Part 3

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

32. INSTALL CAMSHAFT BEARING CAP (for LH Side)

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

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

LH:

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, 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 assembly with the bolt.

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

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

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

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

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

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

36. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

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

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

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

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

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

SST : 09922-10010

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

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

38. 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)

39. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the 2 No. 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 sure to install the idle gear shaft in the correct 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 with the timing marks as shown in the illustration and install the chain.

HINT
The camshaft mark plate is 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 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 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 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.

45. INSPECT VALVE TIMING

(a) Check the camshaft timing marks.

CAUTION:
* 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.

46. INSTALL TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new timing chain case 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 timing chain case oil seal at an angle.
* Make sure that the timing chain case oil seal edge does not stick out of the timing chain case.

47. INSTALL WATER PUMP ASSEMBLY

(a) Install a new gasket and the water pump assembly with the 8 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.

48. 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:

3.0 mm (0.118 in.) or more

NOTICE:
* Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
* If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes after applying seal packing.
* 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 Black 1282B, Three Bond 1282B or equivalent

NOTICE:
* If 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.

Apply seal packing as follows:

(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.

(e) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Bolt length:

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

(f) Fully tighten the bolts in this order: Area 1 and Area 2.

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

(g) Fully tighten the bolts in Area 3.

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

HINT
Tighten the bolts and nuts in the order of upper to lower as shown in the illustration.

(h) Fully tighten the bolts in Area 4.

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

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

HINT
Tighten the bolts in the order of lower to upper as shown in the illustration.

(i) Install a new gasket and the chain cover plate with the 4 bolts.

Torque : 9.1 Nm (93 kgf-cm, 81 in-lbf)