Part 1

2AZ-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY

REASSEMBLY

Part 1 of 2

1. INSTALL RING PIN
(a) Using a plastic hammer, tap in the ring pin.

Standard protrusion:

2. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.

Stud Bolt A - Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
Stud Bolt B - Torque: 22 Nm (220 kgf-cm, 16ft-lbf)
Stud Bolt C - Torque: 9.5 Nm (97 kgf-cm, 84in-lbf)
Stud Bolt D - Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
3. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in the straight pin.

Standard protrusion:

4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, install the oil nozzles with the bolts.
Torque: 7.0 Nm (71 kgf-cm, 62in-lbf)
5. INSTALL PISTON

(a) Using a screwdriver, install a new snap ring at 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 to approximately 80 to 90°C (176 to 194°F).

(c) Align the front marks of the piston and connecting rod, and push in the piston with your thumb.
(d) Using a screwdriver, install a new snap ring on the other 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.

(e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.
6. INSTALL PISTON RING SET

(a) Install the oil ring expander and oil ring rail by hand.

NOTICE:
- Install the expander and oil ring so that their ring ends are at opposite sides.
- Securely install the expander to the inner groove of the oil ring.

(b) Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration.

NOTICE: Install the compression ring No. 2 with the code mark (2N) facing upward.

(a) Install the upper bearing with an oil groove on the cylinder block.

NOTICE:
- Do not apply engine oil to the bearings and the contact surfaces.
- There is an identification mark on the crankshaft bearing No. 1 UPR only.

8. INSTALL NO. 2 CRANKSHAFT BEARING

(a) Install the lower bearing onto the bearing cap.

NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oil.

9. INSTALL UPPER CRANKSHAFT THRUST WASHER

(a) Install the 2 thrust washers under the No. 3 journal of the cylinder block with the oil grooves facing outward.
(b) Apply engine oil to the crankshaft thrust washer.
10. INSTALL CRANKSHAFT
(a) Apply engine oil to the upper bearing and install the crankshaft on the cylinder block.
(b) Apply engine oil to the lower bearing.

(c) Examine the front marks and install the bearing caps on the cylinder block.
(d) Apply a light coat of engine oil to the threads and under the bearing cap bolts.
(e) Install the crankshaft bearing cap bolts.

NOTICE: The main bearing cap bolts are tightened in 2 progressive steps.

(f) Step 1

(1) Install and uniformly tighten the 10 main bearing cap bolts in the sequence shown in the illustration.

Torque: 20 Nm (204 kgf-cm, 15ft-lbf)

(2) Further tighten the 10 main bearing cap bolts in the sequence shown in the illustration.

Torque: 40 Nm (408 kgf-cm, 30ft-lbf)

(g) Step 2

(1) Mark the front of the bearing cap bolts with paint.
(2) Further tighten the bearing cap bolts by 90° in the numerical order shown in the previous illustration.
(h) Check that the paint mark is now at a 90° angle to the front.
(i) Check that the crankshaft turns smoothly.
(j) Check the crankshaft thrust clearance Engine Unit.
11. INSTALL CONNECTING ROD BEARING

(a) Align the bearing claw with the groove of the connecting rod or connecting cap.

NOTICE: Do not apply engine oil to the bearings or the contact surfaces.

12. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

NOTICE: The connecting rod cap bolts are tightened in 2 progressive steps.

(a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.

(b) Check the position of the piston ring ends.

(c) 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.

NOTICE: Match the numbered connecting rod cap with the connecting rod.

(d) Check that the protrusion of the connecting rod cap is facing in the correct direction.
(e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(f) Install the connecting cap bolts.

NOTICE: The connecting cap bolts should be tightened in 2 progressive steps.

(g) Step 1

(1) Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque: 25 Nm (250 kgf-cm, 18ft-lbf)
(h) Step 2

(1) Mark the front of the connecting rod cap bolts with paint.
(2) Further tighten the cap bolts by 90° as shown in the illustration.
(i) Check that the crankshaft turns smoothly.
(j) Check the connecting rod thrust clearance Engine Unit.
13. INSTALL NO. 1 BALANCESHAFT BEARING

(a) Install the bearings in the crankcase and balanceshaft housing.

NOTICE: Do not apply engine oil to the bearings and the contact surfaces.

(b) Apply a light coat of engine oil to the bearings.
14. INSTALL NO. 1 AND NO. 2 BALANCESHAFT SUB-ASSEMBLY

(a) Rotate the No. 1 driven gear of the No. 1 balanceshaft in the rotating direction until it hits the stopper.

NOTICE: Confirm that the matchmarks on the No. 1 and No. 2 driven gears are matched.

(b) Align the timing marks of the No. 1 and No. 2 balanceshafts as shown in the illustration.

(c) Place the No. 1 and No. 2 balanceshafts on the crankcase.
(d) Apply a light coat of engine oil under the heads of the balanceshaft housing bolts.
(e) Install the balanceshaft housing bolts.

NOTICE: The balance shaft housing bolts are tightened in 2 progressive steps.

(f) Step 1

(1) Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 22 Nm (220 kgf-cm, 16ft-lbf)
(g) Step 2

(1) Mark the front side of each balanceshaft housing bolt head with paint.
(2) Further tighten the bolts by 90° as shown in the illustration.
(3) Check that the paint marks are now at a 90° angle to the front.
15. INSTALL STIFFENING CRANKCASE ASSEMBLY

(a) Place a new O-ring on the cylinder block, as shown in the illustration.
(b) Temporarily tighten the pulley set bolt.

