Part 2
1NR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
15. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Check that the straight pin is installed on the No. 2 camshaft.
(b) Put the camshaft timing exhaust gear and No. 2 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.
(c) Tighten the flange bolt with the camshaft timing exhaust gear secured in place.
Text in Illustration
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(d) Make sure that the camshaft timing exhaust gear is locked.
16. INSTALL TIMING CHAIN GUIDE
(a) Install the timing chain guide with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
17. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the crankshaft in the position (90° ATDC) shown in the illustration.
Text in Illustration
HINT
Make sure that the timing mark of the crankshaft is positioned as shown in the illustration.
(b) Set the camshaft timing gear and camshaft timing exhaust gear in the positions (20° ATDC) shown in the illustration.
Text in Illustration
(c) Set the crankshaft in the position (20° ATDC) shown in the illustration.
(d) Align the timing marks of the camshaft with the mark plates of the timing chain and install the timing chain.
Text in Illustration
18. INSTALL TIMING CHAIN TENSION ARM
(a) Install the timing chain tension arm with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
19. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Install a new chain tensioner gasket to the cylinder head.
(b) Install the No. 1 chain tensioner with the 2 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) Install the No. 2 chain vibration damper with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Remove the bar from the No. 1 chain tensioner.
Text in Illustration
(e) Turn the crankshaft approximately 20° counterclockwise to set it to TDC. Make sure that the timing marks and mark plates are correctly positioned and that the chain is securely fit into the tension arm, guide and vibration damper.
Text in Illustration
20. INSTALL TIMING CHAIN COVER OIL SEAL Installation
21. INSTALL THERMOSTAT Installation
22. INSTALL NO. 2 WATER INLET HOUSING GASKET Installation
23. INSTALL WATER INLET Installation
24. INSTALL WATER INLET HOUSING Installation
25. INSTALL TIGHT PLUG Installation
26. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
27. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the crankshaft pulley, and then slide on the crankshaft pulley.
(b) Using SST, install the crankshaft pulley bolt.
SST : 09960-10010
09962-01000
09963-01000
Torque : 128 Nm (1305 kgf-cm, 94 ft-lbf)
28. INSTALL WATER PUMP PULLEY
SST : 09960-10010
09962-01000
09963-00600
(a) Using SST, install the water pump pulley with the 4 bolts.
SST : 09960-10010
09963-00600
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
29. INSTALL OIL FILTER ELEMENT
(a) Clean the inside of the oil filter cap, the threads and gasket groove.
Text in Illustration
(b) Apply a small amount of engine oil to a new oil filter cap gasket 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 small amount of engine oil to the oil filter cap gasket again and temporarily tighten the oil filter cap.
(f) Using SST, tighten the oil filter cap.
Text in Illustration
SST : 09228-06501
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
NOTICE:
* Make sure that the oil filter is installed securely as shown in the illustration.
* Be careful that the oil filter cap gasket does not get caught between the parts.
(g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.
Text in Illustration
NOTICE:
Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.
(h) Install the oil filter drain plug.
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE:
Be careful that the O-ring does not get caught between the parts.
30. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the engine coolant temperature sensor.
(b) Using a 19 mm deep socket wrench, install the engine coolant temperature sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
31. INSTALL KNOCK SENSOR
(a) Install the knock sensor with the bolt.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE:
Make sure that the knock sensor is as shown in the illustration.
32. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Text in Illustration
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
NOTICE:
* Install the oil pressure switch within 3 minutes after applying adhesive.
* Do not start the engine within 1 hour after installation.
33. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring of the sensor.
(b) Install the crankshaft position sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
34. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET
(a) Install the 2 new camshaft bearing cap oil hole gaskets to the No. 1 camshaft bearing cap.
35. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Install a new gasket to the cylinder head cover.
NOTICE:
Remove any oil from the contact surfaces.
(b) Apply seal packing as shown the illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Bead diameter:
2.0 mm (0.0787 in.)
NOTICE:
* Remove any oil from the contact surfaces.
* Install the cylinder head 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 the installation.
(c) Temporarily install the cylinder head cover with 2 new seal washers and the 17 bolts.
Text in Illustration
(d) Apply a light coat of engine oil to the O-rings of the No. 1 crankshaft position sensors.
(e) Temporarily install the 2 No. 1 crankshaft position sensors with the 2 bolts.
(f) Fully tighten the 19 bolts in the order shown in the illustration.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
36. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Using a 27 mm deep socket wrench, install the ventilation valve.
Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)
37. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Apply a light coat of engine oil to 2 new O-rings, and then install them onto the camshaft timing oil control valves.
(b) Install the 2 camshaft timing oil control valves with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
38. INSTALL SPARK PLUG
(a) Using a 14 mm spark plug wrench, install the 4 spark plugs.
Text in Illustration
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
39. INSTALL OIL FILLER CAP GASKET
(a) Install the gasket to the cap.
40. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install the oil filler cap.
41. INSTALL REAR ENGINE OIL SEAL
(a) Apply seal packing in a continuous bead as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
* Remove any oil from the contact surfaces.
* Install a new rear engine oil seal within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(b) Wipe off the excess seal packing, leaving only the specified amount in the areas shown in the illustration.
Text in Illustration
(c) Apply MP grease to the lip of a new rear engine oil seal.
NOTICE:
Keep the lip free from foreign matter.
(d) Using SST and a hammer, tap in the rear engine oil seal until its surface is flush with the cylinder block and oil pan.
SST : 09223-47020
SST : 09950-70010
09951-07150
Oil seal tap in depth:
-0.2 to 1.2 mm (-0.00787 to 0.0472 in.)
NOTICE:
* Uniformly tap in the oil seal.
* Do not tap the rear engine oil seal at an angle.
* Wipe off extra grease from the crankshaft.