Part 2

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - (Continued)

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)

(d) Remove the bar from the chain tensioner.

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 dia1.27 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.

31. 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 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.

32. INSTALL FRONT CRANKSHAFT OIL SEAL Installation

33. INSTALL WATER PUMP ASSEMBLY

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

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

34. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

35. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 oil pan baffle plate with the 6 bolts.

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

36. INSTALL OIL PAN SUB-ASSEMBLY Installation

37. INSTALL OIL STRAINER SUB-ASSEMBLY Installation

38. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Installation

39. INSTALL OIL PAN DRAIN PLUG

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

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

40. POUR ENGINE OIL

HINT
Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.

41. INSTALL SPARK PLUG TUBE GASKET

(a) Using a cutter knife, cut off the seal part of the removed gasket.

Text in Illustration

(b) Using the removed gasket and a hammer, tap in a new gasket until it stops.

Text in Illustration

HINT
If the removed gasket does not fit on the new one, correct the removed one with pliers.

(c) Apply a light coat of MP grease to the gasket lip.

(d) Return the ventilation baffle plate claws to their original positions.

42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover or cylinder head cover.

(b) Apply seal packing 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 surface.
* Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

(d) Install a new gasket to the cylinder head cover.

(e) Install the seal washers to the bolts.

(f) Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

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

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

Standard Bolt:

Text in Illustration

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

43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover or cylinder head cover.

(b) Apply seal packing 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 surface.
* Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

(d) Install a new gasket to the cylinder head cover.

(e) Install the seal washers to the bolts.

Text in Illustration

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

44. INSTALL CRANKSHAFT PULLEY Installation

45. INSTALL PCV VALVE SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the PCV valve.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the PCV valve.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

(c) Install the PCV valve hose.

46. INSTALL SPARK PLUG Installation

47. INSTALL REAR WATER BY-PASS JOINT

(a) Apply soapy water to a new O-ring and install it to the water outlet pipe. Then install 2 new gaskets to the water ports LH and RH.

Text in Illustration

(b) Install the rear water by-pass joint with the 2 bolts and 4 nuts.

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

48. INSTALL WATER INLET HOUSING Installation

49. INSTALL OIL FILTER BRACKET Installation

50. INSTALL OIL FILTER ELEMENT Replacement

51. INSTALL NO. 2 OIL PIPE Installation

52. INSTALL NO. 1 OIL PIPE Installation

53. INSTALL OIL FILLER CAP HOUSING

(a) Install a new gasket and the oil filler cap housing with the 2 nuts.

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

Text in Illustration

(b) Install the oil filler cap.

54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) RH:

(1) Apply a light coat of engine oil to 2 new O-rings.

(2) Install the 2 O-rings to the 2 oil control valves.

(3) Install the 2 oil control valves with the 2 bolts.

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

NOTICE:
Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.

(b) LH:

(1) Apply a light coat of engine oil to 2 new O-rings.

(2) Install the 2 O-rings to the 2 oil control valves.

(3) Install the 2 oil control valves with the 2 bolts.

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

NOTICE:
Be careful that the O-ring is not cracked when installing the camshaft timing oil control valve.

55. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the sensor with the bolt.

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

56. INSTALL VVT SENSOR

(a) RH:

Install the 2 VVT sensors with the 2 bolts.

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

(b) LH:

Install the 2 VVT sensors with the 2 bolts.

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

57. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the drain cock.

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

Text in Illustration

NOTICE:
* Install the drain cock within 3 minutes after applying adhesive.
* Do not expose the drain cock to coolant within 1 hour of the installation.

(c) Rotate the drain cock clockwise to the position shown in the illustration.

NOTICE:
* Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque.
* Do not loosen the drain cock after setting it correctly.

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

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

58. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

(a) Install a new gasket to the sensor.

(b) Using a 19 mm deep socket wrench, install the sensor.

Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

59. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, install the oil pressure switch.

Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)