Part 1
1NR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install the oil strainer to the oil pan with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) Install the No. 1 oil pan baffle plate to the oil pan with the 6 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL OIL PAN SUB-ASSEMBLY
(a) Install a new oil pan O-ring to the cylinder block.
(b) Apply seal packing to the places 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 surfaces.
* Install the oil pan within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil pan.
(c) Install the oil pan with the 10 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT
* Apply adhesive to the threads of bolts C.
* Apply adhesive to bolts C more than 7.0 mm from the bolt tip.
Bolt C:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Bolt Length:
(d) Wipe off any excess seal packing with a clean piece of cloth.
4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
NOTICE:
Do not reuse the No. 2 oil pan.
(a) Apply seal packing in a continuous bead to a new No. 2 oil pan as shown in the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Bead diameter:
3.0 to 4.5 mm (0.118 to 0.177 in.)
NOTICE:
* Remove any oil from the contact surfaces.
* Install the No. 2 oil pan within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
(b) Install the No. 2 oil pan with the 9 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) Install a new gasket and the oil pan drain plug.
Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)
5. INSTALL CYLINDER BLOCK WATER JACKET SPACER
(a) Install the cylinder block water jacket spacer to the cylinder block as shown in the illustration.
6. INSTALL CYLINDER HEAD GASKET
(a) Apply seal packing to a new cylinder head gasket as shown in the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
* Clean the sealing surfaces of the cylinder head gasket, cylinder head and cylinder block.
* Apply seal packing to the bead on the cylinder head gasket.
* Install the cylinder head within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
(b) Place the gasket on the cylinder block surface with the Lot No. stamp facing upward.
Text in Illustration
NOTICE:
* Remove any oil from the contact surface.
* Make sure that the gasket is installed in the correct direction.
7. INSTALL CYLINDER HEAD SUB-ASSEMBLY
NOTICE:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.
(b) Install the bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(c) Using several steps, uniformly install and tighten the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.
Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)
(d) Mark the front side of the cylinder head bolts with paint.
(e) Retighten the cylinder head bolts an additional 90°, and then once more 90° as shown in the illustration.
Text in Illustration
NOTICE:
Do not tighten the same bolt twice consecutively.
(f) Check that the paint mark is now at a 180° angle to the front.
(g) After tightening the cylinder head bolts, wipe off the seal packing material that seeped out from the contact surface between the cylinder head and cylinder block.
Text in Illustration
NOTICE:
* Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.
* Be sure to avoid clogging the bolt holes when wiping off the seal packing.
8. INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
* Keep the lash adjuster free of dirt and foreign matter.
* Only use clean engine oil.
(a) Place the lash adjuster into a container filled with engine oil.
Text in Illustration
(b) Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
SST : 09276-75010
(c) Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed it.
OK:
Plunger moves up and down.
NOTICE:
When bleeding the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.
(e) After bleeding, remove SST. Then, try to press the plunger quickly and firmly by hand.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
(f) Install the lash adjusters.
NOTICE:
Install each lash adjuster to the same place it was removed from.
9. 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.
Text in Illustration
10. INSTALL CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals and camshaft housing.
(c) Install the camshaft to the camshaft housing.
11. INSTALL NO. 2 CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals and camshaft housing.
(c) Install the No. 2 camshaft to the camshaft housing.
12. INSTALL CAMSHAFT BEARING CAP
(a) Apply engine oil to the bearing caps.
(b) Install the 5 bearing caps to the camshaft housing.
(c) Tighten the 5 bolts in the order shown in the illustration.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
13. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
(a) Apply seal packing in a continuous bead as shown in the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Bead diameter:
3.5 to 4.0 mm (0.138 to 0.158 in.)
NOTICE:
* Remove any oil from the contact surfaces.
* Install the camshaft housing 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.
(b) Set the crankshaft in the position (40° BTDC) shown in the illustration.
Text in Illustration
NOTICE:
Turn the crankshaft clockwise when positioning the No. 1 cylinder after the camshaft housing is installed.
HINT
Make sure that the timing mark of the crankshaft is positioned as shown in the illustration.
(c) Set the camshaft and No. 2 camshaft as shown in the illustration.
Text in Illustration
HINT
Make sure that the straight pin of the camshaft is positioned as shown in the illustration.
(d) Install the camshaft housing and tighten the 18 bolts in the order shown in the illustration.
Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)
NOTICE:
* After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
* 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.
* After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.
14. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check that the straight pin is installed on the camshaft.
(b) Put the camshaft timing gear and camshaft together by aligning the straight pin hole and straight pin.
Text in Illustration
NOTICE:
* Do not forcefully push in the camshaft timing gear. This may cause the camshaft straight pin tip to damage the installation surface of the camshaft timing gear.
* Do not turn the camshaft timing gear in the retard direction (clockwise).
(c) Tighten the flange bolt with the camshaft timing gear secured in place.
Text in Illustration
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(d) Check that the camshaft timing gear can move in the retard direction (clockwise) and locks in the most retarded position.
Text in Illustration
