Part 2

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

13. INSTALL RING PIN

(a) Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.





Specified protrusion height:

2.5 to 3.5 mm (0.098 to 0.138 in.)

14. INSTALL NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, install 4 new gaskets and the 4 No. 1 straight screw plugs.





Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)

15. INSTALL NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 No. 2 straight screw plugs.





Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)

16. INSTALL STUD BOLT

NOTICE:
If the stud bolt is deformed or the threads are damaged, replace it.

(a) Using E6 and E8 "TORX" socket wrenches, install the stud bolts.





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for bolts A and B

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) for bolt C

17. INSTALL STRAIGHT PIN

(a) Using a plastic hammer, tap in 4 new straight pins as shown in the illustration.





Protrusion height:

17.5 to 19.5 mm (0.689 to 0.768 in.)

18. INSTALL VALVE SPRING SEAT

(a) Install the valve spring seats to the cylinder head.

19. INSTALL VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to new valve stem oil seals.





NOTICE:
Pay attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal into the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later.

HINT
The intake valve stem oil seals are gray and the exhaust valve stem oil seals are black.

(b) Using SST, push in the valve stem oil seals.





SST : 09201-41020

NOTICE:
Failure to use SST will cause the seal to be damaged or improperly seated.

20. INSTALL EXHAUST VALVE

(a) Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration.





(b) Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.

NOTICE:
Install the same parts in the same combination to the original locations.

(c) Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.





SST : 09202-70020

09202-00010

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.





NOTICE:
Be careful not to damage the retainer.

21. INSTALL INTAKE VALVE

(a) Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.





(b) Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.

NOTICE:
Install the same parts in the same combination to the original locations.

(c) Using SST, compress the inner compression spring and install the 2 valve spring retainer locks.





SST : 09202-70020

09202-00010

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.





NOTICE:
Be careful not to damage the retainer.

22. INSTALL VALVE STEM CAP

(a) Apply a light coat of engine oil to the valve stem caps.

(b) Install the valve stem caps on the valves.

23. INSTALL ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.

(b) Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear 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 engine rear oil seal at an angle.

24. 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:

2.0 to 3.0 mm (0.079 to 0.118 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the engine rear 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 engine rear 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

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 a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.





NOTICE:
* Be sure to install the gasket in the correct direction.
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder head.

(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.

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 head with paint as shown in the illustration.

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

(f) Step 3

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

(2) Check that the painted mark is now facing rearward.

27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

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





NOTICE:
* Be sure to install the gasket in the correct direction.
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the cylinder head.

(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.

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 head with paint as shown in the illustration.

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

(f) Step 3

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

(2) Check that the painted mark is 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's plunger and use the tip to press down on the check ball inside the plunger.





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 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 with a finger.

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 adjuster to the same place where it was 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) Make sure that the 24 No. 1 valve rocker arms are installed as shown in the illustration.





30. INSTALL CAMSHAFT BEARING CAP (for RH Side)

(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 after applying seal packing.
* Do not start the engine for at least 2 hours after installing the camshaft housing sub-assembly RH.

(c) Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.

RH:

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

NOTICE:
* When installing the camshaft housing sub-assembly 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)