Part 2

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (Continued)

22. 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.

23. INSTALL EXHAUST VALVE

(a) Apply a sufficient coat 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 the original locations.

(c) Using SST, compress the spring and install the 2 retainer locks.

SST : 09202-70020

09202-00010

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:
Be careful not to damage the retainer.

24. INSTALL INTAKE VALVE

(a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.

SST : 09202-70020

09202-00010

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:
Be careful not to damage the retainer.

25. INSTALL VALVE STEM CAP

(a) Apply a light coat of engine oil to the valve stem caps.

(b) Install the valve stem caps on the valves.

26. INSTALL ENGINE REAR OIL SEAL

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

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

SST : 09223-15030

SST : 09950-70010

09951-07100

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.

27. 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

Seal diameter:

2.0 to 3.0 mm (0.079 to 0.118 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the 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 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

28. 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)

29. INSTALL KNOCK SENSOR

(a) Install the 2 knock sensors with the 2 bolts as shown in the illustration.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(b) Connect the 2 knock sensor connectors.

(c) Connect the knock sensor wire clamp.

30. INSTALL CYLINDER BLOCK WATER JACKET SPACER RH

(a) Install the water jacket spacer as shown in the illustration.

HINT
Be sure to face the slope to the front of the engine.

31. INSTALL CYLINDER BLOCK WATER JACKET SPACER LH

(a) Install the water jacket spacer as shown in the illustration.

HINT
Be sure to face the slope to the front of the engine.

32. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

(a) 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

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.

(b) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

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 head.

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

NOTICE:
Be careful not to allow oil to adhere to the bottom part of the cylinder head.

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

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

(e) 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 and in the sequence shown in the illustration.

Right:

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

(f) Step 2

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

(2) Tighten the cylinder head bolts another 90°.

(g) Step 3

(1) Tighten the cylinder head bolts by an additional 90°.

(2) Check that the painted mark is now facing rearward.

(h) Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

33. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

(a) Apply a continuous line of the 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

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 start the engine for at least 2 hours after installing.

(b) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

Left:

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

(f) Step 2

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

(2) Tighten the cylinder head bolts by 90°.

(g) Step 3

(1) Tighten the cylinder head bolts by an additional 90°.

(2) Check that the painted mark is now facing rearward.

(h) Tighten the 2 bolts in the order shown in the illustration.

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

(i) Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

34. INSTALL VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
* Keep the lash adjuster free of dirt and foreign objects.
* Only use clean engine oil.

(a) Place the lash adjuster into a container filled with engine oil.

(b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

SST : 09276-75010

(c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.

(d) Check the movement of the plunger and bleed the air.

OK:

Plunger moves up and down.

NOTICE:
When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

(e) After bleeding the air, remove SST. Then, try to quickly and firmly press the plunger with a finger.

OK:

Plunger is very difficult to move.

If the result is not as specified, replace the lash adjuster.

(f) Install the lash adjusters.

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

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

(a) Apply engine oil to the lash adjuster tip and valve stem cap end.

(b) Make sure that the valve rocker arms are installed as shown in the illustration.

36. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

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

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

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

(d) Temporarily tighten the 9 bolts in the order shown in the illustration.

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

37. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Make sure that the valve rocker arm is installed as shown in the illustration.

(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:

3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing sub-assembly RH within 3 minutes.
* Do not start the engine for at least 2 hours after installing.

(c) Install the camshaft housing RH and tighten the 14 bolts in the order shown in the illustration.

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

NOTICE:
* When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
* If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

(d) Tighten the 9 bolts in the order shown in the illustration.

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

38. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

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

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

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

(d) Temporarily tighten the 8 bolts in the order shown in the illustration.

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

39. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Make sure that the valve rocker arm is installed as shown in the illustration.

(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:

3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing sub-assembly LH within 3 minutes.
* Do not start the engine for at least 2 hours after installing.

(c) Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration.

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

NOTICE:
* When installing the camshaft housing LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
* If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.

(d) Tighten the 8 bolts in the order shown in the illustration.

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

40. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 2 chain tensioner with the bolt.

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

(b) While pushing in the tensioner, insert a pin of dia 1.0 mm (0.039 in.) into the hole to fix it.

41. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.

(b) Apply a light coat 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 RH 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 (1,020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the chain tensioner.

42. 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 dia 1.0 mm (0.039 in.) into the hole to hold it.

43. 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 light coat 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 LH 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 chain tensioner.

44. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the chain vibration damper with the 2 bolts.

Torque : 23 Nm (230 kgf-cm, 17 ft-lbf)

45. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 chain vibration dampers.

46. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the 2 timing gear set keys and timing gear as shown in the illustration.

47. 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 with the knock pin groove of the cylinder block.

NOTICE:
Make sure that the idle gear is facing the correct direction.

HINT
Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.

(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.