Part 2

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

22. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

(a) Set the crankshaft key as shown in the illustration.

(b) Turn the drive shaft so that the cutout faces right.

(c) Align the yellow mark links with the timing marks of each gear as shown in the illustration.

(d) Install the gears onto the crankshaft and oil pump shaft with the chain on the gears.

(e) Temporarily tighten the oil pump drive shaft gear with the nut.

(f) Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

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

(g) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.

(h) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

23. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Install the crankshaft timing gear or sprocket.

24. INSTALL NO. 1 CHAIN VIBRATION DAMPER

(a) Install the No. 1 chain vibration damper with the 2 bolts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

25. INSTALL CHAIN SUB-ASSEMBLY

(a) Check the No. 1 cylinder TDC/compression.

(1) Temporarily tighten the crankshaft pulley bolt.

(2) Turn the crankshaft counterclockwise until the timing gear key is facing up.

(3) Remove the crankshaft pulley bolt.

(4) Check the timing mark on each camshaft timing gear.

(b) Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

HINT
* Be sure to position the mark plate at the front of the engine.
* The mark plate on the camshaft side is colored orange.
* Do not pass the chain around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
* Pass the chain through the No. 1 vibration damper.
(c) Place the chain on the crankshaft without passing it around the shaft.

(d) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate (orange) and timing mark.

HINT
* Be sure to position the mark plate at the front of the engine.
* The mark plate on the camshaft side is colored orange.
(e) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.

HINT
When tensioning the chain, turn the camshaft timing gear assembly clockwise slowly to prevent the chain from being misaligned.

(f) Align the mark plate (yellow) and timing mark and install the chain to the crankshaft timing gear.

HINT
The mark plate on the crankshaft side is colored yellow.

(g) Recheck each timing mark at TDC/compression.

26. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper.

27. INSTALL NO. 2 CHAIN VIBRATION DAMPER

(a) Install the No. 2 chain vibration damper with the 2 bolts.

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

28. INSTALL NO. 1 GENERATOR BRACKET

(a) Install the No. 1 generator bracket with the 4 bolts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

29. INSTALL WATER INLET HOUSING

(a) Install a new gasket and the water inlet housing with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

30. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

(b) Install 3 new O-rings.

Seal packing:

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

Seal diameter:

3.0 mm (0.118 in.)

NOTICE:
* Remove any oil from the contact surface.
* Install the chain cover within 3 minutes of applying the seal packing.
* Do not start the engine for at least 2 hours after installing.
(d) Apply seal packing in a continuous line to the timing chain cover, as shown in the following illustration.

NOTICE:
* When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.
* Do not start the engine for at least 2 hours after installation.

Apply seal packing as follows:

(e) Install a new gasket.

NOTICE:
Remove any oil from the contact surface.

(f) Install 2 new O-rings.

(g) Install the timing chain cover with the 19 bolts as shown in the illustration.

Bolt A and C - Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

Bolt B and D - Torque : 51 Nm (520 kgf-cm, 38 ft-lbf)

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

NOTICE:
* When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installation.
* Tighten bolt D through the engine mounting bracket, pressing it against the timing chain or belt cover sub-assembly.
* Tighten bolt C through the oil filter bracket, pressing it against the timing chain or belt cover sub-assembly.

Bolt length:

(h) Install the water pump with the 3 bolts.

Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)

31. INSTALL THERMOSTAT

(a) Install a new gasket onto the thermostat.

(b) Install the thermostat with the jiggle valve facing upward.

HINT
The jiggle valve may be set within 10° on either side, as shown in the illustration.

32. INSTALL WATER INLET

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

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

33. INSTALL CRANKSHAFT PULLEY

(a) Align the pin hole in the crankshaft pulley with the pin position and install the crankshaft pulley.

(b) Provisionally install the bolt.

(c) Using SST, tighten the bolt while holding the crankshaft pulley.

SST : 09213-58013

91651-60855

SST : 09330-00021

Torque : 190 Nm (1940 kgf-cm, 140 ft-lbf)

NOTICE:
Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the timing chain or belt cover sub-assembly.

34. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Using a 24 mm deep socket wrench, install the oil pressure switch.

Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)

NOTICE:
* Install the oil pressure switch within 3 minutes of applying the adhesive.
* Do not start the engine within 1 hour of installation.
35. INSTALL ENGINE WATER TEMPERATURE SENSOR

(a) Install a new gasket to the engine water temperature sensor.

(b) Install the engine water temperature sensor.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

36. INSTALL KNOCK SENSOR

(a) Install the knock sensor with the bolt.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

NOTICE:
Make sure that the knock sensor is in the correct position.

37. INSTALL NO. 1 TAPER SCREW PLUG

(a) Apply adhesive to 2 or 3 threads of the plug, and install the plug.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

NOTICE:
* Install the plug within 3 minutes of applying the adhesive.
* Do not start the engine within 1 hour of installation.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

38. INSTALL CRANKSHAFT POSITION SENSOR

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

(b) Install the crankshaft position sensor with the bolt.

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

39. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Release the ratchet pawl, then fully push in the plunger and hook the hook on the pin so that the plunger is in the position shown in the illustration.

NOTICE:
Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

(b) Install a new gasket, bracket and the No. 1 chain tensioner with the 2 nuts.

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

NOTICE:
If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

(c) Turn the crankshaft counterclockwise, then disconnect the plunger knock pin from the hook.

(d) Turn the crankshaft clockwise, then check that the plunger is extended.

40. INSTALL OIL FILTER SUB-ASSEMBLY

(a) Clean the inside of the oil filter cap, threads and O-ring groove.

(b) Apply a small amount of engine oil to a new O-ring and install it onto the oil filter cap.

(c) Set a new oil filter element into the oil filter cap.

(d) Remove any dirt or foreign matter from the installation surface of the engine.

(e) Apply a small amount of engine oil to the O-ring again and install the oil filter cap.

(f) Using SST, tighten the oil filter cap.

SST : 09228-06501

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
* Make sure that the oil filter is installed securely as shown in the illustration.
* Be careful that the O-ring does not get caught between the parts.
41. INSTALL CYLINDER HEAD COVER GASKET

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

NOTICE:
Remove any oil from the contact surface.

42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Install 3 new gaskets onto the No. 1 camshaft bearing cap.

(b) Apply seal packing as shown the illustration.

Seal packing:

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

NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after the installation.
(c) Install the cylinder head cover with a new seal washer and the 13 bolts.

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

43. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Apply a light coat of engine oil to 2 new O-rings, then install each of them onto the camshaft timing oil control valve.

(b) Install the 2 camshaft timing oil control valves and bracket with the 2 bolts.

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

44. INSTALL CAMSHAFT POSITION SENSOR

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

(b) Install the 2 sensors with the 2 bolts.

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

45. INSTALL SPARK PLUG

(a) Using a socket wrench 14 mm, install the 4 spark plugs.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

46. INSTALL OIL FILLER CAP GASKET

(a) Install the gasket to the cap.

47. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler cap.

48. INSTALL ENGINE HANGER

(a) Install the 2 engine hangers with the 2 bolts.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)