Part 1

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the 3 oil nozzles with the bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
2. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cocks.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the cylinder block water drain cocks.
(1) Temporarily install the drain cocks.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

(2) Within one full rotation, tighten the drain cock to the angle shown in the illustration.
Torque: 45 Nm (459 kgf-cm, 33 ft-lbf)
NOTE: Do not loosen the drain cock to adjust it. If an adjustment is necessary, remove the drain cock and reinstall it.

(c) Install the water drain cock plugs to the water drain cocks.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
3. INSTALL PISTON WITH PIN SUB-ASSEMBLY

(a) Using a screwdriver, install a new snap ring at one end of the piston pin hole.
HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

(b) Gradually heat the piston to approximately 80°C (176°F).
(c) Coat the piston pin with engine oil.

(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
HINT: The piston and pin are a matched set.

(e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

(f) Using a screwdriver, install a new snap ring at the other end of the piston pin hole.
HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

4. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.

(b) Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

(c) Position the piston rings so that the ring ends are as shown in the illustration.
NOTE: Do not align the ring ends.

5. INSTALL CRANKSHAFT BEARING
NOTE: Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

(a) Clean the main journal and both surfaces of the bearing.
(b) Install the upper bearing.

(1) Install the upper bearing to the cylinder block as shown in the illustration.
NOTE: Do not apply engine oil to the bearing and its contact surface.

(c) Install the lower bearing.

(1) Install the lower bearing to the bearing cap.
(2) Using a vernier caliper, measure the distance between the bearing cap's edge and the lower bearing's edge.
Dimension (A - B):
0.7 mm (0.028 in.) or less.
NOTE: Do not apply engine oil to the bearing's contact area and underside.

6. INSTALL CRANKSHAFT

(a) Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward.
(b) Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

(c) Confirm the front marks and numbers of the main bearing caps and install the bearing caps on the cylinder block.
HINT: A number is marked on each main bearing cap to indicate the installation position.

(d) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(e) Temporarily install the 8 main bearing cap bolts to the inside positions.

(f) Insert the main bearing cap by hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.
Bolt length:
100.0 to 102.0 mm (3.937 to 4.016 in.)

(g) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(h) Apply a light coat of engine oil to the threads and under the heads of the 8 main bearing cap bolts.

(i) Install the 8 main bearing cap bolts to the outside positions.
Bolt length:
105.5 to 107.5 mm (4.154 to 4.232 in.)
(j) Install the crankshaft bearing cap bolts.
HINT: The main bearing cap bolts are tightened in 2 progressive steps.

(k) Step 1

(1) Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft-lbf)
If any of the main bearing cap bolts does not meet the specified torque, replace it.
(l) Step 2

(1) Mark the front of the bearing cap bolts with paint.
(2) Tighten the bearing cap bolts another 90° in the order shown in step 1.
(3) Check that the painted mark is now at a 90° angle to the front.
(m) Check that the crankshaft turns smoothly.

(n) Install and uniformly tighten the 8 main bearing cap bolts and seal washers in several steps, in the sequence shown in the illustration.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
Bolt length:
45 mm (1.77 in.) for bolt A
30 mm (1.18 in.) for except bolt A
(o) Check that the crankshaft turns smoothly.
7. INSTALL CONNECTING ROD BEARING
(a) Install the connecting rod bearing to the connecting rod and bearing cap.

(b) Using a vernier caliper, measure the distance between the connecting rod's and bearing cap's edges, and each connecting rod bearing's edge.
Dimension (A - B):
0.7 mm (0.028 in.) or less
NOTE: Do not apply engine oil to the bearing's contact area and underside.

8. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.

(b) Position the piston rings so that the ring ends are as shown in the illustration.
NOTE: Do not align the ring ends.

(c) Using a piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward.
NOTE: Match the numbered connecting rod cap with the connecting rod.

(d) Check that the front mark of the connecting rod cap is facing forward and install it.
(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(f) Install the connecting cap bolts.
HINT: The connecting cap bolts are tightened in 2 progressive steps.

(g) Step 1

(1) Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
(h) Step 2

(1) Mark the front side of each connecting cap bolt with paint.
(2) Tighten the cap bolts another 90° as shown in the illustration.
(3) Check that the painted mark is now at a 90° angle to the front.
(i) Check that the crankshaft turns smoothly.
9. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the crankshaft position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
10. INSTALL NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.
Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)
11. INSTALL NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
12. INSTALL VALVE SPRING SEAT
(a) Install the valve spring seats to the cylinder head.
13. INSTALL INTAKE VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to new oil seals.
NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.
HINT: The intake valve oil seals are white and the exhaust valve oil seals are black.

(b) Using SST, push in the oil seals.
SST: 09201-41020
NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.

14. INSTALL INTAKE VALVE

(a) Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.
NOTE: Install the same parts in the same combination to their original locations.

(d) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTE: Be careful not to damage the retainer.

15. INSTALL EXHAUST VALVE

(a) Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.
(b) Install the valve, compression spring and spring retainer to the cylinder head.
NOTE: Install the same parts in the same combination to their original locations.

(d) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
NOTE: Be careful not to damage the retainer.

16. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
(b) Install the valve stem caps to the cylinder head.
17. 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 water by-pass hose.
18. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to slightly before TDC.

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

(c) Place the cylinder head on the cylinder block.
NOTE: Ensure that no oil is on the mounting surface of the cylinder head.
HINT: The cylinder head bolts are tightened in 3 progressive steps.

(d) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(e) 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)
(f) Step 2

(1) Mark the cylinder head bolt head with paint as shown in the illustration.
(2) Tighten the cylinder heads bolts another 90° in the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.
(2) Check that the painted mark is now facing rearward.
19. INSTALL CYLINDER HEAD SUB-ASSEMBLY (for Bank 2)
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to slightly before TDC.

(1) Mark the cylinder head bolt heads with paint as shown in the illustration.
(2) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
(g) Step 3
(1) Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.
(2) Check that the painted mark is now facing rearward.

(h) Install the 2 bolts in the order shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)