Part 3

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

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.

(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 LH.

SST : 09922-10010

Torque : 100 Nm (1,020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the No. 2 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, just put it on it.

HINT
The chain mark plate is orange.

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

NOTICE:
If reusing the idle sprocket, align one of the idle sprocket's chain plate marks with one of the chain's chain plates when installing the idle sprocket.

(c) 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.

(d) Temporarily tighten the pulley set bolt.

(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)

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

37. 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.

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 Black, Three Bond 1207B or equivalent

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 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

09213-70020

SST : 09330-00021

Torque : 250 Nm (2,549 kgf-cm, 184 ft-lbf)

42. INSTALL OIL PAN BAFFLE PLATE NO.1

(a) Temporarily install the oil pan baffle plate with the 8 bolts.

(b) Tighten the 2 bolts labeled A in the illustration.

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

(c) Tighten the remaining 6 bolts.

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

43. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the 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 with the 3 nuts.

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

(c) Install 2 new O-rings.

44. INSTALL OIL PAN SUB-ASSEMBLY

(a) When replacing a stud bolt, install it by using an E6 "TORX" socket wrench.

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 Block, Three Bond 1207B or equivalent

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.156 in.)

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

(c) Install the oil pan with the 16 bolts and 2 nuts.

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

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

45. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(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:

4.0 to 6.0 mm (0.156 to 0.236 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan No. 2 within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after the installation.

(b) Install the oil pan with the 15 bolts and 2 nuts.

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

(c) Install a new gasket and the drain plug.

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

46. INSTALL OIL FILTER ELEMENT Replacement

47. INSTALL OIL FILTER CAP SUB-ASSEMBLY

48. 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 14 bolts.

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

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

49. 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 bolt except A

50. INSTALL REAR WATER BY-PASS JOINT

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

(b) Install the water by-pass joint with the 2 bolts and 4 nuts.

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

NOTICE:
Be careful that the O-ring does not get caught between the parts.

51. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

(a) Install a new gasket and water inlet thermostat with the 3 nuts.

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

52. INSTALL WATER INLET

(a) Install the 3 water by-pass hoses.

(b) Install 2 new O-rings.

HINT
Apply a small amount of water or soapy water to O-ring (A) in the illustration before installing it.

(c) Install the water inlet with the 4 bolts and nut.

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

NOTICE:
Be careful that the O-ring does not get caught between the parts.

(d) Install the 3 water by-pass hoses.

53. 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).

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

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

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

(e) Tighten the oil check valve bolt (on the cylinder head side).

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

NOTICE:
If the link that connects the gasket is broken, remove the connecting link by using nippers or similar tools.

54. INSTALL NO. 2 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).

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

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

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

(e) Tighten the oil check valve bolt (on the cylinder head side).

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

NOTICE:
If the link that connects the gasket is broken, remove the connecting link by using nippers or similar tools.

55. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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

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

56. INSTALL VVT SENSOR

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

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

57. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive around the ventilation valve.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve.

Torque : 27 Nm (275 kgf-cm, 18 ft-lbf)

58. INSTALL SPARK PLUG

(a) Install the 6 spark plugs.

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

59. INSTALL RADIATOR CAP SUB-ASSEMBLY

(a) Install the radiator cap.