МАСЛЯНЫЙ НАСОС

INSTALL WATER INLET PIPE

Apply soapy water to 2 new O-rings and install them to the inlet pipe.
Install the inlet pipe to the No. 1 heat exchanger cover.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Apply a light coat of engine oil to a new oil pump gasket.
Install the oil pump gasket.
Apply a light coat of engine oil to a new O-ring.
Install the O-ring.

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

Table 1. Text in Illustration
*1	Continuous line area	*2	Dashed line area
*3	Diagonal line area	-	-

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

Apply Seal Packing as Follows

Area	Seal Packing Diameter	Application Position from Inside Edge of Cover
Continuous Line Area	3.0 to 4.0 mm (0.118 to 0.157 in.)	2.5 mm (0.0984 in.)
Dashed Line Area	6.4 mm (0.252 in.) or more, or within OK area shown in illustration	7.0 mm (0.276 in.)
Diagonal Line Area	3.0 to 4.0 mm (0.118 to 0.157 in.)	5.5 mm (0.217 in.)

Table 2. Text in Illustration
*1	Seal Packing Thickness mm (in.)
*2	Seal Packing Width mm (in.)
*3	Seal Packing Thickness
*4	Seal Packing Width
*5	OK Area

Note:

When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

Align the oil pump drive rotor spline and crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Temporarily install the timing chain cover with the 28 bolts and nut.

Standard Bolt

Item	Length	Thread Diameter
Bolt A	25 mm (0.984 in.)	8 mm (0.315 in.)
Bolt B	55 mm (2.17 in.)	8 mm (0.315 in.)
Bolt C	70 mm (2.76 in.)	8 mm (0.315 in.)
Bolt D	35 mm (1.38 in.)	10 mm (0.394 in.)
Bolt E	55 mm (2.17 in.)	10 mm (0.394 in.)
Bolt F	80 mm (3.15 in.)	10 mm (0.394 in.)

Table 3. Text in Illustration
*1	Nut

Note:

Make sure that there is no oil on the bolt threads.

Tighten the 3 bolts in several steps in the sequence shown in the illustration.

47 N*m 479 kgf*cm 35 ft.*lbf

Temporarily install the fluid coupling bracket with the 4 bolts.

Standard Bolt

Item	Length	Thread Diameter
Bolt A	70 mm (2.76 in.)	8 mm (0.315 in.)
Bolt B	80 mm (3.15 in.)	10 mm (0.394 in.)

Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.
Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.

47 N*m 479 kgf*cm 35 ft.*lbf
Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.

23 N*m 235 kgf*cm 17 ft.*lbf
Note:
- Do not start the engine for at least 2 hours after installing.
- After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

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INSTALL SPARK PLUG TUBE GASKET

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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).
Install a new gasket to the cylinder head cover.

Note:
Remove any oil from the contact surface.
Apply seal packing as shown in the illustration.

Seal packing

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

Table 4. Text in Illustration

Seal Packing
Note:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

Table 4. Text in Illustration
	Seal Packing

Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

for bolt A
21 N*m	214 kgf*cm	15 ft.*lbf
except bolt A
12 N*m	122 kgf*cm	9 ft.*lbf

Note:

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

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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).
Install a new gasket to the cylinder head cover.

Note:
Remove any oil from the contact surface.
Apply seal packing as shown in the illustration.

Seal packing

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

Table 5. Text in Illustration

Seal Packing
Note:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

Table 5. Text in Illustration
	Seal Packing

Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

for bolt A
21 N*m	214 kgf*cm	15 ft.*lbf
except bolt A
12 N*m	122 kgf*cm	9 ft.*lbf

Note:

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

Install the noise filter to the cylinder head cover with the bolt.

7.0 N*m 71 kgf*cm 62 in.*lbf

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INSTALL IGNITION COIL ASSEMBLY

Install the 8 ignition coils with the 8 bolts.

10 N*m 102 kgf*cm 7 ft.*lbf

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INSTALL CRANKSHAFT TIMING GEAR KEY

Install the crankshaft timing gear key to the crankshaft.

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CONNECT WIRE HARNESS CLAMP BRACKET

Connect the bracket to the timing chain cover with the bolt.

8.0 N*m 82 kgf*cm 71 in.*lbf

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INSTALL CRANKSHAFT PULLEY

Align the pulley set key with the key groove of the pulley, and slide on the pulley.

