OIL PUMP INSTALLATION

Note

When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.
When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

INSTALL FRONT CRANKSHAFT OIL SEAL
1. Text in Illustration
  
  *1 Oil Seal
  
  *2 Timing Chain Cover
  
  Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
  
  SST
  
  09223-50010
  
  Standard depth
  
  0 to 0.6 mm (0 to 0.236 in.)
  Note
  - Keep the lip of the oil seal free from foreign matter.
  - Do not tap in the oil seal at an angle.
2. Apply MP grease to the lip of the 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.
INSTALL STRAIGHT SCREW PLUG
1. Using a 10 mm socket hexagon wrench, install a new gasket and the straight screw plug.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }

Text in Illustration
*1	Oil Seal
*2	Timing Chain Cover

Standard depth
0 to 0.6 mm (0 to 0.236 in.)

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Install a new gasket and O-ring to the timing chain cover.
Remove any old seal packing material.

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

Apply Seal Packing as Follows

Area	Seal Packing Diameter (Round)	Seal Packing Dimension (Flat)	Seal Packing Application Length
A - A	2.0 to 4.0 mm (0.0787 to 0.157 in.)	-	-
B - B	8.0 to 10 mm (0.315 to 0.394 in.)	-	30 mm (1.18 in.)
C - C	-	13 mm (0.512 in.) or more wide and 6.0 mm (0.236 in.) or more thick	15 mm (0.591 in.)

Note

Be sure to clean and degrease the contact surfaces, especially the 4 areas indicated by the arrows in the illustration.
When the contact surfaces are wet, wipe them off with an oil-free cloth before applying seal packing.
When applying seal packing to area C - C, apply it in the direction of the white arrows in the illustration.
Install the timing chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not start the engine for at least 4 hours after installation.

Text in Illustration
*1	Adhesive
	Bolt and New Seal Washer

Apply adhesive to the 4 bolts labeled B.

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Temporarily install the timing chain cover and a new seal washer with the 13 bolts.

Bolt Length

Item	Specified Condition
Bolt A	60 mm (2.36 in.)
Bolt B	30 mm (1.18 in.)
Bolt C	30 mm (1.18 in.)

Tech Tips

Bolt B and C are identical.

Tighten the 12 bolts labeled B and C.

Torque:

23 N*m { 229 kgf*cm, 17 ft.*lbf }
Tighten the bolt labeled A.

Torque:

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

INSTALL CRANKSHAFT PULLEY
1. Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place to install it.
2. Using SST, install a new pulley bolt.
  
  SST
  
  09213-58014 ( 91551-80840 )
  
  09330-00021
  
  Torque:
  
  300 N*m { 3059 kgf*cm, 221 ft.*lbf }

INSTALL WATER PUMP ASSEMBLY

Remove the adhesive from the threads of the bolt and the bolt hole of the timing chain cover.
Install a new gasket to the timing chain cover so that the protrusions indicated by the arrows in the illustration are aligned.

Text in Illustration
*1	Adhesive

Apply adhesive to 2 or 3 threads of the bolt labeled A shown in the illustration.

Standard Bolt Length

Item	Specified Condition
Bolt A and C	45 mm (1.77 in.)
Bolt B	30 mm (1.18 in.)

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the water pump with the 2 bolts indicated by the arrows in the illustration.

Torque:

23 N*m { 229 kgf*cm, 17 ft.*lbf }
Install the 5 bolts.

Torque:

23 N*m { 229 kgf*cm, 17 ft.*lbf }

CONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS
1. Text in Illustration
  
  *1 Protrusion
  
  Install the sensor wire harness with the bolt and clip.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
  
  Note
  
  Make sure the sensor wire harness is installed in the position shown in the illustration.
INSTALL CAMSHAFT 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 jammed when installing the sensor.
2. Install the sensor with the bolt.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
INSTALL OIL STRAINER SUB-ASSEMBLY
1. Install a new O-ring to the oil strainer.
2. Apply a light coat of engine oil to the O-ring.
3. Install the oil strainer with the 3 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL OIL FILTER BRACKET
1. Install a new gasket to the oil filter bracket.
2. Install the oil filter bracket with the 4 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
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.
6. Using SST, tighten the oil filter cap.
  
  SST
  
  09228-06501
  
  Torque:
  
  for Aluminum Oil Filter Cap
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
  
  for Resin Oil Filter Cap
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }

Text in Illustration
*1	Protrusion

INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

Remove any old seal packing material.

Text in Illustration
*a	4.0 to 7.0 mm

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

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

Standard Seal Packing Dimension

Area	Seal Packing Diameter	Seal Packing Application Length
A - A	4.0 to 7.0 mm (0.157 to 0.276 in.)	12 mm (0.472 in.)

