Part 2

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (Continued)

31. INSTALL NO.1 CAMSHAFT BEARING
(a) Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.

NOTICE:
- Install the bearing while aligning it with the oil hole in the bearing cap.
- Clean the back side of the bearing and the surface of the bearing cap and keep them free of oils and fats.

32. INSTALL NO.2 CAMSHAFT BEARING
(a) Install camshaft bearing No. 2 onto the cylinder head.

NOTE: Clean the back side of the bearing and the bearing surface of the cylinder head and keep them free of oils and fats.

33. INSTALL CAMSHAFTS

NOTE: Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.

(a) Set the crankshaft position.
(1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key in the left horizontal position as indicated.

NOTE: Setting the crankshaft at the wrong angle could cause the piston head and valve head to come into contact with each other when the camshaft is installed. This could cause damage, so always set the camshaft at the correct angle.

(b) Apply new engine oil to the thrust portion and journal of the camshafts.
(c) Install the camshaft of the RH bank.

(1) Place the 2 camshafts on the RH cylinder head with the No. 1 cam lobes facing as shown the illustration.

(2) Install the 8 bearing caps in their correct locations.
(3) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(4) Using several steps, uniformly tighten the 16 bearing cap bolts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)

(5) Using a wrench, turn the camshafts clockwise until each camshaft knock pin comes to a position 90° to the cylinder head.
(d) Install the camshafts of the LH bank.

(1) Place the 2 camshafts on the LH cylinder head with the No.1 cam lobes facing as shown the illustration.

(2) Install the 8 bearing caps in the correct locations as shown.
(3) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(4) Using several steps, uniformly tighten the 16 bearing cap bolts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
34. INSTALL NO.2 CHAIN TENSIONER ASSEMBLY

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

(b) Install the chain tensioner No. 2 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
35. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (for Bank 1)

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

(b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain onto the RH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.

NOTE: Do not push the camshaft timing gear assembly onto the camshaft forcibly when installing it.

(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(e) Remove the pin from the chain tensioner No. 2.
36. INSTALL NO.3 CHAIN TENSIONER ASSEMBLY

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

(b) Install the chain tensioner No. 3 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
37. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (for Bank 2)

(a) Align the yellow mark links with the timing marks (1 dot mark and 2 dot marks) on camshaft timing gears as shown in the illustration.

(b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain onto the LH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.

NOTE: Do not push camshaft timing gear assembly onto the camshaft forcibly when installing it.

(d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(e) Remove the pin from the chain tensioner No. 3.

38. INSTALL NO.1 CHAIN VIBRATION DAMPER
(a) Install the chain vibration damper No. 1 with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)

39. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Align the timing gear set key with the key groove of the timing gear.
(b) Install the timing gear onto the crankshaft with the gear side facing inward.
40. INSTALL CHAIN TENSIONER SLIPPER

41. INSTALL NO.1 CHAIN TENSIONER ASSEMBLY
(a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of dia 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
42. INSTALL CHAIN SUB-ASSEMBLY

(a) Set the No. 1 cylinder to TDC/ compression.
(1) Align the timing marks of the camshaft timing gears and bearing caps.

(2) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

(b) Align the yellow mark link with the timing mark of the crankshaft timing gear.

43. INSTALL NO.2 CHAIN VIBRATION DAMPER
(a) Instal the 2 chain vibration dampers No. 2.
44. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to rotating surface of the idle gear shaft No. 1.

(b) Temporarily install the idle gear shaft No. 1 together with the idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block.

NOTE: Be careful of the idle gear direction.

(c) Using a 10 mm hexagon wrench, tighten the idle gear shaft No. 2.
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
(d) Remove the bar from the chain tensioner.
45. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

(b) Install a new O-ring onto the LH cylinder head as shown in the illustration.

(c) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to 4 locations as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(d) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the timing chain cover as shown in the illustration.
Seal packing:
Water pump part: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Other part: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

- Install the timing chain cover within 3 minutes of applying the seal packing. After installation, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.
- Do not apply seal packing to A as shown in the illustration.

