Part 1

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL STUD BOLT

(a) Install the stud bolts as shown in the illustration.

Torque : 11 Nm (112 kgf-cm, 8.1 ft-lbf) for stud bolt A

Torque : 4.5 Nm (46 kgf-cm, 40 in-lbf) for stud bolt B

2. INSTALL STRAIGHT PIN

(a) Using a plastic-faced hammer, tap into the new straight pin.

Standard protrusion:

Pin A 22.5 to 23.5 mm (0.886 to 0.925 in.)

Pin B 10.5 to 11.5 mm (0.413 to 0.453 in.)

Pin C 8.5 to 9.5 mm (0.335 to 0.374 in.)

Pin D 5.5 to 6.5 mm (0.217 to 0.256 in.)

3. INSTALL TIGHT PLUG

(a) Apply adhesive around tight plugs.

Adhesive:

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

(b) Using SST, install the tight plugs as shown in the illustration.

SST : 09550-60010

09951-00350

SST : 09950-70010

09951-07150

Standard depth:

0.2 to 1.2 mm (0.008 to 0.047 in.)

4. INSTALL OIL JET

(a) Using a screw driver and hammer, tap in a oil jet.

5. INSTALL NO.1 SUB-ASSEMBLY OIL NOZZLE

(a) Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.

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

6. INSTALL HOLE SNAP RING

(a) Using a small screwdriver, install a new snap ring onto one side of the piston pin hole.

HINT
Check that an end gap of the snap ring is not overlapped with the pin hole cutout portion of the piston.

7. INSTALL WITH PIN PISTON SUB-ASSEMBLY

(a) Gradually heat the piston to about 80°C (176°F).

(b) Coat the piston pin with engine oil.

(c) Align the front marks of the piston and connecting rod, and push in the piston pin with thumb.

8. INSTALL HOLE SNAP RING

(a) Using a small screwdriver, install a new snap ring onto the other side of the piston pin hole.

HINT
Make sure that the gap in the snap ring does not overlap with the pin hole cutout portion of the piston.

9. INSTALL PISTON RING SET

(a) Install the oil ring expander and 2 side rails by hand.

(b) Using a piston ring expander, install the 2 compression rings.

NOTICE:
Mark Install the compression ring No. 2 with the painted mark facing upward.

(c) Position the piston rings so that the ring ends are as shown.

10. INSTALL CONNECTING ROD BEARING

(a) Align the bearing claw with the groove of the connecting rod or connecting cap.

NOTICE:
Clean the back side of the bearing and the bearing surface of the connecting rod and keep them free of oils and fats.

11. INSTALL CRANKSHAFT BEARING

HINT
There are 2 types of main bearings with different widths (19.0 mm (0.748 in.) and 22.4 mm (0.882 in.)) for use in the inspection. Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.

(a) Clean each main journal and bearing.

(b) Install the 4 upper bearings.

(1) Install the upper bearings near the center of the cylinder block.

NOTICE:
* The width of the No. 1 and No. 4 journal bearings is different from that of the No. 2 and No. 3 journal bearings. Therefore, confirm whether it is the correct journal bearing prior to installation.
* Do not apply engine oil to the bearing installation surfaces of the cylinder block and the back side of the bearings.
* Check that the oil groove on the cylinder block can be seen through the oil supply holes of the upper bearing.

(c) Install the 4 lower bearings.

(1) Install the lower bearings near the center of the cylinder block.

NOTICE:
Do not apply engine oil to the bearing and its contact surface.

HINT
A number marked on each main bearing cap indicates the installation position.

12. INSTALL CRANKSHAFT

(a) Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block.

(b) Install the 2 upper thrust washers onto the No. 2 journal position of the cylinder block.

(1) Push the crankshaft toward the front (rear) side.

(2) Install the 2 upper thrust washers with the oil grooves facing outward.

(c) Install the 2 lower thrust washers onto the No. 2 bearing cap with the grooves facing outward.

(d) Examine the front marks and numbers, check the sequence number is as shown in the illustration and install the bearing caps on the cylinder block.

(e) Apply a light coat of engine oil to the threads of bearing cap bolts.

(f) Temporarily install the 8 main bearing cap bolts in the inside positions.

(g) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block is under 6 mm (0.23 in.).

(h) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

(i) Apply a light coat of engine oil to the threads of main bearing cap bolts.

(j) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.

Torque : 61 Nm (622 kgf-cm, 45 ft-lbf)

(k) Mark the front side of the bearing cap bolts with paint.

(l) Retighten the bearing cap bolts 90° in the sequence as shown.

(m) Check that the painted mark is now at a 90° angle from the front.

(n) Check that the crankshaft turns smoothly.

(o) Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence shown in the illustration.

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

13. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTIONG ROD

(a) Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.

(b) Check the position of the piston ring ends.

(c) Using a piston ring compressor, push the correct number piston and connecting rod into each cylinder with the front mark of the piston facing forward.

NOTICE:
* Clean the back side of the bearing and the bearing surface of the connecting rod cap and keep them free of oils and fats.
* Match the numbered connecting rod cap with the connecting rod.

(d) Check that the protrusion of the connecting rod cap is facing in the correct direction.

