Reassembly
2AR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY
1. INSTALL ENGINE BALANCER ASSEMBLY
(a) Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned.
Text in Illustration
If the alignment marks are not aligned, realign them.
(1) Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place.
Text in Illustration
(2) Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover.
(b) Install the engine balancer to the stiffening crankcase with the 3 bolts and tighten the bolts in the sequence shown in the illustration.
Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)
2. INSTALL STIFFENING CRANKCASE STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
Text in Illustration
(a) Using an E5 and E8 "TORX" socket wrench, install the stud bolts.
for stud bolt A - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
for stud bolt B - Torque : 9.5 Nm (97 kgf-cm, 84 in-lbf)
3. INSTALL STIFFENING CRANKCASE RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in 2 new ring pins until they stop.
Standard protrusion height:
4.3 to 5.3 mm (0.169 to 0.209 in.)
Text in Illustration
4. INSTALL STIFFENING CRANKCASE ASSEMBLY
(a) Rotate the crankshaft clockwise so that the crankshaft key is at the position 270° from the bottom as shown in the illustration.
Text in Illustration
(b) 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 Dimension:
Application length A:
28 mm (1.10 in.)
Text in Illustration
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
* Do not apply oil for at least 4 hours after the installation.
* Do not start the engine for at least 4 hours after the installation.
(c) Check that the rear cutouts are as shown in the illustration.
Text in Illustration
(d) Clean the bolts and their installation holes.
(e) Apply adhesive to 3 threads or more at the end of bolt A.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(f) Temporarily install the stiffening crankcase with the 11 bolts.
Bolt Length:
HINT
Apply adhesive to bolt A before installing it
(g) Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase.
for bolt A - Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)
except bolt A - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
5. INSTALL NO. 1 OIL PAN BAFFLE PLATE
(a) Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the sequence shown in the illustration.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
6. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new gasket.
Text in Illustration
(b) Align the protrusion of the gasket with the cutout of the oil strainer and install the gasket to the oil strainer.
(c) Install the oil strainer with the 3 bolts in several steps in the sequence shown in the illustration.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
7. INSTALL OIL PAN SUB-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:
2.5 to 3.5 mm (0.0984 to 0.138 in.)
Text in Illustration
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
* Do not apply oil for at least 4 hours after the installation.
* Do not start the engine for at least 4 hours after the installation.
(b) Install the oil pan with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
HINT
Bolt A and nut A are tightened twice.
8. INSTALL OIL FILTER ELEMENT Replacement
9. INSTALL ENGINE REAR OIL SEAL Installation
10. INSTALL CYLINDER BLOCK WATER JACKET SPACER
(a) Install the water jacket spacer to the cylinder block.
11. INSTALL CYLINDER HEAD GASKET Installation
12. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation
13. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation
14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing.
Standard protrusion height:
2.7 to 3.3 mm (0.106 to 0.130 in.)
Text in Illustration
15. INSTALL CAMSHAFT HOUSING STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pin unless it is being replaced.
(a) Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing.
Standard protrusion height:
5.0 to 7.0 mm (0.197 to 0.276 in.)
Text in Illustration
16. INSTALL CAMSHAFT HOUSING STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
(a) Using an E8 "TORX" socket wrench, install the stud bolt.
Torque : 9.5 Nm (97 kgf-cm, 84 in-lbf)
17. INSTALL NO. 1 CAMSHAFT BEARING
(a) Clean the No. 1 camshaft bearing.
Text in Illustration
(b) Install the camshaft bearing to the No. 1 camshaft bearing cap.
(c) Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge.
Dimension A - B or B - A:
0 to 0.7 mm (0 to 0.0276 in.)
18. INSTALL NO. 2 CAMSHAFT BEARING
(a) Clean the No. 2 camshaft bearing.
Text in Illustration
(b) Install the camshaft bearing to the camshaft housing.
(c) Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge.
Standard distance:
1.15 to 1.85 mm (0.0453 to 0.0728 in.)
19. INSTALL OIL CONTROL VALVE FILTER
(a) Install the oil control valve filter to the No. 1 camshaft bearing cap.
20. INSTALL CAMSHAFT Installation
21. INSTALL CAMSHAFT BEARING CAP Installation
22. INSTALL VALVE STEM CAP Installation
23. INSTALL VALVE LASH ADJUSTER ASSEMBLY Installation
24. INSTALL VALVE ROCKER ARM SUB-ASSEMBLY Installation
25. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY Installation
26. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Installation
27. INSTALL CRANKSHAFT TIMING SPROCKET
(a) Install the crankshaft timing sprocket to the crankshaft.
28. ADD ENGINE OIL Installation
29. SET NO. 1 CYLINDER TO TDC/COMPRESSION Installation
30. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
31. INSTALL CHAIN SUB-ASSEMBLY
32. INSTALL CHAIN TENSIONER SLIPPER Installation
33. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation
34. INSTALL TIMING CHAIN GUIDE Installation
35. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION Installation
36. INSTALL TIMING CHAIN COVER PLATE
(a) Install a new gasket and the timing chain cover plate with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
37. INSTALL TIMING CHAIN COVER TIGHT PLUG
(a) Using a 14 mm hexagon wrench, install a new gasket and plug.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
39. INSTALL ENGINE MOUNTING BRACKET RH Installation
40. INSTALL TIMING CHAIN COVER OIL SEAL Installation
41. INSTALL SPARK PLUG TUBE GASKET Installation
42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
43. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the crankshaft pulley.
(b) Using SST, hold the crankshaft pulley and install the pulley bolt.
SST : 09213-54015
SST : 91551-80650
SST : 09330-00021
Torque : 260 Nm (2651 kgf-cm, 192 ft-lbf)
44. INSTALL CRANKSHAFT POSITION SENSOR Installation
45. INSTALL WATER INLET HOUSING
(a) Install a new gasket and the water inlet housing with the 4 bolts and nut.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
46. INSTALL WATER PUMP ASSEMBLY Installation
47. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
48. INSTALL THERMOSTAT Installation
49. INSTALL WATER INLET Installation
50. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
51. INSTALL SEPARATOR CASE
(a) Apply a light coat of engine oil to a new gasket.
(b) Install the gasket to the separator case.
(c) Install the separator case with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
52. INSTALL PCV CASE
(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:
2.5 to 3.5 mm (0.0984 to 0.138 in.)
Text in Illustration
NOTICE:
* Remove any oil from the contact surface.
* Install the PCV case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.
(b) Install the PCV case, and then install the 8 bolts and 2 nuts in the order shown in the illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
HINT
Bolt A is tightened twice.
53. INSTALL PCV VALVE Installation
54. INSTALL CAMSHAFT POSITION SENSOR (for Intake Side) Installation
55. INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side) Installation
56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side) Installation
57. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side) Installation
58. INSTALL OIL FILLER CAP SUB-ASSEMBLY
(a) Install a new gasket to the oil filler cap.
(b) Install the oil filler cap to the cylinder head.
59. INSTALL SPARK PLUG Installation
60. INSTALL ENGINE COVER JOINT
(a) Install the 3 joints.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)