Part 3

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - Continued

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)

41. INSTALL SPARK PLUG TUBE GASKET LH

(a) Using a cutter, cut off the sealing part of the removed plug tube gasket LH.

Text in Illustration

(b) Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.

Text in Illustration

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.

HINT
If the plug tube gasket that will be used to install a new gasket is deformed and cannot be positioned on a new gasket, correct the deformation using pliers.

(c) Return the claws of the ventilation baffle plate to their original positions.

42. INSTALL SPARK PLUG TUBE GASKET

HINT
Perform the same procedure as for the LH side.

43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Apply seal packing as shown in the illustration.

Text in Illustration

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

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

(b) Install 3 new gaskets as shown in the illustration.

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

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

44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Apply seal packing as shown in the illustration.

Text in Illustration

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

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

45. INSTALL REAR WATER BY-PASS JOINT

(a) Install 2 new gaskets and a new O-ring.

HINT
Apply soapy water to the O-ring.

(b) Install the water by-pass joint with the 2 bolts and 4 nuts.

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

NOTICE:
Be careful that the O-ring does not get caught between the parts.

46. INSTALL INLET WATER WITH THERMOSTAT SUB-ASSEMBLY

(a) Install a new gasket and inlet water with thermostat with the 3 nuts.

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

47. INSTALL INLET WATER ASSEMBLY

(a) Install the 3 water by-pass hoses.

(b) Install 2 new O-rings.

HINT
Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installing it.

(c) Install the inlet water assembly with the 4 bolts and nut.

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

NOTICE:
Be careful that the O-ring does not get caught between the parts.

(d) Install the 3 water by-pass hoses.

48. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(b) Using SST, install the pulley bolt.

Text in Illustration

SST : 09213-70011

09213-70020

SST : 09330-00021

Torque : 250 Nm (2549 kgf-cm, 184 ft-lbf)

49. INSTALL OIL FILTER ELEMENT

(a) Clean the inside of the oil filter cap, the threads and O-ring groove.

Text in Illustration

(b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

(c) Set a new oil filter element to the oil filter cap.

(d) Remove any dirt or foreign matter from the installation surface of the engine.

(e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap.

NOTICE:
Be careful that the O-ring does not get caught between the parts.

(f) Using SST, tighten the oil filter cap.

Text in Illustration

SST : 09228-06501

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Make sure that the oil filter is installed securely as shown in the illustration.

50. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cock sub-assemblies.

Text in Illustration

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the water drain cock sub-assemblies as shown in the illustration.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

NOTICE:
Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

51. INSTALL NO. 1 OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the No. 1 oil pipe (on the head cover side).

Text in Illustration

(c) Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head side) with the oil check valve bolt.

(d) Tighten the oil pipe union (on the head cover side).

Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

(e) Tighten the oil check valve bolt (on the cylinder head side).

Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

52. INSTALL NO. 2 OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the No. 2 oil pipe (on the head cover side).

Text in Illustration

(c) Install a new gasket and temporarily install the No. 2 oil pipe (on the cylinder head side) with the oil check valve bolt.

(d) Tighten the oil pipe union (on the head cover side).

Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

(e) Tighten the oil check valve bolt (on the cylinder head side).

Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

53. INSTALL CRANK POSITION SENSOR

(a) Install the crank position sensor with the bolt.

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

54. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Install the 4 camshaft timing oil control valve assemblies with the 4 bolts.

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

55. INSTALL VVT SENSOR

(a) Install the 4 sensors with the 4 bolts.

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

56. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive around the ventilation valve sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve sub-assembly.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

57. INSTALL SPARK PLUG

(a) Install the spark plugs.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

58. INSTALL RADIATOR CAP SUB-ASSEMBLY

(a) Install the radiator cap sub-assembly.

59. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install a new gasket.

(b) Install the oil filler cap sub-assembly.