Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

Part 2 of 3

Continued From Part 1 Part 1

19. 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.

NOTE: 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.

NOTE: Be careful not to damage the retainer.

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.

NOTE: 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.

NOTE: Be careful not to damage the retainer.

21. 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.
22. 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.)

NOTE:
- 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 engine rear oil seal retainer with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)

NOTE: 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
23. 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.
24. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

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

NOTE: 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.
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) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
25. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

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

HINT:
- 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.

(b) Place the cylinder head on the cylinder block.

NOTE: 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 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 by 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)

NOTE: Only use the specifications stated above when tightening the bolts 1 and 2 shown in the illustration.

(h) Seal packing will seep out on the engine's front side. Thoroughly wipe clean any seal packing.
26. 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 SST tip 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 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.

NOTE: 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.

NOTE: Install the lash adjuster to the same place where it was removed from.

27. 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.
28. INSTALL CAMSHAFT BEARING CAP RH

(a) Apply engine oil to the camshaft journals, camshaft housing sub-assembly RH and camshaft bearing caps.
(b) Install the camshaft and No. 2 camshaft to the camshaft housing sub-assembly 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)
29. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

(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:
3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTE:
- 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.

(b) Install the camshaft housing sub-assembly RH and tighten the 12 bolts in the order shown in the illustration.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)

NOTE:
- 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) Install 3 new gaskets.
30. INSTALL CAMSHAFT BEARING CAP

(a) Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the camshaft No. 3 and camshaft No. 4 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)
31. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Apply seal packing in a continuous bead 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.)

HINT:
- 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.

(b) Install the camshaft housing sub-assembly LH and tighten the 13 bolts in the order shown in the illustration.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)

HINT:
- 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) Install 3 new gaskets.
32. 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 (0.039 in.) into the hole to fix it.
33. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(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 (1,020 kgf-cm, 74 ft-lbf)
(e) Remove the pin from the No. 2 chain tensioner assembly.

Continued in Part 3 Part 3