OIL PUMP INSTALLATION


  1. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A0117KIE01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

      SST
      09950-60010   ( 09951-00250, 09951-00410, 09952-06010 )
      09950-70010   ( 09951-07150 )
      Oil seal tap in depth
      -0.5 to 1.0 mm (-0.0197 to 0.0394 in.)

      Note

      Do not tap the oil seal at an angle.

    2. Apply a light coat of MP grease to the timing chain cover oil seal lip.

      Note

      Keep the seal lip free of foreign matter.

  2. INSTALL NO. 2 WATER INLET HOUSING GASKET


    1. Install a new gasket to the water inlet.

  3. INSTALL WATER INLET

    A01179BE01

    1. Temporarily install the water inlet with the 3 bolts.

    2. Fully tighten the 3 bolts in the order shown in the illustration.

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

  4. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01195OE02
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using an 8 mm socket hexagon wrench, install the plug.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note


      • Install the plug within 3 minutes after applying adhesive.

      • Do not start the engine within 1 hour after installation.

    3. Remove any old packing material remaining on the sealing surfaces before applying seal packing.

    4. Clean and degrease the contact surfaces of the timing chain cover, camshaft housing, cylinder head, cylinder block, and oil pan and confirm that no oil, moisture, or other foreign matter remains on the surfaces.

      A011B07E01
      Text in Illustration
      *a Clean and degrease - -
    5. A01194Z

      Install 2 new O-rings.

    6. Apply seal packing to the timing chain cover as shown in the following illustration.

      A011BVGE03
      Text in Illustration
      *a Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent *b Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent

      Note


      • When there is oil on contact surfaces, wipe them with 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.

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

      Tech Tips

      Areas A - A and B - B are the joints between the cylinder block and oil pan, cylinder block and cylinder head, and cylinder head and camshaft housing.

      Seal Packing Application Chart
      Area Seal Packing Diameter Seal Packing

      Continuous Line Area

      Except A - A and B - B

      		 3.5 to 4.5 mm (0.138 to 0.177 in.) Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Dashed Line Area 2.0 to 3.0 mm (0.0787 to 0.118 in.) Toyota Genuine Seal Packing Black 1282B, Three Bond 1282B or equivalent
    7. A011985

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

    8. A0117GSE01

      Temporarily install the engine mounting bracket RH with the 3 bolts.

      Bolt Length
      Item Length
      Bolt A 80 mm (3.150 in.)
      Bolt B 40 mm (1.575 in.)
    9. A011A38E01

      Temporarily install the water pump and a new water pump gasket to the timing chain cover with the 5 bolts.

      Bolt Length
      Item Length
      Bolt A 40 mm (1.575 in.)
      Bolt B 40 mm (1.575 in.)
      Bolt F 18 mm (0.709 in.)

    10. Fully tighten the 2 F bolts shown in the illustration.

      Torque:
      Bolt F
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    11. Temporarily tighten the timing chain cover with the 21 bolts and a new seal washer.

      A011B48E01
      Text in Illustration
      *1 Seal Washer - -

      Tech Tips


      • Apply adhesive to the threads of bolt E.

      • Apply adhesive to bolt E more than 7.0 mm (0.275 in.) from the bolt tip.

      Bolt E
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Bolt Length
      Item Length
      Bolt A 40 mm (1.575 in.)
      Bolt B 40 mm (1.575 in.)
      Bolt C 35 mm (1.378 in.)
      Bolt D, E 25 mm (0.984 in.)

    12. Fully tighten the timing chain cover with the 27 bolts as shown in the illustration.

      Torque:
      Bolt A
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      Bolt B, D, E
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Bolt C
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. INSTALL CRANKSHAFT PULLEY ASSEMBLY


    1. A01170JE01

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

    2. Using SST, install the crankshaft pulley bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      128 N*m  { 1305 kgf*cm, 94 ft.*lbf }

  6. INSTALL WATER PUMP PULLEY

    A011BEJE01
    SST
    09960-10010   ( 09962-01000, 09963-00600 )

    1. Using SST, install the water pump pulley with the 4 bolts.

      SST
      09960-10010   ( 09963-00600 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  7. INSTALL CRANKSHAFT POSITION SENSOR


    1. A0118BR

      Apply a light coat of engine oil to the O-ring of the sensor.

    2. A011BVM

      Install the crankshaft position sensor with the bolt.

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

  8. INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET


    1. A011ASE

      Install the 2 new camshaft bearing cap oil hole gaskets to the No. 1 camshaft bearing cap.

  9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01186E

      Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surfaces.

    2. A0117SHE03
      Text in Illustration
      *1 Seal Packing
      *a Bead Diameter

      Apply seal packing as shown the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Bead diameter
      2.0 mm (0.0787 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head 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 the installation.

    3. A011BQBE01
      Text in Illustration
      *1 Seal Washer

      Temporarily install the cylinder head cover with 2 new seal washers and the 17 bolts.

    4. A0118R8

      Apply a light coat of engine oil to the O-rings of the No. 1 crankshaft position sensors.

    5. A011A0K

      Temporarily install the 2 No. 1 crankshaft position sensors with the 2 bolts.

    6. A011BQBE02

      Fully tighten the 20 bolts in the order shown in the illustration.

