OIL PUMP INSTALLATION


  1. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL

    SST
    09608-06041

    1. A0136PME01

      Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

      Standard distance
      0.5 to -1 mm (0.0197 to -0.0394 in.)

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  2. INSTALL OIL PUMP GASKET


    1. A0137PCE02

      Install a new oil pump gasket.

  3. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. Apply seal packing in a continuous bead to the engine unit as shown in the following illustration.

      A013715E01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal width
      4.5 to 5.5 mm (0.1772 to 0.2165 in.)

      Note


      • When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.

      • Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing.

    2. Apply seal packing in a continuous bead to the timing chain cover as shown in the following illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.

      • Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing.

      Tech Tips

      Apply seal packing referring to the table and illustration below.

      Seal packing diameter
      Continuous line area 3.0 mm (0.1181 in.)
      Alternate long and short dashed line area 3.5 to 4.5 mm (0.1378 to 0.1772 in.)
      Dashed line area 3.0 to 3.5 mm (0.1181 to 0.1378 in.)
      A01386IE03
    3. A0136CXE02

      Using several steps, uniformly install and tighten the 11 bolts in the sequence shown in the illustration.

      Torque:
      Bolts 9, 10, and 11
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Bolts except 9, 10, and 11
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  4. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any grease from the installation surfaces of the cylinder block and oil pan.

    2. A01383YE01
      Text in Illustration
      *a Contact surface between timing chain cover and cylinder block
      *b Contact surface between oil seal retainer and cylinder block

      Apply seal packing to the oil pan and install it to the cylinder block.

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

      Note


      • The start and end points of seal packing application must be on the seal surface with the cylinder block.

      • Be sure to apply seal packing to the contact surfaces between the timing chain cover and cylinder block, and between the oil seal retainer and cylinder block.

      • Install the oil pan within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A0137BEE03

      Tighten the specified 6 bolts in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    4. A0137BEE02

      Tighten the 7 bolts and 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf, for A }
      10 N*m  { 102 kgf*cm, 7 ft.*lbf, for B }

  5. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. Install the water pump gasket.

    2. A0137L2E01

      Temporarily install the engine water pump with the 5 bolts.

    3. Tighten the 5 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  6. INSTALL OIL FILTER BRACKET


    1. A013897E04

      Using several steps, uniformly install and tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  7. INSTALL CRANKSHAFT PULLEY


    1. Align the pulley set key with the key groove of the pulley.

    2. A0137GLE01

      Using SST, hold the pulley in place and tighten the bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      170 N*m  { 1734 kgf*cm, 125 ft.*lbf }

  8. INSTALL CRANK POSITION SENSOR


    1. A0136B3

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

    2. Install the sensor with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01362Q

      Fit a new cylinder head cover gasket into the groove on the cylinder head cover and onto the center bosses shown by the arrows.

      Note

      Make sure that the gasket is securely inserted until it completely sits on the roots of the bosses.

    2. A0135Y6E02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the upper section of the contact surfaces of the cylinder head and timing chain cover.

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

      Note

      Install the cylinder head cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

    3. A01388RE03

      Tighten the 13 bolts and 2 nuts to the specified torque in the order shown in the illustration.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

    4. After tightening all of them, make sure that "1" and "2" are tightened with the specified torque.

  10. INSTALL WATER BY-PASS PIPE NO.1

    A0136FGE01

    1. Install a new water by-pass pipe gasket to the cylinder head as shown in the illustration.

      Text in Illustration
      *a Water By-pass Pipe Side
    2. A0137OTE01

      Connect the water by-pass hose with No. 1 water by-pass pipe to the timing chain cover with the hose clip.

    3. Install the No. 1 water by-pass pipe with the bolt and 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  11. INSTALL COMPRESSOR MOUNTING BRACKET NO.1


    1. Install the compressor mounting bracket with the 2 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  12. INSTALL EXHAUST MANIFOLD


    1. Install a new exhaust manifold gasket.

    2. A0137U7E01

      Install the exhaust manifold with the 3 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  13. INSTALL FAN BELT ADJUSTING BAR


    1. A01381M

      Instal the fan belt adjusting bar with the bolt.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  14. INSTALL GENERATOR ASSEMBLY


    1. A0137E9E02

      Install the generator assembly with the 4 bolts.

      Torque:
      Bolt A
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
      Bolt B
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

    2. Install the generator wire to terminal B with the nut.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    3. Install the terminal cap.

    4. Connect the generator connector.

  15. INSTALL IGNITION COIL NO.1


    1. A0138SF

      Install the 3 No. 1 ignition coils with the 3 bolts.

      Torque:
      8.9 N*m  { 91 kgf*cm, 79 in.*lbf }

    2. Connect the 3 connectors.

  16. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Clean the bolts and their holes.

    2. A0137IYE23
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the 2 or 3 threads of the bolt end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using SST, hold the crankshaft.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    4. A0138G0E01

      Install the flywheel sub-assembly with the 6 bolts in the order shown in the illustration.

      Torque:
      78 N*m  { 796 kgf*cm, 58 ft.*lbf }

  17. INSTALL CLUTCH DISC ASSEMBLY


    1. A0136R3E04

      Insert SST into the clutch disc assembly, and then insert them into the flywheel sub-assembly.

      Text in Illustration
      A0137RP Flywheel Side
      SST
      09301-00131

      Note

      Do not insert the clutch disc assembly in the wrong direction.

  18. INSTALL CLUTCH COVER ASSEMBLY


    1. A0137J5E02
      Text in Illustration
      *a Temporarily
      *b Matchmark

      Align the matchmark on the clutch cover assembly and the flywheel sub-assembly.

    2. Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips

      Move SST up and down, right and left gently after checking that the clutch disc assembly is in the center and tighten the bolts.

      SST
      09301-00131

  19. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Align the input shaft with the clutch disc assembly and install the manual transaxle assembly to the engine assembly.

    2. Install the 5 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Note


      • Be careful not to pinch wire harnesses, etc.

      • Do not forcefully pry on the manual transaxle assembly.

      • To avoid damage to the input shaft, do not forcefully shake the manual transaxle assembly.

      • Insert knock pins into the knock pin holes securely so that the end face of the manual transaxle assembly fits close against the engine assembly before tightening the bolts.

  20. INSTALL STARTER ASSEMBLY (for Standard)


    1. A01374KE02

      Install the starter with the 2 bolts.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

    2. Connect the wire harness to terminal 30 and install the nut.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    3. Connect the wire harness to terminal 50 and install the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Install the wire harness clamp with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  21. REMOVE STARTER ASSEMBLY (for Cold Area)


    1. A01384LE02

      Install the starter with the 2 bolts.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

    2. Connect the wire harness to terminal 30 and install the nut.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    3. Connect the wire harness to terminal 50 and install the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Install the wire harness clamp with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  22. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the engine and transaxle assembly to the crossmember sub-assembly and the engine mounting member with the bolt.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }

  23. INSTALL ENGINE ASSEMBLY W/ TRANSAXLE

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