Part 2
2AZ-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - Continued
19. INSTALL NO. 2 CHAIN SUB-ASSEMBLY
(a) Set the crankshaft key into the left horizontal position.
(b) Turn the oil pump drive shaft so that the cutout faces upward.
(c) Align the yellow mark links with the timing mark of each gear as shown in the illustration.
Text in Illustration
(d) Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.
(e) Temporarily tighten the oil pump drive shaft gear with the nut.
(f) Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.
Text in Illustration
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
(g) Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
Text in Illustration
(h) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)
(i) Rotate the crankshaft 90° clockwise, and position the crankshaft key to face up as shown in the illustration.
20. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the crankshaft timing sprocket.
21. INSTALL NO. 1 CHAIN VIBRATION DAMPER
(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
22. INSTALL CHAIN SUB-ASSEMBLY
(a) Set the No. 1 cylinder to TDC/compression.
(1) Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks of the camshaft timing gears with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.
Text in Illustration
(2) Check that the crankshaft is positioned with the crankshaft key facing up as shown in the illustration.
(3) Install the chain onto the crankshaft timing sprocket with the gold or pink mark link aligned with the timing mark on the crankshaft.
Text in Illustration
(4) Using SST and a hammer, tap in the crankshaft timing sprocket.
SST : 09309-37010
(5) Align the gold or yellow mark links with each timing mark located on the camshaft timing gear and sprocket, then install the chain.
Text in Illustration
23. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Text in Illustration
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
24. INSTALL TIMING CHAIN GUIDE
(a) Install the timing chain guide with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
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.
Text in Illustration
(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.
Text in Illustration
