Part 1

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL RING PIN
(a) Using a plastic hammer, tap into the ring pin.

Standard Protrusion:

2. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.

Stud Bolt A - Torque: 22 Nm (220 kgf-cm, 16ft-lbf)
Stud Bolt B - Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
Stud Bolt C - Torque: 9.5 Nm (97 kgf-cm, 84in-lbf)
Stud Bolt D - Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
Stud Bolt E (with oil cooler) - Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
3. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in the straight pins.

Standard Protrusion:

4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the oil nozzles with the bolts.
Torque: 7.0 Nm (71 kgf-cm, 62in-lbf)
5. INSTALL PISTON

(a) Using a screwdriver, install a new snap ring at one end of the piston pin hole.
HINT: Make 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 to 90°C (176 to 194°F).

(c) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
(d) Using a screwdriver, install a new snap ring on the other end of the piston pin hole.
HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

(e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
6. INSTALL PISTON RING SET

(a) Install the oil ring expander and oil ring rail by hand.
NOTICE:
- Install the expander and oil ring so that their ring ends are at opposite sides.
- Securely install the expander to the inner groove of the oil ring.

(b) Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.
NOTICE: Install compression ring No. 2 with the code mark (2N or 2A) facing upward.

(a) Install the upper bearing with an oil groove on the cylinder block.
NOTICE: Do not apply engine oil to the bearings and the contact surfaces.

8. INSTALL NO. 2 CRANKSHAFT BEARING

(a) Install the lower bearing on the bearing cap.
NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.

9. INSTALL UPPER CRANKSHAFT THRUST WASHER

(a) Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.
(b) Apply engine oil to the crankshaft thrust washer.
10. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crankshaft on the cylinder block.
(b) Apply engine oil to the lower bearing.

(c) Examine the front marks and install the bearing caps on the cylinder block.
(d) Apply a light coat of engine oil to the threads and under the bearing cap bolts.
(e) Install the crankshaft bearing cap bolts.
NOTICE: The main bearing cap bolts are tightened in 2 progressive steps.

(f) Step 1

(1) Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15ft-lbf)

(2) Retighten the 10 main bearing cap bolts in the sequence shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30ft-lbf)
(g) Step 2

(1) Mark the front of the bearing cap bolts with paint.
(2) Retighten the bearing cap bolts by 90 °in the numerical order shown in the illustration.
(h) Check that the paint mark is now at a 90 °angle to the front.
(i) Check that the crankshaft turns smoothly.
(j) Check the crankshaft thrust clearance Engine Unit.
11. INSTALL CONNECTING ROD BEARING

(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
NOTICE: Do not apply engine oil to the bearings and the contact surfaces.

12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
NOTICE: The connecting rod cap bolts are tightened in 2 progressive steps.

(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.

(b) Check the position of the piston ring ends.

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

(d) Check that the protrusion of the connecting rod cap is facing in the correct direction.
(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.
NOTICE: The connecting cap bolts should be 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 (250 kgf-cm, 18ft-lbf)
(h) Step 2

(1) Mark the front of the connecting rod cap bolts with paint.
(2) Retighten the cap bolts by 90° as shown in the illustration.
(i) Check that the crankshaft turns smoothly.
(j) Check the connecting rod thrust clearance Engine Unit.
13. INSTALL NO. 1 BALANCESHAFT BEARING

(a) Install the bearings in the crankcase and balanceshaft housing.
NOTICE: Do not apply engine oil to the bearings and the contact surfaces.

(b) Apply a light coat of engine oil to the bearings.
14. INSTALL NO. 1 AND NO. 2 BALANCESHAFT SUB-ASSEMBLY

(a) Rotate the driven gear No. 1 of balanceshaft No. 1 in the rotating direction until it hits the stopper.
NOTICE: Confirm that the matchmarks on driven gears No. 1 and No. 2 are aligned.

(b) Align the alignment marks of the No. 1 and No. 2 balanceshafts as shown in the illustration.

(c) Place the No. 1 and No. 2 balanceshafts on the crankcase.
(d) Apply a light coat of engine oil under the heads of the balanceshaft housing bolts.
(e) Install the balanceshaft housing bolts.
NOTICE: Tighten the balance shaft housing bolts in 2 progressive steps.

(f) Step 1

(1) Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 22 Nm (220 kgf-cm, 16ft-lbf)
(g) Step 2

(1) Mark the front side of each balanceshaft housing bolt head with paint.
(2) Retighten the bolts by 90° as shown in the illustration.
(3) Check that the paint marks are now at a 90° angle to the front.