Part 3

2UR-GSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (Continued)

45. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

46. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Installation

47. INSTALL OIL CONTROL VALVE FILTER

(a) for Bank 1:

(1) Install the oil control valve filter to the cylinder head cover spacer LH.

(2) Install a new gasket and the cylinder head cover spacer LH with the 2 bolts.

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

(b) for Bank 2:

(1) Install the oil control valve filter to the cylinder head cover spacer.

(2) Install a new gasket and the cylinder head cover spacer with the 2 bolts.

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

48. INSTALL SPARK PLUG TUBE GASKET

(a) Install the 8 new spark plug tube gaskets to each cylinder head sub-assembly.

NOTICE:
* Install the gaskets in the correct direction.
* Push in each gasket until its bottom surface contacts the cylinder head.

49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 1)

(a) Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.

(b) Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

NOTICE:
Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.

Seal packing:

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

NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head cover sub-assembly 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 installing the cylinder head cover sub-assembly.

(d) Install the cylinder head cover sub-assembly LH with 3 new seal washers and the 16 bolts.

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

Except bolt A - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(e) Install a new fuel pump spacer gasket.

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

(a) Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.

(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

NOTICE:
Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.

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

Except bolt A - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(e) Install a new fuel pump spacer gasket.

51. INSTALL NO. 1 V-BANK COVER BRACKET (for Bank 1)

(a) Install the No. 1 V-bank cover bracket to the cylinder head cover sub-assembly LH.

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

52. INSTALL NO. 1 V-BANK COVER BRACKET (for Bank 2)

(a) Install the No. 1 V-bank cover bracket to the cylinder head cover sub-assembly RH.

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

53. INSTALL CRANKSHAFT PULLEY Installation

54. INSTALL OIL FILTER BRACKET

(a) Install 2 new gaskets and the filter bracket with the 2 bolts and 2 nuts.

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

(b) Install the oil filter bracket stay with the 2 bolts.

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

55. INSTALL OIL COOLER ASSEMBLY

(a) Temporarily install the oil cooler assembly with the bolt.

(b) Install the union bolt to the oil cooler assembly with a new gasket.

(c) Tighten the bolt and union bolt.

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

Union bolt - Torque : 59 Nm (602 kgf-cm, 43 ft-lbf)

56. INSTALL OIL FILTER ELEMENT

(a) Clean the inside of the oil filter cap, the threads and O-ring groove.

(b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

(c) Set a new oil filter element in the oil filter cap.

(d) Remove any dirt or foreign matter from the installation surface of the oil filter bracket.

(e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap.

(f) Using SST, tighten the oil filter cap.

SST : 09228-06501

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
* Make sure that the oil filter is installed securely as shown in the illustration.
* Be careful that the O-ring does not get caught between the parts.

57. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the cylinder block water drain cock sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the cylinder block water drain cock sub-assembly as shown in the illustration.

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

NOTICE:
* Do not rotate the cylinder block water drain cock sub-assembly more than 1 revolution (360°) after tightening to the specified torque.
* Do not loosen the cylinder block water drain cock sub-assembly to adjust them. If an adjustment is necessary, remove the cylinder block water drain cock sub-assembly and reinstall them.

(c) Install the cylinder block water drain cock plugs to the cylinder block water drain cock sub-assembly.

Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)

58. INSTALL FRONT WATER BY-PASS JOINT

(a) Install the front water by-pass joint and 2 new gaskets with the 4 nuts.

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

59. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (for Bank 1)

(a) Turn the camshaft timing gear assembly intermediate shaft index slot in the counterclockwise direction by hand, to set it to the maximum retard angle position.

HINT
* When a camshaft lobe opens a valve, the intermediate shaft becomes difficult to turn.
* The position where the intermediate shaft stops is the maximum retard angle.

(b) Install a new O-ring to the timing chain cover.

(c) Align the joint of the camshaft timing control motor assembly LH and the keyway of the camshaft timing gear assembly, and install the camshaft timing control motor assembly LH with the 3 bolts.

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

NOTICE:
* Check that [L] is printed on the label of the camshaft timing control motor assembly LH.
* Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor assembly LH (the surface that contacts the timing chain cover sub-assembly).
* When installing the camshaft timing control motor assembly LH, do not use excessive force.
* Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor assembly LH.
* Install the camshaft timing control motor assembly LH with the arrow facing upward, as shown in the illustration.
* Do not drop the camshaft timing control motor assembly LH. If dropped, replace it.
* Do not disassemble the camshaft timing control motor assembly LH. If disassembled, replace it.

60. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (for Bank 2)

(a) Turn the camshaft timing gear assembly intermediate shaft index slot in the counterclockwise direction by hand, to set it to the maximum retard angle position.

(c) Align the joint of the camshaft timing control motor assembly RH and the keyway of the camshaft timing gear assembly, and install the camshaft timing control motor assembly RH with the 3 bolts.

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

NOTICE:
* Check that [R] is printed on the label of the camshaft timing control motor assembly RH.
* Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor assembly RH (the surface that contacts the timing chain cover sub-assembly).
* When installing the camshaft timing control motor assembly RH, do not use excessive force.
* Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor assembly RH.
* Install the camshaft timing control motor assembly RH with the arrow facing upward, as shown in the illustration.
* Do not drop the camshaft timing control motor assembly RH. If dropped, replace it.
* Do not disassemble the camshaft timing control motor assembly RH. If disassembled, replace it.

61. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH

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

(b) Install the O-ring to the camshaft timing oil control valve assembly LH.

(c) Install the camshaft timing oil control valve assembly LH with the bolt.

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

62. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH

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

(b) Install the O-ring to the camshaft timing oil control valve assembly RH.

(c) Install the camshaft timing oil control valve assembly RH with the bolt.

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

63. INSTALL CRANKSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.

(b) Install the crankshaft position sensor with the bolt.

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

64. INSTALL CAMSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring on each camshaft position sensor.

(b) Install the camshaft position sensor with the bolt.

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

65. INSTALL VVT SENSOR

(a) for Bank 1:

(1) Apply a light coat of engine oil to the O-ring on each VVT sensor.

(2) Install the 2 VVT sensors with the 2 bolts.

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

(b) for Bank 2:

(1) Apply a light coat of engine oil to the O-ring on the VVT sensor.

(2) Install the 2 VVT sensors with the 2 bolts.

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

66. INSTALL SPARK PLUG Installation

67. INSTALL OIL FILLER CAP HOUSING

(a) Align the protrusion of a new oil filler cap gasket with the cutout of the oil filler cap housing, and install the oil filler cap gasket gasket to the oil filler cap housing.

(b) Install the oil filler cap housing with the 2 bolts.

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

68. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install a new oil filler cap gasket to the oil filler cap.

(b) Install the oil filler cap sub-assembly to the oil filler cap housing.