Reassembly

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL NO. 1 BALANCESHAFT BEARING





(a) Align the bearing claw with the claw groove, and push in the 8 bearings.
NOTICE: Do not apply engine oil to the contact surfaces of the balanceshaft bearing and balanceshaft housing.

(b) Apply a light coat of the engine oil to the bearings.
2. INSTALL NO. 1 AND NO. 2 BALANCESHAFTS





(a) Rotate the No. 1 driven gear of the No. 1 balanceshaft in the rotating direction until it hits the stopper.





(b) Confirm that the timing marks on the No. 1 and No. 2 balanceshaft are aligned.





(c) Align the timing marks on the No. 1 and No. 2 balanceshafts as shown in the illustration.
(d) Place the No. 1 and No. 2 balancshafts onto the crankcase.
(e) Apply a light coat of engine oil to the threads and under the heads of the bolts.





(f) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 22 Nm (220 kgf-cm, 16 ft-lbf)





(g) Mark the front of the bolts with paint.





(h) Further tighten the bolts by 90° as shown in the illustration.
(i) Check that the paint mark is now at a 90° angle to the front.
3. INSTALL STIFFENING CRANKCASE ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and crankcase.
(b) Place a new O-ring on the cylinder block as shown in the illustration.





(c) With the No. 1 crank pin of the crankshaft placed at the 6 o'clock position, install the No. 1 and No. 2 balanceshafts and align the adjusting holes as shown in the illustration.





(d) Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.098 to 0.118 in.)) as 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 seal packing.
- Do not add engine oil for at least 2 hours after installing the crankcase.





(e) Temporarily install the crankcase with the 11 bolts.










(f) Uniformly tighten the bolts.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)





(g) Confirm that the timing marks on the balanceshafts are aligned when the key groove the is placed at the 6 o'clock position, as shown in the illustration.
4. INSTALL OIL PUMP ASSEMBLY Installation
5. INSTALL REAR CRANKSHAFT OIL SEAL Installation
6. INSTALL NO. 1 TAPER HEAD SCREW PLUG





(a) Apply adhesive to 2 or 3 threads of the plug, and install it.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:
- Install the plug within 3 minutes of applying adhesive.
- Do not add coolant for at least an hour after installing the plug.

7. INSTALL OIL CONTROL VALVE FILTER
(a) Check that there are no foreign objects on the mesh part of the oil control valve filter.





(b) Using a 8 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the plug.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
8. INSTALL INLET WATER HOUSING





(a) Install the 2 new O-rings onto the inlet water housing.





(b) Using several steps, uniformly install and tighten the 5 bolts in the sequence shown in the illustration.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
(c) Using E5 "TORX" socket wrench, remove the 6 stud bolts from the inlet water housing.





Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
9. INSTALL INLET WATER HOUSING DRAIN COCK ASSEMBLY





(a) Apply adhesive to 2 or 3 threads of the drain cock.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent





(b) After tightening the drain cock to the specified torque, further tighten it one turn or less to set the drain cock pipe as specified in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE:
- Install the drain cock within 3 minutes of applying adhesive.
- Do not add coolant for at least an hour after installing the drain cock.
- Do not turn the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque.
- Do not loosen the drain cock after setting it correctly.

(c) Install the plug onto the water drain cock.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
10. INSTALL CYLINDER BLOCK WATER JACKET SPACER





(a) Install the cylinder block water jacket spacer into the cylinder block as shown in the illustration.
11. INSTALL CYLINDER HEAD GASKET Installation
12. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation
13. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY





(a) Apply a light coat of engine oil onto the new O-ring.





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





(a) Clamp the camshaft in a vise, then install the camshaft timing sprocket with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
16. INSTALL NO. 1 CAMSHAFT BEARING
(a) Clean the installation surfaces and the inner and outer surfaces of the bearing.
NOTICE: Keep the installation surfaces and the back surfaces of the bearing free of engine oil.





