OIL PUMP INSTALLATION

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Apply a light coat of engine oil to 2 new oil pump gaskets and new oil hole cover gasket.
Install the 2 new oil pump gaskets and new oil hole cover gasket to the stiffening crankcase.
Align the drive rotor spline and the crankshaft timing sprocket as shown in the illustration.

Apply seal packing in a line to the timing chain cover sub-assembly as shown in the following illustration.

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

Seal Packing Application Chart

Area	Seal Packing Diameter (Round)	Distance from Edge of Cover to Center of Seal Packing	Seal Packing Application Length
Area	Seal Packing Dimension (Flat)	Distance from Edge of Cover to Center of Seal Packing	Seal Packing Application Length
Dashed Line	2.5 to 3.5 mm (0.0984 to 0.138 in.)	2.5 mm (0.0984 in.)	-
Dashed Line	-	2.5 mm (0.0984 in.)	-
A - A	2.5 to 3.5 mm (0.0984 to 0.138 in.)	2.5 mm (0.0984 in.)	-
A - A	-	2.5 mm (0.0984 in.)	-
B - B	5.0 mm (0.197 in.)	3.0 mm (0.118 in.)	28 mm (1.10 in.)
B - B	7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick	3.0 mm (0.118 in.)	28 mm (1.10 in.)
C - C	7.0 mm (0.276 in.)	5.0 mm (0.197 in.)	25 mm (0.984 in.)
C - C	13.0 mm (0.512 in.) or more wide and 3.0 mm (0.118 in.) or more thick	5.0 mm (0.197 in.)	25 mm (0.984 in.)
D - D	5.0 mm (0.197 in.)	3.0 mm (0.118 in.)	26 mm (1.02 in.)
D - D	7.0 mm (0.276 in.) or more wide and 3.0 mm (0.118 in.) or more thick	3.0 mm (0.118 in.)	26 mm (1.02 in.)
E	2.5 to 3.5 mm (0.0984 to 0.138 in.)	3.0 mm (0.118 in.)	-
E	-	3.0 mm (0.118 in.)	-

Note

When the contact surfaces are wet, clean the surfaces with non-residue solvent before applying seal packing.
Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.
Do not apply oil for at least 4 hours after the installation.
Do not start the engine for at least 4 hours after the installation.

Temporarily install the timing chain cover sub-assembly with the 17 bolts and 2 nuts.

Bolt Length

Item	Length	Thread Diameter
Bolt A	30 mm (1.18 in.)	8 mm (0.315 in.)
Bolt B	35 mm (1.38 in.)	10 mm (0.394 in.)
Bolt C	45 mm (1.77 in.)	8 mm (0.315 in.)

Note

Make sure there is no oil on the bolts. If there is oil on the bolts, clean them before installing them.

Tighten the 17 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

Torque:

for bolt 1, 2, 3 and 4

55 N*m { 561 kgf*cm, 41 ft.*lbf }

except bolt 1, 2, 3 and 4

21 N*m { 214 kgf*cm, 15 ft.*lbf }

INSTALL ENGINE MOUNTING BRACKET RH
1. Install the engine mounting bracket RH, and install the 5 bolts in the order shown in the illustration.
  
  Torque:
  
  for bolt 1, 2 and 3
  
  55 N*m { 561 kgf*cm, 41 ft.*lbf }
  
  for bolt 4 and 5
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Note
  
  After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket RH within 10 minutes.
INSTALL TIMING CHAIN COVER OIL SEAL
1. Apply MP grease to the lip of a new oil seal.
  Note
  - Do not allow foreign matter to contact the lip of the oil seal.
  - Do not allow MP grease to contact the dust seal.
2. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.
  
  SST
  
  09223-22010
  Note
  
  Keep the lip of the oil seal free from foreign matter.
  
  Do not tap in the oil seal at an angle.
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the crankshaft pulley.
2. Using SST, hold the crankshaft pulley and install the pulley bolt.
  
  SST
  
  09213-54015
  
  09330-00021
  
  Torque:
  
  260 N*m { 2651 kgf*cm, 192 ft.*lbf }
  
  Tech Tips
  
  SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)
INSTALL CRANKSHAFT POSITION SENSOR
1. Apply a light coat of engine oil to the O-ring of the sensor.
  
  Note
  
  Make sure that the O-ring is not cracked or does not jump out of position during installation.
2. Text in Illustration
  
  *1 Adhesive
  
  Apply adhesive to 2 or 3 threads of the bolt.
  
  Adhesive
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent.
3. Install the sensor with the bolt.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
4. Connect the sensor connector.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the V-ribbed belt tensioner with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Apply a light coat of engine oil to 3 new gaskets.
2. Install the 3 gaskets to the camshaft bearing caps.
3. Install a new gasket to the cylinder head cover.
  
  Note
  
  Remove any oil from the contact surfaces.
4. Apply seal packing as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Standard seal diameter
  
  3.0 to 6.0 mm (0.118 to 0.236 in.)
  
  Application width A
  
  5.0 mm (0.197 in.)
  Note
  
  Remove any oil from the contact surfaces.
  
  Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
5. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.
6. Install 3 new seal washers and the 16 bolts, and then tighten the bolts in the order shown in the illustration.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
  
  Note
  
  Do not apply oil for at least 4 hours after the installation.
INSTALL IGNITION COIL ASSEMBLY
1. Install the 4 ignition coil assemblies with the 4 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the 4 ignition coil assembly connectors.
REMOVE ENGINE STAND

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