Part 2

2AZ-FXE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY - Continued

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 matter.

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

NOTICE:
Wipe off excess 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, 19 ft-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, 22 ft-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, 18 ft-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, 9 ft-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, 80 in-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, 40 ft-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, 22 ft-lbf)

No. 3 bearing cap - Torque : 9.0 Nm (92 kgf-cm, 80 in-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.

No. 2 bearing cap - Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)

No. 3 bearing cap - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

31. INSTALL KEYS

(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, 18 ft-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.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(d) Install the clamp of the crankshaft position sensor onto the water pump.

46. INSTALL CRANKSHAFT PULLEY Installation

47. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation

48. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation

49. INSPECT VALVE CLEARANCE Adjustments

50. ADJUST VALVE CLEARANCE Adjustments

51. INSTALL CAMSHAFT POSITION SENSOR

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

(b) Install the sensor with the bolt.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

52. INSTALL CYLINDER HEAD COVER GASKET

(a) Install the gasket to the cylinder head cover.

NOTICE:
Remove any oil from the contact surfaces.

53. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation

54. INSTALL OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, install the oil filter union.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

55. INSTALL OIL FILTER SUB-ASSEMBLY

(a) Check and clean the oil filter installation surface.

(b) Apply clean engine oil to the gasket of a new oil filter.

(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.

(d) When using a torque wrench:

(1) Using SST, tighten the oil filter.

SST : 09228-06501

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(e) When not using a torque wrench:

(1) Using SST, tighten it an additional 3/4 turn.

SST : 09228-06501

56. INSTALL SPARK PLUG

(a) Install the spark plugs.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

57. 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

(b) Install the ventilation valve.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

58. INSTALL OIL FILLER CAP GASKET

(a) Install a new gasket to the cap.

59. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler cap.