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

  10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    A011BX4E01
    *1 Stopper

    1. Install the V-ribbed belt tensioner and engine cover bracket with the 2 bolts.

      Note

      Attach stopper of the bracket to the auto tensioner.

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

  11. INSTALL NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)

    A0119MWE01

    1. Temporarily install the No. 2 idle pulley with the 4 bolts.

    2. Fully tighten the 4 bolts in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  12. INSTALL NO. 1 WATER BY-PASS PIPE

    A0118TEE01
    Text in Illustration
    *1 Water By-Pass Hose
    *2 No. 1 Water By-pass Pipe
    *3 No. 2 Water By-Pass Hose
    *4 Protector
    *5 Clip

    1. Connect the water by-pass hose to the water inlet with the clip.

      Note

      Install the clip so that its claws face away from the engine.

    2. Temporarily install the No. 1 water by-pass pipe with the 3 bolts.

    3. Fully tighten the 3 bolts in the order shown in the illustration.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    4. Engage the No. 2 water by-pass hose to the 3 clamps as shown in the illustration.

  13. INSTALL NO. 2 VENTILATION HOSE

    A0118CBE01
    Text in Illustration
    *a View A
    *b Upper
    *c Clip center installation range
    *d Paint mark of the hose

    1. Install the ventilation hose to the cylinder head with the clip.

      Note


      • Install the clip so that its claws are within the clip center installation range.

      • The protrusion of the head cover should overlap the paint mark of the hose.

  14. INSTALL VENTILATION HOSE

    A0117Y7E01
    Text in Illustration
    *a View A
    *b Left
    *c Rear
    *d Clip center installation range

    1. Install the ventilation hose to the cylinder head with the clip.

      Note

      Install the clip so that its claws are within the clip center installation range.

  15. INSTALL NO. 1 IGNITION COIL


    1. Install the 4 ignition coils with the 4 bolts.

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

  16. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the oil level dipstick guide.

      Tech Tips

      Apply engine oil to the O-ring and install the oil level dipstick guide into the oil pan.

    2. A011708E01

      Temporarily install the engine oil level dipstick guide with the 2 bolts.

    3. Fully tighten the 2 bolts in the order shown in the illustration.

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

  17. INSTALL ENGINE OIL LEVEL DIPSTICK

  18. INSTALL NO. 4 ENGINE WIRE


    1. Engage the 7 clamps and install the No. 4 engine wire.

    2. Install the ground bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    3. Connect the 4 fuel injector connectors.

    4. Connect the 4 ignition coil connectors.

    5. Connect the 2 camshaft timing oil control valve connectors.

  19. INSTALL INTAKE MANIFOLD ASSEMBLY


    1. Install a new No. 2 intake manifold to head gasket onto the cylinder head.

    2. Install the EGR delivery chamber onto the No. 2 intake manifold to head gasket.

    3. Install a new intake manifold to head gasket onto the EGR delivery chamber.

    4. A011BRYE01

      Temporarily install the intake manifold with the 5 bolts and 2 nuts.

    5. Fully tighten the 5 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  20. INSTALL EGR PIPE CONNECTOR


    1. Install 2 new EGR pipe gaskets onto the intake manifold and the EGR valve.

    2. A0118NGE01

      Temporarily install the EGR pipe connector with the 4 nuts.

    3. Fully tighten the A nuts first, and then tighten nut B.

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

  21. INSTALL INTAKE MANIFOLD STAY

    A011A6UE01

    1. Temporarily install the manifold stay with the bolt and nut.

    2. Fully tighten the bolt and nut in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  22. CONNECT NO. 4 WATER BY-PASS HOSE

    A0116XFE01
    Text in Illustration
    *a View A
    *b Upper
    *c Clip center installation range

    1. Connect the No. 4 water by-pass hose to the EGR valve with the clip.

      Note

      Install the clip so that its claws are within the clip center installation range.

  23. CONNECT NO. 2 WATER BY-PASS HOSE

    A0117I2E01
    Text in Illustration
    *a View A
    *b Upper
    *c Clip installation range
    *d Paint mark of the hose

    1. Connect the No. 2 water by-pass hose to the throttle body with the clip.

      Note


      • Install the clip so that its claws are within the clip installation range.

      • Line up the rib of the throttle with motor body assembly with the center of the paint mark.

  24. CONNECT VENTILATION HOSE

    A011BXFE01
    Text in Illustration
    *a View A
    *b Upper
    *c Left
    *d Clip center installation range

    1. Connect the ventilation hose to the intake manifold with the clip.

      Note

      Install the clip so that its claws are within the clip center installation range.

  25. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Install the new exhaust manifold to head gasket and the new inlet EGR gasket onto the cylinder head.

    2. A011B97E01

      Temporarily install the exhaust manifold converter with the 3 bolts and 4 nuts.

    3. Fully tighten the 3 bolts and 4 nuts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  26. INSTALL MANIFOLD STAY

    A011A6UE01

    1. Temporarily install the manifold stay with the bolt and nut.

    2. Fully tighten the bolt and nut in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  27. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    A011ARDE01

    1. Temporarily install the exhaust manifold heat insulator with the bolt and 2 nuts.

    2. Fully tighten the bolt and 2 nuts in the order shown in the illustration.

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

  28. INSTALL GENERATOR ASSEMBLY

    A011BS7E01

    1. Install the generator with the 2 bolts.

      Torque:
      Bolt A
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
      Bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  29. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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