(c) Turn the crankshaft to set the crank pins of the No. 1 and No. 4 cylinders to the bottom.

HINT: Make sure that the timing mark on the balanceshaft drive gear is positioned as shown in the illustration.

(d) Apply seal packing in a continuous bead (diameter: 2.5 to 3.0 mm (0.098 to 0.118 in.)) to the places 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 after applying seal packing.
- Do not start the engine for at least 2 hours after installing the stiffening crankcase.

(e) Install the stiffening crankcase so that the reference holes on the balanceshafts are positioned as shown in the illustration.

(f) Temporarily install the crankcase with the 11 bolts.
Bolt length:

(g) Uniformly tighten the 11 bolts in the sequence shown in the illustration.
Torque: 24 Nm (245 kgf-cm, 18ft-lbf)
(h) Wipe off any excess seal packing with a clean piece of cloth.

(i) Turn the crankshaft again to set the key groove to the bottom. Make sure that the timing marks are aligned as shown in the illustration.

HINT: A 'o' is stamped as a timing mark.

(j) Remove the pulley set bolt.
16. INSTALL OIL PUMP ASSEMBLY

(a) Install a new gasket and oil pump with the 3 bolts.
Torque: 19 Nm (194 kgf-cm, 14ft-lbf)
17. INSTALL ENGINE REAR OIL SEAL

(a) Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge.
SST: 09223-15030
SST: 09950-70010
09951-07100

NOTICE: Keep the lip free from foreign materials.

(b) Apply MP grease to a new oil seal lip.

NOTICE: Wipe off extra grease on the crankshaft.

18. INSTALL NO. 1 TAPER SCREW PLUG

(a) Apply adhesive to 2 or 3 threads of the plug, and install the plug.
Torque: 26 Nm (265 kgf-cm, 19ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
19. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign matter is on the mesh part of the filter.

(b) Using an 8 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.
Torque: 30 Nm (306 kgf-cm, 22ft-lbf)

NOTICE: Do not touch the mesh when installing the oil control valve filter.

20. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Apply adhesive to the threads of the drain cock.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the water drain cock within the range shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18ft-lbf)

NOTICE: Do not rotate the drain cock more than 1 revolution (360°) after tightening it to the specified torque.

(c) Install the water drain cock plugs to the water drain cocks.
Torque: 13 Nm (130 kgf-cm, 9ft-lbf)
21. INSTALL CYLINDER BLOCK WATER JACKET SPACER

(a) Install the water jacket spacer as shown in the illustration.

HINT: Be sure to face the slope to the front of the engine.

22. INSTALL CYLINDER HEAD GASKET Installation
23. INSTALL CYLINDER HEAD SUB-ASSEMBLY Installation
24. 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, 80in-lbf)
25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Installation
26. INSTALL CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise.
(b) Tighten the flange bolt with the camshaft timing sprocket fixed.
Torque: 54 Nm (551 kgf-cm, 40ft-lbf)
27. INSTALL NO. 1 CAMSHAFT BEARING

(a) Install the No. 1 camshaft bearing.
28. INSTALL NO. 2 CAMSHAFT BEARING Installation
29. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the camshaft.

(b) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps into the cylinder head.
(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 tighten the 10 bearing cap bolts in the sequence shown in the illustration.
No. 1 bearing cap - Torque: 30 Nm (301 kgf-cm, 22ft-lbf)
No. 3 bearing cap - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
30. INSTALL NO. 2 CAMSHAFT
(a) Apply a light coat of engine oil to the journal portion of the No. 2 camshaft.

(b) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
(c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

(a) Install the 2 keys.
32. INSTALL NO. 2 CHAIN SUB-ASSEMBLY Installation
33. INSTALL CRANKSHAFT TIMING SPROCKET Installation
34. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
35. INSTALL CHAIN SUB-ASSEMBLY Installation
36. INSTALL CHAIN TENSIONER SLIPPER Installation
37. INSTALL TIMING CHAIN GUIDE Installation
38. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE Installation
39. INSTALL TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST: 09223-22010
(b) Apply a light coat of MP grease to the lip of the oil seal.

NOTICE:
- Keep the lip free from foreign matter.
- Do not tap on the oil seal at an angle.
- Make sure that the oil seal edge does not stick out of the timing chain case.

NOTICE: Keep the gap between the timing chain cover edge and the oil seal free of foreign matter.

40. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY Installation
41. INSTALL OIL PAN SUB-ASSEMBLY Installation
42. INSTALL OIL PAN DRAIN PLUG

(a) Install a new gasket and oil pan drain plug.
Torque: 25 Nm (255 kgf-cm, 18ft-lbf)
43. INSTALL WATER PUMP ASSEMBLY Installation
44. INSTALL WATER PUMP PULLEY Installation
45. INSTALL CRANKSHAFT POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring of the sensor.

(b) Confirm that the wire harness of the sensor is placed as shown in the illustration.

(d) Install the clamp of the crankshaft position sensor onto the water pump.
46. INSTALL CRANKSHAFT PULLEY Installation
47. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation
48. INSPECT VALVE CLEARANCE Adjustments
49. ADJUST VALVE CLEARANCE Adjustments

Continue to Part 2