Part 2

2TR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (Continued)

31. INSTALL NO.2 CHAIN SUB-ASSEMBLY

(a) Install the timing sprocket No.2 as shown in the illustration.

NOTE: Check that the No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balanceshafts are at the bottom side.

HINT: Install the sensor plate with the front mark facing forward.

(b) As shown in the illustration, install the chain on the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.

(c) Fit the other mark link of the crankshaft timing sprocket behind the large timing mark of the balanceshaft drive gear.
(d) Insert the balanceshaft drive gear shaft through the balanceshaft drive gear so that it fits into the thrust plate hole.

(e) Align the small timing mark of the balanceshaft drive gear with the timing mark of the balanceshaft timing gear.
(f) Install the bolt to the balanceshaft drive gear and tighten it.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

(g) Check that each timing mark is matched with the corresponding mark link.

NOTE: Check that the No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balanceshafts are at the bottom side.

32. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the chain tensioner assembly No.2 with the nut.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

NOTE: Assemble the chain tensioner with the pin installed, then remove the pin after assembly. When doing this, avoid pushing the vibration damper against the chain.

(b) Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.
(c) Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

33. INSTALL NO. 3 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper No.3 with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

34. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper No.2 with the bolt.
Torque: 27 Nm (270 kgf-cm, 20 ft-lbf)
(b) Remove a pin from the chain tensioner assy No.2 and release the plunger.

35. INSTALL NO. 1 WITH HEAD TAPER SCREW PLUG
(a) Install the screw plug No.1 to the cylinder block.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
36. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

(a) Using a hexagon wrench, install the oil filter bracket union.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

(b) Install a new oil filter bracket gasket to the oil filter bracket.
(c) Install a new O-ring to the oil filter bracket union.

NOTE: Apply a light coat of engine oil to the new O-ring and oil filter bracket.

(d) Install 2 new gaskets and the 2 screw plugs to the oil filter bracket.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

(e) Install the oil filter bracket with the 2 bolts and nut.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

(f) Using a 27 mm socket wrench, install the oil filter union.
Torque: 43 Nm (439 kgf-cm, 32 ft-lbf)

37. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten the oil filter.
SST: 09228-07501
(1) When using a torque wrench:
Using a torque wrench, tighten the oil filter.
Torque: 17 Nm (175 kgf-cm, 13 ft-lbf)
(2) When not using a torque wrench:
Tighten it an additional 3/4 turn.

38. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width:
2 to 3 mm (0.079 to 0.118 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 4 hours after installing.

(b) Install the oil seal retainer with the 6 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
39. INSTALL CYLINDER HEAD GASKET

(a) Apply a continuous bead (seal width: 4 to 7 mm (0.15 to 0.28 in.)) of seal packing to the cylinder block upper side and cylinder head gasket upper side as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Seal width:
4 to 7 mm (0.15 to 0.28 in.)

NOTICE:
- Remove any oil from the contact surface.
- Install the cylinder head gasket within 3 minutes after applying the seal packing.
- Install the cylinder head bolt within 15 minutes after applying the seal packing.
- Do not put into engine oil within 4 hours of installation.

(b) Install a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

- Make sure that the installation direction is correct.
- Place the cylinder head gently to avoid damaging the gasket with the bottom part of the head.

40. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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

(a) Place the cylinder head on the cylinder block.
(b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(c) Step 1
(1) Install and uniformly tighten the 10 cylinder head bolts with the plate washers, in several steps, in the sequence shown.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)

(d) Step 2
(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Retighten the cylinder head bolts by 90°.
(e) Step 3
(1) Retighten the cylinder head bolts by an additional 90°.
(2) Check that the painted mark is now facing rearward.

(f) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.

41. INSTALL CAMSHAFT TIMING SPROCKET
(a) Clamp the camshaft in a vise and then install the camshaft timing sprocket to the camshaft with the sprocket bolt.
Torque: 78 Nm (795 kgf-cm, 58 ft-lbf)

NOTE: Be careful not to damage the camshaft in the vise.

42. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin.
(b) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.

CAUTION: Be sure not to turn the camshaft timing gear in the retard direction (the right angle).

(c) Check that there is no clearance between the gear's fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 78 Nm (795 kgf-cm, 58 ft-lbf)
(e) Check that the camshaft timing gear can move in the retard direction (the right angle), and is locked at the most retarded position.

43. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Set the 16 rocker arms to the lash adjusters.

NOTE: Before and after setting the camshaft and No.2 camshaft, firmly set the rocker arm to the lash adjuster.

44. INSTALL CAMSHAFTS
(a) Apply clean engine oil to the camshaft's cam portion and the cylinder head journals.
(b) Set the camshaft and No.2 camshaft as shown in the illustration.

