OIL PUMP INSTALLATION

INSTALL TIMING CHAIN CASE OIL SEAL
1. Using SST, tap in a new oil seal until its surface is flush with the timing chain case edge.
  
  SST
  
  09223-22010
  
  09506-35010
  Note
  
  Keep the lip free from foreign matter.
  
  Do not tap on the oil seal at an angle.
  
  Make sure that the oil seal edge does not stick out of the timing chain case.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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

Seal packing

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

Seal diameter

3.0 mm (0.118 in.)
Note
- Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
- When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
- Install the chain cover within 3 minutes.
- Do not start the engine for at least 2 hours after installing.

Seal diameter
3.0 mm (0.118 in.)

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

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

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 15 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing it.

Seal Packing Chart

Area	Seal Packing Diameter	Application Position from Inside Seal Line
Continuous Line Area	4.5 mm (0.177 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Short Dashed Line Area	3.5 mm (0.138 in.) or more	2.0 to 3.0 mm (0.0787 to 0.118 in.)
Dashed Line Area	3.5 mm (0.138 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area	6.0 mm (0.236 in.) or more	5.0 mm (0.197 in.)

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

Type X:

Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Bolt Length
Item	Length
Bolt A	40 mm (1.57 in.)
Bolt B	55 mm (2.17 in.)
Bolt C	25 mm (0.984 in.)

Note

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

Type Y:

Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Bolt Length
Item	Length
Bolt A	40 mm (1.57 in.)
Bolt B	55 mm (2.17 in.)
Bolt C	28 mm (1.102 in.)

Note

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

Fully tighten the bolts in Area 1 and Area 2.

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Fully tighten the bolts and nuts in Area 3.

Torque:

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

Tech Tips

Tighten the bolts and nuts from top to bottom as shown in the illustration.
Fully tighten the bolts in Area 4.

Torque:

Bolt A

43 N*m { 438 kgf*cm, 32 ft.*lbf }

Except bolt A

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

Tech Tips

Tighten the bolts from bottom to top as shown in the illustration.

INSTALL OIL PAN SUB-ASSEMBLY
1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Install 2 new O-rings.
3. Apply seal packing in a continuous line as shown in the illustration.
  
  Seal Packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal Diameter
  
  3.0 to 4.0 mm (0.118 to 0.157 in.)
  Note
  
  Remove any oil from the contact surfaces.
  
  Install the oil pan sub-assembly within 3 minutes after applying seal packing.
  
  Do not start the engine for at least 2 hours after installing.
4. Text in Illustration
  
  *a Nut
  
  Install the oil pan sub-assembly with the 16 bolts and 2 nuts.
  
  Torque:
  
  Bolts A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Except bolts A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Text in Illustration
  
  *a Bolt
  
  *b Nut
  
  Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
1. Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Apply seal packing in a continuous line as shown in the illustration.
  
  Seal Packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Seal Diameter
  
  3.0 to 4.0 mm (0.118 to 0.157 in.)
  Note
  
  Remove any oil from the contact surface.
  
  Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
  
  Do not start the engine for at least 2 hours after installing.
3. Text in Illustration
  
  *a Nut
  
  Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Apply seal packing as shown in the illustration.
  
  Seal Packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  
  Remove any oil from the contact surfaces.
  
  Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.
  
  Do not start the engine for at least 2 hours after installing.
2. Install 3 new gaskets as shown in the illustration.
3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
4. Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.
  
  Torque:
  
  Bolts A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Except Bolts A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Tech Tips
  
  After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Apply seal packing as shown in the illustration.
  
  Seal Packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  
  Remove any oil from the contact surface.
  
  Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.
  
  Do not start the engine for at least 2 hours after installation.
2. Install 3 new gaskets shown in the illustration.
3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.
4. Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.
  
  Torque:
  
  Bolts A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Except Bolts A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Tech Tips
  
  After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

Seal Diameter
3.0 to 4.0 mm (0.118 to 0.157 in.)

Text in Illustration
*a	Nut

Text in Illustration
*a	Bolt
*b	Nut

Seal Diameter
3.0 to 4.0 mm (0.118 to 0.157 in.)

Text in Illustration
*a	Nut

INSTALL WATER INLET HOUSING

Install 2 new O-rings.

Tech Tips

Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.
Install the 2 stud bolts.

Torque:

4.0 N*m { 41 kgf*cm, 35 in.*lbf }

Text in Illustration
*1	Drain Cock Plug
*2	Drain Cock Assembly
*a	Bolt
*b	Nut

Install the water inlet housing with the 2 bolts and nut.

Torque:: 10 N*m { 102 kgf*cm, 7 ft.*lbf }

Note

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

Connect the No. 1 water by-pass hose to the water inlet housing.
Apply adhesive around the drain cock assembly.

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Install the drain cock assembly to the water inlet housing.

Torque:

30 N*m { 306 kgf*cm, 22 ft.*lbf }
Install the drain cock plug to the drain cock assembly.

Torque:

13 N*m { 130 kgf*cm, 9 ft.*lbf }
Install a new gasket to the thermostat.
Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

Tech Tips

The jiggle valve may be set within 10° of either side of the prescribed position.
Install the water inlet with the 2 nuts.

