Part 2

1UR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

Continued From Part 1 Part 1

REASSEMBLY

Part 2

23. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)

(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(a) Install the vibration damper with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
25. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)
HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.

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

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

(c) Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Remove the hexagon wrench from the chain tensioner.
27. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) While pushing down the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.
28. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)

(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(c) Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.
HINT: The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears.

(d) Install the crankshaft timing gear to the crankshaft.
(e) Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly.
(f) Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
NOTE:
Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

(g) Remove the pin from the No. 2 chain tensioner.
29. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)
HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner.

30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)

(c) Install the chain tensioner and gasket with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
31. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)

(a) Install the vibration damper with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Remove the hexagon wrench from the No. 1 chain tensioner.
32. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY
(a) for Bank 1:

(1) Using a wrench, hold the hexagonal portion of the No. 3 camshaft.
(2) Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.
Torque: 79 Nm (806 kgf-cm, 58 ft-lbf)

(3) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.
Torque: 100 Nm (1020 kgf-cm, 74 ft-lbf)
(b) for Bank 2:

(1) Using a wrench, hold the hexagonal portion of the No. 1 camshaft.
(2) Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.
Torque: 79 Nm (806 kgf-cm, 58 ft-lbf)

(3) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.
Torque: 100 Nm (1020 kgf-cm, 74 ft-lbf)
33. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Temporarily install the crankshaft pulley bolt.
(b) Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.
(c) Remove the crankshaft pulley bolt.

34. INSTALL WATER INLET PIPE [1][2]Installation
35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY [1][2]Installation
36. INSTALL WATER PUMP Installation
37. INSTALL OIL CONTROL VALVE FILTER
(a) for Bank 1:

(1) Install the oil control valve filter in the cylinder head.
(2) Install a new gasket and the cylinder head cover spacer with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for Bank 2:

(1) Install the oil control valve filter in the cylinder head.
(2) Install a new gasket and the cylinder head cover spacer with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
38. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3, No. 7).
(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
NOTE:
Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Remove any oil from the contact surface.
- Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly.

(d) Install the cylinder head cover sub-assembly with 2 new seal washers and the 15 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
(e) Install a new fuel pump spacer gasket.
39. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps. (No. 1, No. 3, No. 6).
(b) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
NOTE:
Remove any oil from the contact surface.

(a) Perform a visual inspection on the spark plug tube gasket.
Standard:

(b) Install the 8 spark plug tube gaskets to the cylinder head cover sub-assembly.
41. INSTALL CRANKSHAFT PULLEY Installation
42. INSTALL FRONT WATER BY-PASS JOINT

(a) Install the front water by-pass joint and 2 new gaskets with the 4 nuts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
43. INSTALL OIL FILTER BRACKET

(a) Install 2 new gaskets and the filter bracket with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
44. INSTALL OIL FILTER ELEMENT Replacement
45. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the drain cock.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the drain cocks as shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
- Do not rotate the water drain cocks more than 1 revolution (360°) after tightening the water drain cocks to the specified torque.
- Do not loosen the water drain cocks to adjust them. If an adjustment is necessary, remove the cylinder block water drain cocks and reinstall them.

(c) Install the cylinder block water drain cock plugs to the water drain cocks.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
46. INSTALL CAMSHAFT TIMING CONTROL MOTOR (for Bank 1) Installation
47. INSTALL CAMSHAFT TIMING CONTROL MOTOR (for Bank 2) Installation
48. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) for Bank 1:

(1) Apply a light coat of engine oil to a new O-ring.
(2) Install the O-ring to the camshaft timing oil control valve assembly.
(3) Install the camshaft timing oil control valve assembly with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for Bank 2:

(a) Install the crankshaft position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
50. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the camshaft position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
51. INSTALL VVT SENSOR
(a) for Bank 1:

(1) Install the 2 VVT sensors with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) for Bank 2:

(1) Install the 2 VVT sensors with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
52. INSTALL SPARK PLUG Installation
53. INSTALL OIL FILLER CAP HOUSING

(a) Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing.

(b) Install the oil filler cap housing with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
54. INSTALL OIL FILLER CAP SUB-ASSEMBLY