Part 3
1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - (Continued)
41. INSTALL SPARK PLUG TUBE GASKET
(a) Using a utility knife, cut off the seal part of the removed gasket.
Text in Illustration
(b) Using the removed gasket and a hammer, tap in a new gasket until it stops.
Text in Illustration
HINT
If the removed gasket does not fit on the new one, correct the removed one with pliers.
(c) Apply a light coat of MP grease to the gasket lip.
(d) Return the ventilation baffle plate claws to the original positions.
42. 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 or cylinder head cover.
(b) Apply seal packing as shown in the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
2 to 3 mm (0.0787 to 0.118 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
(c) Install 3 new gaskets as shown in the illustration.
(d) Install a new gasket to the cylinder head cover.
(e) Install a new seal washer to the bolt.
(f) Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.
Text in Illustration
for bolt A and D - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for bolt B and C - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Bolt Length:
NOTICE:
Do not start the engine for at least 2 hours after the installation.
43. 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 or cylinder head cover.
(b) Apply seal packing as shown in the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
2 to 3 mm (0.0787 to 0.118 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
(c) Install 3 new gaskets as shown in the illustration.
(d) Install a new gasket to the cylinder head cover.
(e) Install a new seal washer to the bolt.
(f) Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.
Text in Illustration
for bolt A and D - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for bolt B and C - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Bolt Length:
NOTICE:
Do not start the engine for at least 2 hours after the installation.
44. INSTALL CRANKSHAFT PULLEY Installation
45. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the ventilation valve.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the ventilation valve.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
(c) Install the ventilation valve hose.
46. INSTALL SPARK PLUG Installation
47. INSTALL REAR WATER BY-PASS JOINT
(a) Apply soapy water to a new O-ring and install it to the water outlet pipe. Then install 2 new gaskets to the water ports LH and RH.
Text in Illustration
(b) Install the rear water by-pass joint with the 2 bolts and 4 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
48. INSTALL WATER INLET HOUSING Installation
49. INSTALL OIL FILTER BRACKET Installation
50. INSTALL OIL FILTER ELEMENT Replacement
51. INSTALL NO. 2 OIL PIPE Installation
52. INSTALL NO. 1 OIL PIPE Installation
53. INSTALL OIL FILLER CAP HOUSING
(a) Install a new gasket and the oil filler cap housing with the 2 nuts.
Text in Illustration
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Install the oil filler cap.
54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) RH:
(1) Apply a light coat of engine oil to 2 new O-rings.
(2) Install the 2 O-rings to the 2 oil control valves.
(3) Install the 2 oil control valves with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.
(b) LH:
(1) Apply a light coat of engine oil to 2 new O-rings.
(2) Install the 2 O-rings to the 2 oil control valves.
(3) Install the 2 oil control valves with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.
55. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
56. INSTALL VVT SENSOR
(a) RH:
Install the 2 VVT sensors with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) LH:
Install the 2 VVT sensors with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
57. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the drain cock end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the drain cock.
Text in Illustration
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTICE:
* Install the drain cock within 3 minutes after applying adhesive.
* Do not expose the drain cock to coolant within 1 hour of the installation.
(c) Rotate the drain cock clockwise as shown in the illustration.
NOTICE:
* Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque.
* Do not loosen the drain cock after setting it correctly.
(d) Install the water drain cock plugs to the water drain cocks.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
58. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm deep socket wrench, install the sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
59. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
NOTICE:
Do not apply adhesive to the oil inlet port of the oil pressure switch.
(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)