Part 3

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

Part 3 of 3

51. INSTALL WATER PUMP ASSEMBLY

(a) Install a new gasket and the water pump with the 16 bolts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
NOTE:
Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent.

52. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter:
A
3.0 to 4.0 mm (0.118 to 0.158 in.)
B
3.0 mm (0.118 in.)
NOTICE:
- Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
- When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain cover within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

(b) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
NOTICE:
- When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain 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 installing.

Seal Packing Application Chart:

(d) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

(e) Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.
Bolt length:

NOTE:
Make sure that there is no oil on the bolt threads.

(f) Fully tighten the 3 bolts as shown in the illustration.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

(g) Fully tighten the 3 bolts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

(h) Fully tighten the 7 bolts and 2 nuts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT:
Tighten the bolts and nuts in the order from upper to lower as shown in the illustration.

(i) Fully tighten the 12 bolts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT:
Tighten the bolts in the order from lower to upper as shown in the illustration.

(j) Install a new gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 Nm (93 kgf-cm, 81 in-lbf)
53. 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 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.

(d) Install 2 new O-rings.
54. 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)
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 0.156 in.)
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing.

(b) Install the oil pan with the 16 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
55. 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:
4.0 to 6.0 mm (0.156 to 0.236 in.)
- Remove any oil from the contact surface.
- Install the oil pan No. 2 within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing.

(b) Install the oil pan with the 15 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) Install a new gasket and the drain plug.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
56. INSTALL SPARK PLUG TUBE GASKET

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

(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.
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.
HINT:
If a 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.
57. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Remove any oil from the contact surface.
- Install the head cover within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing.

(b) Install 3 new gaskets as shown in the illustration.
(c) Install a new gasket to the head cover.

(d) Install the head cover with the 14 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
58. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(b) Install 3 new gaskets as shown in the illustration.
(c) Install a new gasket to the head cover.

(d) Install the head cover with the 12 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
59. 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)
NOTE:
Be careful that the O-ring does not get caught between the parts.

60. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

(a) Install a new gasket and water inlet with thermostat with the 3 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
61. INSTALL WATER INLET SUB-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 water inlet with the 4 bolts and nut.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTE:
Be careful that the O-ring does not get caught between the parts.

(d) Install the 3 water by-pass hoses.
62. 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.
SST: 09213-70011
09213-70020
SST: 09330-00021
Torque: 250 Nm (2,550 kgf-cm, 184 ft-lbf)
63. INSTALL OIL FILTER ELEMENT

(a) Clean the inside of the oil filter cap, the threads and O-ring groove.
(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 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.
NOTE:
Be careful that the O-ring does not get caught between the parts.

(f) Using SST, tighten the oil filter cap.
SST: 09228-06501
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTE:
Make sure that the oil filter is installed securely as shown in the illustration.

64. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cocks.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the water drain cocks as shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTE:
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)
65. INSTALL NO. 1 OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
NOTE:
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 oil pipe (on the head cover side).
(c) Install a new gasket and temporarily install the 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)
NOTE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

66. INSTALL NO. 2 OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
NOTE:
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 oil pipe (on the head cover side).
(c) Install a new gasket and temporarily install the 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)
NOTE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

67. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
68. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Install the 4 oil control valves with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
69. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the 4 sensors with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
70. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive around the ventilation valve.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
71. INSTALL SPARK PLUG
(a) Install the spark plugs.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
72. INSTALL RADIATOR CAP SUB-ASSEMBLY
(a) Install the radiator cap.
73. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install a new gasket.
(b) Install the oil filler cap.