Part 1

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL STUD BOLT

NOTICE:
It is not necessary to remove a stud bolt unless it is being replaced.

(a) Install the oil pan stud bolt.

(1) Using E6 and E8 "TORX" socket wrenches, install the 6 stud bolts as shown in the illustration.

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

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

Install the cylinder head cover LH stud bolt.

(1) Using an E6 "TORX" socket wrench, install the stud bolt as shown in the illustration.

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

2. INSTALL RING PIN

NOTICE:
It is not necessary to remove a ring pin unless it is being replaced.

(a) Using a plastic-faced hammer, tap in new ring pins to the camshaft housing.

Standard protrusion height:

2.7 to 3.3 mm (0.106 to 0.130 in.)

Text in Illustration

3. INSTALL STRAIGHT PIN

NOTICE:
It is not necessary to remove a straight pin unless it is being replaced.

(a) Using a plastic-faced hammer, tap in new straight pins to the camshaft housing.

Standard Protrusion Height:

Text in Illustration

4. INSTALL REAR CRANKSHAFT OIL SEAL

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

SST : 09223-78010

NOTICE:
* Keep the lip free from foreign matter.
* Do not tap the oil seal at an angle.

(b) Apply MP grease to the lip of the oil seal.

5. INSTALL ENGINE REAR OIL SEAL RETAINER

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

(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

Standard seal diameter:

2 to 3 mm (0.0787 to 0.118 in.)

Text in Illustration

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

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

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

NOTICE:
* When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.
* When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.
* Do not start the engine for at least 2 hours after installation.

6. INSTALL CYLINDER BLOCK WATER JACKET SPACER

(a) Install the 2 water jacket spacers as shown in the illustration.

Text in Illustration

NOTICE:
Make sure that face the "L mark", "R mark" and "UP mark" are oriented as shown in the illustration.

7. INSTALL KNOCK SENSOR Installation

8. INSTALL NO. 1 WATER OUTLET PIPE Installation

9. INSTALL CYLINDER HEAD GASKET Installation

10. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation

11. INSTALL NO. 2 CYLINDER HEAD GASKET Installation

12. INSTALL CYLINDER HEAD LH Installation

13. INSTALL VALVE STEM CAP

(a) Apply a light coat of engine oil to the valve stem caps.

(b) Install the 24 valve stem caps to the cylinder head.

14. INSTALL VALVE LASH ADJUSTER ASSEMBLY

(a) Inspect the valve lash adjuster Engine Unit.

(b) Install the 24 valve lash adjusters to the cylinder head.

NOTICE:
Install the lash adjuster at the same place it was removed from.

15. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.

Install the 24 valve rocker arms as shown in the illustration.

Text in Illustration

16. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

(a) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

(b) Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing.

(c) Check the marks and numbers on the camshaft bearing caps and place each of them in the proper position facing the proper direction.

(d) Temporarily install the 8 bolts in the order shown in the illustration.

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

17. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Make sure that the valve rocker arm is installed as shown in the illustration.

Text in Illustration

(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:

3.5 to 4.5 mm (0.138 to 0.177 in.)

Text in Illustration

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

(c) Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

Text in Illustration

NOTICE:
* When installing the camshaft housing sub-assembly LH, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
* If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly LH, clean the installation surfaces and reapply seal packing.
* If the camshaft housing sub-assembly LH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
* Do not start the engine for at least 2 hours after installing.

(d) Tighten the 8 bolts in the order shown in the illustration.

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

NOTICE:
Thoroughly wipe clean any seal packing.

18. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

(a) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

(b) Install the camshaft and No. 2 camshaft to the camshaft housing.

(c) Check the marks and numbers on the camshaft bearing caps and place each of them in the proper position facing the proper direction.

(d) Temporarily install the 8 bearing cap bolts in the order shown in the illustration.

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

19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

Text in Illustration

(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:

3.5 to 4.5 mm (0.138 to 0.177 in.)

Text in Illustration

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

(c) Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

Text in Illustration

NOTICE:
* When installing the camshaft housing RH, it is necessary to correctly position the camshafts as shown in the illustration.
Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur.
* If any of the bolts are loosened during installation, remove the camshaft housing sub-assembly RH, clean the installation surfaces and reapply seal packing.
* If the camshaft housing sub-assembly RH is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
* Do not start the engine for at least 2 hours after installing.

(d) Tighten the 8 bolts in the order shown in the illustration.

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

NOTICE:
Thoroughly wipe clean any seal packing.

20. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (for Bank 2)

(a) Install the No. 3 chain tensioner assembly with the bolt.

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

(b) Push in the tensioner and insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the tensioner.

Text in Illustration

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

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration

(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

SST : 09922-10010

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

Text in Illustration

(e) Remove the pin from the No. 3 chain tensioner assembly.

22. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 1)

(a) Install the No. 2 chain tensioner assembly with the bolt.

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

(b) Push in the No. 2 chain tensioner assembly and insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the tensioner.

Text in Illustration

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

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration

(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

SST : 09922-10010

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

Text in Illustration

(e) Remove the pin from the No. 2 chain tensioner assembly.

24. 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)

25. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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

26. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Align the key groove of the timing sprocket with the timing sprocket set key.

(b) Install the timing sprocket to the crankshaft with the sprocket facing inward as shown in the illustration.

Text in Illustration

27. INSTALL NO. 1 IDLE GEAR SHAFT

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

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

Text in Illustration

NOTICE:
Make sure that the idle gear is installed facing the proper direction.

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

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

28. INSTALL NO. 1 CHAIN SUB-ASSEMBLY

(a) Align the mark plate 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 around 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 when tightening 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 it to the RH block bore center line (TDC/compression).

Text in Illustration

29. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the stopper plate of the tensioner clockwise and push in the plunger of the tensioner as shown in the illustration.

Text in Illustration

(b) Turn the stopper plate of the tensioner counterclockwise and insert a pin of 1.27 mm (0.0500 in.) into the holes on the stopper plate and tensioner to fix the stopper plate in place.

(c) Install the chain tensioner with the 2 bolts.

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

(d) Remove the pin from the No. 1 chain tensioner.