(b) Align the claws and install No. 1 camshaft bearing onto No. 1 camshaft bearing cap.
17. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean the installation surfaces and the inner and outer surfaces of the bearing.
NOTICE: Keep the installation surfaces and the back surfaces of the bearing free of engine oil.





(b) Install the No. 2 camshaft bearing onto the cylinder head.
18. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion.





(b) Place the camshaft on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.
(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.





(d) 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.
No. 1 bearing cap - Torque: 30 Nm (301 kgf-cm, 22 ft-lbf)
No. 3 bearing cap - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

NOTICE:
- Determine the thrust direction of the camshaft by checking the location of the No. 1 bearing cap. Then tighten the bolts.
- Install the camshaft with the timing with the timing mark of the camshaft timing gear on top.

19. INSTALL NO. 2 CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion.





(b) Place the camshaft on the cylinder head with the No. 2 cam lobes facing the directions shown in the illustration.
(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.





(d) 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.
No. 2 bearing cap - Torque: 30 Nm (301 kgf-cm, 22 ft-lbf)
No. 3 bearing cap - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)

NOTICE:
- Determine the thrust direction of the camshaft by checking the location of the No. 2 bearing cap. Then tighten the bolts.
- Install the camshaft with the timing with the timing mark of the camshaft timing gear on top.

20. INSTALL NO. 2 CHAIN SUB-ASSEMBLY Installation
21. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET Installation
22. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
23. INSTALL CHAIN SUB-ASSEMBLY Installation
24. INSTALL CHAIN TENSIONER SLIPPER Installation
25. INSTALL TIMING CHAIN GUIDE Installation
26. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE Installation
27. INSTALL FRONT CRANKSHAFT OIL SEAL
(a) Apply MP grease to the tip of a oil seal.
NOTICE: Keep the lip free of foreign objects.





(b) Using SST and a hammer, tap in the new oil seal until its surface is flush with the timing chain cover edge.
SST: 09223-22010
NOTICE: Do not tap the oil seal at an angle.

28. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Installation
29. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation
30. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
31. INSTALL CRANKSHAFT POSITION SENSOR





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





(b) Install the crankshaft position sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Install the wire harness onto the harness clamp bracket.
32. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.





(b) Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) to the oil pan mating surface as 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 oil pan within 3 minutes of applying seal packing.
- Do not expose the seal to engine oil within 2 hours of installation.
- Do not start the engine for at least 2 hours after the installation





(c) Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
33. INSTALL OIL PAN DRAIN PLUG





(a) Install the oil drain plug with a new gasket.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
34. INSTALL WATER PUMP ASSEMBLY Installation
35. INSTALL WATER PUMP PULLEY Installation
36. INSTALL CRANKSHAFT PULLEY Installation
37. INSPECT VALVE CLEARANCE Adjustments
38. ADJUST VALVE CLEARANCE Adjustments
39. INSTALL CAMSHAFT POSITION SENSOR





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





(b) Install the camshaft position sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
40. INSTALL CYLINDER HEAD COVER GASKET





(a) Install the cylinder head cover gasket onto the cylinder head cover.
41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing material from the contact surface.





(b) Apply seal packing to the 2 locations 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 oil pan within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the oil pan.





(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Bolt A - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
Bolt B - Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)
Nut - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
42. INSTALL OIL FILTER UNION





(a) Using a 12 mm socket hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
43. INSTALL OIL FILTER SUB-ASSEMBLY Replacement
44. INSTALL SPARK PLUG Installation
45. INSTALL VENTILATION VALVE SUB-ASSEMBLY





(a) Apply adhesive to the threads of the ventilation valve.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent





(b) Using a deep socket wrench 22 mm, install the ventilation valve onto the cylinder head cover.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
46. INSTALL OIL FILLER CAP GASKET





(a) Install the oil filler cap gasket onto the oil filler cap.
47. INSTALL OIL FILLER CAP SUB-ASSEMBLY





(a) Install the oil filler cap onto the cylinder head cover.