Part 1

2UR-GSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY

(a) Apply a light coat of engine oil to a new O-ring.

(b) Install the new O-ring to the oil drain pipe sub-assembly.

(c) Install the oil drain pipe sub-assembly with the bolt.

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

2. 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 (0.0787 to 0.118 in.)

Application position from inside edge of retainer:

3.5 mm (0.138 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil seal retainer.
* When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is not damaged.
* When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is folded correctly.

(b) Install the engine rear oil seal retainer with the 6 bolts.

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

3. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Apply a light coat of engine oil to a new O-ring.

(b) Install the new O-ring to the oil strainer sub-assembly.

(c) Install the oil strainer sub-assembly with the 2 bolts.

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

NOTICE:
Make sure that the O-ring is not twisted or damaged.

4. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate with the 8 bolts.

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

5. INSTALL OIL PAN SUB-ASSEMBLY

(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.)

Application position from inside edge of oil pan:

6.0 mm (0.236 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.

(b) Install the oil pan sub-assembly with the 14 bolts and 2 nuts.

Bolt A - Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

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

Nut - Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

6. 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 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 No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.

(b) Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts.

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

7. INSTALL VENTILATION PIPE GASKET

(a) Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.

SST : 09950-60010

09951-00360

SST : 09950-70010

09951-07100

HINT
* Do not tap the ventilation pipe gasket at an angle.
* Do not tap the ventilation pipe gasket excessively.

8. INSTALL HEAT EXCHANGER ASSEMBLY

(a) Apply seal packing in a continuous line as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1282B, Three Bond 1282B 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.

(b) Install the heat exchanger assembly with the 11 bolts and 2 nuts.

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

NOTICE:
* Install the No. 1 heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the cover.

(c) Install the bolt.

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

9. INSTALL CYLINDER BLOCK WATER JACKET SPACER

(a) Install the 2 cylinder block water jacket spacers as shown in the illustration.

HINT
* Face the cutouts away from the center of the engine.
* Face each "Up" mark as shown in the illustration.

10. INSTALL NO. 2 CYLINDER HEAD GASKET (for Bank 1) Installation

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

12. INSTALL CYLINDER HEAD GASKET (for Bank 2) Installation

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

14. INSTALL VALVE ROCKER ARM PIVOT

(a) Install the 32 valve rocker arm pivots to the cylinder head assembly.

Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

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

(a) Apply engine oil to the valve rocker arm pivot and valve adjusting shim.

(b) Install the 32 No. 1 valve rocker arm sub-assembly on the cylinder heads.

(c) Make sure that the 32 No. 1 valve rocker arm sub-assembly are installed as shown in the illustration.

16. INSTALL NO. 3 CAMSHAFT Installation

17. INSTALL NO. 4 CAMSHAFT Installation

18. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation

19. INSTALL CAMSHAFT Installation

20. INSTALL NO. 2 CAMSHAFT Installation

21. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation

22. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Install the crankshaft timing gear key.

(b) Temporarily install the crankshaft pulley set bolt, and set the crankshaft timing gear key in the position as shown in the illustration.