Note

Remove any oil from the contact surface.
Install the oil pan within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
Do not start the engine for at least 4 hours after installation.

Install the oil pan with the 18 bolts and 2 nuts.

Torque:

11 N*m { 107 kgf*cm, 8 ft.*lbf }

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Remove any old seal packing material.

Apply seal packing to the cylinder head as shown in the illustration.

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

Standard Seal Packing Dimension

Area	Seal Packing Diameter	Seal Packing Application Length
A	6.0 mm (0.236 in.)	8.0 mm (0.315 in.)
B	6.0 mm (0.236 in.)	10 mm (0.394 in.)

Install a new cylinder head cover gasket to the cylinder head cover.

Install the cylinder head cover gasket so that the triangle tabs of the cylinder head cover gasket are aligned with the protrusions of the cylinder head cover as shown in the parts of the illustration labeled A and B.
Install the cylinder head cover gasket to the groove of the cylinder head cover moving from C and D in the direction of the black arrows shown in the illustration.
Install the cylinder head cover gasket to the groove of the cylinder head cover moving from C and D towards E as shown by the white arrows in the illustration.
Install the cylinder head gasket to the groove of the cylinder head cover moving from D towards F as shown by the striped arrow in the illustration.

Install the cylinder head cover gasket to the cylinder head cover pins and cutouts as shown in the parts of the illustration labeled G and H.

Text in Illustration
*1	Triangle Tab of Cylinder Head Cover Gasket	*2	Protrusion of Cylinder Head Cover
*3	Cylinder Head Cover Pin	*4	Cutout of Cylinder Head Cover

Note

Make sure that the rib of the cylinder head cover gasket is securely inserted into the groove of the cylinder head cover.

Text in Illustration
*a	CORRECT
*b	INCORRECT
	Rib of Cylinder Head Cover Gasket

Install the cylinder head cover with the 14 bolts and nut, and tighten the bolts and nut in the order shown in the illustration.

Torque:

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

Tech Tips

Partially tighten the bolt indicated by the number 6 in the illustration until the cylinder head cover contacts the cylinder head, and then tighten the bolts and nut in the order shown in the illustration.

INSTALL NOZZLE HOLDER CLAMP SEAT
1. Install the 4 nozzle holder clamp seats.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL OIL FILLER CAP SUB-ASSEMBLY

INSTALL VENTILATION HOSE

Tech Tips

The direction of the hose clamp is indicated in the illustration.

Text in Illustration
*1	Paint Mark
*a	Upper Side
*b	Front Side of Vehicle

INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

Text in Illustration
*a	CORRECT
*b	INCORRECT
	Paint Mark

Attach the 10 clamps to install the 2 vacuum transmitting hoses.

Tech Tips

Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled A in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.
Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled B in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

INSTALL VACUUM REGULATING VALVE ASSEMBLY
1. Install the vacuum regulating valve with the 2 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Connect the 2 vacuum hoses.
3. Connect the vacuum regulating valve connector.
INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
1. Using a 4 mm hexagon socket wrench, install the VSV with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Connect the 2 vacuum hoses.
3. Connect the VSV connector.
INSTALL INJECTOR ASSEMBLY

Note

Before installing the injector, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head and injector. If there is foreign matter, remove it before installing the injector.
1. Install 4 new nozzle seats to the cylinder head.
2. Text in Illustration
  
  *1 New O-Ring
  
  Install a new O-ring to each injector.
3. Apply a light coat of engine oil to the O-ring on each injector.
4. Install the 4 injectors to the cylinder head.
  
  Note
  
  Fit the injectors to the nozzle seats.
5. Text in Illustration
  
  *1 Washer
  
  Install the nozzle holder clamps and washers as shown in the illustration.
  
  Note
  
  Pay attention to the mounting orientation (beveled edge) of the washer.
6. Temporarily install the nozzle holder clamp bolts.
  
  Note
  
  When temporarily installing the nozzle holder clamp bolt to the nozzle holder clamp, make sure that the bolt and clamp are not at an angle.
  
  Tech Tips
  
  Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.
7. Temporarily install the 4 injection pipes.
8. Temporarily install the No. 1 leakage pipe and 4 new gaskets with the 4 union bolts and bolt.
9. Tighten the 4 nozzle holder clamp bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
INSTALL NO. 1 NOZZLE LEAKAGE PIPE
1. Tighten the 4 union bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
2. Tighten the bolt.
  
  Torque:
  
  21 N*m { 209 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 NOZZLE LEAKAGE PIPE
1. Temporarily install the No. 2 nozzle leakage pipe and a new gasket with the check valve and bolt.
2. Tighten the check valve.
  
