Part 2

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

21. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration

(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

Text in Illustration

SST : 09922-10010

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the No. 3 chain tensioner assembly.

22. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 1)

(a) Install the No. 2 chain tensioner assembly with the bolt.

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

(b) Push in the No. 2 chain tensioner assembly and insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the tensioner.

Text in Illustration

23. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration

(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

Text in Illustration

SST : 09922-10010

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the No. 2 chain tensioner assembly.

24. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.

Torque : 23 Nm (229 kgf-cm, 17 ft-lbf)

25. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 No. 2 chain vibration dampers.

26. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Align the key groove of the timing sprocket with the timing sprocket set key.

(b) Install the timing sprocket to the crankshaft with the sprocket facing inward as shown in the illustration.

Text in Illustration

27. 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.

Text in Illustration

NOTICE:
Make sure that the idle gear is installed facing the proper 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.

28. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plate and timing marks as shown in the illustration and install the chain.

Text in Illustration

HINT
The camshaft mark plates are orange.

(b) Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.

Text in Illustration

NOTICE:
When the idle sprocket assembly is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

(d) Align the mark plate and timing marks as shown in the illustration and install the chain to the crankshaft timing sprocket.

Text in Illustration

HINT
The crankshaft mark plate is yellow.

(e) Temporarily tighten the pulley set bolt.

(f) Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

Text in Illustration

29. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the stopper plate of the tensioner clockwise and push in the plunger of the tensioner as shown in the illustration.

Text in Illustration

(b) Turn the stopper plate of the tensioner counterclockwise and insert a pin of dia1.27 mm (0.0500 in.) into the holes on the stopper plate and tensioner to fix the stopper plate in place.

(c) Install the chain tensioner with the 2 bolts.

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

(d) Remove the pin from the No. 1 chain tensioner.

31. INSPECT VALVE TIMING

(a) Check the camshaft timing marks.

NOTICE:
* Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.
* If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

(b) Check that each camshaft timing mark is positioned as shown in the illustration.

Text in Illustration

HINT
for the intake camshaft:

Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

(c) If the valve timing is misaligned, reinstall the timing chain.

(d) Remove the pulley set bolt.

32. INSTALL FRONT CRANKSHAFT OIL SEAL Installation

33. INSTALL WATER PUMP ASSEMBLY

(a) Install a new gasket and the water pump with the 8 bolts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

34. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

35. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate with the 6 bolts.

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

36. INSTALL OIL PAN SUB-ASSEMBLY Installation

37. INSTALL OIL STRAINER SUB-ASSEMBLY Installation

38. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Installation

39. INSTALL OIL PAN DRAIN PLUG

(a) Install the drain plug and a new gasket.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

40. POUR ENGINE OIL

HINT
Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.