Part 1

2UZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new ones.

1. INSTALL TIGHT PLUG
(a) Install the tight plug.

(1) Apply adhesive to the tight plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(2) Using SST and a hammer, tap in a new tight plug as shown in the illustration.
SST: 09950-60010
09951-00350
SST: 09950-70010
09951-07100
2. INSTALL STUD BOLT
(a) Install the stud bolt.

For A - Torque: 8.0 Nm (80 kgf-cm, 71 in-lbf)
For B - Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)
For C - Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
For D - Torque: 14 Nm (145 kgf-cm, 10 ft-lbf)
For E - Torque: 8.0 Nm (80 kgf-cm, 71 ft-lbf)
3. INSTALL STRAIGHT PIN
(a) Install the straight pin.

4. INSTALL RING PIN
(a) Install the ring pin.

5. INSTALL PISTON

(a) Using a screwdriver, install a new snap ring on one side of the piston pin hole.

(b) Gradually heat the piston to about 60°C (140°F).

(c) Coat the piston pin with engine oil.
(d) Position the piston front mark with respect to the outside mark on the connecting rod as shown in the illustration.

NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2".

(e) Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.

(f) Using a screwdriver, install a new snap ring on the other side of the piston pin hole.
6. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.

(b) Using a piston ring expander, install the 2 piston rings with the code mark facing upward.

(c) Position the piston rings so that the ring ends are as shown in the illustration.

NOTE: Do not align the ring ends.

7. INSTALL CONNECTING ROD BEARING

(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting rod cap.
8. INSTALL CRANKSHAFT BEARING

HINT:
- Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions.
- Upper bearings have an oil groove and oil holes; lower bearings do not.

(a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

(b) Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

HINT: A number is marked on each bearing cap to indicate the installation position.

9. INSTALL CRANKSHAFT THRUST WASHER SET

(a) Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

(b) Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.
10. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY
11. INSTALL CRANKSHAFT

(a) Place the crankshaft on the cylinder block.
(b) Install the 5 crankshaft bearing caps in their proper locations.

HINT: Place the bearing caps level and let them return to their original positions by their own weight.

NOTE: Do not install the bearing cap by tapping it.

(c) Install the crankshaft bearing cap bolts.

HINT:
- The bearing cap bolts are tightened in 2 progressive steps.
- If any one of the bearing cap bolts is broken or deformed, replace it.

(1) Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
(2) Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt.

(3) Mark the front of the crankshaft bearing cap bolts with paint.
(4) Retighten the crankshaft bearing cap bolts by 90° in the order shown.
(5) Check that the painted mark is now at a 90° angle to the front.
(6) Check that the crankshaft turns smoothly.
12. INSTALL PISTON AND CONNECTING ROD

(a) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

NOTE: The shape of the piston varies for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2".

(b) Place the connecting rod cap on the connecting rod.

(1) Match the numbered connecting rod cap with the connecting rod.
(2) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.

(3) Check that the outside mark of the connecting rod cap is facing in the correct direction.
(c) Install the connecting rod cap bolts.

HINT:
- The connecting rod cap bolts are tightened in 2 progressive steps.
- If any one of the connecting rod cap bolts is broken or deformed, replace it.

(1) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(2) Install and alternately tighten the 2 connecting rod cap bolts in several steps.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

(3) Mark the front of the connecting cap bolt with paint.
(4) Retighten the cap bolts 90° as shown in the illustration.
(5) Check that the painted mark is now at a 90° angle to the front.
(d) Check that the crankshaft turns smoothly.
13. INSTALL NO. 1 TIGHT PLUG

(a) Apply adhesive to the tight plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using SST and a hammer, tap in a new tight plug as shown in the illustration.
SST: 09950-60010
09951-00300
SST: 09950-70010
09951-07100
14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN
(a) Install the camshaft bearing cap setting ring pin.

15. INSTALL STUD BOLT
(a) Install the stud bolt.

For A and C - Torque: 9.0 Nm (90 kgf-cm, 80 in-lbf)
For B - Torque: 15. Nm (150 kgf-cm, 11 ft-lbf)
16. INSTALL VALVE STEM OIL SEAL

(a) Apply a light coat of engine oil to a new oil seal.

NOTE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later.

HINT: The intake valve oil seal is gray/brown and the exhaust valve oil seal is black/gray.

(b) Using SST, push in a new oil seal.
SST: 09201-41020

NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.

