Part 1

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
For stud bolt A - Torque: 11 Nm (112 kgf-cm, 8.1 ft-lbf)
For stud bolt B - Torque: 4.5 Nm (46 kgf-cm, 40 in-lbf)
For stud bolt C - Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

2. INSTALL STRAIGHT PIN
(a) Using a plastic-faced hammer, tap in the straight pin.
Standard protrusion:
22.5 to 23.5 mm (0.886 to 0.925 in.) for pin A
10.5 to 11.5 mm (0.413 to 0.453 in.) for pin B
8.5 to 9.5 mm (0.335 to 0.374 in.) for pin C
5.5 to 6.5 mm (0.217 to 0.256 in.) for pin D

3. INSTALL TIGHT PLUG
(a) Apply adhesive around the tight plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
(b) Using SST, install the tight plugs as shown in the illustration.
SST: 09950-60010
09951-00350
SST: 09950-70010
09951-07150
Standard depth:
0.2 to 1.2 mm (0.008 to 0.047 in.)

4. INSTALL OIL JET

(a) Using a screwdriver and hammer, tap in the oil jet.
5. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
6. INSTALL PISTON PIN HOLE SNAP RING

(a) Using a screwdriver, install a new snap ring on one side of the piston pin hole.

HINT: Check that an end gap of the snap ring is not overlapped to the pin hole cutout portion of the piston.

7. INSTALL WITH PIN PISTON SUB-ASSEMBLY

(a) Gradually heat the piston to about 80°C (176°F).

(b) Coat the piston pin with engine oil.
(c) Align the front marks of the piston and connecting rod, and push in the piston pin with a thumb.
8. INSTALL PISTON PIN HOLE SNAP RING

(a) Using a screwdriver, install a new snap ring on the other side of the piston pin hole.

HINT: Be sure that an end gap of the snap ring is not overlapped to the pin hole cutout portion of the piston.

9. INSTALL PISTON RING SET

(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression rings.

NOTE: Install the No. 2 compression ring with the painted mark facing upward.

(a) Align the bearing claw with the groove of the connecting rod or connecting cap.

NOTE: Clean the backside of the bearing and the contact surface of the connecting rod and prevent oil from adhering to them.

11. INSTALL CRANKSHAFT BEARING

HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.

(a) Clean each main journal and bearing.

(b) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.

NOTE: Do not apply engine oil to the bearing and its contact surface.

(c) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.

NOTE: Do not apply engine oil to the bearing and its contact surface.

HINT: The number marked on each main bearing cap indicates the installation position.

12. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crankshaft on the cylinder block.

(b) Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block.
(1) Push the crankshaft toward the front (rear) side.
(2) Install the 2 upper thrust washers with the oil grooves facing outward.

(d) Examine the front marks and numbers and install the bearing caps on the cylinder block.
(e) Apply a light coat of engine oil to the threads of the bearing cap bolts.
(f) Temporarily install the 8 main bearing cap bolts to the inside positions.

(g) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes less than 6 mm (0.23 in.).

(h) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(i) Apply a light coat of engine oil to the threads of the main bearing cap bolts.

(j) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft-lbf)

(k) Mark the front side of the bearing cap bolts with paint.
(l) Retighten the bearing cap bolts 90° in the sequence as shown.
(m) Check that the painted mark is now at a 90° angle to the front.
(n) Check that the crankshaft turns smoothly.

(o) Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence as shown in the illustration.
Torque: 26 Nm (262 kgf-cm, 19 ft-lbf)
13. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.
(b) Check the positions of the piston ring ends.
(c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

NOTICE:
- Clean the backside of the bearing and the contact surface of the connecting rod cap and prevent oil from adhering to them.
- Match the numbered connecting rod cap with the connecting rod.

(d) Check that the protrusion of the connecting rod cap is facing the correct direction.
(e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

(f) Tighten the bolts alternately with the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)

(g) Mark the front side of each connecting cap bolt with paint.
(h) Retighten the cap bolts 90° as shown.
(i) Check that the crankshaft turns smoothly.
14. INSTALL RING PIN
(a) Using a plastic-faced hammer, tap in new ring pins until it reaches the specified protrusion height.
Specified protrusion height:
2.7 to 3.3 mm (0.106 to 0.130 in.)

15. INSTALL STRAIGHT PIN
(a) Using a plastic-faced hammer, tap in new straight pins until it reaches the specified protrusion height.

