OIL PUMP INSTALLATION


  1. INSTALL OIL PUMP ASSEMBLY


    1. A00DUXT

      Install the oil pump with the 3 bolts.

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

  2. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00DQ9GE05

      Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

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

      Application Specification
      Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing
      A - A 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.)
      B - B -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the oil pan.

    3. A00DRAC

      Install the No. 2 oil pan with the 10 bolts and 2 nuts.

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

  3. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. A00DS3T

      Temporarily install the crankshaft pulley bolt.

    2. Set the crankshaft key as shown in the illustration.

    3. Turn the drive shaft so that the cutout faces upward.

    4. Remove the crankshaft pulley bolt.

    5. A00DQ1SE01

      Align the yellow mark plates with the timing mark of each gear as shown in the illustration.

    6. Install the gears onto the crankshaft and oil pump shaft with the chain on the gears.

    7. Temporarily install the oil pump drive shaft gear with the nut.

    8. A00DRMW

      Install the damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. A00DRCSE01

      Temporarily install the crankshaft pulley with the pulley bolt.

    10. Using SST, hold the crankshaft. Then tighten the drive shaft gear nut.

      SST
      09330-00021
      09213-58014   ( 91551-80840 )
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    11. Remove SST, the crankshaft pulley bolt and crankshaft pulley.

  4. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A00DQQJE01

      Install the crankshaft timing sprocket as shown in the illustration.

  5. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A00DS1L

      Install the chain vibration damper with the 2 bolts.

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

  6. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A00DS2FE02
      Text in Illustration
      *1 Timing Gear Key

      Temporarily install the crankshaft pulley bolt.

    2. Turn the crankshaft counterclockwise to position the timing gear key at the top.

    3. A00DSWBE02
      Text in Illustration
      *1 Timing Mark

      Check that the timing marks on the camshaft timing gears are aligned as shown in the illustration.

    4. Remove the crankshaft pulley bolt.

  7. INSTALL CHAIN SUB-ASSEMBLY


    1. A00DTG8E01
      Text in Illustration
      *1 Mark Plate (Orange)
      *2 Timing Mark

      Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

      Tech Tips


      • Be sure to position the mark plate at the front of the engine.

      • The mark plate on the camshaft side is colored orange.

      • Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.

      • Pass the chain through the No. 1 vibration damper.

    2. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plates (orange) and timing mark, and then install the chain.

    3. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.

      Tech Tips

      To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.

    4. A00DTBOE03
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (Pink)

      Align the mark plates (pink) and timing marks and install the chain to the crankshaft timing gear.

      Tech Tips

      The mark plates on the crankshaft side are colored pink.

  8. INSTALL CHAIN TENSIONER SLIPPER


    1. A00DS61

      Install the chain tensioner slipper to the cylinder block.

  9. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Check each timing mark at TDC/compression.

      A00DRWME02
      Text in Illustration
      *1 Timing Mark *2 Mark Plate (Orange)
      *3 Mark Plate (Pink) -

  10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A00DU13E03

      Install a new gasket.

      Note

      Remove any oil from the contact surface.

    2. A00DQKR

      Install the water pump with the 3 bolts.

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

    3. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head, camshaft housing, stiffening crankcase and cylinder block.

      A00DTT9E03
    4. A00DQMC

      Install 3 new O-rings.

    5. Apply seal packing as shown in the illustration.

      A00DTFGE03
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the timing chain cover.

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

      A00DPROE01
      Seal Packing
      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Application Specification
      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.0 mm (0.0984 to 0.118 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -
      A - A 2.5 to 3.0 mm (0.0984 to 0.118 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      B - B 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Opposite edge of seal packing

      5.0 mm (0.197 in.)

      		 - -
      C - C 7.0 to 8.0 mm (0.276 to 0.315 in.)

      Opposite edge of seal packing

      7.5 mm (0.295 in.)

      		 - -
      F 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.5 mm (0.610 in.) 50.4 mm (1.98 in.)
      G 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 143.1 mm (5.63 in.)
      H 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 153.4 mm (6.04 in.)
      I 4.5 to 5.5 mm (0.177 to 0.217 in.) - 16.0 mm (0.630 in.) 385.8 mm (1.27 ft.)
      J 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      K 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 121.9 mm (4.80 in.)
      L 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 147.2 mm (5.80 in.)
      M 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.1 mm (0.201 in.) 173.0 mm (6.81 in.)
      N 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 385.8 mm (1.27 ft.)
      O 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -

      Note


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

      • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.

      • Do not add engine oil for at least 2 hours after installation.

    7. Clean the bolts and their installation holes.

    8. Install the timing chain cover.

    9. A00DRLH

      Temporarily install the engine mounting bracket with the 3 bolts.

      Note


      • Install the mounting bracket within 10 minutes after installing the timing chain cover.

      • Do not add engine oil for at least 2 hours after installation.

    10. A00DPKQ

      Install 2 new O-rings.

    11. A00DUZI

      Temporarily install the oil filter bracket with the 4 bolts.

      Note


      • Install the oil filter bracket within 10 minutes after installing the timing chain cover.

      • Do not add engine oil for at least 2 hours after installation.

    12. A00DQ3SE07
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 5 and a half threads or more of the end of bolt E.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the timing chain cover with the 26 bolts and seal washer in the order shown in the illustration.

      A00DQ8WE01
      Torque:
      for bolt A, E
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }
      for bolt B
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt C
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


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

      • Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying the seal packing.

      • Do not add engine oil for at least 2 hours after installation.

      Bolt Length
      Item Length Thread Diameter
      Bolt A, E 35 mm (1.38 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt C 80 mm (3.15 in.) 10 mm (0.394 in.)
      Bolt D 40 mm (1.57 in.) 6 mm (0.236 in.)

      Tech Tips

      Apply adhesive to bolt E before installing it.

  11. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A00DR6QE01

      Apply MP grease to the lip of a new 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.

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

      SST
      09223-22010

      Note


      • Wipe off any extra grease from the crankshaft.

      • Do not tap in the oil seal at an angle.

  12. INSTALL CRANKSHAFT PULLEY


    1. A00DQCVE01
      Text in Illustration
      *1 Hold
      *2 Turn

      Align the key groove of the pulley with the pulley set key.

    2. Temporarily install the pulley with the pulley bolt.

    3. Using SST, hold the pulley in place and tighten the bolt.

      SST
      09330-00021
      09213-58014   ( 91551-80840 )
      Torque:
      190 N*m  { 1940 kgf*cm, 140 ft.*lbf }

  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00DUQOE01

      Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

      Note

      Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

    2. A00DPIV

      Install a new gasket, the chain tensioner and bracket with the 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

    3. A00DPZBE01
      Text in Illustration
      *1 Release
      *2 Pin
      *3 Hook
      *4 Turn

      Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.

    4. A00DUECE01
      Text in Illustration
      *1 Plunger
      *2 Plunger Extended
      *3 Turn

      Turn the crankshaft clockwise and check that the plunger is extended.

  14. INSTALL SPARK PLUG TUBE GASKET


    1. A00DU3AE01
      Text in Illustration
      *1 Part to Cut Off

      Using a cutter knife, cut off the seal part of the removed gasket.

    2. A00DU33E02
      Text in Illustration
      *1 Plug Tube Gasket without Sealing Part
      *2 New Plug Tube Gasket
      *3 Claw

      Using a hammer and a plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.

      Tech Tips

      If a plug tube gasket that will be used to install a new gasket is deformed and cannot be positioned on a new gasket, correct the deformation using pliers.

      Note


      • Keep the lip free of foreign matter.

      • Do not tap in the plug tube gasket at an angle.

    3. Return the claws of the ventilation baffle plate to their original positions.

  15. INSTALL CYLINDER HEAD COVER GASKET


    1. A00DQEY

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

      Note

      Remove any oil from the contact surfaces.

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00DSLL

      Install 3 new gaskets to the camshaft bearing cap.

    2. A00DQZZ

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard diameter
      4.0 mm (0.157 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover sub-assembly 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. A00DQSC

      Install the cylinder head cover with a new seal washer and the 13 bolts.

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

  17. INSTALL RADIO SETTING CONDENSER


    1. A005TG3

      Install the setting condenser with the bolt.

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

  18. INSTALL IGNITION COIL ASSEMBLY


    1. A005RTQE01
      Text in Illustration
      *1 Cylinder Head Cover
      *2 Spark Plug Tube
      *3 Plug Cap

      Install the 4 ignition coils with the 4 bolts.

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

      Note

      When installing the ignition coil, do not damage the plug cap with the cylinder head cover opening or the upper edge of the spark plug tube.

    2. A005T4M

      Connect the 4 ignition coil connectors.

  19. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A005VE6E05

      Install the thermostat to the water inlet.

      Note

      The jiggle valve must be set within 10° on either side of the position shown in the illustration.

  20. INSTALL WATER INLET


    1. A005S2M

      Install the water inlet with the 2 nuts.

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

  21. CONNECT WATER INLET HOSE


    1. A00DU85

      Connect the water inlet hose to the water inlet housing.

  22. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A00DS82

      Connect the No. 3 water by-pass hose to the water inlet housing.

  23. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A005S94

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

    2. Install the O-ring to the dipstick guide.

    3. Install the dipstick guide with the bolt.

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

    4. Install the engine oil level dipstick.

  24. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine assembly with transaxle Click here.