Torque:

10 N*m { 102 kgf*cm, 7 ft.*lbf }

INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the pulley bolt.
  
  SST
  
  09213-70011 ( 09213-70020 )
  
  09330-00021
  
  Torque:
  
  250 N*m { 2550 kgf*cm, 184 ft.*lbf }
INSTALL OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
  
  Note
  
  Do not touch the mesh when installing the oil control valve filter RH.
2. Text in Illustration
  
  *a Oil Check Valve Bolt
  
  Install a new gasket and temporarily install the oil pipe (on the cylinder head sub-assembly side) with the oil check valve bolt.
3. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the cylinder head cover sub-assembly side).
4. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).
  
  Torque:
  
  65 N*m { 663 kgf*cm, 48 ft.*lbf }
  
  Note
  
  If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
5. Tighten the oil pipe union (on the cylinder head sub-assembly side).
  
  Torque:
  
  65 N*m { 663 kgf*cm, 48 ft.*lbf }
6. Install the bolt (A) to the cylinder head sub-assembly.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL NO. 1 OIL PIPE
1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
  
  Note
  
  Do not touch the mesh when installing the oil control valve filter.
2. Text in Illustration
  
  *a Oil Pipe Union
  
  Install a new gasket and temporarily install the oil pipe (on the cylinder head sub-assembly side) with the oil check valve bolt.
3. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the cylinder head cover sub-assembly side).
4. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).
  
  Torque:
  
  65 N*m { 663 kgf*cm, 48 ft.*lbf }
  
  Note
  
  If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
5. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).
  
  Torque:
  
  65 N*m { 663 kgf*cm, 48 ft.*lbf }
INSTALL CRANKSHAFT POSITION SENSOR
1. Apply a light coat of engine oil to the O-ring on the crank position sensor.
2. Install the crank position sensor with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the crank position sensor connector.
INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
1. Install the bolt and No. 1 vacuum switching valve.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL RADIO SETTING CONDENSER
1. Install the 2 bolts and 2 radio setting condensers.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.
  
  Torque:
  
  Bolt A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Using an 8 mm socket wrench, install the 2 stud bolts.
  
  Torque:
  
  Bolt B
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Install the No. 1 front engine mounting bracket LH with the 6 bolts.
  
  Torque:
  
  54 N*m { 550 kgf*cm, 40 ft.*lbf }
  Note
  
  Install the water inlet and No. 1 front engine mounting bracket LH within 15 minutes after installing the timing chain cover assembly.
  
  Do not start the engine for at least 2 hours after installation.
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.
  
  Torque:
  
  54 N*m { 550 kgf*cm, 40 ft.*lbf }
INSTALL WATER PUMP PULLEY
1. Temporarily install the water pump pulley with the 4 bolts.
2. Using SST, hold the water pump pulley.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-00700 )
3. Tighten the 4 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 TIMING GEAR COVER
1. Install the No. 2 timing gear cover with the 2 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.
  
  Tech Tips
  
  Each bolt length is as follows:
  
  A: 70 mm (2.76 in.)
  
  B: 33 mm (1.30 in.)
2. Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
3. Tighten the other bolts.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Install a new gasket as shown in the illustration.
2. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay by tightening the bolt and nut in the order shown in the illustration.
  
  Torque:
  
  34 N*m { 347 kgf*cm, 25 ft.*lbf }
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.
2. Install the engine oil level dipstick guide with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
1. Install a new O-ring to the No. 2 engine oil level dipstick guide.
2. Apply a light coat of engine oil to the O-ring.
3. Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.
4. Install the No. 2 engine oil level dipstick guide with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
5. Install the engine oil level dipstick.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Install a new gasket as shown in the illustration.
2. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL IGNITION COIL ASSEMBLY
1. Install the 6 ignition coils with the 6 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the 6 ignition coil connectors.
3. Connect the 3 wire harness clamps.
INSTALL THROTTLE BODY BRACKET
1. Install the throttle body bracket with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 SURGE TANK STAY
1. Install the No. 1 surge tank stay with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Text in Illustration
*a	Oil Check Valve Bolt

Text in Illustration
*a	Oil Pipe Union

INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE

DO NOT apply oil to the bolts listed below:

Tightening Part
Surge Tank and Intake Manifold
No. 1 Surge Tank Stay and Surge Tank
Throttle Body Bracket and Surge Tank

Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.
Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

Torque:

Bolt

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

Nut

16 N*m { 163 kgf*cm, 12 ft.*lbf }
Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Connect the connector to the intake air control valve assembly.
Connect the 2 water by-pass hoses to the throttle body assembly.
Connect the fuel vapor feed hose to the intake air surge tank assembly.
Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.
Connect the ventilation hose.
Connect the union to connector tube hose.

INSTALL ENGINE HANGER

Install the 2 engine hangers with the 4 bolts as shown in the illustration.

Part No.
No. 1 Engine hanger 12281-31120
No. 2 Engine hanger 12282-31100
Bolts 91671-10825

Torque:: 33 N*m { 337 kgf*cm, 24 ft.*lbf }

Attach the engine sling device and hang the engine with the chain block.

REMOVE ENGINE FROM ENGINE STAND
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

Tech Tips

See the steps from "Install Automatic Transaxle Assembly" through "Install Engine Assembly with Transaxle" Click here.