Part 1
2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, install the 3 oil nozzles with the bolts.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
2. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the 2 drain cocks.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the water drain cocks as shown in the illustration.
Torque : 30 Nm (306 kgf-cm, 22 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)
3. INSTALL PISTON WITH PIN SUB-ASSEMBLY
(a) Using a screwdriver, install a new snap ring at one end of the piston pin hole.
HINT
Be sure that the end gap of the snap ring is not aligned with the service hole of the piston.
(b) Gradually heat the piston to approximately 80°C (176°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
Front Mark:
HINT
The piston and pin are a matched set.
(e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
(f) Using a screwdriver, install a new snap ring at the other end of the piston pin hole.
HINT
Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
4. INSTALL PISTON RING SET
(a) Install the oil ring expander by hand.
(b) Using a piston ring expander, install the 2 oil ring rails as shown in the illustration.
(c) Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.
HINT
* Install the compression ring No. 1 with the code mark (1N) facing upward.
* Install the compression ring No. 2 with the code mark (2N) facing upward.
(d) Position the piston rings so that the ring ends are as shown in the illustration.
NOTICE:
Do not align the ring ends.
5. INSTALL CRANKSHAFT BEARING
(a) Clean the main journal and both surfaces of the bearing.
NOTICE:
Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.
(b) Install the upper bearing.
(1) Install the upper bearing to the cylinder block as shown in the illustration.
NOTICE:
* Do not apply engine oil to the bearings and the contact surfaces.
* Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.
* Do not allow coolant to come into contact with the bearing inner surface.
* If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
(c) Install the lower bearing.
(1) Install the lower bearings to the bearing caps.
(2) Using a vernier caliper, measure the distance between the bearing cap's edge and the lower bearing's edge.
Dimension (A - B):
0.7 mm (0.0276 in.) or less.
NOTICE:
* Do not apply engine oil to the bearings and the contact surfaces.
* Do not allow coolant to come into contact with the bearing inner surface.
* If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
6. INSTALL CRANKSHAFT
(a) Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
(b) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.
(c) Confirm the front marks and numbers of the main bearing caps and install the bearing caps on the cylinder block.
HINT
A number is marked on each main bearing cap to indicate the installation position.
(d) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(e) Temporarily install the 8 main bearing cap bolts to the inside positions.
(f) Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
Bolt length:
100 to 102 mm (3.94 to 4.02 in.)
(g) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(h) Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.
(i) Install the 8 main bearing cap bolts to the outside positions.
Both length:
(j) Install the crankshaft bearing cap bolts.
HINT
The main bearing cap bolts are tightened in 2 progressive steps.
(k) Step 1:
(1) Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque : 61 Nm (622 kgf-cm, 45 ft-lbf)
If any of the main bearing cap bolts does not meet the specified torque, replace it.
(l) Step 2:
(1) Mark the front of the bearing cap bolts with paint.
(2) Tighten the bearing cap bolts another 90° in the order shown in step 1.
(3) Check that the painted marks are now at a 90° angle to the front.
(m) Check that the crankshaft turns smoothly.
(n) Install and uniformly tighten the 8 main bearing cap bolts in several steps, in the sequence shown in the illustration.
Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)
Bolt length:
(o) Check that the crankshaft turns smoothly.
7. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearing to the connecting rod and bearing cap.
(b) Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges, and each connecting rod bearing's edge.
Dimension (A - B):
0.7 mm (0.028 in.) or less
NOTICE:
Do not apply engine oil to the bearing's contact area and underside.
8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
(b) Position the piston rings so that the ring ends are as shown in the illustration.
NOTICE:
Do not align the ring ends.
(c) Using a piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connecting rod.
Front mark:
(d) Check that the front mark of the connecting rod cap is facing forward.
(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(f) Install the connecting rod cap bolts.
HINT
The connecting rod cap bolts are tightened in 2 progressive steps.
(g) Step 1:
(1) Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
(h) Step 2:
(1) Mark the front side of each connecting rod cap bolt with paint.
(2) Tighten the cap bolts another 90° in the order in step 1.
(3) Check that the painted marks are now at a 90° angle to the front.
(i) Check that the crankshaft turns smoothly.
9. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
10. INSTALL NO. 2 STRAIGHT SCREW PLUG
(a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)
11. INSTALL NO. 1 STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 straight screw plugs.
Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
12. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.
13. INSTALL VALVE STEM OIL SEAL
(a) Apply a light coat of engine oil to new oil seals.
NOTICE:
Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.
HINT
The intake valve oil seals are gray and the exhaust valve oil seals are black.
(b) Using SST, push in the oil seals.
SST : 09201-41020
NOTICE:
Failure to use SST will cause the seal to be damaged or improperly seated.
14. INSTALL INTAKE VALVE
(a) Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination to original locations.
(c) Using SST and wooden blocks, compress the spring and install the retainer lock.
SST : 09202-70020
09202-00010
(d) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the retainer.
15. INSTALL EXHAUST VALVE
(a) Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.
NOTICE:
Install the same parts in the same combination to their original locations.
(c) Using SST and wooden blocks, compress the spring and install the retainer lock.
SST : 09202-70020
09202-00010
(d) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTICE:
Be careful not to damage the retainer.
16. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the valve stem caps to the cylinder head.
17. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY
(a) Install the water outlet pipe with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)