17. INSTALL VALVE

(a) Install the following parts:
(1) Valve (1)
(2) Spring seat (2)
(3) Valve spring (3)
(4) Spring retainer (4)

(b) Using SST, compress the valve spring and place the 2 spring retainer locks around the valve stem.
SST: 09202-70020
09202-00010

(c) Using a plastic hammer and the valve stem (not in use) tip wrapped with vinyl tape, lightly tap the valve stem tip to assure proper fit.

NOTE: Be careful not do damage the valve stem tip.

18. INSTALL VALVE LIFTER
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
19. INSTALL SPARK PLUG TUBE GASKET

(a) Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST: 09950-60010
09951-00240
09951-00440
09952-06010
SST: 09950-70010
09951-07100

NOTE: Be careful of the installation direction.

(b) Apply a light coat of MP grease to the gasket lip.
(c) Return the 4 ventilation case claws to the original positions.
20. INSTALL CAMSHAFT SETTING OIL SEAL

(a) Insert a new oil seal into the camshaft timing tube until it reaches the stopper.

NOTICE:
- Be careful of the installation direction.
- Do not turn over the oil seal lip.

21. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY

(a) Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
(b) Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several steps.
SST: 09960-10010
09962-01000
09963-00500
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)

NOTE: Be careful not to damage the timing tube.

(d) Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
(e) Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (795 kgf-cm, 58 ft-lbf)
(f) Install the seal washer and screw plug.
Torque: 15 Nm (152 kgf-cm, 11 ft-lbf)
22. INSTALL CAMSHAFT SUB GEAR

(a) Install the gear spring [1], sub gear [2] and wave washer [3].

HINT: Attach the pins on the gears to the gear spring ends.

(b) Using snap ring pliers, install the snap ring.

(d) Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt.
SST: 09960-10010
09962-01000
09963-00500
(e) Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.

Recommended service bolt:

23. INSTALL OIL PUMP SEAL

(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST: 09316-60011
09316-00011
(b) Apply MP grease to the oil seal lip.
24. INSTALL ENGINE REAR OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST: 09223-56010
(b) Apply MP grease to the oil seal lip.
25. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
(1) Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
(2) Thoroughly clean all components to remove all the loose material.
(3) Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
(1) Use a nozzle that has been cut to a 3 to 4 mm (0.12 to 0.16 in.) opening.
(2) Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
(3) Immediately remove the nozzle from the tube and reinstall the cap.

(c) Install a new O-ring to the cylinder block.
(d) Install the oil seal retainer with the 7 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
26. INSTALL OIL PUMP ASSEMBLY

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block.
(1) Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
(2) Thoroughly clean all components to remove all the loose material.
(3) Using a non-residue solvent, clean both sealing surfaces.
(b) Apply seal packing to the oil pump as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTE: Avoid applying an excessive amount to the surface, especially around the oil passage.

(1) Use a nozzle that has been cut to a 2 to 3 mm (0.08 to 0.12 in.) opening.
(2) Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
(3) Immediately remove the nozzle from the tube and reinstall the cap.

(c) Install a new O-ring to the cylinder block.
(d) Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.

(e) Install the oil pump with a new stud bolt and the 7 bolts. Uniformly tighten the bolts diagonally.

HINT:
- Use a 6mm hexagon wrench to tighten the hexagon head bolt.
- The following chart is the reference of the oil pump bolt length.

For bolts A, B, C and E - Torque: 16 Nm (160 kgf-cm, 11 ft-lbf)
For bolt D - Torque: 31 Nm (311 kgf-cm, 23 ft-lbf)
27. INSTALL OIL STRAINER SUB-ASSEMBLY

(a) Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)

HINT: Use bolts 12 mm (0.47 in.) in length.

28. INSTALL STUD BOLT
(a) Install the stud bolt.

Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)
29. INSTALL OIL PAN SUB-ASSEMBLY

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 1 oil pan, cylinder block, oil pump and rear oil seal retainer.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the No. 1 oil pan as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Use a nozzle that has been cut to a 3 to 5 mm (0.12 to 0.20 in.) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove the nozzle from the tube and reinstall the cap.

(c) Temporarily install the oil pan with the 18 bolts and 2 nuts.

HINT: The following chart is the reference for the oil pump bolt length.

(d) Set the oil pan as shown in the illustration.

NOTE: Make sure that the clearance between the rear end of the oil pan and cylinder block is 0.2 mm (0.008 in.) or less.

If the clearance is more than 0.2 mm (0.008 in.), the oil pan will be stretched.
(e) Uniformly tighten the bolts and nuts diagonally.
For bolts A and D - Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
For bolts B, C and nut - Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
30. INSTALL OIL PAN BAFFLE PLATE NO.1

(a) Install the baffle plate with the 2 bolts and 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)

HINT: Use bolts 12 mm (0.47 in.) in length.