Part 2

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

15. INSTALL STIFFENING CRANKCASE ASSEMBLY

(a) Place a new O-ring on the cylinder block, as shown in the illustration.
(b) Temporarily tighten the pulley set bolt.

(c) Turn the crankshaft to set the crank pins of the No. 1 and No. 4 cylinders to the bottom.
HINT: Make sure that the timing mark on the balanceshaft drive gear is positioned as shown in the illustration.

(d) Apply seal packing in a continuous bead (diameter: 2.5 to 3.0 mm (0.098 to 0.118 in.)) to the places shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surfaces.
- Install the crankcase within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installing the crankcase stiffener.

(e) Install the stiffening crankcase so that the adjusting holes on the balanceshafts are positioned as shown in the illustration.

(f) Temporarily install the crankcase with the 11 bolts.
Bolt Length:

(g) Uniformly tighten the 11 bolts in the sequence shown in the illustration.
Torque: 24 Nm (245 kgf-cm, 18ft-lbf)
(h) Wipe off the excess seal packing with a clean piece of cloth.

(i) Turn the crankshaft again to set the key groove to the bottom. Make sure that the timing marks are aligned as shown in the illustration.
HINT: An 'o' is stamped as a timing mark.

(j) Remove the pulley set bolt.
16. INSTALL OIL PUMP ASSEMBLY

(a) Install a new gasket and oil pump with the 3 bolts.
Torque: 19 Nm (194 kgf-cm, 14ft-lbf)
17. INSTALL ENGINE REAR OIL SEAL

(a) Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge.
SST: 09223-15030
SST: 09950-70010
09951-07100
NOTICE: Keep the lip free from foreign materials.

(b) Apply MP grease to a new oil seal lip.
NOTICE: Wipe off extra grease on the crankshaft.

18. INSTALL NO. 1 TAPER SCREW PLUG (w/o Oil Cooler)

(a) Apply adhesive to 2 or 3 threads of the plug, and install the plug.
Torque: 26 Nm (265 kgf-cm, 19ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
19. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign matter is on the mesh part of the filter.

(b) Using an 8 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.
Torque: 30 Nm (306 kgf-cm, 22ft-lbf)
NOTICE: Do not touch the mesh when installing the oil control valve filter.

20. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (w/o Oil Cooler)

(a) Apply adhesive around the drain cock.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the water drain cock within the range shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18ft-lbf)
NOTICE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.
Torque: 13 Nm (130 kgf-cm, 9ft-lbf)
21. INSTALL CYLINDER BLOCK WATER JACKET SPACER

(a) Install the water jacket spacer as shown in the illustration.
HINT: Be sure to face the slope to the front of the engine.

22. INSTALL CYLINDER HEAD GASKET Installation
23. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation
24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.

(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation
26. INSTALL CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise.
(b) Tighten the flange bolt with the camshaft timing sprocket secured.
Torque: 54 Nm (551 kgf-cm, 40ft-lbf)
27. INSTALL NO. 1 CAMSHAFT BEARING

(a) Install the No. 1 camshaft bearing.
28. INSTALL NO. 2 CAMSHAFT BEARING Installation
29. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the camshaft.

(b) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.
(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(d) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
No. 1 Bearing cap - Torque: 30 Nm (301 kgf-cm, 22ft-lbf)
No. 3 Bearing cap - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
30. INSTALL NO. 2 CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

(b) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(a) Install the 2 keys.
32. INSTALL NO. 2 CHAIN SUB-ASSEMBLY Installation
33. INSTALL CRANKSHAFT TIMING SPROCKET Installation
34. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
35. INSTALL CHAIN SUB-ASSEMBLY Installation
36. INSTALL CHAIN TENSIONER SLIPPER Installation
37. INSTALL TIMING CHAIN GUIDE Installation
38. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE Installation
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 gap between the timing chain cover edge and the oil seal free of foreign matter.

40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
41. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
42. INSTALL OIL PAN SUB-ASSEMBLY Installation
43. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and oil pan drain plug with a new gasket.
Torque: 25 Nm (255 kgf-cm, 18ft-lbf)
44. INSTALL WATER PUMP ASSEMBLY Installation
45. INSTALL WATER PUMP PULLEY Installation
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 Installation
48. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation
49. INSPECT VALVE CLEARANCE Adjustments
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, 80in-lbf)
52. INSTALL CYLINDER HEAD COVER GASKET

(a) Install the gasket to the cylinder head cover.
NOTICE: Remove any oil from the contact surface.

53. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
54. INSTALL OIL FILTER UNION (w/o Oil Cooler)

(a) Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22ft-lbf)
55. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)
(a) Clean the oil cooler contact surface on the cooler mounting.

(b) Install a new O-ring to the oil cooler.
(c) Apply a light coat of engine oil to the threads and under the head of the union bolt.

(d) Install the oil cooler with the plate washer, oil filter union and nut.
Oil Filter Union - Torque: 79 Nm (806 kgf-cm, 58ft-lbf)
Nut - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
(e) Apply adhesive to the threads of the oil filter union.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(f) Install the union bolt.
Torque: 25 Nm (255 kgf-cm, 18ft-lbf)
56. 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, 10ft-lbf)
(e) When not using a torque wrench:

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

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

(a) Apply adhesive to the threads of the ventilation valve.

(b) Install the ventilation valve.
Torque: 19 Nm (194 kgf-cm, 14ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
59. INSTALL OIL FILLER CAP GASKET

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

(a) Install the oil filler cap.