(e) Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.

(f) Install the timing chain cover with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)

- Take care not to wrap the chain and slipper beyond the timing chain cover seal line.
- After installing the timing chain cover, install the water pump within 15 minutes.

HINT: Each bolt length is as follows:

46. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 17 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf) for 10 mm (0.39 in.) head
Torque: 23 Nm (235 kgf-cm, 17 ft-lbf) for 12 mm (0.47 in.) head
47. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

(b) Install the 4 stud bolts (for 2WD).
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

(d) Install a new O-ring onto the oil pump.

(e) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 1.16 in.)) to the oil pan as shown in the illustration (for 2WD).
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE: Install the oil pan within 3 minutes of applying the seal packing. After installation, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(f) Apply a continuous bead of the seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration (for Pre Runner and 4WD).
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE: Install the oil pan within 3 minutes of applying the seal packing. After installation, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(g) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps (for 2WD).
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)

HINT: Each bolt length is as follows:

(h) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps (for Pre Runner and 4WD).
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)

HINT: Each bolt length is as follows:

48. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Install a new gasket, then install the oil strainer with the 2 nuts (for 2WD).
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Install a new gasket, then install the oil strainer with the 2 nuts (for Pre Runner and 4WD).
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
49. INSTALL NO.2 OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No. 2.

(b) Apply a continuous bead of the seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration (for 2WD).
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE: Install the oil pan No. 2 within 3 minutes of applying the seal packing. After installation, oil pan No. 2 bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(c) Apply a continuous bead of seal packing (diameter 3 to 4mm(0.12 to 0.16 in.)) as shown in the illustration (for Pre Runner and 4WD).
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE: Install the oil pan No. 2 within 3 minutes of applying the seal packing. After installation, the oil pan No. 2 bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(d) Install the oil pan No. 2 with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps (for 2WD).
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)

(e) Install the oil pan No. 2 with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps (for Pre Runner and 4WD).
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
50. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug with a new gasket.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)

51. INSTALL CRANKSHAFT PULLEY
(a) Using SST, fix the pulley and tighten the bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 185 ft-lbf)
52. SET NO.1 CYLINDER TO TDC/COMPRESSION
53. INSPECT VALVE CLEARANCE
54. ADJUST VALVE CLEARANCE
55. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
(b) Install the gasket onto the cylinder head cover.

(c) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE: Install the cylinder head cover within 3 minutes of applying the seal packing. After installation, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

(d) Install the seal washers onto the bolts.

(e) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

HINT: Each bolt length is as follows:

56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
(b) Apply adhesive to the threads of the ventilation valve.
Adhesive:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
(c) Install the ventilation valve onto the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
(d) Install the gasket onto the cylinder head cover.

(e) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE: Install the cylinder head cover of 3 minutes of applying the seal packing. After installation, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(f) Install the seal washers onto the bolts.

(g) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

HINT: Each bolt length is as follows:

57. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign objects on the mesh part of the 2 filters.
(b) Install 2 new gaskets onto each new plug.
(c) Insert the filters into the plugs.
(d) Apply adhesive to 2 or 3 threads of the plugs.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(e) Install the plugs onto each cylinder head.
Torque: 62 Nm (632 kgf-cm, 46 ft-lbf)

58. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)

59. INSTALL VVT SENSOR
(a) Apply a light coat of engine oil to the O-ring of each VVT sensor.
(b) Install the 2 VVT sensors with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
60. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the drain cocks end.
Adhesive:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(b) Tighten the drain cocks to the specified torque, and rotate them clockwise as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

- Do not rotate the drain cocks more than 1 complete revolution (360°) after tightening the drain cocks to the specified torque.
- Do not loosen the drain cocks after setting it correctly.

61. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O-ring onto the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push the oil level gauge guide end into the guide hole of the oil pan.
(d) Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

62. INSTALL ENGINE HANGERS
(a) Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
(b) Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)