SCAVENGING PUMP INSTALLATION

INSTALL REAR CRANKSHAFT OIL SEAL

1. 

   Place the oil seal retainer on wooden blocks.

2. Using SST and a hammer, tap in a new oil seal as shown in the illustration.

   09223-56010

   Standard depth A
   2.7 to 3.7 mm (0.106 to 0.147 in.)

   Note:
   

   • Keep the lip free from foreign matter.

   • Do not tap on the seal at an angle.

INSTALL REAR ENGINE OIL SEAL RETAINER

Note:

When the contact surfaces shown below are wet, wipe them with an oil-free cloth before applying seal packing.

1. 

   Apply seal packing in a continuous line as shown in the illustration.

   Seal diameter
   3.0 to 5.0 mm (0.118 to 0.197 in.)

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

   Note:
   

   • Remove any oil from the contact surface.

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

2. Apply engine oil to the oil seal lip.

3. Make sure that the lip of the oil seal is properly installed.

4. 

   Install and uniformly tighten the 10 bolts in the order shown in the illustration.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

   Note:
   

   • When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.

   • When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.

INSTALL OIL STRAINER SUB-ASSEMBLY

1. Apply a light coat of engine oil to a new O-ring, and install it to the oil strainer.

2. Install the oil strainer with the 2 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

INSTALL ENGINE OIL LEVEL SENSOR

1. Install a new gasket and the sensor with the 4 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

1. 

   Apply a light coat of engine oil to 2 new O-rings, and set them to the oil filter bracket.

2. Install the oil filter bracket with the 3 bolts and 2 nuts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

3. Connect the 2 wire harness clamps.

INSTALL OIL FILTER ELEMENT

1. 

   Clean the inside of the oil filter cap, its threads and its O-ring groove.

2. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

3. Set a new oil filter element in the oil filter cap.

4. Remove any dirt or foreign matter from the installation surface of the engine.

5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap by hand.

6. 

   Using SST, tighten the oil filter cap.

   09228-06501

   25 N*m

   255 kgf*cm

   18 ft.*lbf

   Note:
   

   • Make sure that the oil filter is installed securely as shown in the illustration.

   • Be careful that the O-ring does not get caught between any surrounding parts.

7. 

   Install the No. 2 engine under cover seal to the No. 2 engine under cover with the 2 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

INSTALL TIMING GEAR COVER SPACER (w/ Intercooler)

1. Install the timing gear cover spacer with the 2 bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

INSTALL CRANKSHAFT PULLEY

1. 

   Align the crankshaft pulley and the crankshaft knock pin, and temporarily install the crankshaft pulley with the 3 bolts.

   Table 2. Text in Illustration

   *1	Service Hole
   *2	Protrusion

2. Install the 2 bolts to the bolt holes of the crankshaft rear side.

3. Using a bar, turn the crankshaft until the crankshaft pulley service hole is a little to the right of bottom dead center.

4. Install a 14 mm x 1.5 pitch service bolt with a length of 70 mm or more to the crankshaft pulley service hole, and hold the crankshaft using the timing chain cover protrusion.

5. 

   Uniformly tighten the 3 bolts in 2 passes in the order shown in the illustration.

   115 N*m

   1168 kgf*cm

   84 ft.*lbf

6. Remove the service bolt.

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

1. 

   Install the V-ribbed belt tensioner with the 5 bolts.

   for bolt A and C
   43 N*m	438 kgf*cm	32 ft.*lbf
   for bolt B
   21 N*m	214 kgf*cm	15 ft.*lbf

   Table 3. Bolt Length

   Item	Quantity	Length
   Bolt A	1	116 mm (4.57 in.)
   Bolt B	2	40 mm (1.58 in.)
   Bolt C	2	95 mm (3.74 in.)

2. Install the No. 1 idler pulley with the bolt.

   43 N*m

   438 kgf*cm

   32 ft.*lbf

3. Install the V-ribbed belt tensioner bracket with the 3 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

CONNECT NO. 2 OIL COOLER HOSE

1. Align the white paint marks on the oil cooler hose and oil filter bracket and connect the hose.

   Note:

   Make sure to maintain a space between the oil cooler hose and crankshaft pulley and the oil cooler hose and V-ribbed belt idler pulley.

CONNECT NO. 1 OIL COOLER HOSE

1. Face the pink paint mark on the oil cooler hose toward the front side of the engine and connect the hose to the oil filter bracket.

   Note:

   Make sure to maintain a space between the oil cooler hose and crankshaft pulley.

INSTALL STIFFENER INSULATOR RH (w/ Intercooler)

1. Install the stiffener insulator RH with the 2 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

INSTALL NO. 2 INLET TURBO OIL PIPE SUB-ASSEMBLY

1. Install a new gasket and connect the No. 2 inlet turbo oil pipe with the union bolt.

   29 N*m

   296 kgf*cm

   21 ft.*lbf

INSTALL NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE

1. Apply a light coat of engine oil to a new O-ring, and install it to the No. 1 engine oil level dipstick guide.

2. Install the No. 1 engine oil level dipstick guide with the 2 bolts.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

INSTALL GENERATOR ASSEMBLY

1. 

   Temporarily install the generator with the 3 bolts and 2 nuts.

2. Uniformly tighten the 3 bolts and 2 nuts in the order shown in the illustration.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

3. Connect the generator cable and install the nut and bolt.

   for bolt
   13 N*m	133 kgf*cm	10 ft.*lbf
   for nut (130A Type and 150A Type:)
   9.8 N*m	100 kgf*cm	87 in.*lbf
   for nut (180A Type:)
   12 N*m	122 kgf*cm	9 ft.*lbf

INSTALL NO. 1 INTAKE AIR CONNECTOR PIPE

1. Install the No. 1 intake air connector pipe with the bolt. Then tighten the hose clamp.

   for bolt
   21 N*m	214 kgf*cm	15 ft.*lbf
   for hose clamp
   6.0 N*m	61 kgf*cm	53 in.*lbf

2. Connect the 4 connectors and attach the 5 wire harness clamps.