Installation

2GR-FSE ENGINE MECHANICAL: CYLINDER HEAD GASKET: INSTALLATION

1. INSTALL CYLINDER HEAD GASKET

(a) Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

2.5 to 3.0 mm (0.0984 to 0.118 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head gasket within 3 minutes after applying the seal packing.
* Do not apply engine oil within 2 hours after installation.
(b) Place the cylinder head gasket on the cylinder block surface with 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.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

(a) 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.

(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.

Right:

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) Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

3. INSTALL NO. 2 CYLINDER HEAD GASKET

(a) Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

2.5 to 3.0 mm (0.0984 to 0.118 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head gasket within 3 minutes after applying the seal packing.
* Do not start the engine for at least 2 hours after installation.
(b) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

Bank 2:

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.
4. INSTALL CYLINDER HEAD LH

(a) 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.

(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 in the sequence shown in the illustration.

Left:

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

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

(g) Thoroughly wipe off seal packing that has seeped out onto the front side of the engine.

5. INSTALL FUEL INJECTOR SEAL Installation

6. INSTALL FUEL INJECTOR ASSEMBLY

HINT
Installation.

7. INSTALL REAR WATER BY-PASS JOINT Reassembly

8. INSTALL VALVE STEM CAP

(a) Install the 24 valve stem caps.

9. 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 SST tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

Text in Illustration

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 high-pressure air from the compression 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 quickly and firmly press the plunger with a finger.

OK:

Plunger is very difficult to move.

(f) If the result is not as specified, replace the lash adjuster.

(g) Install the lash adjusters.

NOTICE:
Install the lash adjuster to the same position it was removed from.

10. 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 No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

Text in Illustration

11. INSTALL NO. 1 CHAIN VIBRATION DAMPER Reassembly

12. INSTALL NO. 2 CHAIN VIBRATION DAMPER Reassembly

13. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

(a) Apply a light coat of engine oil to the No. 3 camshaft journals and camshaft housing sub-assembly LH.

(b) Install the No. 3 camshaft sub-assembly to the camshaft housing sub-assembly LH.

14. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY

(a) Apply a light coat of engine oil to the No. 4 camshaft journals and camshaft housing sub-assembly LH.

(b) Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH.

15. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

(a) Apply engine oil to the camshaft bearing caps.

(b) Make sure of the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.

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

16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Make sure that the valve rocker arm is installed as shown in the illustration.

Text in Illustration

(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:

3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the camshaft housing sub-assembly LH within 3 minutes.
* Do not start the engine for at least 2 hours after installation.
(c) Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.

LH:

Text in Illustration

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

NOTICE:
* When installing the camshaft housing sub-assembly LH, 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 sub-assembly LH, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing sub-assembly LH 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.
(d) Tighten the 8 bolts in the order shown in the illustration.

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

17. INSTALL CAMSHAFT

(a) Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly RH.

(b) Install the camshaft to the camshaft housing sub-assembly RH.

18. INSTALL NO. 2 CAMSHAFT

(a) Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly RH.

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

19. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

(a) Apply engine oil to the camshaft bearing caps.

(b) Make sure of the marks and numbers on the camshaft bearing caps and place each in the proper position and direction.

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

20. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

Text in Illustration

(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:

3.5 to 4.0 mm (0.138 to 0.158 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 installation.
(c) Install the camshaft housing sub-assembly RH and tighten the 14 bolts in the order shown in the illustration.

RH:

Text in 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 sub-assembly RH, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing sub-assembly RH 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.
(d) Tighten the 9 bolts in the order shown in the illustration.

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

21. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 3 chain tensioner assembly with the bolt.

Text in Illustration

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(b) While pushing in the tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

22. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration

(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear LH with the No. 2 chain sub-assembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

SST : 09922-10010

Text in Illustration

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the No. 3 chain tensioner assembly.

23. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 2 chain tensioner assembly with the bolt.

Text in Illustration

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(b) While pushing in the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold it.

24. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) Align the mark plates (yellow) with the timing marks of the camshaft timing gear assemblies as shown in the illustration.

Text in Illustration

(b) Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

(c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly. Install the camshaft timing gear assembly and camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly installed.

(d) Using SST to hold the hexagonal portion of each camshaft, tighten the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.

SST : 09922-10010

Text in Illustration

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(e) Remove the pin from the No. 2 chain tensioner assembly.

25. INSTALL CHAIN SUB-ASSEMBLY Reassembly

26. INSTALL CHAIN TENSIONER SLIPPER Reassembly

27. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly

28. INSTALL VALVE TIMING Reassembly

29. INSTALL TIMING CHAIN CASE OIL SEAL Reassembly

30. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

HINT
See the steps from "Timing Chain Cover Sub-Assembly" through "Install Engine And Transmission Assembly" [1][2]Installation.