NOTE: Before and after setting the camshaft and No.2 camshaft, firmly set the rocker arm to the lash adjuster.

45. INSTALL CAMSHAFT BEARING CAP

(a) Temporarily install the camshaft bearing cap No.1.
(b) Check the proper location of each camshaft bearing cap No.2 and install them.

(e) Tighten the 21 bolts and 20 washers in the order shown in the illustration.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
Torque: 16 Nm (160 kgf-cm, 11 ft-lbf)

46. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the timing sprocket as shown in the illustration.

47. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the vibration damper with the bolt and nut.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
48. INSTALL CHAIN SUB-ASSEMBLY

(a) As shown in the illustration, install the chain on the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.

HINT:
- The camshaft mark plate is yellow.
- The crankshaft mark plate is orange.

(b) Use a rope to tie the chain of the crankshaft timing sprocket. Tie the rope near the sprocket.

NOTE: After the chain tensioner has been installed, the rope must be removed.

HINT: The rope is tied so that the chain will not jump a tooth.

49. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the tensioner slipper with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
50. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Install a new gasket and the chain tensioner No.1 with the bolt and nut.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(c) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

51. INSTALL TIMING CHAIN GUIDE
(a) Install a new O-ring and the chain guide with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)

52. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 8 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
53. INSTALL TIMING CHAIN COVER

(a) Install 3 new O-rings to the timing chain cover as shown in the illustration.

(b) Apply adhesive to the timing gear case plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Using a 10 mm socket hexagon wrench, install the timing chain cover plug.
Torque: 17 Nm (170 kgf-cm, 12 ft-lbf)
(d) Apply seal packing in a continuous bead to the timing chain cover as shown in the following illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width:

NOTICE:
- Be sure to clean and degrease the contact surfaces, especially 4 areas indicated by * in the illustration.
- When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.
- Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not start the engine for at least 4 hours after installing.

(e) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.
(f) Temporarily install the the timing chain cover with the 19 bolts and 2 nuts, but do not tighten the bolts and nuts yet.
(g) Excluding bolts A, fully tighten the bolts and nuts in this order: Area 1, Area 2 and Area 3.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

HINT: Bolt length:

75 mm (2.95 in.) for bolt A (M10)

75 mm (2.95 in.) for bolt B (M8)

87 mm (3.43 in.) for bolt C

95 mm (3.74 in.) for bolt D

(h) Fully tighten the bolts labeled A in this order: Area 2 and Area 3.
Torque: 46 Nm (469 kgf-cm, 34 ft-lbf)
(i) Fully tighten the bolts labeled E in Area 4.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

HINT: Bolt length: 35 mm (1.37 in.) for bolt E

54. INSTALL OIL PAN SUB-ASSEMBLY
(a) Install the stud bolt.
(1) Using an E5 "torx" socket wrench, install the stud bolts labeled A for the oil pan as shown in the illustration.
(2) Using an E7 "torx" socket wrench, install the stud bolts labeled B for the oil strainer as shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf) for stud bolt A
Torque: 3.0 Nm (31 kgf-cm, 27 in-lbf) for stud bolt B

(b) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width:
2 to 3 mm (0.08 to 0.12 in.)

- 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 4 hours after installing.

(d) Temporarily install the oil pan with the 16 bolts and 2 nuts.

HINT: Bolt length:

20 mm (0.79 in.) for bolt A

40 mm (1.57 in.) for bolt B

(e) Uniformly tighten the 16 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)

55. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
56. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width:
2.5 to 3.5 mm (0.098 to 0.138 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 4 hours after installing.

(b) Temporarily install the oil pan with the 18 bolts and 2 nuts.
(c) Uniformly tighten the 18 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(d) Install a new gasket and the drain plug.
Torque: 38 Nm (382 kgf-cm, 28 ft-lbf)

57. 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 new pulley bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 260 Nm (2,650 kgf-cm, 192 ft-lbf)

NOTE: Do not reuse the pulley bolt.

58. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Apply seal packing as shown in the illustration.
(b) Install the 2 gaskets to the head cover.
Seal packing:
Toyota Genuine Seal Packing Black, 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 4 hours after installing.

(d) Fully tighten the bolts (A) shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(e) Fully tighten the bolts (B) shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

HINT: Make sure the tightening torque of bolts (A).

59. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Install the camshaft timing oil control valve assembly with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)

60. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply engine oil to the O-ring.
(b) Install the crankshaft position sensor with the bolt.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)

61. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply engine oil to the O-ring.
(b) Install the camshaft position sensor with the bolt.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)

62. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Install the ventilation valve sub-assembly.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)

63. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install the oil filler cap assembly.