Part 2

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

PART 2

21. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation

22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Installation

23. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Installation

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

25. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the 2 timing gear set keys and timing gear as shown in the illustration.





26. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.





Torque : 23 Nm (230 kgf-cm, 17 ft-lbf)

27. INSTALL NO. 2 CHAIN VIBRATION DAMPER

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





28. INSTALL IDLE SPROCKET ASSEMBLY

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





Text in Illustration





(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.

NOTICE:
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.

29. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plate and timing mark as shown in the illustration and install the chain.





Text in Illustration





HINT
The camshaft mark plate is orange.

(b) Temporarily place the chain on the crankshaft.





NOTICE:
Do not pass the chain over the crankshaft.

(c) Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.





Text in Illustration





NOTICE:
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.





Text in Illustration





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).





Text in Illustration





30. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

31. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.





Text in Illustration





(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 No. 1 chain tensioner assembly with the 2 bolts.





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

(d) Remove the hexagon wrench from the No. 1 chain tensioner assembly.

32. 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.





Text in 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.

33. 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

Oil seal tap in depth:

0 to 1.0 mm (0 to 0.0393 in.)

NOTICE:
* 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.

34. INSTALL WATER PUMP ASSEMBLY

(a) Install a new water pump gasket and the water pump assembly with the 7 bolts.





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

NOTICE:
Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

36. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the baffle plate with the 8 bolts.





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

HINT
Temporarily tighten the 8 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.

37. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.





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

(b) Install a new gasket and the oil strainer sub-assembly with the 3 nuts.





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

(c) Install 2 new O-rings.





38. INSTALL OIL PAN SUB-ASSEMBLY

(a) When replacing a stud bolt, install it by using an E6 "TORX" socket wrench.





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

(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:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installation.

(c) Install the oil pan with the 16 bolts and 2 nuts.





Text in Illustration





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

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for bolts except A

39. INSTALL NO. 2 OIL PAN 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

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan No. 2 within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installation.

(b) Install the oil pan with the 15 bolts and 2 nuts.





Text in Illustration





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

40. INSTALL OIL PAN DRAIN PLUG

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

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