Part 2

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT:

REASSEMBLY (Continued)

31. INSTALL KEYS

(a) Install the 2 keys.
32. INSTALL NO. 2 CHAIN SUB-ASSEMBLY ()

33. INSTALL CRANKSHAFT TIMING SPROCKET ()

34. INSTALL NO. 1 CHAIN VIBRATION DAMPER ()

35. INSTALL CHAIN SUB-ASSEMBLY ()

36. INSTALL CHAIN TENSIONER SLIPPER ()

37. INSTALL TIMING CHAIN GUIDE ()

38. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE ()

39. INSTALL TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST: 09223-22010
(b) Apply a light coat of MP grease to the lip of the oil seal.

NOTICE:
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.
- Make sure that the oil seal edge does not stick out of the timing chain cover.

40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (Installation)

41. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY ()

42. INSTALL OIL PAN SUB-ASSEMBLY ()

43. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and oil pan drain plug.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
44. INSTALL WATER PUMP ASSEMBLY
(a) Remove any old seal packing material from the contact surface.

(b) Apply a continuous line of seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
2.2 to 2.5 mm (0.09 to 0.10 in.)

- Remove any oil from the contact surface.
- The parts must be set within 3 minutes after applying seal packing. Otherwise, the material must be removed and reapplied.

(c) Install the water pump and bracket with the 4 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

NOTE: Tighten the outside bolts and nuts with the clamp.

45. INSTALL WATER PUMP PULLEY

(a) Using SST, install the water pump pulley with the 4 bolts.
SST: 09960-10010
09962-01000
09963-00700
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
46. INSTALL CRANKSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring of the sensor.

(b) Confirm that the wire harness of the sensor is placed as shown in the illustration.

(d) Install the clamp of the crankshaft position sensor onto the water pump.
47. INSTALL CRANKSHAFT PULLEY ()

48. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (Installation)

49. INSPECT VALVE CLEARANCE (Testing and Inspection)

50. ADJUST VALVE CLEARANCE (Adjustments)

51. INSTALL CAMSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring of the sensor.

(b) Install the sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
52. INSTALL CYLINDER HEAD COVER GASKET

(a) Install the cylinder head cover gasket to the cylinder head cover.

NOTE: Remove any oil from the contact surface.

53. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.

(b) Apply seal packing to the 2 locations shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Block, Three Bond 1207B or equivalent

- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the cylinder head cover.

(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Bolt A - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
Bolt B - Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)
Nut - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
54. INSTALL OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
55. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) When using a torque wrench:

(1) Using SST, tighten the oil filter.
SST: 09228-06501
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(e) When not using a torque wrench:

(1) Using SST, tighten it an additional 3/4 turn.
SST: 09228-06501
56. INSTALL SPARK PLUG

(a) Install the spark plugs.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
57. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive on the threads of the ventilation valve.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
58. INSTALL OIL FILLER CAP GASKET

(a) Install the gasket to the cap.
59. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler cap.