Specified protrusion height:

16. INSTALL STUD BOLT
(a) Using the torx socket wrench E5 and E7, install the stud bolts.
For stud bolt A - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
For stud bolt B - Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
For stud bolt C - Torque: 20 Nm (199 kgf-cm, 14 ft-lbf)

17. INSTALL UNION

(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
(b) Using a deep socket wrench 12, install the unions.
Torque: 15 Nm (150 kgf-cm, 11 ft-lbf)

18. INSTALL TIGHT PLUG

(a) Apply adhesive around the tight plug.
(b) Using SST, tap in the tight plugs to the specified depth.
SST: 09950-60010
09951-00250
SST: 09950-70010
09951-07150
Specified depth:
1.5 mm (0.059 in.)

19. INSTALL WITH HEAD STRAIGHT SCREW PLUG
(a) Using a straight hexagon wrench 14, install a new gasket and straight screw plug.
Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)

20. INSTALL VALVE STEM OIL SEAL OR RING

HINT: The intake valve stem oil seal is light brown and the exhaust valve stem oil seal is gray.

(a) Apply a light coat of engine oil to the valve guide bush.

(b) Using SST, push in a new valve stem oil seal.
SST: 09201-41020
21. INSTALL VALVE SPRING SEAT

(a) Install the valve spring seat.
22. INSTALL VALVE

(a) Apply engine oil to the valve as shown in the illustration.

(b) Place the cylinder head on a wooden block.
(c) Install the valve, inner compression spring and valve spring retainer.
(d) Using SST, compress the inner compression spring and place the 2 valve spring retainer locks around the valve stem.
SST: 09202-70020
09202-00010

(e) Using a pin punch 5, lightly tap the valve stem tip to ensure a proper fit.

NOTE: Be careful not to damage the valve stem tip.

23. INSTALL VALVE LIFTER

(a) Apply engine oil to the valve stem end and valve lifter, and install the valve lifter to the valve stem.
(b) Check that the valve lifter rotates smoothly by hand.
24. INSTALL ENGINE REAR OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST: 09223-78010
(b) Apply MP grease to the oil seal lip.
25. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.

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

NOTE: Parts must be assembled within 3 minutes of application. Otherwise the seal packing must be removed and reapplied.

(c) Install the oil seal retainer with the 5 bolts and 2 nuts.
For nut - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
For bolt - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
26. 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 knock sensor connectors.
27. INSTALL NO. 1 WATER OUTLET PIPE

(a) Install the water outlet pipe with the 3 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
28. INSTALL CYLINDER HEAD GASKET
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

(b) Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

(c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.
- Be careful of the installation direction.
- Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

29. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Place the RH cylinder head on the cylinder head gasket.
(b) Install the 8 cylinder head bolts and plate washers.

HINT:
- The cylinder head bolts are tightened in 2 successive steps (procedures "A" and "B").
- If any cylinder head bolt is broken or deformed, replace it.
(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.

(3) Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration (Procedure "A").
Torque: 36 Nm (367 kgf-cm, 27 ft-lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

NOTE: Do not drop the washers into the cylinder head.

(4) Mark the front side of each cylinder head bolt with paint.
(5) Retighten the cylinder head bolts by 180° as shown (Procedure "B").
(6) Check that the painted marks are now at 180° opposite to the engine front.
30. INSTALL NO. 2 CYLINDER HEAD GASKET
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

(c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

NOTICE:
- Be careful of the installation direction.
- Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

31. INSTALL CYLINDER HEAD LH
(a) Place the LH cylinder head on the cylinder head gasket.
(b) Install the 8 cylinder head bolts and plate washers.

HINT:
- The cylinder head bolts are tightened in 2 successive steps (procedures "A" and "B").
- If any cylinder head bolt is broken or deformed, replace it.

(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.

(c) Install the 2 cylinder head bolts.
(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(2) Install the 2 cylinder head bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
32. INSTALL NO. 1 CAMSHAFT BEARING

(a) Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.

HINT:
- Install the bearing while aligning it with the oil hole in the bearing cap.
- Clean the backside of the bearing and the contact surface of the bearing cap and prevent oil from adhering to them.

33. INSTALL NO. 2 CAMSHAFT BEARING

(a) Install the No. 2 camshaft bearing to the cylinder head.

NOTE: Clean the backside of the bearing and the bearing surface of the cylinder head.