Part 1

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL TIGHT PLUG

NOTICE:
If water leaks from the tight plug or the plug corrodes, replace it.

(a) Apply adhesive around the tight plugs.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Using SST, tap in the tight plugs.

SST : 09950-60010

09951-00340

SST : 09950-70010

09951-07100

2. INSTALL STRAIGHT PIN

(a) Using a plastic hammer, tap in new straight pins to the cylinder block.

Standard protrusion:

3. INSTALL STUD BOLT

(a) Using E8 and E10 "TORX" socket wrenches, install the stud bolt.

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

B bolt - Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)

4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the No. 1 oil nozzle sub-assembly.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

5. INSTALL PISTON SUB-ASSEMBLY WITH PIN

(a) Using a screwdriver, install a new piston pin hole snap ring at one end of the piston pin hole.

HINT
Confirm that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

(b) Gradually heat the piston to approximately 80°C (176°F).

(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

HINT
The piston and pin are a matched set.

(e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

(f) Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.

HINT
Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

6. INSTALL PISTON RING SET

(a) Install the oil ring expander and 2 side rails by hand.

(b) Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

(c) Position the piston rings so that the ring ends are as shown in the illustration.

NOTICE:
Do not align the ring ends.

7. INSTALL CRANKSHAFT BEARING

NOTICE:
Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

(a) Clean the main journal and both surfaces of the bearing.

(b) Install the upper bearing.

(1) Install the upper crankshaft bearings to the cylinder block as shown in the illustration.

NOTICE:
* Do not apply engine oil to the bearings and the contact surfaces.
* Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal.

(c) Install the lower bearing.

(1) Install the lower crankshaft bearings to the crankshaft bearing caps.

(2) Using a vernier caliper, measure the distance between the crankshaft bearing cap's edge and the lower crankshaft bearing's edge.

Dimension (A - B):

0.7 mm (0.0276 in.) or less.

NOTICE:
Do not apply engine oil to the crankshaft bearings and the contact surfaces.

8. REMOVE CRANKSHAFT THRUST WASHER SET

(a) Apply engine oil to the crankshaft thrust washer.

(b) Install the 2 upper crankshaft thrust washers under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

9. INSTALL CRANKSHAFT

(a) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

(b) Confirm the projection and numbers of the main bearing caps and install the bearing caps on the cylinder block.

HINT
A number is marked on each main bearing cap to indicate the installation position.

(c) Apply a light coat of engine oil to the threads and under the head of the bearing cap bolts.

(d) Temporarily install the 8 main bearing cap bolts to the inside positions.

(e) Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

Bolt length:

100 to 102 mm (3.94 to 4.02 in.)

(f) Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.

(g) Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

(h) Install the 8 main bearing cap bolts to the outside positions.

Bolt length:

105.5 to 107.5 mm (4.15 to 4.23 in.)

(i) Install the crankshaft bearing cap bolts.

HINT
The main bearing cap bolts are tightened in 2 progressive steps.

(j) Step 1

(1) Install and uniformly tighten the 16 crankshaft bearing cap bolts in the sequence shown in the illustration.

Torque : 61 Nm (622 kgf-cm, 45 ft-lbf)

If any of the main bearing cap bolts does not meet the torque specified, replace it.

(k) Step 2

(1) Mark the front of the bearing cap bolts with paint.

(2) Retighten the bearing cap bolts 90° in the order above.

(3) Check that the painted mark is now at a 90° angle to the front.

(l) Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

Torque : 52 Nm (525 kgf-cm, 38 ft-lbf)

HINT
* Bolt (A) length: 45 mm (1.77 in.)
* Except bolt (A) length: 30 mm (1.18 in.)

(m) Check that the crankshaft turns smoothly.

(n) Check the crankshaft thrust clearance Engine Unit.

10. INSTALL CONNECTING ROD BEARING

(a) Install the connecting rod bearing to the connecting rod and connecting rod cap.

(b) Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges and the connecting rod bearing's edge.

Dimension (A - B):

0.7 mm (0.0276 in.) or less

NOTICE:
Do not apply engine oil to the bearings and the contact surfaces.

11. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.

(b) Position the piston rings so that the ring ends are as shown in the illustration.

NOTICE:
Do not align the ring ends.

(c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

NOTICE:
Match the numbered connecting rod cap with the connecting rod.

(d) Check that the front mark of the connecting rod cap is facing forward.

(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.

(f) Install the connecting cap bolts.

HINT
The connecting cap bolts are tightened in 2 progressive steps.

(g) Step 1

(1) Install and alternately tighten the bolts of the connecting rod cap in several steps.

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

(h) Step 2

(1) Mark the front side of each connecting cap bolt with paint.

(2) Tighten the cap bolts another 90° as shown in the illustration.

