Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - Continued

21. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Installation

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

23. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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

Torque : 23 Nm (230 kgf-cm, 17 ft-lbf)

24. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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

25. INSTALL CRANKSHAFT TIMING SPROCKET

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

26. 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:
Be careful of the idle gear installation 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.

27. 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.

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 onto 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

28. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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

Text in Illustration

(b) Move the stopper plate downward to set the lock, and 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.

30. 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.

31. INSTALL TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new timing chain case oil seal until its surface is flush with the timing gear case edge.

Text in Illustration

SST : 09223-22010

SST : 09506-35010

Oil seal tap in depth:

0 to 1.0 mm (0 to 0.0394 in.)

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.
* Make sure that the oil seal edge does not stick out of the timing chain case.

32. INSTALL WATER PUMP ASSEMBLY

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

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

NOTICE:
Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

33. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Text in Illustration

Seal packing:

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

Seal diameter:

3.0 mm (0.118 in.)

NOTICE:
* Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
* If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes.
* Do not start the engine for at least 2 hours after installing.

(b) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Text in Illustration

Seal packing:

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

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

NOTICE:
* If there is oil on the contact surfaces, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

Seal Packing Application Chart

(d) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Text in Illustration

(e) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Text in Illustration

Bolt Length

NOTICE:
Make sure that there is no oil on the bolt and nut threads.

(f) Fully tighten the bolts in this order: Area 1 and Area 2.

Text in Illustration

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

(g) Fully tighten the bolts in Area 3.

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

HINT
First tighten the upper bolts and nuts followed by lower bolts and nuts as shown in the illustration.

(h) Fully tighten the bolts in Area 4.

Bolt A - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

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

HINT
Tighten the bolts in the order of lower to upper as shown in the illustration.

(i) Install a new chain cover plate gasket and the chain cover plate with the 4 bolts.

Torque : 9.1 Nm (93 kgf-cm, 81 in-lbf)

34. INSTALL WATER INLET HOUSING

(a) Install 2 new O-rings.

HINT
Apply a small amount of water or soapy water to 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.

Text in Illustration

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

NOTICE:
Be careful 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 drain cock.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

(g) Install the 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 in 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)

35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH

Text in Illustration

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

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

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

Torque : 54 Nm (550 kgf-cm, 40 ft-lbf)

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.

36. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate with the 7 bolts.

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

HINT
Temporarily tighten the 7 bolts. Fully tighten the 2 bolts (A) shown in the illustration before tightening the other bolts.

37. INSTALL OIL PAN SUB-ASSEMBLY

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

Text in Illustration

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

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

(b) Install 2 new O-rings.

Text in 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.)

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

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

Text in Illustration

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

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

38. INSTALL OIL STRAINER SUB-ASSEMBLY

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

Text in Illustration

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

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

Text in Illustration

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

39. 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.

Text in 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.)

NOTICE:
* Remove any oil from the contact surface.
* Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

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

Text in Illustration

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