Reassembly
2ZR-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL STIFFENING CRANKCASE RING PIN
NOTICE:
It is not necessary to remove a ring pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in 2 new ring pins until they stop.
Standard Ring Pin:
2. INSTALL STIFFENING CRANKCASE STUD BOLT
NOTICE:
If a stud bolt is deformed or the threads are damaged, replace it.
(a) Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
3. INSTALL STIFFENING CRANKCASE ASSEMBLY
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three bond 1207B or equivalent
Standard Seal Diameter:
Application Length A:
56 mm (2.20 in.)
NOTICE:
* Remove any oil from the contact surfaces.
* Install the crankcase 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 installing the stiffening crankcase assembly.
(b) Install the stiffening crankcase with the 11 bolts in the sequence shown in the illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Bolt Length:
(c) Recheck the torque for bolts 1 and 2.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(d) Wipe off any excess seal packing with a clean piece of cloth.
4. INSTALL OIL PUMP ASSEMBLY Installation
5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Installation
6. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and the drain plug.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
7. INSTALL ENGINE REAR OIL SEAL Installation
8. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to the threads of the cylinder block water drain cock.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the drain cock as shown in the illustration.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE:
* Do not rotate the drain cock more than 1 revolution (360°) after tightening it to the specified torque.
* Do not loosen the drain cock to adjust it. If an adjustment is necessary, remove the drain cock and reinstall it.
* Install the drain cock within 3 minutes of applying adhesive.
* Do not start the engine for at least 1 hour after installing the drain cock.
(c) Install the drain cock plug to the drain cock.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
9. INSTALL NO. 1 TAPER SCREW PLUG
(a) Apply adhesive to 2 or 3 threads of the taper screw plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the taper screw plug.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
NOTICE:
* Install the plug within 3 minutes of applying adhesive.
* Do not start the engine for at least 1 hour after installation.
10. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive to the threads of the ventilation valve sub-assembly.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
NOTICE:
* Install the ventilation valve sub-assembly within 3 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing the ventilation valve sub-assembly.
(b) Install the ventilation valve sub-assembly.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
11. INSTALL CYLINDER HEAD GASKET Installation
12. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation
13. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem ends.
(b) Install the 16 valve stem caps to the cylinder head.
NOTICE:
Do not drop the valve stem caps into the cylinder head.
14. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Inspect each valve lash adjuster before installing it Inspection.
(b) Install the 16 valve lash adjusters to the cylinder head.
NOTICE:
Install the valve lash adjuster to the same place it was removed from.
15. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Apply engine oil to the valve lash adjuster tips and valve stem cap ends.
(b) Make sure that the No. 1 valve rocker arms are installed as shown in the illustration.
16. INSTALL CAMSHAFT HOUSING STRAIGHT PIN
NOTICE:
It is not necessary to remove a straight pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in a new straight pin to the specified protrusion height.
Standard Straight Pin:
17. INSTALL NO. 1 CAMSHAFT BEARING Installation
18. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign matter is on the mesh part of the oil control valve filter.
(b) Install the oil control valve filter.
NOTICE:
Do not touch the mesh when installing the oil control valve filter.
19. INSTALL NO. 2 CAMSHAFT BEARING Installation
20. INSTALL NO. 2 CAMSHAFT Installation
21. INSTALL CAMSHAFT Installation
22. INSTALL CAMSHAFT BEARING CAP Installation
23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY Installation
24. INSTALL CAMSHAFT TIMING SPROCKET Installation
25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation
26. 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.
27. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
(a) Install the crankshaft position sensor plate with the "F" mark facing forward.
28. INSTALL NO. 2 CHAIN SUB-ASSEMBLY Installation
29. INSTALL CRANKSHAFT TIMING SPROCKET Installation
30. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
31. SET NO. 1 CYLINDER TO TDC/COMPRESSION Installation
32. INSTALL CHAIN SUB-ASSEMBLY Installation
33. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION Installation
34. INSTALL CHAIN TENSIONER SLIPPER Installation
35. INSTALL NO. 2 CHAIN VIBRATION DAMPER Installation
36. INSTALL INLET WATER SUB-ASSEMBLY STUD BOLT
NOTICE:
If a stud bolt is deformed or the threads are damaged, replace it.
(a) Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
37. INSTALL INLET WATER SUB-ASSEMBLY
(a) Install a new gasket and the inlet water sub-assembly with the bolt and 2 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
39. INSTALL TIMING CHAIN COVER OIL SEAL Installation
40. INSTALL CRANKSHAFT PULLEY Installation
41. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation
42. INSTALL OIL FILTER CAP ASSEMBLY Replacement
43. INSTALL SPARK PLUG TUBE GASKET
(a) Using a cutter knife, cut off the seal part of the removed gasket.
(b) Using a hammer and the plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.
NOTICE:
* Keep the lip free of foreign matter.
* Do not tap in the plug tube gasket.
HINT
If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.
(c) Return the claws of the ventilation baffle plate to their original positions.
44. INSTALL CYLINDER HEAD COVER GASKET
(a) Install a new cylinder head cover gasket to the cylinder head cover.
NOTICE:
* Remove any oil from the contact surfaces.
* Misalignment between the center of the cylinder head cover rib and the center of the cylinder head gasket tab is within 4 mm (0.157 in.).
45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Install 2 new gaskets to the camshaft bearing cap.
(b) Apply seal packing as shown the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard diameter:
4.0 mm (0.157 in.)
NOTICE:
* Remove any oil from the contact surfaces.
* Install the cylinder head cover sub-assembly 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)
NOTICE:
Misalignment between the contact surfaces of the timing chain cover and the camshaft housing and the center of the cylinder head gasket tab is within 4 mm (0.157 in.).
46. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
NOTICE:
* Install the oil pressure switch within 3 minutes after applying adhesive.
* Do not start the engine within 1 hour after installation.
(b) Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
47. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket and the engine coolant temperature sensor.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
48. INSTALL KNOCK SENSOR
(a) Install the knock sensor with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
Make sure that the knock sensor is in the correct position.
49. 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)
50. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
* Do not allow foreign matter to contact the oil seal face of the oil control valve (connecting surface with cylinder head cover).
* Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve.
51. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring of the sensor.
(b) Install the camshaft position sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
Make sure that the O-ring is not cracked or jammed when installing the sensor.
52. INSTALL SPARK PLUG Installation
53. INSTALL ENGINE COVER JOINT BOLT
(a) Install the 3 engine cover joint bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
54. INSTALL WIRING HARNESS CLAMP BRACKET
(a) Install the wiring harness clamp bracket with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
55. INSTALL OIL FILLER CAP GASKET
(a) Install the gasket to the oil filler cap.
56. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install the oil filler cap.
