Part 2

2UZ-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY (Continued)

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.

31. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove any oil packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 1 and No. 2 oil pans.
- 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.

NOTE: Do not use a solvent which will affect the painted surfaces.

(b) Apply seal packing to the No. 2 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) Install the No. 2 oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several steps.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)

HINT: Use bolts 14 mm (0.55 in.) in length.

32. INSTALL WATER PUMP ASSEMBLY

(a) Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several steps.
Bolt - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
Stud bolt and nut - Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)

HINT: Use bolts 35 mm (1.38 in.) in length.

33. INSTALL CYLINDER HEAD SUB-ASSEMBLY

(a) Place 2 new cylinder head gaskets in position on the cylinder block.

HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank.

NOTE: Be careful of the installation direction.

(b) Place the 2 cylinder heads in position on the cylinder head gaskets.
(c) Install the cylinder head bolts.

HINT:
- The cylinder head bolts are tightened in 2 progressive steps (Procedures "A" and "B").
- If any cylinder head bolt is broken or deformed, replace it.

(1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(2) Install the plate washer to the cylinder head bolt.
(3) Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several steps in the order shown in the illustration, then do the other side in the same way (Procedure "A").
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

NOTE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(4) Mark the front of the cylinder head bolt head with paint.
(5) Retighten the cylinder head bolts by 90° in the numerical order shown (Procedure "B").
(6) Retighten the cylinder head bolts by an additional 90°.
(7) Check that the painted mark is now at a 180° angle to front.
34. INSTALL CAMSHAFTS

NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Set the crankshaft position.
(1) Using the crankshaft damper bolt, turn the crankshaft, and set the set key of the crankshaft at the position of 90° counterclockwise from the timing mark (dot) of the oil pump body.

CAUTION: Having the crankshaft at a wrong angle can cause the piston head and valve head to come into contact with each other when installing the camshaft, causing damage. So always set the crankshaft at the correct angle.

(b) Install the camshafts of the RH bank.

(1) Apply engine oil to the thrust portions of the intake and exhaust camshafts.
(2) Align the timing marks (1-dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts.
(3) Set the timing marks (1-dot mark) of the camshaft drive and driven main gears at approx. 10° angle.

(4) Apply seal packing to the camshaft housing plug.
- Remove the old packing (FIPG) material.
- Apply seal packing to the housing plug.

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

(5) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

NOTE: Be careful of the installation direction.

(6) Apply seal packing to the front bearing cap.
- Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
Thoroughly clean all components to remove all the loose material.
Using a non-residue solvent, clean both sealing surfaces.
- Apply seal packing to the bearing cap as shown in the illustration.
Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 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.

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

NOTE: Do not apply seal packing to the front bearing cap grooves.

(7) Install the front bearing cap.

HINT: The thrust position of the camshaft will be determined after installing the front bearing cap.

(8) Install the other bearing caps in the order shown with the arrow mark facing forward.

(9) Push in the camshaft setting oil seal.

(10) Install new seal washers to the bearing cap bolts (A and B).
(11) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E).

NOTE: Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C).

HINT:
Each bolt length is as follows:
94 mm (3.70 in.) for A with seal washer
72 mm (2.83 in.) for B with seal washer
25 mm (0.98 in.) for C
55 mm (2.17 in.) for D
40 mm (1.57 in.) for E

(12) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.

(13) Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration.
For bolt C - Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
For others - Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)

(14) Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.
(15) Remove the service bolt.
(c) Install the camshafts of the LH bank.

(1) Apply MP grease to the thrust portion of the camshafts.
(2) Align the timing marks (2-dot marks) of the camshaft drive and driven main gears, and place the 2 camshafts.

(3) Apply seal packing to the camshaft housing plug.
- Remove the old packing (FIPG) material.
- Apply seal packing to the housing plug.

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

(4) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

CAUTION: Be careful of the installation direction.

(5) Apply seal packing to the front bearing cap.
- Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
Thoroughly clean all components to remove all the loose material.
Using a non-residue solvent, clean both sealing surfaces.
- Apply seal packing to the bearing cap as shown in the illustration.
Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 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.

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

NOTE: Do not apply seal packing to the front bearing cap grooves.

(6) Install the front bearing cap.

HINT: The thrust position of the camshaft will be determined after installing the front bearing cap.

(7) Install the other bearing cap in the order shown with the arrow mark facing forward.

(8) Push in the camshaft setting oil seal.

(9) Install a new seal washer to the bearing cap bolts (A and B).
(10) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E).

NOTE: Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C).

HINT:
Each bolt length is as follows:
94 mm (3.70 in.) for A with seal washer
72 mm (2.83 in.) for B with seal washer
25 mm (0.98 in.) for C
55 mm (2.17 in.) for D
40 mm (1.57 in.) for E

(11) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.

