Reassembly

2ZR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL STIFFENING CRANKCASE ASSEMBLY

(a) Apply seal packing in a continuous bead (diameter: 2.5 mm (0.0984 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 after applying 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 REAR ENGINE 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 of foreign matter.
* Do not tap on the oil seal at an angle.
(b) Apply MP grease to a new oil seal lip.

NOTICE:
Wipe off extra grease on the crankshaft.

3. INSTALL OIL PUMP ASSEMBLY Installation

4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Installation

5. 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)

6. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-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 seal packing.
* 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)

7. 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) Install the ventilation valve.

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

NOTICE:
* Install the crankcase within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the ventilation valve.
8. INSTALL CYLINDER HEAD GASKET Installation

9. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation

10. INSTALL VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
* Keep the lash adjuster free of dirt and foreign matter.
* Only use clean engine oil.
(a) Place the lash adjuster into a container filled with engine oil.

(b) Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

SST : 09276-75010

(c) Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

(d) Check the movement of the plunger and bleed it.

OK:

Plunger moves up and down.

NOTICE:
When bleeding air from the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.

(e) After bleeding, remove SST. Then, try to press the plunger quickly and firmly by hand.

OK:

Plunger is very difficult to move.

(f) If the result is not as specified, replace the lash adjuster.

(g) Install the lash adjusters.

NOTICE:
Install the lash adjuster to the same place it was removed from.

11. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Apply engine oil to the lash adjuster tip and valve stem cap end.

(b) Make sure that the valve rocker arms are installed as shown in the illustration.

12. INSTALL NO. 1 CAMSHAFT BEARING

(a) Clean the both surfaces of the bearings.

(b) Install the 2 No. 1 camshaft bearings.

(c) Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.

Dimension (A - B):

0.7 mm (0.0276 in.) or less

NOTICE:
Position the bearings to the center of the bearing cap by measuring dimensions A and B.

13. INSTALL OIL CONTROL VALVE FILTER

(a) Check that no foreign matter is 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.

14. INSTALL NO. 2 CAMSHAFT BEARING

(a) Clean both surfaces of the bearings.

(b) Install the 2 No. 2 camshaft bearings.

(c) Using a vernier caliper, measure the distance between the bearing cap edge and the camshaft bearing edge.

Dimension (A):

1.05 to 1.75 mm (0.041 to 0.069 in.)

NOTICE:
Position the bearings to the center of the bearing cap by measuring dimension A.

15. 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.

16. INSTALL CAMSHAFT

(a) Clean the camshaft journals.

(b) Apply a light coat of engine oil to the camshaft journals, camshaft housing.

(c) Install the camshaft to the camshaft housing.

17. INSTALL CAMSHAFT BEARING CAP

(a) Apply engine oil to the bearing caps.

(b) Make sure of the marks and numbers on the camshaft bearing caps and place them in each 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)

18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

(a) Make sure that the valve rocker arms are installed as shown in the illustration.

(b) Apply seal packing in a continuous bead as shown in the illustration.

Seal packing:

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

Bead 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 within 3 minutes and tighten the bolts within 15 minutes after applying 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.
19. 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 (clockwise).

(d) Measure the clearance between the gear and the camshaft flange.

Clearance:

0.1 to 0.4 mm (0.004 to 0.016 in.)

(e) Tighten the flange bolt with the camshaft timing gear secured in place.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

(f) Check that the camshaft timing gear can move in the retard direction (clockwise) and locks in the most retarded position.

20. 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 (clockwise).

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

(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.

21. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.

HINT
Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

22. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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

23. INSTALL NO. 2 CHAIN SUB-ASSEMBLY Installation

24. INSTALL CRANKSHAFT TIMING SPROCKET Installation

25. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation

26. INSTALL NO. 2 CHAIN VIBRATION DAMPER Installation

27. INSTALL CHAIN SUB-ASSEMBLY Installation

28. INSTALL CHAIN TENSIONER SLIPPER Installation

29. 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)

30. INSTALL INLET WATER HOUSING

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

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

31. INSTALL TIMING CHAIN COVER OIL SEAL

(a) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

SST : 09223-22010

(b) Apply a light coat of MP grease to the lip of the oil seal.

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.
* Make sure that the oil seal edge does not stick out of the timing chain cover.
32. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

33. INSTALL CRANKSHAFT PULLEY Installation

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 after applying adhesive.
* Do not start the engine within 1 hour after installation.
35. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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

(b) Using a 19 mm deep socket wrench, install the temperature sensor.

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

36. INSTALL KNOCK CONTROL SENSOR

(a) Install the knock control sensor with the bolt.

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

NOTICE:
Make sure that the knock control 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 after applying adhesive.
* Do not start the engine within 1 hour after 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 engage the hook to 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 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, engage the hook again.

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

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

40. INSTALL OIL FILTER CAP ASSEMBLY Replacement

41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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

NOTICE:
Remove any oil from the contact surfaces.

(b) Install 3 new gaskets to the No. 1 camshaft bearing cap.

Seal packing:

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

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

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

42. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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

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

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

43. INSTALL CAMSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-rings of the sensors.

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

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

44. INSTALL SPARK PLUG

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

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

45. INSTALL ENGINE COVER JOINT

(a) Install the 2 engine cover joints.

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