Part 2

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

34. INSTALL WATER INLET HOUSING

(a) Install 2 new O-rings.

HINT
Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.

(b) Install the 2 stud bolts.

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

(c) Install the water inlet housing with the 2 bolts and nut.

Text in Illustration

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

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

(d) Connect the No. 1 water by-pass hose.

(e) Apply adhesive around the drain cock.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(f) Install the drain cock assembly to the water inlet housing.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

(g) Install the drain cock plug to the drain cock assembly.

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

(h) Install a new gasket to the thermostat.

(i) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

HINT
The jiggle valve may be set within 10° of either side of the prescribed position.

(j) Install the water inlet with the 2 nuts.

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

35. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH

(a) Using an E8 "TORX" socket wrench, install the 2 stud bolts.

Text in Illustration

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

(b) Install the No. 1 front engine mounting bracket LH with the 6 bolts.

Torque : 54 Nm (550 kgf-cm, 40 ft-lbf)

NOTICE:
* Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
* Do not start the engine for at least 2 hours after installation.

36. INSTALL NO. 1 OIL PAN BAFFLE PLATE

(a) Install the No. 1 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 the 2 bolts (A) shown in the illustration before tightening the other bolts.

37. INSTALL OIL PAN SUB-ASSEMBLY

(a) Using an E8 "TORX" socket wrench, install the 2 stud bolts.

Text in Illustration

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

(b) Install 2 new O-rings.

Text in Illustration

Seal packing:

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

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 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.

Text in Illustration

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

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

38. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

Text in Illustration

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

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

Text in Illustration

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

39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Using an E6 "TORX" socket wrench, install the 2 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.

Text in Illustration

Seal packing:

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

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

(c) Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

Text in Illustration

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

40. INSTALL OIL PAN DRAIN PLUG

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

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

41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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

Text in 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.

(c) Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

(d) Install the head cover with the 12 bolts and a new seal washer.

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

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

HINT
After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

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

Text in Illustration

Seal packing:

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

NOTICE:
* Remove any oil from the contact surfaces.
* Install the cylinder head cover sub-assembly LH 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.

(c) Install a new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly LH.

(d) Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.

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

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

HINT
After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

43. 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 outlet with the 2 bolts and 4 nuts.

Text in Illustration

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

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

44. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

(b) Install the engine oil level dipstick guide with the bolt.

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

45. INSTALL CRANKSHAFT PULLEY Installation

46. INSTALL OIL FILTER CAP ASSEMBLY Replacement

47. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive around the drain cock sub-assembly.

Text in Illustration

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the water drain cocks as shown in the illustration.

Text in 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)

48. 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) with the union.

Text in Illustration

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

(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 side cutters or a similar tool.

49. 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) with the union.

Text in Illustration

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

(d) Install the 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 side cutters or a similar tool.

50. INSTALL CRANK POSITION SENSOR Installation

51. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation

52. INSTALL VVT SENSOR Installation

53. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive around the ventilation valve sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Using a deep socket wrench 19 mm, install the ventilation valve sub-assembly.

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

54. INSTALL SPARK PLUG Installation

55. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install a new oil filler gasket.

(b) Install the oil filler cap sub-assembly.