Part 2

2AZ-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

25. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Install the No. 1 crankshaft position sensor plate with the "F" mark facing forward.





26. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head or cylinder block.

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





Text in Illustration





Seal packing:

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

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





Text in Illustration





Seal packing:

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

NOTICE:
* Remove any oil from the contact surfaces.
* Install the chain cover within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installation.

(d) Apply adhesive to the threads of bolt A.





Text in Illustration





Seal packing:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(e) Temporarily tighten the timing chain cover with the 12 bolts and 2 nuts.

Bolt Length





(f) Temporarily install the engine mounting bracket RH with the 3 bolts.

(g) Fully tighten the bolts in the order shown in the illustration.





Text in Illustration





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

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

Bolt C - Torque : 55 Nm (561 kgf-cm, 41 ft-lbf)

Nut - Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

(h) Using an E10 "TORX" socket, install the stud bolt.





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

27. INSTALL IDLER PULLEY BRACKET

(a) Install the idler pulley bracket with the bolt and nut.

Torque : 60 Nm (607 kgf-cm, 44 ft-lbf)

28. INSTALL IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley sub-assembly and idler pulley cover plate with the bolt.

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

29. INSTALL TIMING CHAIN CASE OIL SEAL Installation

30. INSTALL OIL PAN SUB-ASSEMBLY

(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block or oil pan.





Text in Illustration





(b) Apply a continuous bead of seal packing (Diameter 3.0 to 4.0 mm (0.118 to 0.157 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 surfaces.
* Install the oil pan within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil pan.

(c) Install the oil pan sub-assembly to the cylinder block.

(d) 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)

31. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and oil pan drain plug.

Torque : 40 Nm (408 kgf-cm, 29 ft-lbf)

32. INSTALL WATER PUMP ASSEMBLY Installation

33. INSTALL WATER PUMP PULLEY Installation

34. INSTALL CRANKSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.





Text in Illustration





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





Text in Illustration





(c) Install the crankshaft position sensor with the 2 bolts.

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

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

35. INSTALL CRANKSHAFT PULLEY Installation

36. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Release the ratchet pawl, then fully push in the plunger and hook the pin so that the plunger is in the position shown in the illustration.





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(b) Install a new gasket and the chain tensioner with the 2 nuts.





Text in Illustration





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

NOTICE:
If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

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





Text in Illustration





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





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37. INSPECT VALVE CLEARANCE Adjustments

38. ADJUST VALVE CLEARANCE Adjustments

39. INSTALL CAMSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring of the camshaft position sensor.





Text in Illustration





(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 gasket to the cylinder head cover.

NOTICE:
Remove any oil from the contact surfaces.

41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove any old packing material from the contact surfaces.





(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 add engine oil for at least 2 hours after installing the cylinder head cover.

(c) Install the cylinder head cover with the 8 bolts and 2 nuts.





Text in Illustration





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 COOLER ASSEMBLY

(a) Clean the oil cooler contact surface on the cooler mounting.

(b) Install a new O-ring to the oil cooler.





Text in Illustration





(c) Apply a light coat of engine oil to the threads and under the head of the union bolt.

(d) Install the oil cooler with the plate washer, oil filter union and nut.

Oil Filter Union - Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)

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

43. INSTALL OIL FILTER SUB-ASSEMBLY

(a) Check and clean the oil filter installation surfaces.

(b) Apply clean engine oil to the gasket of a new oil filter sub-assembly.

(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.

(d) When using a torque wrench:

(1) Using SST, tighten the oil filter.





SST : 09228-06501

Torque : 18 Nm (183 kgf-cm, 13 ft-lbf)

(e) When not using a torque wrench:

(1) Using SST, tighten it an additional 3/4 turn.





Text in Illustration





SST : 09228-06501

44. INSTALL SPARK PLUG

(a) Install the 4 spark plugs.

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

45. INSTALL VENTILATION VALVE SUB-ASSEMBLY

(a) Apply adhesive to the threads of the ventilation valve sub-assembly.





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Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Install the ventilation valve sub-assembly.

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

46. INSTALL OIL FILLER CAP GASKET

(a) Install a new gasket to the oil filler cap.

47. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler cap sub-assembly.