Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - (Continued)

25. INSTALL WATER INLET PIPE

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

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

(b) Install the No. 1 water by-pass hose.

26. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

(a) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
Be careful of the installation direction.

(b) 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.
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

HINT
The cylinder head bolts are tightened in 3 progressive steps.

(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(d) 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.

Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

(e) Step 2

(1) Mark the cylinder head bolt heads with paint as shown in the illustration.

(2) Tighten the cylinder head bolts another 90°.

(f) Step 3

(1) Tighten the cylinder head bolts by an additional 90°.

(2) Check that the painted marks are now facing rearward.

27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

(a) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)

(e) Step 2

(1) Mark the cylinder head bolt heads with paint as shown in the illustration.

(2) Tighten the cylinder head bolts by 90°.

(f) Step 3

(1) Tighten the cylinder head bolts by an additional 90°.

(2) Check that the painted marks are now facing rearward.

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

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

28. 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 the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

SST : 09276-75010

(c) Squeeze SST and the 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 air from the high-pressure 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 press the plunger quickly and firmly by hand.

OK:

Plunger is very difficult to move.

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

(f) Install the lash adjusters.

NOTICE:
Install the lash adjusters to the same locations they were removed from.

29. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Apply engine oil to the lash adjuster tip and valve stem cap end.

(b) Install the valve rocker arms as shown in the illustration.

30. INSTALL CAMSHAFT BEARING CAP (for RH Bank)

(a) Apply engine oil to the camshaft journals, camshaft housing and bearing caps.

(b) Install the camshaft and No. 2 camshaft to the camshaft housing RH.

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

(d) Temporarily tighten the 8 bolts in the order shown in the illustration.

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

31. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Make sure that the valve rocker arm is installed as shown in the 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 4.5 mm (0.138 to 0.177 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 installing.

(c) Install the camshaft housing RH and tighten the 12 bolts in the order shown in the 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, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing 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)

32. INSTALL CAMSHAFT BEARING CAP (for LH Bank)

(a) Apply engine oil to the camshaft journals, camshaft housing and bearing caps.

(b) Install the No. 3 camshaft and No. 4 camshaft to the camshaft housing LH.

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

(d) Temporarily tighten the 8 bolts in the order shown in the illustration.

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

33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Make sure that the valve rocker arm is installed as shown in the 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 4.5 mm (0.138 to 0.177 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 installing.

(c) Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration.

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

NOTICE:
* When installing the camshaft housing 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, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing 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)

34. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

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

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

(b) While pulling up the tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to secure it.

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

(a) Align the mark plates (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.

(b) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No. 2 chain installed.

(c) Apply a light coat of engine oil to the bolt threads and bolt-seating surface. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

SST : 09922-10010

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

(d) Remove the pin from the chain tensioner.

36. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the chain tensioner with the bolt.

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

(b) While pushing in the tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to hold it.

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

(a) Align the mark plates (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration.

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

(c) Apply a light coat of engine oil to the bolt threads and bolt-seating surface. Using SST to hold the hexagonal portion of each camshaft, tighten the bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

SST : 09922-10010

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

(d) Remove the pin from the chain tensioner.

38. 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)

39. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 chain vibration dampers.

40. INSTALL CRANKSHAFT TIMING SPROCKET

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

41. 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:
Be careful of the idle gear direction.

HINT
Check that no foreign objects are on the No. 1 and No. 2 idle gear shafts.

(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.

42. 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) Do not pass the chain over the crankshaft, just temporarily place it on the crankshaft.

NOTICE:
When the idle sprocket is reused, align the mark 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 marks 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).

43. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

44. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

(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 chain tensioner with the 2 bolts.

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

(d) Remove the hexagon wrench from the chain tensioner.

45. 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.