OIL PUMP INSTALLATION

INSTALL TIMING GEAR CASE SUB-ASSEMBLY
1. Place a new gasket on the cylinder block.
2. Install the timing gear case with the 5 bolts.
  
  Torque:
  
  23 N*m { 230 kgf*cm, 17 ft.*lbf }
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Install a new gasket and oil strainer with the 2 bolts and 2 nuts.
  
  Torque:
  
  21 N*m { 210 kgf*cm, 15 ft.*lbf, for nut }
  
  18 N*m { 180 kgf*cm, 13 ft.*lbf, for bolt }
INSTALL OIL PAN SUB-ASSEMBLY
1. Remove any old packing (FIPG) material and do not drop any oil on the contact surfaces of the oil pan and cylinder block
  - Using a gasket scraper, remove all the old packing (FIPG) material from the installation.
  - 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.
2. Apply seal packing to the oil pan as shown in the illustration.
  
  Tech Tips
  
  Apply at least 5 mm (0.20 in.) (preferably slightly more) of seal packing to the portions of the oil pan in contact with the timing gear case and rear oil seal retainer.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  - Apply seal packing with a nozzle with a 4 to 5 mm (0.16 - 0.20 in) opening.
  Tech Tips
  
  Do not apply an excessive amount to the surface, especially near the oil passages.
  
  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.
3. Install the oil pan with the 16 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several steps.
  
  Torque:
  
  18 N*m { 180 kgf*cm, 13 ft.*lbf }
INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2
1. Install the spacer and timing belt idler No.2 with the bolt.
  
  Torque:
  
  33 N*m { 340 kgf*cm, 24 ft.*lbf }
2. Check that the timing belt idler sub-assembly No.2 moves smoothly.
INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1
1. Inspect the 3 bolts.
  Tech Tips
  
  The bolt lengths for bolt types A, B and C shown in the illustration are:
  
  A
  
  76.5 mm (3.012 in.)
  
  B
  
  42.9 mm (1.689 in.), Color : Yellow
  
  C
  
  41.3 mm (1.626 in.), Color : Silver
  
  Bolt C is combined with the timing belt idler sub-assembly No.1.
2. Install the timing belt idler No.1 with the 3 bolts.
  
  Torque:
  
  19 N*m { 195 kgf*cm, 14 ft.*lbf }
INSTALL CRANKSHAFT TIMING PULLEY
1. Align the pulley set key with the key groove of the timing pulley.
2. Using SST and a hammer, tap in the timing pulley with the flange side facing inward.
  
  SST
  
  09223-46011
INSTALL WATER PUMP ASSEMBLY
1. Install a new gasket, the water pump and tension spring bracket with the 6 bolts.
  
  Torque:
  
  23 N*m { 230 kgf*cm, 17 ft.*lbf }
INSTALL TIMING BELT COVER NO.2
1. Install the timing belt cover with the 4 bolts.
  
  Torque:
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
INSTALL CAMSHAFT TIMING PULLEY
1. Install the woodruff key to the key groove of the camshaft.
2. Align the pulley set key with the timing mark outward.
3. Using SST, install the pulley with the bolt.
  
  Torque:
  
  98 N*m { 1,000 kgf*cm, 72 ft.*lbf }
INSTALL INJECTION PUMP
1. Install the injection or supply pump assembly to timing gear case, and temporarily tighten the 2 nuts.
2. Install injection pump stay No.1 to the injection or supply pump assembly rear end, and temporarily tighten the 3 bolts.
3. Rotate the pump body to make the marking of pump flange conform to the making of timing of gear case.
4. Tighten the 2 nuts to install the injection or supply pump assembly.
  
