Reassembly

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: 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 BALANCE SHAFTS

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

NOTICE:
Confirm that the matchmarks on the No. 1 and No. 2 driven gears are matched.

(b) Confirm that the alignment marks on the No. 1 and No. 2 balanceshafts are aligned.

(d) Place the No. 1 and No. 2 balance shafts 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 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) Place a new O-ring on the cylinder block as shown in the illustration.

(b) With the No. 1 crank pin of the crankshaft placed at the TDC position, install the No. 1 and No. 2 balanceshafts and align the adjusting holes as shown in the illustration.

Seal Packing:

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

NOTICE:
* Remove any oil from the contact surfaces.
* Install the crankcase within 3 minutes of applying seal packing.
* Do not add engine oil for at least 2 hours after installing the crankcase.
(d) Temporarily install the crankcase with the 11 bolts.

(e) Uniformly tighten the bolts.

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

(f) Confirm that the timing marks on the balanceshafts are aligned when the key groove is placed at the TDC 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 an 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 CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the drain cock.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the water drain cock within the range shown in the illustration.

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

NOTICE:
Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cock to the specified torque.

(c) Install the water drain cock plug to the water drain cock.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

9. INSTALL CYLINDER BLOCK WATER JACKET SPACER

(a) Install the water jacket spacer as shown in the illustration.

HINT
Be sure to face the slope to the front of the engine.

10. INSTALL CYLINDER HEAD GASKET Installation

11. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation

12. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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

(b) Install the O-ring to the camshaft timing oil control valve.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

13. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation

14. 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)

15. 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 the No. 1 camshaft bearing onto the No. 1 camshaft bearing cap.

16. 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.

17. INSTALL CAMSHAFT

(a) Apply a light coat of engine oil to the journal portion.

(b) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.

(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(d) Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

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)

18. INSTALL NO. 2 CAMSHAFT

(a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

(b) 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)

19. INSTALL KEYS

(a) Install the 2 keys.

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 Installation

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 to the O-ring of the sensor.

(b) Confirm that the wire harness of the sensor is placed as shown in the illustration.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(d) Install the clamp of the crankshaft position sensor onto the water pump.

32. INSTALL OIL PAN SUB-ASSEMBLY Installation

33. INSTALL OIL PAN DRAIN PLUG

(a) Install the oil pan drain plug with a new gasket.

Torque : 25 Nm (255 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 of the sensor.

(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 surfaces.
* Install the cylinder head cover within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installing the cylinder head cover.
(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 22 mm deep socket wrench, 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.