(3) Check the painted mark is now at a 90° angle to the front.

(i) Check that the crankshaft turns smoothly.

(j) Check the connecting rod thrust clearance Engine Unit.

12. INSTALL RING PIN

(a) Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.

Specified protrusion height:

2.5 to 3.5 mm (0.098 to 0.138 in.)

13. INSTALL NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs.

Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)

14. INSTALL NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs.

Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)

15. INSTALL STUD BOLT

NOTICE:
If the stud bolt is deformed or the threads are damaged, replace it.

(a) Using E6 and E8 "TORX" socket wrenches, install the stud bolts.

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

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

16. INSTALL STRAIGHT PIN

(a) Using a plastic hammer, tap in 4 new straight pins as shown in the illustration.

Specified protrusion height:

17.5 to 19.5 mm (0.689 to 0.768 in.)

17. INSTALL VALVE SPRING SEAT

(a) Install the valve spring seats to the cylinder head.

18. INSTALL VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to new valve stem oil seals.

NOTICE:
Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later.

HINT
The intake valve oil seals are gray and the exhaust valve oil seals are black.

(b) Using SST, push in the oil seals.

SST : 09201-41020

NOTICE:
Failure to use SST will cause the seal to be damaged or improperly seated.

19. INSTALL INTAKE VALVE

(a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.

(b) Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.

NOTICE:
Install the same parts in the same combination to the original locations.

(c) Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.

SST : 09202-70020

09202-00010

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:
Be careful not to damage the retainer.

20. INSTALL EXHAUST VALVE

(a) Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration.

(b) Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.

NOTICE:
Install the same parts in the same combination to the original locations.

(c) Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.

SST : 09202-70020

09202-00010

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:
Be careful not to damage the retainer.

21. INSTALL VALVE STEM CAP

(a) Apply a light coat of engine oil to the valve stem caps.

(b) Install the valve stem caps on the valves.

22. INSTALL ENGINE REAR OIL SEAL RETAINER

(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:

2.0 to 3.0 mm (0.079 to 0.118 in.)

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

(b) Install the engine rear oil seal retainer with the 6 bolts.

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

NOTICE:
Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

23. INSTALL WATER INLET PIPE

(a) Install the water inlet pipe with the 2 bolts.

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

(b) Install the No. 1 water by-pass hose.

24. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

(a) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

NOTICE:
Be careful not to allow oil to adhere to the bottom part of the cylinder head.

HINT
The cylinder head bolts are tightened in 3 progressive steps.

(b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(c) Step 1

(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.

Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

(d) Step 2

(1) Mark the cylinder head bolt head with paint as shown in the illustration.

(2) Tighten the cylinder head bolts another 90°.

(e) Step 3

(1) Tighten the cylinder head bolts by an additional 90°.

(2) Check that the painted mark is now facing rearward.

(f) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.

25. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

(a) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

NOTICE:
* Be careful of the installation direction.
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

(b) Place the cylinder head on the cylinder block.

NOTICE:
Be careful not to allow oil to adhere to the bottom part of the cylinder head.

HINT
The cylinder head bolts are tightened in 3 progressive steps.

(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(d) Step 1

(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.

Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

(e) Step 2

(1) Mark the cylinder head bolt head with paint as shown in the illustration.

(2) Tighten the cylinder head bolts another 90°.

(f) Step 3

(1) Tighten the cylinder head bolts by an additional 90°.

(2) Check that the painted mark is now facing rearward.

(g) Tighten the 2 bolts in the order shown in the illustration.

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

NOTICE:
Only use the specifications stated above when tightening the bolts 1 and 2 shown in the illustration.

(h) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.

26. INSTALL VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
* Keep the lash adjuster free of dirt and foreign objects.
* Only use clean engine oil.

(a) Place the lash adjuster into a container filled with engine oil.

(b) Insert the SST tip 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 lash adjuster together to move the plunger up and down 5 to 6 times.

(d) Check the movement of the plunger and bleed the air.

OK:

Plunger moves up and down.

NOTICE:
When bleeding air from 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, air will not bleed.

(e) After bleeding the air, remove SST. Then, try to press the plunger quickly and firmly with a finger.

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 the lash adjuster to the same place where it was removed from.

27. 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.

28. INSTALL CAMSHAFT BEARING CAP RH

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

(b) Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly 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)

29. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(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:

3.5 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.
* Do not start the engine for at least 2 hours after installing.

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

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

NOTICE:
* When installing the camshaft housing 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.

(c) Tighten the 8 bolts in the order shown in the illustration.

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

(d) Install 3 new gaskets.

30. INSTALL CAMSHAFT BEARING CAP

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

(b) Install the camshaft No. 3 and camshaft No. 4 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)