Part 3

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

51. INSTALL OIL PAN BAFFLE PLATE NO.1

(a) Install the oil pan baffle plate with the 7 bolts.

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

HINT
Temporarily tighten the 7 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.

52. INSTALL OIL PAN SUB-ASSEMBLY

(a) When replacing a stud bolt, install it by using an E8 "TORX" socket wrench.

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

(b) Install 2 new O-rings.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.158 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(d) Install the oil pan with the 16 bolts and 2 nuts.

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

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

53. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.

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

(b) Install a new gasket and the oil strainer with the bolt and 2 nuts.

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

54. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Using an E6 "TORX" socket, install the stud bolts as shown in the illustration.

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

(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:

3.0 to 4.0 mm (0.118 to 0.158 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the No. 2 oil pan within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(c) Install the oil pan with the 16 bolts and 2 nuts.

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

55. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and the drain plug.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for RH Bank)

(a) Apply seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
* Remove any oil from the contact surface.
* Install the head cover within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.
(b) Install 3 new gaskets as shown in the illustration.

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

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

HINT
Double check the tightening torque of bolt 1.

57. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for LH Bank)

(a) Apply seal packing as shown in the illustration.

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

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

HINT
Double check the tightening torque of bolts 1 and 10.

58. INSTALL WATER OUTLET

(a) Install 2 new gaskets and a new O-ring.

HINT
Apply soapy water to the O-ring.

(b) Install the water by-pass joint with the 2 bolts and 4 nuts.

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

Torque : 10 Nm (103 kgf-cm, 7 ft-lbf for nuts)

NOTICE:
Be careful that the O-ring does not get caught between the parts.

59. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(b) Using SST, install the pulley bolt.

SST : 09213-70011

09213-70020

SST : 09330-00021

Torque : 250 Nm (2550 kgf-cm, 184 ft-lbf)

60. INSTALL OIL FILTER ELEMENT

(a) Clean the inside of the oil filter cap, the threads and O-ring groove.

(b) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

(c) Set a new oil filter element to the oil filter cap.

(d) Remove dirt or foreign matter from the installation surface of the engine.

(e) Apply a light coat of engine oil to the O-ring again and install the oil filter cap.

NOTICE:
* Be careful that the O-ring does not get caught between the parts.
* The O-ring must not be twisted on the groove.
(f) Using SST, tighten the oil filter cap.

SST : 09228-06501

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Make sure that the oil filter is installed securely as shown in the illustration.

(g) Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

NOTICE:
Remove dirt and foreign matter from the installation surface.

(h) Install the oil filter drain plug to the oil filter cap.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

NOTICE:
Make sure that the O-ring does not get caught between the parts.

61. 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 water drain cocks as shown in the illustration.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

62. INSTALL NO. 1 OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

(d) Tighten the oil pipe union (on the head cover side).

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

(e) Tighten the oil pipe union (on the cylinder head side).

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or a similar tool.

63. INSTALL OIL PIPE

(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

(b) Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

(c) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

(d) Install bolt (A) to the cylinder head.

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

(e) Tighten the oil pipe union (on the head cover side).

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

(f) Tighten the oil pipe union (on the cylinder head side).

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using nippers or a similar tool.

64. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the sensor with the bolt.

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

65. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Install the 4 oil control valves with the 4 bolts.

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

66. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the 4 sensors with the 4 bolts.

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

67. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive around the ventilation valve.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

68. INSTALL SPARK PLUG

(a) Install the 6 spark plugs.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

69. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install a new gasket.

(b) Install the oil filler cap.