(e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

(f) Using SST, tighten the bolts alternately to the specified torque.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

(g) Mark the front side of the each connecting cap bolt with paint.

(h) Retighten the cap bolts 90° as shown.

(i) Check that the crankshaft turns smoothly.

14. INSTALL RING PIN

(a) Using a plastic-faced hammer, tap in the new ring pins to the specified protrusion height.

Specified protrusion height:

2.7 to 3.3 mm (0.106 to 0.130 in.)

15. INSTALL STRAIGHT PIN

(a) Using a plastic-faced hammer, tap in the new straight pins to the specified protrusion height.

Specified protrusion height:

16. INSTALL STUD BOLT

(a) Using the torx socket wrenchs E5 and E7, install the stud bolts.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) for stud bolt A

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

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) for stud bolt C

17. INSTALL UNION

(a) Apply adhesive to 2 or 3 threads of the bolt end.

Adhesive:

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

(b) Using a deep socket wrench 12, install the unions.

Torque : 15 Nm (150 kgf-cm, 11 ft-lbf)

18. INSTALL TIGHT PLUG

(a) Apply adhesive around the tight plug.

(b) Using SST, tap in the tight plugs to the specified depth.

SST : 09950-60010

09951-00250

SST : 09950-70010

09951-07150

Specified depth:

1.5 mm (0.059 in.)

19. INSTALL WITH HEAD STRAIGHT SCREW PLUG

(a) Using a straight hexagon wrench 14, install a new gasket and straight screw plug.

Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)

20. INSTALL VALVE STEM OIL O SEAL OR RING

HINT
The intake valve stem oil seal is light brown and the exhaust valve stem oil seal is gray.

(a) Apply a light coat of engine oil to the valve guide bush.

(b) Using SST, push in a new valve stem oil seal.

SST : 09201-41020

21. INSTALL VALVE SPRING SEAT

22. INSTALL VALVE

(a) Apply the engine oil to the valve as shown in the illustration.

(b) Place the cylinder head on a wooden block.

(c) Install the valve, inner compression spring and valve spring retainer.

(d) Using SST, compress the inner compression spring and place the 2 valve spring retainer rocks around the valve stem.

SST : 09202-70020

09202-00010

(e) Using a pin punch 5, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:
Be careful not to damage the valve stem tip.

23. INSTALL VALVE LIFTER

(a) Apply the engine oil to the valve stem end and valve lifter, and install the valve lifter onto the valve stem.

(b) Check that the valve lifter rotates smoothly by hand.

24. INSTALL REAR ENGINE OIL SEAL RETAINER

(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.

(b) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shown in the illustration.

Seal packing:

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

NOTICE:
Parts must be assembled within 3 minutes of application. Otherwise, the seal packing must be removed and reapplied.

(c) Install the oil seal retainer with the 5 bolts and 2 nuts.

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

Torque : 10 Nm (102 kgf-cm, 7.4 ft-lbf) for nuts

25. INSTALL KNOCK CONTROL SENSOR

(a) Install the 2 knock sensors with the 2 bolts as shown in the illustration.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(b) Connect the knock sensor connectors.

(c) Connect the knock sensor wire.

26. INSTALL NO.1 WATER OUTLET PIPE

(a) Install the water outlet pipe with the 3 bolts.

Torque : 10 Nm (102 kgf-cm, 7.4 ft-lbf)

27. INSTALL CYLINDER HEAD GASKET

(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

(b) Apply a continuous bead of seal packing (diameter 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.

Seal packing:

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

NOTICE:
Install the cylinder head within 3 minutes of applying the seal packing. After installation, cylinder head bolts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.

(c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
* Be careful of the installation direction.
* Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

28. INSTALL CYLINDER HEAD SUB-ASSEMBLY

(a) Place the RH cylinder head on the cylinder head gasket.

(b) Install the 8 cylinder head bolts.

HINT
* The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)).
* If any cylinder head bolts are broken or deformed, replace them.

(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(2) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.

Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

If any cylinder head bolts do not meet the torque specification, replace them.

NOTICE:
Do not drop the washers into the cylinder head.

(3) Mark the front of the cylinder head bolt with paint.

(4) Retighten the cylinder head bolts by 180° as shown.

(5) Check that the painted marks are now at 180° from the engine front.

29. INSTALL NO.2 CYLINDER HEAD GASKET

(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

(b) Apply a continuous bead of seal packing (Diameter 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.

NOTICE:
* Be careful of the installation direction.
* Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

30. INSTALL CYLINDER HEAD LH

(a) Place the LH cylinder head on the cylinder head gasket.

(b) Install the 8 cylinder head bolts.

HINT
* The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)).
* If any cylinder head bolts are broken or deformed, replace them.

(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(2) Using several steps, uniformly install and tighten the 8 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.

(4) Retighten the cylinder head bolts by 180° as shown.

(5) Check that the painted marks are now at 180° from the engine front.

(c) Install the 2 cylinder head bolts.

(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.

(2) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.

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

31. INSTALL NO.1 CAMSHAFT BEARING

(a) Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.

NOTICE:
* Install the bearing while aligning it with the oil hole in the bearing cap.
* Clean the back side of the bearing and the surface of the bearing cap and keep them free of oils and fats.