Part 2

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY (Continued)

34. INSTALL CAMSHAFTS

NOTE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

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

NOTE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft 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 onto the RH cylinder head with the cam lobes of No. 1 cylinder facing each direction as shown in the illustration.

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

(4) Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
For 10 mm (0.39 in.) head - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
For 12 mm (0.47 in.) head - Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)

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

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

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

(a) While pushing in the tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it.

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

(a) Align the mark links (yellow) with the timing marks (1-dot mark) of the 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 to the RH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.

NOTE: Do not push the camshaft timing gear assembly to 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 No. 2 chain tensioner.
37. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) While pushing in the tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it.

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

(a) Align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the 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 to the LH camshafts.
(c) Temporarily install the 2 camshaft timing gear bolts.

NOTE: Do not push the camshaft timing gear assembly to 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 No. 3 chain tensioner.
39. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
40. 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 facing inward as shown in the illustration.
41. INSTALL CHAIN TENSIONER SLIPPER
42. 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 dia3.5 mm (0.138 in.) into the holes on 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 ft-lbf)
43. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to the TDC / compression.

(1) Align the timing marks of the camshaft timing gears and bearing caps.

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

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

(c) Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.
44. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Instal the 2 No. 2 chain vibration dampers.
45. INSTALL NO. 1 IDLE GEAR SHAFT
(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

(b) Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft 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 No. 2 idle gear shaft.
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
(d) Remove the bar from the chain tensioner.
46. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST: 09226-10010
(b) Apply MP grease to the oil seal lip.
47. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Remove any old packing (FIPG) 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 to the LH cylinder head as shown in the illustration.

(c) Apply a continuous bead of seal packing (diameter 3.0 to 4.0 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 3.0 to 4.0 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

NOTICE:
- Install the timing chain cover within 3 minutes after applying seal packing. After installing it, 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 the "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)

NOTICE:
- Pay attention not to wrap the chain and slipper over 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:
A: 25 mm (0.98 in.)
B: 55 mm (2.17 in.)

48. INSTALL WATER PUMP ASSEMBLY

(a) Install a new gasket and the water pump with the 17 bolts.
For 10 mm (0.39 in.) head - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
For 12 mm (0.47 in.) head - Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
49. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing (FIPG) 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.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)

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

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

(e) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
For bolt A - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
For bolt B - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
For bolt C - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
For nut - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

HINT:
Each bolt length is as follows:
A: 25 mm (0.98 in.)
B: 45 mm (1.77 in.)
C: 14 mm (0.55 in.)

50. INSTALL OIL STRAINER SUB-ASSEMBLY

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

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

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

(c) Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
For bolt - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
For nut - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
52. INSTALL OIL PAN DRAIN PLUG
(a) Install the drain plug and a new gasket.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
53. INSTALL CRANKSHAFT PULLEY

(a) Using SST, install the pulley set bolt.
SST: 09213-54015
91651-60855
SST: 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 184 ft-lbf)
54. SET NO. 1 CYLINDER TO TDC / COMPRESSION Adjustments
55. INSPECT VALVE CLEARANCE Adjustments
56. ADJUST VALVE CLEARANCE Adjustments
57. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing (FIPG) 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 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 after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

(c) Install the gasket to the cylinder head cover.
(d) Install the seal washers to the bolts.

(e) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
For bolt A - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
For bolt B - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
For nut - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
58. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove any old packing (FIPG) 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 Adhesive 1324, Three Bond 1324 or Equivalent
(c) Install the ventilation valve to the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)

(d) 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 after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

(e) Install the gasket to the cylinder head cover.
(f) Install the seal washers to the bolts.

(g) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
For bolt A - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
For bolt B - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
For nut - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
59. INSTALL OIL CONTROL VALVE FILTER

(a) Check that no foreign objects are present on the mesh part of the 2 filters.
(b) Install 2 new gaskets to each new plug.
(c) Insert the filters to 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 to each cylinder head.
Torque: 62 Nm (632 kgf-cm, 46 ft-lbf)
60. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
61. 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)
62. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the drain cocks end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

(b) After applying the specified torque, rotate the drain cock clockwise as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
- Install the drain cock within 3 minutes after applying adhesive.
- Do not expose the drain cock to coolant within 1 hour after installing.
- Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock with the specified torque.
- Do not loosen the drain cock after setting it correctly.

63. INSTALL OIL LEVEL GAUGE GUIDE

(a) Install a new O-ring to the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push in 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)
64. INSTALL NO. 2 ENGINE HANGER

(a) Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
65. INSTALL NO. 1 ENGINE HANGER
(a) Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)