Part 2

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

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)