Part 1
4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL REAR ENGINE OIL SEAL
(a) Place the oil seal retainer on wooden blocks.
(b) Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
SST : 09223-15030
SST : 09950-70010
09951-07100
NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.
2. INSTALL REAR ENGINE 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 (0.0787 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 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
3. INSTALL OUTLET WATER PIPE SUB-ASSEMBLY
(a) Install the outlet water pipe sub-assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL KNOCK CONTROL SENSOR
(a) Install the 2 knock sensors with the 2 bolts as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(b) Connect the 2 knock sensor connectors.
(c) Connect the knock sensor wire clamp.
5. INSTALL CYLINDER BLOCK WATER JACKET SPACER RH
(a) Install the water jacket spacer as shown in the illustration.
Text in Illustration
HINT
Be sure to face the slope to the front of the engine.
6. INSTALL CYLINDER BLOCK WATER JACKET SPACER LH
(a) Install the water jacket spacer as shown in the illustration.
HINT
Be sure to face the slope to the front of the engine.
7. INSTALL CYLINDER HEAD GASKET Installation
8. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation
9. INSTALL NO. 2 CYLINDER HEAD GASKET Installation
10. INSTALL CYLINDER HEAD LH Installation
11. INSTALL VALVE LASH ADJUSTER ASSEMBLY Installation
12. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Installation
13. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY Installation
14. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY Installation
15. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation
16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Installation
17. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Installation
18. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) Installation
19. INSTALL NO. 2 CAMSHAFT Installation
20. INSTALL CAMSHAFT Installation
21. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation
22. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Installation
23. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Installation
24. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) Installation
25. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the 2 timing gear set keys and timing gear as shown in the illustration.
26. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque : 23 Nm (230 kgf-cm, 17 ft-lbf)
27. INSTALL NO. 2 CHAIN VIBRATION DAMPER
(a) Install the 2 No. 2 chain vibration dampers.
28. INSTALL IDLE SPROCKET ASSEMBLY
(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
Text in Illustration
(b) Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.
NOTICE:
Make sure that the idle gear is facing the correct direction.
HINT
Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.
(c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.
Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)
HINT
After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.
29. INSTALL CHAIN SUB-ASSEMBLY
(a) Align the mark plate and timing mark as shown in the illustration and install the chain.
Text in Illustration
HINT
The camshaft mark plate is orange.
(b) Temporarily place the chain on the crankshaft.
NOTICE:
Do not pass the chain over the crankshaft.
(c) Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the banks.
Text in Illustration
NOTICE:
When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.
(d) Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing sprocket.
Text in Illustration
HINT
The crankshaft mark plate is yellow.
(e) Temporarily tighten the pulley set bolt.
(f) Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).
Text in Illustration
30. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.
31. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
Text in Illustration
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
(c) Install the No. 1 chain tensioner assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
32. INSPECT VALVE TIMING
(a) Check the camshaft timing marks.
NOTICE:
* Check each timing mark from a viewpoint directly inline with the center of the camshaft and the timing mark on each camshaft timing gear.
* If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
(b) Check that each camshaft timing mark is positioned as shown in the illustration.
Text in Illustration
HINT
For the intake camshaft:
Be sure to check mark A at the point when marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.
(c) If the valve timing is misaligned, reinstall the timing chain.
(d) Remove the pulley set bolt.
33. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST : 09223-22010
SST : 09506-35010
Oil seal tap in depth:
0 to 1.0 mm (0 to 0.0393 in.)
NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.
* Make sure that the oil seal edge does not stick out of the timing chain case.
34. INSTALL WATER PUMP ASSEMBLY
(a) Install a new water pump gasket and the water pump assembly with the 7 bolts.
Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)
NOTICE:
Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.
35. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY [1][2]Installation
36. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) 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.
37. 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 a new gasket and the oil strainer sub-assembly with the 3 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) Install 2 new O-rings.
38. 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)
(b) 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 0.157 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installation.
(c) Install the oil pan with the 16 bolts and 2 nuts.
Text in Illustration
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for bolt A)
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf for bolts except A)