  Torque:
  
  32 N*m { 321 kgf*cm, 23 ft.*lbf }
3. Tighten the bolt.
  
  Torque:
  
  32 N*m { 321 kgf*cm, 23 ft.*lbf }
INSTALL NO. 3 FUEL HOSE

Text in Illustration
*1	New O-Ring

Text in Illustration
*1	Washer

INSTALL FUEL TUBE SUB-ASSEMBLY

Temporarily install the fuel tube and 2 new gaskets with the check valve and union bolt.
Tighten the check valve.

Torque:

32 N*m { 321 kgf*cm, 23 ft.*lbf }
Tighten the union bolt.

Torque:

23 N*m { 235 kgf*cm, 17 ft.*lbf }
Connect the fuel tube connector to the injector.

Text in Illustration
*1	Fuel Tube Connector
*2	Injector
*3	Retainer
*4	O-Ring

Turn the retainer in the direction indicated by the arrow until it makes a "click" sound.

Note

If the fuel tube connector is not inserted to the correct position on the injector, the retainer cannot be turned far enough in the direction of the arrow.

Connect the exhaust fuel addition injector connector.

INSTALL FUEL HOSE PROTECTOR
1. Install the fuel hose protector with the bolt.
  
  Torque:
  
  21 N*m { 209 kgf*cm, 15 ft.*lbf }
INSTALL WATER INLET HOUSING
1. Install a new gasket and the inlet housing with the 3 nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL NO. 4 WATER BY-PASS HOSE
INSTALL NO. 2 WATER BY-PASS PIPE
1. Install a new O-ring to the No. 2 water by-pass pipe.
2. Install the No. 2 water by-pass pipe with the 2 bolts.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
INSTALL NO. 1 OIL COOLER BRACKET
1. Apply engine oil to the 2 new O-rings labeled B in the illustration.
  
  Note
  
  Do not apply engine oil to the new O-ring labeled A in the illustration.
2. Install 3 new O-rings to the oil cooler bracket.
3. Install the No. 1 oil cooler bracket with the 6 bolts and nut.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL NO. 1 TURBO OIL PIPE
1. Text in Illustration
  
  *1 Gasket
  
  Install the No. 1 turbo oil pipe and 2 new gaskets with the 2 union bolts.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Make sure the gasket of union bolt A contacts the No. 1 turbo oil pipe as shown in the illustration when tightening the union bolt.
INSTALL NO. 3 WATER BY-PASS PIPE
1. Install a new O-ring to the No. 3 water by-pass pipe.
2. Install the No. 3 water by-pass pipe with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 8 WATER BY-PASS HOSE
INSTALL NO. 6 WATER BY-PASS HOSE
INSTALL OIL COOLER ASSEMBLY
1. Apply engine oil to the 2 new O-rings labeled B in the illustration.
  
  Note
  
  Do not apply engine oil to the new O-ring labeled A in the illustration.
2. Install 3 new O-rings to the oil cooler bracket.
3. Install the oil cooler with the 5 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL WATER BY-PASS HOSE

Tech Tips

Make sure the claws of hose clamp A are positioned above the paint mark as shown in the illustration.

Text in Illustration

*1 Paint Mark

*a Upper Side
INSTALL NO. 1 CYLINDER BLOCK INSULATOR
1. Install the No. 1 cylinder block insulator to the cylinder block.
  
  Note
  
  Be sure to install the oil cooler before installing the No. 1 cylinder block insulator.

Text in Illustration
*1	Gasket

INSTALL INTAKE MANIFOLD

Install a new gasket to the cylinder head.

Tech Tips

Install the gasket with the part labeled A facing the right side of the vehicle as shown in the illustration.

Text in Illustration
*1	Nut

Install the intake manifold with the 7 bolts and 2 nuts.

Torque:: 23 N*m { 235 kgf*cm, 17 ft.*lbf }

Bolt Length

Item	Specified Condition
Bolt A	90 mm (3.54 in.)
Bolt B	25 mm (0.984 in.)

INSTALL NO. 2 INTAKE MANIFOLD
1. Install a new gasket and the No. 2 intake manifold with the bolt and 2 nuts.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
INSTALL ENGINE COVER BRACKET
1. Install the engine cover bracket with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL GAS FILTER BRACKET
1. Install the gas filter bracket with the 2 bolts.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
INSTALL NO. 1 GAS FILTER
1. Text in Illustration
  
  *1 Protrusion
  
  *2 Groove
  
  Install the No. 1 gas filter to the gas filter bracket.
  
  Note
  
  Make sure the protrusion of the No. 1 gas filter is aligned with the groove of the gas filter bracket.
2. Connect the vacuum hose.
INSTALL DIESEL TURBO PRESSURE SENSOR
1. Text in Illustration
  
  *1 Protrusion
  
  Install the sensor with the bolt.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
  
  Note
  
  Make sure the protrusion of the gas filter bracket is inserted into the hole of the sensor.
2. Connect the vacuum hose.
INSTALL INTAKE MANIFOLD INSULATOR
1. Install the intake manifold insulator to the intake manifold.
INSTALL COMMON RAIL ASSEMBLY
1. Install the common rail with the 2 bolts.
  