(12) Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration.
For bolt C - Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
For others - Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)

(13) Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.
(14) Remove the service bolt.
35. INSTALL REAR TIMING BELT PLATE RH
(a) Install the rear timing belt plate with the bolt and stud bolt.
Torque: 7.5 Nm (80 kgf-cm, 66 in-lbf)
36. INSTALL NO. 2 REAR TIMING BELT PLATE RH
(a) Install the rear timing belt plate with the 2 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 in-lbf)
37. INSTALL REAR TIMING BELT PLATE LH
(a) Install the rear timing belt plate with the bolt.
Torque: 7.5 Nm (80 kgf-cm, 66 in-lbf)
38. INSTALL NO. 2 REAR TIMING BELT PLATE LH
(a) Install the rear timing belt plate with the 2 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 in-lbf)
39. INSTALL CRANKSHAFT TIMING PULLEY

(a) Fit the timing pulley set key to the key groove of the pulley.
(b) Using SST and a hammer, tap in the timing pulley with the flange side facing inward.
SST: 09223-46011
40. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY

(a) Install the idler with the bolt.
Torque: 35 Nm (352 kgf-cm, 25 ft-lbf)
(b) Check that the idler moves smoothly.
41. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the pivot bolt.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.
Torque: 35 Nm (352 kgf-cm, 25 ft-lbf)
(c) Check that the idler bracket moves smoothly.
42. INSTALL CAMSHAFT TIMING PULLEYS

(a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
(b) Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" and "L" marks forward.
(c) Hold the hexagonal portion of the camshaft.
(d) Using a 5 mm hexagon wrench, install the 8 bolts.
Torque: 8.1 Nm (83 kgf-cm, 72 in-lbf)
43. INSTALL TIMING BELT

NOTE: The engine should be cold.

(a) Set the No. 1 cylinder to TDC/compression.

(1) Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.

HINT:
By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy:
1/2 teeth turn for the left bank camshaft timing pulley
1 tooth turn for the right bank camshaft timing pulley

(2) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.

(b) Install the timing belt.
(1) Remove any oil or water on each pulley. Keep them clean after removal.

NOTE: Only wipe the pulleys; do not use any cleansing agent.

(2) Face the front mark (arrow) on the timing belt forward.
(3) Connect the timing belt to the crankshaft timing pulley.
- Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.

(4) Connect the No. 2 timing belt to the idler.
(5) Connect the timing belt to the camshaft timing pulley LH.
- Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.

(6) Connect the timing belt to the water pump pulley.
(7) Connect the timing belt to the camshaft timing pulley (RH bank).

- Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
(8) Connect the No. 1 timing belt to the idler.

(c) Set the belt tensioner.
(1) Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure.
(2) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
(3) Release the press.
(4) Install the dust boot to the belt tensioner.

(d) Install the belt tensioner.
(1) Temporarily install the belt tensioner with the 2 bolts.
(2) Alternately tighten the 2 bolts.
Torque: 26 Nm (270 kgf-cm, 19 ft-lbf)
(3) Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
(e) Check the valve timing.

(1) Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC.

NOTE: Always turn the crankshaft pulley clockwise.

(2) Check that each pulley aligns with the timing marks as shown in the illustration.
If the timing marks are not aligned, remove the timing belt and reinstall it.
44. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Install the sensor plate as shown in the illustration.

NOTE: Take care not to install it in a wrong direction.

45. INSTALL TIMING GEAR COVER SPACER

(a) Install the gasket to the cover spacer.
(b) Install the cover spacer.
46. INSTALL NO. 1 TIMING BELT COVER

(a) Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 in-lbf)
47. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

(a) Align the pulley set key with the key groove of the crankshaft damper.
(b) Using SST and a hammer, tap in the crankshaft damper.
SST: 09223-46011

(c) Using SST, install the damper bolt.
SST: 09213-70011
SST: 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft-lbf)
48. INSPECT VALVE CLEARANCE Adjustments
49. ADJUST VALVE CLEARANCE Adjustments
50. INSTALL FAN BRACKET SUB-ASSEMBLY

(a) Install the idler pulley with the 2 bolts and 2 nuts.
For 12 mm head - Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)
For 14 mm head - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)

HINT:
Each bolt length is as follows:
106 mm (4.17 in.) for 12 mm head [A]
114 mm (4.49 in.) for 14 mm head [B]

51. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (160 kgf-cm, 11 ft-lbf)

HINT: Use a bolt 106 mm (4.17 in.) in length.

52. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY

(a) Install the timing belt cover and fit the claws and pins into each part.
(b) Install the timing belt cover with the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)

HINT: Use bolts 106 mm (4.17 in.) in length.

53. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)
54. INSTALL SEMICIRCULAR PLUG

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semicircular plug grooves.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps.
Torque: 6.0 Nm (60 kgf-cm, 53 in-lbf)
56. INSTALL OIL FILLER CAP HOUSING

(a) Install a new gasket and the oil filler cap housing with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
57. INSTALL OIL FILLER CAP SUB-ASSEMBLY
58. INSTALL SPARK PLUG
Torque: 18 Nm (178 kgf-cm, 13 ft-lbf)
59. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply seal packing to 2 or 3 threads.
Seal packing:
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

(b) Install the 2 drain cocks.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

HINT: After tightening to the specified torque, rotate the drain union clockwise until its drain port is facing forward.

60. INSTALL ENGINE HANGERS

(a) Install the 2 engine hangers with the 4 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)