Part 1
1UR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
Part 1 of 2
REASSEMBLY
1. INSTALL NO. 1 VENTILATION CONNECTOR
(a) Install the No. 1 ventilation connector as shown in the illustration.
Acceptable angle (A):
-5° to 5°
Tap-in depth (B):
0.2 to 3.2 mm (0.008 to 0.126 in.)
NOTE:
After the installation of the ventilation connector, do not rotate it.
HINT: Connect the No. 1 ventilation connector so that its flat surface faces the rear part of the engine.
2. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the new O-ring to the oil drain pipe sub-assembly.
(c) Install the oil drain pipe sub-assembly with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
3. 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.)
Application position from inside edge of retainer:
3.5 mm (0.138 in.)
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing the oil seal retainer.
- When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is not damaged.
- When installing the engine rear oil seal retainer, make sure that the lip of the oil seal is folded correctly.
(b) Install the engine rear oil seal retainer with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the new O-ring to the oil strainer sub-assembly.
(c) Install the oil strainer sub-assembly with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTE:
Make sure that the O-ring is not twisted or damaged.
5. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) Install the No. 1 oil pan baffle plate with the 8 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
6. INSTALL 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
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
Application position from inside edge of oil pan:
6.0 mm (0.236 in.)
- Remove any oil from the contact surface.
- Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.
(b) Install the oil pan sub-assembly with the 14 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
7. 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
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
- Remove any oil from the contact surface.
- Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing the oil pan sub-assembly.
(b) Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
8. INSTALL VENTILATION PIPE GASKET
(a) Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe.
SST: 09950-60010
09951-00360
SST: 09950-70010
09951-07100
- Do not tap the ventilation pipe gasket at an angle.
- Do not tap the ventilation pipe gasket excessively.
9. INSTALL NO. 1 HEAT EXCHANGER COVER
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.156 in.)
NOTE:
Remove any oil from the contact surface.
(b) Install the No. 1 heat exchanger cover with the 11 bolts and 2 nuts the cover.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
- Install the No. 1 heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing the cover.
10. INSTALL OIL RETURN PIPE GASKET
(a) Install a new oil return pipe gasket.
11. INSTALL CYLINDER BLOCK WATER JACKET SPACER
(a) Install the 2 cylinder block water jacket spacers as shown in the illustration.
- Face the cutouts (indicated by the arrows in the illustration) in the opposite direction to the engine.
- Face each "Up" mark as shown in the illustration.
12. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1) Installation
13. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2) Installation
14. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the 32 valve stem caps to the cylinder head.
15. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Inspect the valve lash adjuster before installing it Engine Unit.
(b) Install the 32 valve lash adjusters to the cylinder head.
NOTE:
Install the lash adjusters to their original positions they were removed from.
16. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.
(b) Make sure that the 32 valve rocker arms are installed as shown in the illustration.
17. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation
18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2) Installation
19. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation
20. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1) Installation
21. INSTALL CRANKSHAFT TIMING GEAR KEY
(a) Install the 2 crankshaft timing gear keys.
22. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.
Continued in Part 2 Part 2