Reassembly

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL TIGHT PLUG
(a) Apply adhesive around the new tight plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three bond 1324 or equivalent
(b) Using SST, install the 2 tight plugs.

SST: 09950-60010
09951-00200
SST: 09950-70010
09951-07100
Standard depth:

2. INSTALL RING PIN
(a) Using a plastic hammer, install 12 new ring pins.

Standard protrusion height:

3. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, install 8 new straight pins.

Standard protrusion height:

4. INSTALL STUD BOLT
(a) Install the 8 stud bolts into the cylinder block.

Torque:

5. INSTALL PISTON

(a) Using a small screwdriver, install a new snap ring onto one end of the piston pin hole.
HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

(b) Gradually heat the piston up to 80 to 90°C (176 to 194°F).

(c) Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin comes into contact with the snap pin hole.
HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

6. INSTALL PISTON RING SET
(a) Install the expander and 2 side rails by hand.

(b) Using a piston ring expander, install the 2 compression rings with the paint mark as shown in the illustration.
NOTE: Install No. 2 compression ring with the cord mark (2N) facing upward.

(a) Install the upper bearing with an oil groove onto the cylinder block.
NOTE: Do not apply engine oil to the bearing or its contact surface.

8. INSTALL NO. 2 CRANKSHAFT BEARING

(a) Install the lower bearing onto the bearing cap.
NOTE: Do not apply engine oil to the bearing or its contact surface.

9. INSTALL CRANKSHAFT THRUST WASHER UPPER

(a) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil groove facing outward.
10. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block.

(b) Examine the front marks and numbers and install the bearing caps onto the cylinder block in the order shown in the illustration.
(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 install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)

(e) Mark the front of the bearing cap bolts with paint.
(f) Retighten the 8 bearing cap bolts by 90° in the same sequence.
(g) Check that the paint marks are now at a 90° angle to the front.
(h) Check that the crankshaft turns smoothly.
11. INSTALL CONNECTING ROD BEARING

(a) Align the bearing claw with the oil groove of the connecting rod or connecting rod cap.
NOTE: Do not apply engine oil to the bearing or its contact surface.

12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.

(d) Check that the front mark of the connecting rod cap is facing in the correct direction.
NOTE: Match the numbered connecting rod cap with the connecting rod.

(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
(f) Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque.
Torque: 24.5 Nm (250 kgf-cm, 18 ft-lbf)

(g) Mark the front of the connecting rod bolts with paint.
(h) Retighten the cap bolts 90°as shown in the illustration.
(i) Check that the crankshaft turns smoothly.
13. INSTALL BALANCE SHAFT

(a) Rotate the No. 1 driven gear of the No. 1 balance shaft in the rotating direction until it hits the stopper.
(b) Confirm that the matchmarks on the No. 1 and No. 2 driven gears are aligned.

(c) Align the matchmarks of the No. 1 and No. 2 balance shafts as shown in the illustration.
(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: 21.6 Nm (224 kgf-cm, 16 ft-lbf)
(g) Mark the front of the bolts with paint.
(h) Retighten the bolts 90°as shown in the illustration.

(i) Check that the paint mark is now at a 90°angle to the front.
14. INSTALL STIFFENING CRANKCASE ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and crankcase.

(b) Apply a continuous bead of seal packing (Diameter 2.5 to 3.0 mm (0.098 to 0.118 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 surface,
- 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) With the No. 1 crank pin of the crankshaft placed at the 6 o'clock position, install the No. 1 and No. 2 balance shafts and align the adjusting holes as shown in the illustration.

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

HINT:
- Bolt length: 112 mm (4.41 in.) for A of 12 mm head
- 35 mm (1.38 in.) for B of 12 mm head

(f) Uniformly tighten the bolts.
Torque: 32.5 Nm (331 kgf-cm, 24 ft-lbf)

(g) Confirm that the timing marks of the balance shafts are aligned when the key groove is placed at the 6 o'clock position, as shown in the illustration.
15. INSTALL ENGINE REAR OIL SEAL Replacement

16. INSTALL NO. 1 TAPER 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

HINT:
- Install the plug within 3 minutes of applying adhesive.
- Do not add coolant for at least an hour after installing the plug.

17. INSTALL OIL CONTROL VALVE FILTER

(a) Check that there is no foreign objects on the mesh part of the oil control valve filter.
(b) Using a 6 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)
18. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the drain cock.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) After tightening the drain cock to the specified torque, turn the drain cock clockwise as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
- Install the drain cock within 3 minutes of applying adhesive.
- Do not add coolant for at least an hour after installing the drain cock.
- Do not turn the drain cock by more than 1 revolution (360°) after tightening the drain cock to the specified torque.
- Do not loosen the drain cock after setting it correctly.

19. INSTALL CYLINDER HEAD GASKET

(a) Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.
- Place the cylinder head gently in order to avoid damaging the gasket with the bottom part of the head.

20. INSTALL CYLINDER HEAD SUB-ASSEMBLY
NOTE: The cylinder head bolts are tightened in 2 successive steps.

(a) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

(b) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque: 78.5 Nm (800 kgf-cm, 58 ft-lbf)

(c) Mark the front of the cylinder head bolts with paint.
(d) Retighten the cylinder head bolts so that the paint marks are at a 90° angle to the front.
21. 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.
(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
22. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation

23. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET Installation

24. INSTALL NO. 2 CAMSHAFT BEARING Installation

25. INSTALL NO. 1 CAMSHAFT BEARING

(a) Clean the contact surfaces of the bearing and the No. 1 bearing cap.
(b) Align the bearing claw with the claw groove of the No. 1 bearing cap and push in the bearing.
NOTE: Do not apply engine oil to the bearing and its contact surface.

26. INSTALL CAMSHAFT Installation

27. INSTALL OIL PUMP ASSEMBLY Installation

28. INSTALL CHAIN SUB-ASSEMBLY Installation

29. INSTALL CRANKSHAFT TIMING SPROCKET
30. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation

31. INSTALL CHAIN SUB-ASSEMBLY Installation

32. INSTALL CHAIN TENSIONER SLIPPER Installation

33. INSTALL TIMING CHAIN GUIDE Installation

34. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 Installation

35. INSTALL TIMING CHAIN COVER OIL SEAL Replacement

36. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation

37. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation

38. INSTALL CRANKSHAFT PULLEY Installation

39. INSTALL OIL PAN SUB-ASSEMBLY Installation

40. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, then install it onto the oil pan.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
41. INSTALL WATER PUMP ASSEMBLY Installation

42. INSTALL WATER PUMP PULLEY Installation

43. INSTALL CRANKSHAFT POSITION SENSOR Installation

44. INSTALL CAMSHAFT POSITION SENSOR Installation

45. INSTALL OIL FILTER UNION
(a) Using a 12 mm socket hexagon wrench, install the oil filter union.
Torque: 29.5 Nm (301 kgf-cm, 22 ft-lbf)
46. INSTALL OIL FILTER SUB-ASSEMBLY Replacement

47. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal

48. CHECK VALVE CLEARANCE Adjustments

49. ADJUST VALVE CLEARANCE Adjustments

50. INSTALL CAMSHAFT Adjustments

51. INSTALL NO. 2 CAMSHAFT Adjustments

52. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Adjustments

53. INSTALL CYLINDER HEAD GASKET
(a) Install the gasket onto the cylinder head cover.
54. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation

55. 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
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
56. INSTALL OIL FILLER CAP SUB-ASSEMBLY
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)