OIL PUMP INSTALLATION


  1. 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 }

  2. 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 }

  3. 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. A003EYYE01

      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 }

  4. 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.

  5. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1


    1. A003AJJE02

      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. A003GWBE04

      Install the timing belt idler No.1 with the 3 bolts.

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

  6. 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 }

  7. 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 }

  8. INSTALL CAMSHAFT TIMING PULLEY


    1. A003GQCE02

      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 }

  9. INSTALL INJECTION PUMP


    1. A003IAA

      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. A003D9C

      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.

  10. SET NO.1 CYLINDER TO TDC/COMPRESSION


    1. A003B0KE01

      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. A003CC1E01

      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.

  11. 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. A003AITE01

      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. A003HABE01

      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. A003DNBE01

      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.

  12. CHECK VALVE TIMING


    1. A003HBZE01

      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. A003GE0E01

      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 }

  13. INSTALL TIMING BELT GUIDE


    1. A003GOQE01

      Install the belt guide with the cup side facing outward.

  14. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. Remove the 2 nuts and wire harness clamp bracket.

    2. A003DN0E01

      Install the 2 gaskets to the timing belt cover.

    3. A003GQ3

      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.

  15. INSTALL CRANKSHAFT PULLEY


    1. Align the pulley set key with the key groove of the pulley, and slide the pulley to the crankshaft.

    2. A003EICE01

      Using SST, install the new pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      235 N*m  { 2,400 kgf*cm, 173 ft.*lbf }

  16. INSTALL VANE PUMP DRIVE PULLEY


    1. A003D8T

      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 }

  17. INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. Temporarily install the compressor mounting bracket with the 4 bolts.

    2. A003HN3E01

      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. A003DN6

      Temporarily tighten the bolt and spacer.

    4. A003CUFE01

      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 }

  18. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    Click here

  19. 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 }

  20. INSTALL VENTURI ASSEMBLY


    1. Install a new gasket and venturi.

    2. A003G5UE01

      Connect the throttle control motor connector.

    3. A003I6AE01

      Connect the throttle open switch connector.

  21. INSTALL INTAKE AIR CONNECTOR BRACKET


    1. A003AY3

      Install the 2 bolts and intake air connector bracket.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  22. INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. A003FXV

      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.

  23. INSTALL WATER PUMP PULLEY

  24. INSTALL FAN & GENERATOR V BELT (w/o Air Conditioning)


    1. A003DCSE01

      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

  25. INSTALL FAN & GENERATOR V BELT (w/ Air Conditioning)


    1. A003DB6E01

      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

  26. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (w/ Air Conditioning System)


    1. A003G4BE01

      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

  27. INSTALL VANE PUMP V BELT


    1. A003FMXE01

      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

  28. 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.

  29. CONNECT WATER HOSE (for Heater)

  30. INSTALL RADIATOR HOSE NO.4

  31. INSTALL RADIATOR HOSE INLET

  32. ADD ENGINE COOLANT


    1. Fill the radiator reservoir assembly with coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 12.3 liters (13.0 US qts, 10.8 Imp. qts)
      w/ Front Heater 13.3 liters (14.1 US qts, 11.7 Imp. qts)
      w/ Front and Rear Heaters 15.3 liters (16.2 US qts, 13.5 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    2. A003EJI

      Add coolant up to the B line mark in the radiator reservoir assembly and install the reservoir cap.

    3. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    4. A003FFY

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  33. ADD ENGINE OIL

  34. CHECK FOR ENGINE OIL LEAKS

  35. 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.

  36. 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.

  37. 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 }

  38. INSTALL FRONT DOOR SCUFF PLATE RH

  39. INSTALL FRONT SEAT ASSEMBLY RH


    1. A003DBM

      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 }