Reassembly

2GR-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL REAR ENGINE OIL SEAL

(a) Place the rear engine oil seal retainer on wooden blocks.

(b) Using SST, tap in a new rear engine oil seal until its surface is flush with the rear engine oil seal retainer edge.





SST : 09223-15030

SST : 09950-70010

09951-07100

Oil seal tap in depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196)

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the rear engine oil seal at an angle.

2. INSTALL REAR ENGINE OIL SEAL RETAINER

(a) Apply seal packing in a continuous line as shown in the illustration.





Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

Text in Illustration





NOTICE:
* Remove any oil from the contact surfaces.
* Install the rear engine oil seal retainer within 3 minutes after applying seal packing.

(b) Install the rear engine oil seal retainer with the 6 bolts.





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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:
* Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.
* Do not start the engine for at least 2 hours after installation.

3. INSTALL WATER INLET PIPE

(a) Install the water inlet pipe with the 2 bolts.

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

(b) Install the No. 1 water by-pass hose with the clamp.

4. INSTALL CYLINDER HEAD GASKET Installation

5. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation

6. INSTALL NO. 2 CYLINDER HEAD GASKET Installation

7. INSTALL CYLINDER HEAD LH Installation

8. INSTALL VALVE STEM CAP Installation

9. INSTALL VALVE LASH ADJUSTER ASSEMBLY Installation

10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Installation

11. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation

12. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Installation

13. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation

14. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Installation

15. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Installation

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

17. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Installation

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

19. 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)

20. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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

21. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the 2 keys and crankshaft timing sprocket as shown in the illustration.





22. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.





Text in Illustration





(b) Temporarily install the No. 1 idle gear shaft and idle sprocket 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.

NOTICE:
Make sure the idle gear is installed in the correct position.

HINT
Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.

(c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

HINT
After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.

23. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plates 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.

(c) Turn the camshaft timing gear assembly on bank 1 counterclockwise to tighten the chain between the banks.





Text in Illustration





NOTICE:
When the idle sprocket assembly is reused, align the chain plate with the mark indicating 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 install the pulley set bolt.

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





Text in Illustration





24. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

25. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and then push the plunger deep into the tensioner.





Text in Illustration





(b) Move the stopper plate downward to set the lock, and then insert a hexagon wrench into the hole of the stopper plate.

(c) Install the No. 1 chain tensioner assembly with the 2 bolts.

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

(d) Remove the hexagon wrench from the No. 1 chain tensioner assembly.

26. INSPECT VALVE TIMING

(a) Check the camshaft timing marks.

NOTICE:
* Check each timing mark from a viewpoint directly in line 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 where marks B, C, and D are positioned in a 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.

27. INSTALL FRONT CRANKSHAFT OIL SEAL Installation

28. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

29. INSTALL ENGINE WATER PUMP ASSEMBLY Installation

30. INSTALL WATER INLET HOUSING

(a) Install 2 new O-rings.





HINT
Apply a small amount of water or soapy water to the O-ring (A) shown in the illustration before installation.

(b) Install the 2 stud bolts.





Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(c) Install the water inlet housing with the 2 bolts and nut.





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

Text in Illustration





NOTICE:
Make sure that the O-ring does not get caught between the parts.

(d) Connect the No. 1 water by-pass hose.

(e) Apply adhesive around the air drain cock.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(f) Install the air drain cock assembly to the water inlet housing.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

(g) Install the air drain cock plug to the drain cock assembly.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(h) Install a new gasket to the thermostat.

(i) Align the thermostat jiggle valve with the upper stud bolt and insert the thermostat into the water inlet housing.





HINT
The jiggle valve may be set within 10° of either side of the prescribed position.

(j) Install the water inlet with the 2 nuts.

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

31. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) Install the front No. 1 engine mounting bracket LH with the 6 bolts.





Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

Text in Illustration





NOTICE:
* Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
* Do not start the engine for at least 2 hours after installation.

(b) Using an E8 "TORX" socket wrench, install the 2 stud bolts.

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

32. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Temporarily install the No. 1 oil pan baffle plate with the 2 bolts labeled 1 and 7.





(b) Install the remaining 5 bolts and tighten the bolts in the sequence shown in the illustration.

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

33. INSTALL OIL PAN SUB-ASSEMBLY

(a) Using an E8 "TORX" socket wrench, install the 4 stud bolts.





Text in Illustration





for stud bolt A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

for stud bolt B - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Install 2 new O-rings.

(c) Apply seal packing in a continuous line as shown in the illustration.





Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

Text in Illustration





NOTICE:
* Remove any oil from the contact surfaces.
* Install the oil pan within 3 minutes after applying seal packing.

(d) Install the oil pan with the 16 bolts and 2 nuts.





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

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

Text in Illustration





NOTICE:
Do not start the engine for at least 2 hours after installation.

34. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration.





Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

Text in Illustration





(b) Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.





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

Text in Illustration





35. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the 2 stud bolts as shown in the illustration.





Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(b) Apply seal packing in a continuous line as shown in the illustration.





Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

Text in Illustration





NOTICE:
* Remove any oil from the contact surfaces.
* Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.

(c) Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.





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

Text in Illustration





NOTICE:
Do not start the engine for at least 2 hours after installation.

36. INSTALL OIL PAN DRAIN PLUG

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

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

37. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY





(a) Install 3 new gaskets as shown in the illustration.

(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

(c) Apply seal packing as shown in the illustration.





Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Text in Illustration





NOTICE:
* Remove any oil from the contact surfaces.
* Install the head cover within 3 minutes after applying seal packing.

(d) Install the head cover with the 12 bolts and a new seal washer.





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

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

Text in Illustration





NOTICE:
Do not start the engine for at least 2 hours after installation.

HINT
After tightening all the bolts, check the tightening torque of bolts 1 and 11. Retighten the bolts if necessary.

38. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH





(a) Install 3 new gaskets as shown in the illustration.

(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH.

(c) Apply seal packing as shown in the illustration.





Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Text in Illustration





NOTICE:
* Remove any oil from the contact surfaces.
* Install the cylinder head cover sub-assembly LH within 3 minutes after applying seal packing.

(d) Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.





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

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

Text in Illustration





NOTICE:
Do not start the engine for at least 2 hours after installation.

HINT
After tightening all bolts, check the tightening torque of bolts 1 and 10. Retighten the bolts if necessary.

39. INSTALL WATER OUTLET

(a) Install 2 new gaskets and a new O-ring.

HINT
Apply soapy water to the O-ring.

(b) Install the water outlet with the 2 bolts and 4 nuts.





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

Text in Illustration





NOTICE:
Make sure that the O-ring does not get caught between the parts.

40. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

(b) Install the engine oil level dipstick guide.

41. INSTALL NO. 1 OIL COOLER BRACKET

(a) Using an E8 "TORX" socket, install the 2 stud bolts as shown in the illustration.





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

(b) Install a new gasket to the No. 1 oil cooler bracket.

(c) Install the oil cooler pipe with the bolt and 2 nuts.

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

(d) Install a new gasket to the No. 1 oil pan.

(e) Install the No. 1 oil cooler bracket with oil cooler pipe with the 3 bolts and 3 nuts.

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

42. INSTALL OIL COOLER ASSEMBLY

(a) Install a new O-ring.

(b) Install the oil cooler assembly with the union bolt.

Torque : 68 Nm (693 kgf-cm, 50 ft-lbf)

(c) Install the No. 4 water by-pass hose with the bolt, hose clamp and 2 clamps.





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

Text in Illustration





HINT
Make sure to install the hose to the upper part of the hose clamp as shown in the illustration.

(d) Install the water pipe sub-assembly and a new gasket with the 2 nuts and clamp.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

43. INSTALL CRANKSHAFT PULLEY Installation

44. INSTALL OIL FILTER ELEMENT Replacement

45. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cock sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the water drain cocks as shown in the illustration.





Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

Text in Illustration





NOTICE:
Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

46. INSTALL NO. 1 OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe to the head cover with the union.

(c) Install a new gasket and temporarily install the oil pipe to the cylinder head with the union.

(d) Tighten the oil pipe union on the head cover side.

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

(e) Tighten the oil pipe union on the cylinder head side.

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

47. INSTALL OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe to the head cover with the union.

(c) Install a new gasket and temporarily install the oil pipe to the cylinder head with the union.

(d) Install the bolt to the cylinder head.

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

(e) Tighten the oil pipe union to the head cover side.

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

(f) Tighten the oil pipe union to the cylinder head side.

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

48. INSTALL CRANK POSITION SENSOR Installation

49. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) Installation

50. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) Installation

51. INSTALL VVT SENSOR (for Bank 1) Installation

52. INSTALL VVT SENSOR (for Bank 2) Installation

53. INSTALL PCV VALVE SUB-ASSEMBLY Installation

54. INSTALL SPARK PLUG Installation

55. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install a new oil filler gasket.

(b) Install the oil filler cap sub-assembly.