Part 1

2AZ-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

1. INSTALL NO. 1 BALANCE SHAFT BEARING

(a) Install the bearings in the crankcase and balance shaft housing.

NOTICE:
Do not apply engine oil to the bearings or the contact surfaces.

(b) Apply a light coat of engine oil to the bearings.

2. INSTALL NO. 1 AND NO. 2 BALANCE SHAFT SUB-ASSEMBLY

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

Text in Illustration

NOTICE:
Confirm that the alignment marks on the No. 1 and No. 2 driven gears are aligned.

(b) Align the timing marks of the No. 1 and No. 2 balance shafts as shown in the illustration.

Text in Illustration

(d) Apply a light coat of engine oil under the heads of the balance shaft housing bolts.

(e) Install the balance shaft housing bolts.

NOTICE:
The balance shaft housing bolts are tightened in 2 progressive steps.

(f) Step 1

(1) Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.

Torque : 22 Nm (220 kgf-cm, 16 ft-lbf)

(g) Step 2

(1) Mark the front of each balance shaft housing bolt head with paint.

Text in Illustration

(2) Further tighten the bolts 90° as shown in the illustration.

(3) Check that the paint marks are 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) Temporarily tighten the pulley set bolt.

(c) Turn the crankshaft to set the crank pins of the No. 1 and No. 4 cylinders to the bottom.

Text in Illustration

HINT
Make sure that the timing mark on the balance shaft drive gear is positioned as shown in the illustration.

(d) Apply seal packing in a continuous bead (diameter: 2.5 to 3.0 mm (0.0984 to 0.118 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 surfaces.
* Install the crankcase within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installing the stiffening crankcase.
(e) Install the stiffening crankcase so that the reference holes on the balance shafts are positioned as shown in the illustration.

Text in Illustration

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

Bolt Length:

(g) Uniformly tighten the 11 bolts in the sequence shown in the illustration.

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

(h) Wipe off any excess seal packing with a clean piece of cloth.

(i) Turn the crankshaft again to set the key groove to the bottom. Make sure that the timing marks are aligned as shown in the illustration.

Text in Illustration

HINT
'o' marks are stamped as timing marks.

(j) Remove the pulley set bolt.

4. INSTALL OIL PUMP ASSEMBLY

(a) Install a new gasket and oil pump assembly with the 3 bolts.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

5. INSTALL ENGINE REAR OIL SEAL

(a) Apply MP grease to a new oil seal lip.

(b) 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 from foreign matter.
* Wipe off excess grease on the crankshaft.
6. INSTALL OIL CONTROL VALVE FILTER

(a) Check that no foreign matter is on the mesh part of the filter.

(b) Using an 8 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.

Text in Illustration

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

NOTICE:
Do not touch the mesh when installing the oil control valve filter.

7. INSTALL UNION BOLT

(a) Apply adhesive to the threads of the union bolt.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the union bolt.

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

8. INSTALL CYLINDER BLOCK WATER JACKET SPACER

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

Text in Illustration

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

9. INSTALL CYLINDER HEAD GASKET Installation

10. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation

11. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.

Text in Illustration

(b) Install the camshaft timing oil control valve with the bolt.

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

12. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation

13. INSTALL CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise.

(b) Install the camshaft timing sprocket with the flange bolt.

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

14. INSTALL NO. 1 CAMSHAFT BEARING

(a) Install the No. 1 camshaft bearing.

15. INSTALL NO. 2 CAMSHAFT BEARING

(a) Install the No. 2 camshaft bearing.

16. INSTALL CAMSHAFT

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

(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.

Text in 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)

17. 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.

Text in Illustration

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)

18. INSTALL KEY

(a) Install the 2 keys.