Using SST, install the pulley set bolt.

09213-70011

09330-00021

300 N*m

3059 kgf*cm

221 ft.*lbf

Table 6. Text in Illustration
*a	Hold
	Turn

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INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

Install the idler pulley with the bolt.

43 N*m 438 kgf*cm 32 ft.*lbf

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INSTALL WATER PUMP PULLEY

Temporarily install the pulley with the 4 bolts.
Using SST, hold the pulley and tighten the 4 bolts.

09960-10010 09962-01000 09963-01000

21 N*m 214 kgf*cm 15 ft.*lbf

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INSTALL WATER INLET HOUSING

Install a new gasket to the timing chain cover.
Install the water inlet with the 3 bolts.

21 N*m 214 kgf*cm 15 ft.*lbf

Table 7. Text in Illustration

*1 Gasket

Table 7. Text in Illustration
*1	Gasket

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INSTALL NO. 1 ENGINE COVER

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INSTALL NO. 2 ENGINE COVER

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INSTALL FRONT WATER BY-PASS JOINT

Install 2 new gaskets and the water by-pass joint with the 4 nuts.

21 N*m 214 kgf*cm 15 ft.*lbf
Connect the No. 2 water by-pass hose to the water by-pass joint.

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INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

Connect the 2 hoses.
Install the water by-pass pipe with the 2 bolts.

10 N*m 102 kgf*cm 7 ft.*lbf

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INSTALL NO. 1 WATER BY-PASS HOSE

Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.

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INSTALL GENERATOR ASSEMBLY

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CONNECT OIL COOLER PIPE ASSEMBLY

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CONNECT VANE PUMP ASSEMBLY

Tip:

Before performing the following procedures, move the spacer until the vane pump can be installed.

Table 8. Text in Illustration
*1	Spacer

Connect the vane pump to the timing chain cover with the 2 bolts.

21 N*m 214 kgf*cm 15 ft.*lbf

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INSTALL INTAKE MANIFOLD

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INSTALL OIL FILTER BRACKET

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INSTALL NO. 1 OIL COOLER BRACKET

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INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

Connect the 4 hoses.
Install the water by-pass pipe with the 3 bolts.

10 N*m 102 kgf*cm 7 ft.*lbf

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INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

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INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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INSTALL OIL FILTER ELEMENT

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CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

Connect the fuel tube with the 2 bolts.

10 N*m

102 kgf*cm

7 ft.*lbf

Table 9. Text in Illustration
*A	LH Side
*B	RH Side

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CONNECT COOLER COMPRESSOR ASSEMBLY

Install the cooler compressor with the stud bolt.

10 N*m 102 kgf*cm 7 ft.*lbf
Install the 3 bolts and nut.

25 N*m 250 kgf*cm 18 ft.*lbf

Note:
Tighten the bolts and nut in the order shown in the illustration to install the cooler compressor.

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CONNECT WATER PIPE AND HOSE SUB-ASSEMBLY

Connect the water pipe and hose to the cylinder head cover with the 2 bolts.

18 N*m 184 kgf*cm 13 ft.*lbf
Connect the 3 hoses.

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CONNECT ENGINE WIRE

Connect the 2 clamps and power steering oil pressure switch connector.
Engine Room RH Side:
1. Connect the 5 clamps.
2. Connect the throttle position sensor and throttle control motor connector.
3. Install the ground wire with the 2 bolts.
  
  8.0 N*m 82 kgf*cm 71 in.*lbf
4. Connect the noise filter connector.
5. Connect the 2 VVT sensor connectors.
6. Connect the injector connector.
7. Connect the 4 ignition coil connectors.
8. Connect the 2 camshaft timing oil control valve connectors.
Engine Room LH Side:
1. Connect the cooler compressor connector.
2. Connect the 3 clamps.
3. Connect the camshaft position sensor connector.
4. Connect the 2 camshaft timing oil control valve connectors.
5. Connect the engine coolant temperature sensor connector.
6. Connect the 4 clamps.
7. Install the ground wire with the 2 bolts.
  
  8.0 N*m 82 kgf*cm 71 in.*lbf
8. Connect the noise filter connector.
9. Connect the 2 VVT sensor connectors.
10. Connect the 4 ignition coil connectors.
11. Connect the injector connector.
12. Connect the 2 connectors and 2 clips to the engine room junction block.
13. Install the engine room relay block cover.