Part 3
2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - Continued
40. 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)
41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Apply seal packing as shown in the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
* Remove any oil from the contact surface.
* Install the head cover within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(b) Install 3 new gaskets as shown in the illustration.
(c) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
(d) Install the head cover with the 12 bolts and a new seal washer.
Bolts A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Except bolts A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
HINT
After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Apply seal packing as shown in the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
* Remove any oil from the contact surfaces.
* Install the cylinder head cover sub-assembly LH within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(b) Install 3 new gaskets as shown in the illustration.
(c) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly LH.
(d) Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.
Bolts A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Except bolts A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
HINT
After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.
43. 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.
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.
44. INSTALL ENGINE OIL DIPSTICK GUIDE (w/ Oil Cooler)
(a) Apply a light coat of engine oil to a new O-ring and install it to the engine oil dipstick guide.
(b) Install the engine oil dipstick guide.
45. INSTALL ENGINE OIL DIPSTICK GUIDE (w/o Oil Cooler)
(a) Apply a light coat of engine oil to a new O-ring and install it to the engine oil dipstick guide.
(b) Install the engine oil dipstick guide with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
46. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)
(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.
Text in Illustration
(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)
47. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)
(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 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
48. INSTALL CRANKSHAFT PULLEY Installation
49. INSTALL OIL FILTER ELEMENT Replacement
50. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive around the drain cock sub-assembly.
Text in Illustration
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the water drain cocks as shown in the illustration.
Text in Illustration
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
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)
51. 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 (on the head cover side) with the union.
Text in Illustration
(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) 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.
52. 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 (on the head cover side) with the union.
Text in Illustration
(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.
(d) Install the bolt (A) to the cylinder head.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(e) Tighten the oil pipe union (on the head cover side).
Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)
(f) 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.
53. INSTALL CRANKSHAFT POSITION SENSOR Installation
54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Installation
55. INSTALL VVT SENSOR
Installation
56. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive around the ventilation valve sub-assembly.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using a deep socket wrench 19 mm, install the ventilation valve sub-assembly.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
57. INSTALL SPARK PLUG Installation
58. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install a new oil filler gasket.
(b) Install the oil filler cap sub-assembly.