  Torque:
  
  21 N*m { 209 kgf*cm, 15 ft.*lbf }
INSTALL NO. 4 FUEL HOSE
INSTALL INJECTION PIPE SUB-ASSEMBLY
1. Using a 14 mm union nut wrench, tighten the 4 nuts at the common rail end of the injection pipes.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
2. Using a 14 mm union nut wrench, tighten the 4 nuts at the injector end of the injection pipes.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
3. Install the 4 injection pipe clamps with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL FUEL INLET PIPE SUB-ASSEMBLY
1. Temporarily install the fuel inlet pipe with the 2 clamps and nut.
2. Using a 14 mm union nut wrench, first tighten the nut at the common rail end of the fuel inlet pipe.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
3. Using a 14 mm union nut wrench, tighten the nut at the supply pump end of the fuel inlet pipe.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
4. Tighten the No. 2 injection pipe clamp nut.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Install a new O-ring to the engine oil level dipstick guide.
2. Install the engine oil level dipstick guide with the 2 bolts.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
3. Install the engine oil level dipstick.
INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
1. Text in Illustration
  
  *1 Protrusion
  
  Install a new gasket.
  
  Note
  
  Make sure the protrusion of the gasket is facing upward as shown in the illustration.
2. Install the electric EGR control valve.

Text in Illustration
*1	Protrusion
*2	Groove

Text in Illustration
*1	Protrusion

Text in Illustration
*1	Protrusion

INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

Install a new gasket to the electric EGR control valve.

Text in Illustration
*1	Nut

Temporarily install the No. 2 EGR pipe with the 3 bolts and 2 nuts.

Bolt Length

Item	Specified Condition
Bolt A	25 mm (0.984 in.)
Bolt B	70 mm (2.76 in.)

Tighten the 2 bolts labeled A shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Tighten the bolt and 2 nuts labeled B shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Connect the electric EGR control valve connector.

INSTALL EGR VALVE BRACKET
1. Install the 2 EGR valve brackets with the 3 bolts.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 in.*lbf }
CONNECT NO. 8 WATER BY-PASS HOSE
INSTALL NO. 7 WATER BY-PASS HOSE
INSTALL DIESEL THROTTLE BODY ASSEMBLY
1. Install a new gasket and the diesel throttle body with the 2 bolts and 2 nuts.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
2. Connect the No. 6 and No. 7 water by-pass hoses.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the V-ribbed belt tensioner with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  As the heads of the bolts are not as thick as those of typical bolts, be careful not to damage them during installation.
INSTALL ENGINE MOUNTING BRACKET
1. Temporarily install the engine mounting bracket with the 2 bolts labeled A.
2. Temporarily install the 2 bolts and 2 nuts labeled B in the illustration.
3. Tighten the 2 bolts labeled A in the illustration.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
4. Tighten the 2 bolts and 2 nuts labeled B in the illustration.
  
  Torque:
  
  80 N*m { 816 kgf*cm, 59 ft.*lbf }
INSTALL NO. 4 WATER BY-PASS PIPE
1. Install a new O-ring to the No. 4 water by-pass pipe.
2. Install the No. 4 water by-pass pipe with the bolt.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }

INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

Text in Illustration
*1	No. 2 Idler Pulley Cover Plate
*2	No. 2 Idler Pulley

Install the No. 2 idler pulley and No. 2 idler pulley cover plate with the bolt.

Torque:: 40 N*m { 408 kgf*cm, 30 ft.*lbf }

Note

Make sure the No. 2 idler pulley cover plate is facing the direction shown in the illustration.

INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
1. Install the No. 1 idler pulley with the bolt.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
INSTALL IDLER PULLEY COVER PLATE
1. Install the idler pulley cover plate to the No. 1 idler pulley.
INSTALL VACUUM PUMP ASSEMBLY
1. Apply a light coat of engine oil to 2 new O-rings.
2. Install the 2 O-rings to the vacuum pump.
3. Install the vacuum pump with 3 new bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Connect the vacuum hose.
INSTALL GENERATOR ASSEMBLY
1. Install the generator with the 3 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Make sure that the wire harness of the crankshaft position sensor does not get caught between the cylinder block and generator when installing the generator.
2. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  8.4 N*m { 85 kgf*cm, 74 in.*lbf }
3. Connect the generator wire to terminal B with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
4. Connect the generator connector and attach the clamp.
5. Install the terminal cap.
CONNECT ENGINE WIRE
1. Connect the connectors and attach the clamps, and then connect the engine wire to the engine with the bracket bolts.
INSTALL ENGINE ASSEMBLY

Click here