Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY Continued

29. 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 24 No. 1 valve rocker arms are installed as shown in the illustration.

30. INSTALL CAMSHAFT BEARING CAP (for RH Side)

(a) Apply engine oil to the camshaft journals, camshaft housing, and bearing caps.

(b) Install the camshaft and No. 2 camshaft to the camshaft housing RH.

(c) Make sure of the marks and numbers on the camshaft bearing caps and place them in each 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)

31. 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 4.5 mm (0.138 to 0.177 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing sub-assembly RH within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the camshaft housing sub-assembly RH.

(c) Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

RH:

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

NOTICE:
* When installing the camshaft housing sub-assembly 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 8 bolts in the order shown in the illustration.

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

32. INSTALL CAMSHAFT BEARING CAP (for LH Side)

(a) Apply engine oil to the camshaft journals, camshaft housing, and bearing caps.

(b) Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing LH.

(c) Make sure of the marks and numbers on the camshaft bearing caps and place them in each 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)

33. 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 4.5 mm (0.138 to 0.177 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing sub-assembly LH within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the camshaft housing sub-assembly LH.

(c) Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

LH:

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

NOTICE:
* When installing the camshaft housing sub-assembly 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)

34. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 2 chain tensioner assembly 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 (0.0394 in.) into the hole to fix it.

35. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for RH Side)

(a) Align the mark plates (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 LH with the No. 2 chain sub-assembly 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 (1020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the No. 2 chain tensioner assembly.

36. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 3 chain tensioner assembly 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 (0.0394 in.) into the hole to hold it.

37. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for LH Side)

(a) Align the mark plates (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration.

SST : 09922-10010

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the No. 3 chain tensioner assembly.