Part 2

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

Part 2 of 3

30. INSTALL CYLINDER BLOCK WATER JACKET SPACER RH

(a) Install the water jacket spacer as shown in the illustration.
HINT:
Be sure to face the slope to the front of the engine.

31. INSTALL CYLINDER BLOCK WATER JACKET SPACER LH
(a) Install the water jacket spacer as shown in the illustration.
HINT:
Be sure to face the slope to the front of the engine.

32. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

(a) Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
2.5 to 3.0 mm (0.098 to 0.118 in.)
- Remove any oil from the contact surface.
- Install the cylinder head gasket within 3 minutes after applying the seal packing.
- Do not apply engine oil within 2 hours of installation.

(b) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
- Be careful of the installation direction.
- Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

(c) Place the cylinder head on the cylinder block.
NOTE:
Be careful not to allow oil to adhere to the bottom part of the cylinder head.
HINT:
The cylinder head bolts are tightened in 3 progressive steps.

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

Right:

(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft-lbf)

(f) Step 2
(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Tighten the cylinder head bolts another 90°.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional 90°.
(2) Check that the painted mark is now facing rearward.

(h) Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

33. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

(a) Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
2.5 to 3.0 mm (0.098 to 0.118 in.)
- Remove any oil from the contact surface.
- Install the cylinder head gasket within 3 minutes after applying the seal packing.
- Do not start the engine for at least 2 hours after installing.

Left:

(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft-lbf)

(f) Step 2
(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Tighten the cylinder head bolts by 90°.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional 90°.
(2) Check that the painted mark is now facing rearward.

(h) Tighten the 2 bolts in the order shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)

(i) Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

34. INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.

(a) Place the lash adjuster into a container filled with engine oil.

(b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
SST: 09276-75010
(c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed the air.
OK:
Plunger moves up and down.
NOTE:
When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

(e) After bleeding the air, remove SST. Then, try to quickly and firmly press the plunger with a finger.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
(f) Install the lash adjusters.
NOTE:
Install the lash adjuster to the same position it was removed from.

35. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Apply engine oil to the lash adjuster tip and valve stem cap end.

(b) Make sure that the valve rocker arms are installed as shown in the illustration.

36. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
(a) Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
(b) Install the camshaft and camshaft No. 2 to the camshaft housing RH.

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

(d) Temporarily tighten the 9 bolts in the order shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
37. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Make sure that the valve rocker arm is installed as shown in the 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 4.0 mm (0.138 to 0.158 in.)
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly RH within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

(c) Install the camshaft housing RH and tighten the 14 bolts in the order shown in the illustration.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
- 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, clean the installation surfaces, and reapply seal packing.
- If the camshaft housing 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.

(d) Tighten the 9 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
38. INSTALL CAMSHAFT BEARING CAP (for Bank 2)
(a) Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
(b) Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing LH.

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

(d) Temporarily tighten the 8 bolts in the order shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
39. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Make sure that the valve rocker arm is installed as shown in the 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 4.0 mm (0.138 to 0.158 in.)
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly LH within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

(c) Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
- When installing the camshaft housing 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, clean the installation surfaces, and reapply seal packing.
- If the camshaft housing 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.

(d) Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
40. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 2 chain tensioner with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) While pushing in the tensioner, insert a pin of dia 1.0 mm (0.039 in.) into the hole to fix it.

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

(a) Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the 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. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.
SST: 09922-10010
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(e) Remove the pin from the chain tensioner.
42. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the chain tensioner with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) While pushing in the tensioner, insert a pin of dia 1.0 mm (0.039 in.) into the hole to hold it.
43. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the 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. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No. 2 chain installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
SST: 09922-10010
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(e) Remove the pin from the chain tensioner.
44. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the chain vibration damper with the 2 bolts.
Torque: 23 Nm (230 kgf-cm, 17 ft-lbf)
45. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 chain vibration dampers.
46. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the 2 timing gear set keys and timing gear as shown in the illustration.
47. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
(b) Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.
NOTE:
Make sure that the idle gear is facing the correct direction.
HINT:
Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.

(c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
HINT:
After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.

48. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plate and timing mark as shown in the illustration and install the chain.
HINT:
The camshaft mark plate is orange.

(b) Rest the chain on top of the crankshaft.

(c) Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.
NOTE:
When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

(d) Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing sprocket.
HINT:
The crankshaft mark plate is yellow.

(e) Temporarily tighten the pulley set bolt.

(f) Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
49. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.
50. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(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 lock pin of the chain tensioner.
51. INSPECT VALVE TIMING
(a) Check the camshaft timing marks.
NOTICE:
- Check each timing mark from a viewpoint directly inline 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.

HINT:
For the 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.
52. INSTALL TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST: 09223-22010
SST: 09506-35010
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.
- Make sure that the oil seal edge does not stick out of the timing chain case.

53. INSTALL WATER PUMP ASSEMBLY

(a) Install a new gasket and the water pump with the 16 bolts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
NOTE:
Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

54. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
A
3.0 to 4.0 mm (0.118 to 0.158 in.)
B
3.0 mm (0.118 in.)
NOTICE:
- Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
- When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain cover within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

(b) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
NOTICE:
- When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain cover 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.

Seal Packing Application Chart:

(d) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

(e) Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.
Bolt length:

NOTE:
Make sure that there is no oil on the bolt threads.

(f) Fully tighten the 3 bolts as shown in the illustration.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

(g) Fully tighten the 3 bolts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

(h) Fully tighten the 7 bolts and 2 nuts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT:
Tighten the bolts and nuts in the order from upper to lower as shown in the illustration.

(i) Fully tighten the 12 bolts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT:
Tighten the bolts in the order from lower to upper as shown in the illustration.

(j) Install a new gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 Nm (93 kgf-cm, 81 in-lbf)

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