Part 1

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL ENGINE REAR 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 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:

3.0 to 4.0 mm (0.118 to 0.157 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 WATER OUTLET PIPE SUB-ASSEMBLY

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

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

4. INSTALL KNOCK 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 HEAD GASKET Installation

6. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation

7. INSTALL NO. 2 CYLINDER HEAD GASKET Installation

8. INSTALL CYLINDER HEAD LH Installation

9. INSTALL VALVE STEM CAP Installation

10. INSTALL VALVE LASH ADJUSTER ASSEMBLY Installation

11. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Installation

12. INSTALL NO. 3 CAMSHAFT Installation

13. INSTALL NO. 4 CAMSHAFT Installation

14. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Installation

15. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Installation

16. INSTALL CAMSHAFT Installation

17. INSTALL NO. 2 CAMSHAFT Installation

18. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Installation

19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Installation

20. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Installation

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

22. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Installation

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

24. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the chain vibration damper with the 2 bolts.

Torque : 23 Nm (230 kgf-cm, 17 ft-lbf)

25. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 chain vibration dampers.

26. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the 2 timing gear set keys and timing sprocket as shown in the illustration.

27. INSTALL IDLE SPROCKET ASSEMBLY

(a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.

(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.

28. INSTALL CHAIN SUB-ASSEMBLY

(a) Align the mark plates and timing marks as shown in the illustration and install the chain.

HINT
The camshaft mark plates are orange.

(b) Rest the chain on top of the crankshaft.

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.

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).

29. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

30. 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 pin of 1.27 mm (0.050 in.) diameter into the hole of the stopper plate.

(c) Install the chain tensioner with the 2 bolts.

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

(d) Remove the lock pin of the chain tensioner.

31. 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.

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.

32. 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

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.
33. INSTALL WATER PUMP ASSEMBLY

(a) Install a new gasket and the water pump 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.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

34. 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 installation.
(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 installation.

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.

Text in Illustration

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

Bolt length:

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

(f) Fully tighten the 3 bolts shown in the illustration.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf for bolt A)

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf for bolts except A)

(g) Fully tighten the 3 bolts 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)