  Torque:
  
  21 N*m { 210 kgf*cm, 15 ft.*lbf }
5. Tighten the 3 bolts to install the injection pump stay No.1.
  
  Torque:
  
  Injection pump stay No.1 x Cylinder Block
  
  21 N*m { 210 kgf*cm, 15 ft.*lbf }
  
  Injection pump stay No.1 x Injection Pump
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
6. Connect the 3 fuel hoses.
7. Connect the engine speed sensor connector.
8. Connect the spill control valve connector.
9. Connect the correction unit connector.
10. Connect the timer control valve connector.
11. Connect the fuel temperature sensor connector.
12. Connect the engine wire clamp.
SET NO.1 CYLINDER TO TDC/COMPRESSION
1. Using the crankshaft pulley bolt, align its groove with the timing pointer by turning the crankshaft clockwise.
  
  Note
  
  Do not turn the crankshaft pulley counterclockwise.
2. Set the timing and drive pulleys at each position.
  Note
  
  The engine should be cold.
  
  When turning the crankshaft or camshaft, the valve heads will hit against the piston top. Do not turn them more than necessary.
INSTALL TIMING BELT
Tech Tips

If reusing the timing belt, align the points marked during removal, and install the timing belt with the arrow pointing in the direction of engine revolution.
1. Remove any oil or water on each pulleys, and keep them clean.
2. Install the timing belt on the crankshaft timing pulley and timing belt idlers.
3. Using SST, slightly turn the injection pump drive pulley clockwise. Hang the timing belt on the pulley, and align the timing marks of the drive pulley and timing belt case.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-01000 )
4. Using SST, slightly turn the camshaft timing pulley clockwise. Hang the timing belt on the timing pulley, and align the timing marks of the timing pulley and timing belt case.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-01000 )
5. Check that the timing belt has tension between the injection pump drive and camshaft timing pulleys.
6. Install the timing belt on the timing belt idler No.2.
CHECK VALVE TIMING
1. Loosen the timing belt idler No.1 bolt (A), and stretch the timing belt.
2. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
  
  Note
  
  Always turn the crankshaft clockwise.
3. Check each pulley aligns with the timing marks as shown in the illustration.
  
  If the timing marks do not align, remove the timing belt and reinstall it.
4. Tighten the timing belt idler No.1 bolt (A).
  
  Torque:
  
  44 N*m { 450 kgf*cm, 33 ft.*lbf }
INSTALL TIMING BELT GUIDE
1. Install the belt guide with the cup side facing outward.
INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
1. Remove the 2 nuts and wire harness clamp bracket.
2. Install the 2 gaskets to the timing belt cover.
3. Install the timing belt cover with the 11 bolts.
  
  Torque:
  
  11 N*m { 105 kgf*cm, 8 ft.*lbf }
4. Install the 2 nuts and wire harness clamp bracket.
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the timing pulley.
2. Using SST and a hammer, tap in the timing pulley with the flange side facing inward.
  
  SST
  
  09223-46011
INSTALL VANE PUMP DRIVE PULLEY
1. w/o Air conditioning:
  1. Install the vane pump drive pulley and vane pump pulley spacer with the 4 bolts.
    
    Torque:
    
    19 N*m { 195 kgf*cm, 14 ft.*lbf }
2. w/ Air conditioning:
  1. Install the 2 vane pump drive pulleys with the 4 bolts.
    
    Torque:
    
    18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Temporarily install the compressor mounting bracket with the 4 bolts.
2. Using several steps, uniformly install and tighten the 4 bolts in the sequence shown in the illustration.
  
  Torque:
  
  85 N*m { 870 kgf*cm, 63 ft.*lbf }
3. Temporarily tighten the bolt and spacer.
4. Temporarily install the compressor mounting bracket with the 3 bolts.
5. Using several steps, uniformly install and tighten the 3 bolts in the sequence shown in the illustration.
  
  Torque:
  
  47 N*m { 475 kgf*cm, 36 ft.*lbf }
INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
1. Install the compressor and magnetic clutch with the 4 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
INSTALL INJECTION PIPE SET
1. Connect the 2 lower clamps on the intake manifold.
2. Install the 4 injection pipes.
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
3. Secure the injection pipes with the 2 upper pipe clamps and 2 nuts.
  
