in the illustration.

(2) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

(h) Step 3:

(1) Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.

(2) Check that the painted marks are now facing rearward.

(i) Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.

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

(a) Check the piston protrusions for each cylinder.

(1) Clean the cylinder block with solvent.

(2) Set the piston of the cylinder to be measured to slightly before TDC.

(b) Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.

Bank 2:

Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

(g) Step 2:

(1) Mark the cylinder head bolt heads with paint as shown in the illustration.

(2) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

(h) Step 3:

(1) Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.

(2) Check that the painted marks are now facing rearward.

(i) Install the 2 bolts in the order shown in the illustration.

Bank 2:

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

(j) Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.

20. INSTALL VALVE LASH ADJUSTER ASSEMBLY

(a) Be sure to inspect the valve lash adjuster before installing it Engine Unit.

(b) Install the lash adjusters.

NOTICE:
Install each lash adjuster to the same place it was removed from.

21. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.

(b) Install the valve rocker arms.

NOTICE:
Make sure that the valve rocker arms are installed as shown in the illustration.

22. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.

(b) Install the camshaft and No. 2 camshaft to the camshaft housing.

(c) Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper position and direction.

(d) Uniformly install the 9 bolts in several steps in the order shown in the illustration.

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

23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1)

(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

Standard seal diameter:

3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after the installation.

(b) Uniformly install the camshaft housing, and install the 14 bolts in several steps in the order shown in the illustration.

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

NOTICE:
Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

(c) Uniformly install the 9 bolts in several steps in the order shown in the illustration.

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

NOTICE:
Thoroughly wipe clean any seal packing.

(d) Install 3 new gaskets.

24. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.

(b) Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing.

(c) Confirm the marks and numbers on the camshaft bearing caps and place them each in their proper position and direction.

(d) Uniformly install the 8 bolts in several steps in the order shown in the illustration.

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

25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2)

(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

Standard seal diameter:

5.0 to 5.5 mm (0.197 to 0.217 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after the installation.

(b) Uniformly install the camshaft housing and tighten the 13 bolts in several steps in the order shown in the illustration.

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

NOTICE:
Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

(c) Uniformly install the 8 bolts in several steps in the order shown in the illustration.

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

NOTICE:
Thoroughly wipe clean any seal packing.

(d) Install 3 new gaskets.

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 plates (yellow) of the No. 2 chain 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 flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.

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. 2 chain tensioner.