Part 1

2ZR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL STIFFENING CRANKCASE ASSEMBLY





(a) Apply seal packing in a continuous bead (diameter: 2.5 mm (0.098 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 surface.
- Install the crankcase within 3 minutes of applying the seal packing.
- Do not start the engine for at least 2 hours after installing the stiffening crankcase.





(b) Install the stiffening crankcase with the 11 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)
Bolt length:






(c) Recheck the torque for bolts 1 and 2.
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)
(d) Wipe off any excess seal packing with a clean piece of cloth.
2. INSTALL OIL PUMP ASSEMBLY





(a) Install the oil pump assembly with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft-lbf)
3. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.





(b) Apply seal packing in a continuous bead (diameter: 4 mm (0.157 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 surface.
- Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.
- Do not expose the seal to engine oil for 2 hours after installation.





(c) Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL OIL PAN DRAIN PLUG





(a) Install a new gasket and the oil pan drain plug.
Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)
5. INSTALL CYLINDER BLOCK WATER DRAIN COCK ASSEMBLY





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





(b) Install the water drain cock as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE:
- Do not rotate the drain cock more than 1 revolution (360°) after tightening it to the specified torque.
- Install the water drain cock within 3 minutes after applying the adhesive.
- Do not start the engine for at least 2 hours after installing the water drain cock.

(c) Install the water drain cock plug to the water drain cock.
Torque: 13 Nm (130 kgf-cm, 9 ft-lbf)
6. INSTALL VENTILATION VALVE SUB-ASSEMBLY





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





(b) Install the ventilation valve.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
NOTICE:
- Install the crankcase within 3 minutes after applying the adhesive.
- Do not start the engine for at least 2 hours after installing the ventilation valve.

7. INSTALL CYLINDER HEAD GASKET





(a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
NOTICE:
- Remove any oil from the contact surface.
- Pay attention to the mounting orientation of the cylinder head gasket.
- Do not damage the cylinder gasket when installing the cylinder head onto the cylinder block.

8. INSTALL CYLINDER HEAD SUB-ASSEMBLY
HINT: The cylinder head bolts are tightened in 2 successive steps.

(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.





(b) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with as a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)





(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts by additional 90° and one more additional 45° as shown in the illustration.
(e) Check that the paint mark is now at a 135° angle from the front.
9. INSTALL VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.

(a) Place the lash adjuster into a container filled with engine oil.





(b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
SST: 09276-75010
(c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 or 6 times.
(d) Check the movement of the plunger and bleed the air.
OK:
Plunger moves up and down.
NOTICE: When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

(e) After bleeding the air, remove the SST. Then, try to press the plunger quickly and firmly with a finger.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
(f) Install the lash adjusters.
NOTICE: Install the lash adjuster into its original position.

10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Apply engine oil to the lash adjuster tip and valve stem cap end.





(b) Install the valve rocker arms as shown in the illustration.
11. INSTALL NO. 1 CAMSHAFT BEARING
(a) Clean the both surfaces of the bearing.
(b) Install the 2 No. 1 camshaft bearings.





(c) Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.
Dimension (A - B):
0.7 mm (0.0276 in.) or less
NOTICE: Position the bearing to the center of the bearing cap by measuring dimension A - B.

12. INSTALL OIL CONTROL VALVE FILTER
(a) Check that there is no foreign matter on the mesh part of the filter.





(b) Install the oil control valve filter.
NOTICE: Do not touch the mesh when installing the oil control valve filter.

13. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean both surfaces of the bearing.
(b) Install the 2 No. 2 camshaft bearings.





(c) Using vernier calipers, measure the distance between the bearing cap's edge and the camshaft bearing's edge.
Dimension (A):
1.05 to 1.75 mm (0.042 to 0.068 in.)
NOTICE: Position the bearing to the center of the bearing cap by measuring dimension A.

14. INSTALL NO. 2 CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.





(c) Install the No. 2 camshaft to the camshaft housing.
15. INSTALL CAMSHAFT
(a) Clean the camshaft journals.
(b) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.





(c) Install the camshaft to the camshaft housing.
16. INSTALL CAMSHAFT BEARING CAP
(a) Apply engine oil to the camshaft journals, camshaft housing and bearing caps.





(b) Check the marks and numbers on the camshaft bearing caps and place them in the proper position and direction.
HINT: Make sure that the knock pin of the camshaft is positioned as shown in the illustration.





(c) Tighten the 10 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
17. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY





(a) Make sure that the valve rocker arm is installed as shown in the illustration.





(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:
3.5 to 4.0 mm (0.138 to 0.158 in.)
NOTICE:
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly RH within 3 minutes of applying the seal packing.
- Do not start the engine for at least 2 hours after installing.





(c) Set the camshaft and No. 2 camshaft as shown in the illustration.
(d) Install the camshaft housing and tighten the 17 bolts in the order shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
NOTICE:
- After installing the camshaft housing, make sure that the cam lobes are positioned as shown in the illustration.
- If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
- If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
- After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.

18. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check that the knock pin is installed on the camshaft.





(b) Put the camshaft timing gear and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.
NOTICE: Do not forcefully push in the camshaft timing gear assembly. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear assembly.





(c) Turn the camshaft timing gear as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
NOTICE: Do not turn the camshaft timing gear in the retard direction (the right angle).





(d) Measure the clearance between the gear and the camshaft.
Clearance:
0.1 to 0.4 mm (0.004 to 0.016 in.)





(e) Tighten the flange bolt with the camshaft timing gear fixed in place.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)





(f) Check that the camshaft timing gear can move to the retard angle side (the right direction) and is locked in the most retarded position.
19. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Check that the knock pin is installed on the camshaft.





(b) Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
NOTICE: Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle).

(d) Check that there is no clearance between the gear's flange and the camshaft.





(e) Tighten the flange bolt with the camshaft timing exhaust gear fixed.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
(f) Check the camshaft timing exhaust gear lock.
(1) Make sure that the camshaft timing exhaust gear is locked.
20. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE





(a) Install the sensor plate with the "F" mark facing forward.

Contiued in part 2 Part 2