  Torque:
  
  5.0 N*m { 50 kgf*cm, 44 in.*lbf }
INSTALL VENTURI ASSEMBLY
1. Install a new gasket and venturi.
2. Connect the throttle control motor connector.
3. Connect the throttle open switch connector.
INSTALL INTAKE AIR CONNECTOR BRACKET
1. Install the 2 bolts and intake air connector bracket.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY
1. Install a new gasket and intake air connector with the bolt and 3 nuts.
  
  Torque:
  
  bolt
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
  
  Nut
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
2. Connect the turbo pressure sensor connector.
3. Connect the ventilation hose.
INSTALL WATER PUMP PULLEY
INSTALL FAN & GENERATOR V BELT (w/o Air Conditioning)
1. Install the V belt.
2. Using a bar, adjust the tension of the V belt.
3. Tighten the bolts A and B.
  
  Torque:
  
  Bolt A
  
  75 N*m { 765 kgf*cm, 55 ft.*lbf }
  
  Bolt B
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
4. Check the tension of the V belt. Click here
INSTALL FAN & GENERATOR V BELT (w/ Air Conditioning)
1. Install the V belt.
2. Tightening the bolt C, adjust the tension of the V belt.
3. Tighten the bolts A and B.
  
  Torque:
  
  Bolt A
  
  75 N*m { 765 kgf*cm, 55 ft.*lbf }
  
  Bolt B
  
  18 N*m { 185 kgf*cm, 13 ft.*lbf }
4. Check the tension of the V belt. Click here
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (w/ Air Conditioning System)
1. Install the V belt.
2. Tightening the bolt B, adjust the tension of the V belt.
3. Tighten nut A.
  
  Torque:
  
  39 N*m { 400 kgf*cm, 29 ft.*lbf }
4. Check the tension of the V belt. Click here
INSTALL VANE PUMP V BELT
1. Install the V belt.
2. Using a bar, adjust the tension of the V-ribbed belt.
3. Tighten the bolt A and nut B.
  
  Torque:
  
  Bolt (A)
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
  
  Nut (B)
  
  64 N*m { 635 kgf*cm, 47 ft.*lbf }
4. Check the tension of the V belt. Click here
BLEED INJECTION PIPE
1. Move the priming pump in the upper part of the fuel filter assembly up and down, and fill the injection pump assembly and fuel system with fuel.
2. Loosen one of the union nuts (in the nozzle side).
3. Crank the engine until fuel comes out from the union nut (in the nozzle side).
4. Tighten the union nut.
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
5. The above operation should be carried out each injection pipe.
CONNECT WATER HOSE (for Heater)
INSTALL RADIATOR HOSE NO.4
INSTALL RADIATOR HOSE INLET
ADD ENGINE COOLANT
1. Close the engine drain plug.
  
  Torque:
  
  57 N*m { 581 kgf*cm, 42 ft.*lbf }
2. Close the radiator drain cock plug.
3. Slowly fill the cooling system with coolant.
  
  Tech Tips
  
  The coolant level inside the radiator should be abserved after pressing the radiator hose inlet and radiator hose outlet by hand..
4. Slowly pour coolant into the radiator reserve tank until it reaches the FULL line.
5. Install the radiator cap to the radiator reserve tank.
6. Press the inlet and outlet radiator hoses several times by hand while warming up the engine.
7. Stop the engine, and wait until the engine coolant cools down.
8. Add coolant to the FULL line of the radiator reservoir.
ADD ENGINE OIL
CHECK FOR ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.
2. Warm up the engine.
3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17.1 psi), and check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block, and cylinder head.
CHECK FOR FUEL LEAKS
1. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance.
  
  Tech Tips
  
  When checking for fuel leaks, make sure that there is pressure in the fuel line.
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
1. Install the 5 bolts and engine service hole cover.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL FRONT DOOR SCUFF PLATE RH
INSTALL FRONT SEAT ASSEMBLY RH
1. Connect the front seat inner belt assembly connector and install the front seat assembly.
2. Align the front seat assembly adjuster pin with the holes in the body.
3. Move the front seat assembly to the rearmost position.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.
5. Move the front seat assembly fully forward.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.
7. Move the front seat assembly to the rearmost position.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }
9. Move the front seat assembly fully forward.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }