Part 2
1AR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - (Continued)
32. INSTALL CHAIN SUB-ASSEMBLY Installation
33. INSTALL CHAIN TENSIONER SLIPPER Installation
34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation
35. INSTALL TIMING CHAIN GUIDE Installation
36. CHECK NO. 1 CYLINDER TDC/COMPRESSION Installation
37. INSTALL TIMING CHAIN COVER PLATE
(a) Install a new gasket and the timing chain cover plate with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
38. INSTALL TIMING CHAIN COVER TIGHT PLUG
(a) Using a 14 mm hexagon wrench, install a new gasket and the plug.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
40. INSTALL ENGINE MOUNTING BRACKET RH Installation
41. INSTALL TIMING CHAIN COVER OIL SEAL Installation
42. INSTALL SPARK PLUG TUBE GASKET
(a) Visually check the spark plug tube gasket.
OK:
If the result is not as specified, replace the spark plug tube gasket.
(b) Install the 4 plug tube gaskets to the cylinder head cover.
NOTICE:
After pressing in the spark plug tube gasket, make sure the gasket protrudes 1.0 mm (0.0394 in.) or less from the cylinder head cover.
43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Apply a light coat of engine oil to 3 new gaskets.
(b) Install the 3 gaskets to the camshaft bearing caps.
(c) Install a new gasket to the cylinder head cover.
NOTICE:
Remove any oil from the contact surface.
(d) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.0 to 6.0 mm (0.118 to 0.236 in.)
Application width A:
5.0 mm (0.197 in.)
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.
(e) Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.
(f) Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
NOTICE:
Do not apply oil for at least 4 hours after the installation.
44. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the crankshaft pulley.
(b) Using SST, hold the crankshaft pulley and install the pulley bolt.
SST : 09213-54015
SST : 09330-00021
SST : 91551-80650
Torque : 260 Nm (2651 kgf-cm, 192 ft-lbf)
45. INSTALL CRANKSHAFT POSITION SENSOR Installation
46. INSTALL INLET WATER HOUSING
(a) Install a new gasket and the inlet water housing with the 4 bolts and nut.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
47. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler) Installation
48. INSTALL WATER PUMP ASSEMBLY Installation
49. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
50. INSTALL THERMOSTAT Installation
51. INSTALL INLET WATER Installation
52. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
53. INSTALL SEPARATOR CASE
(a) Apply a light coat of engine oil to a new gasket.
(b) Install the gasket to the separator case.
(c) Install the separator case with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
54. INSTALL VENTILATION CASE SUB-ASSEMBLY
(a) 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:
2.5 to 3.5 mm (0.0984 to 0.138 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the ventilation case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
(b) Install the ventilation case, and install the 8 bolts and 2 nuts in the order shown in the illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT
Bolt A should be tightened twice.
55. INSTALL VENTILATION VALVE SUB-ASSEMBLY Installation
56. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side) Installation
57. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side) Installation
58. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side) Installation
59. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side) Installation
60. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install a new gasket to the oil filler cap.
(b) Install the oil filler cap to the cylinder head.
61. INSTALL SPARK PLUG Installation
62. INSTALL ENGINE COVER JOINT
(a) Install the 3 joints.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)