INSTALL OIL PUMP ASSEMBLY
Install the oil pump with the 3 bolts.
INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
Apply a continuous bead of seal packing (Diameter 4.0 mm (0.157 in.)) 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 oil pan within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing the oil pan.
Install the No. 2 oil pan with the 10 bolts and 2 nuts.
INSTALL OIL PAN DRAIN PLUG
Install a new gasket and the drain plug.
INSTALL CRANKSHAFT TIMING GEAR KEY
Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.
Tech Tips
Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
Install the crankshaft position sensor plate with the "F" mark facing forward.
INSTALL NO. 2 CHAIN SUB-ASSEMBLY
Temporarily install the crankshaft pulley bolt.
Turn the crankshaft counterclockwise to position the timing gear key to the 9 o'clock position.
Turn the drive shaft so that the cutout faces the 12 o'clock position.
| *1 | Front |
| *2 | Mark Plate (Yellow) |
| *3 | Timing Mark |
| *4 | Oil Pump Drive Gear |
| *5 | Oil Pump Drive Shaft Gear |
Align the yellow mark links with the timing marks of each gear as shown in the illustration.
Tech Tips
Be sure to position the mark plate at the front of the engine.
Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.
Temporarily tighten the oil pump drive shaft gear with the nut.
Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.
Temporarily tighten the crankshaft pulley with the bolt.
Using SST, install the oil pump drive shaft gear nut while holding the crankshaft pulley.
Remove the crankshaft pulley and bolt.
INSTALL CRANKSHAFT TIMING SPROCKET
Install the crankshaft timing sprocket.
INSTALL NO. 1 CHAIN VIBRATION DAMPER
Install the chain vibration damper with the 2 bolts.
SET NO. 1 CYLINDER TO TDC / COMPRESSION
| *1 | Timing Gear Key |
Temporarily install the crankshaft pulley bolt.
Turn the crankshaft to position the timing gear key to the top.
| *1 | Timing Mark (Rectangle) |
| *2 | Timing Mark |
| *3 | Mark (Circle) |
Check that the timing marks on the camshaft timing gear and camshaft timing sprocket are aligned as shown in the illustration.
Tech Tips
There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.
Remove the crankshaft pulley bolt.
INSTALL CHAIN SUB-ASSEMBLY
| *1 | Mark Plate (Orange) |
| *2 | Timing Mark (Rectangle) |
| *3 | Mark (Circle) |
| *a | Place the Chain on the Sprocket |
| *b | Pass the Chain through the Damper |
Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.
Tech Tips
There are 3 marks on the camshaft timing sprocket. Make sure to align the mark plate with the timing mark (rectangle).
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.
Place the chain on the crankshaft without passing it around the shaft.
| *1 | Mark Plate (Orange) |
| *2 | Timing Mark |
| *a | Tension the Chain |
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain.
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.
| *1 | Mark Plate (Yellow or Pink) |
| *2 | Timing Mark |
Align the mark plate (yellow or pink) and timing mark and install the chain to the crankshaft timing gear.
CHECK NO. 1 CYLINDER TO TDC / COMPRESSION
Check each timing mark at TDC/compression.
| *1 | Timing Mark | *2 | Mark Plate (Orange) |
| *3 | Mark Plate (Yellow or Pink) | *4 | Timing Mark (Rectangle) |
| *5 | Mark (Circle) | - | - |
Tech Tips
There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.
INSTALL CHAIN TENSIONER SLIPPER
Install the chain tensioner slipper to the cylinder block.
INSTALL NO. 2 CHAIN VIBRATION DAMPER
Install the No. 2 chain vibration damper with the 2 bolts.
INSTALL TIMING CHAIN COVER OIL SEAL
Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
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.
Tech Tips
Tap in the oil seal so that it is positioned within 1.0 mm from the edge of the timing chain case.
Apply MP grease to the lip of the oil seal.
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
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, and cylinder block.
Install 3 new O-rings.
Apply seal packing as shown in the illustration.
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Seal diameter |
|---|
| 5.0 mm (0.197 in.) |
Note
Remove any oil from the contact surfaces.
Install the chain cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.
Apply seal packing to the timing chain cover in a line as shown in the following illustration.
Note
When the contact surfaces are wet, wipe them with 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 installation.
| Seal Packing | |||||||
|---|---|---|---|---|---|---|---|
|
| Application Specification | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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|
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.
Clean the bolt and fitting hole.
Install the timing chain cover.
Temporarily tighten the engine mounting bracket RH with the 3 bolts.
Note
Install the mounting bracket within 10 minutes after installing the chain cover.
Do not start the engine for at least 2 hours after installation.
| Bolt Length | ||||
|---|---|---|---|---|
|
Install 2 new O-rings.
Temporarily tighten the oil filter bracket with the 4 bolts.
Note
Install the oil filter bracket within 10 minutes after installing the chain cover.
Do not start the engine for at least 2 hours after installation.
| Bolt Length | ||||
|---|---|---|---|---|
|
Install the timing chain cover with the 25 bolts and seal washer as shown in the illustration.
| *1 | Seal Washer | - | - |
Note
Apply adhesive 1324 to screw part of the bolt F.
When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying the seal packing.
Do not add engine oil for at least 2 hours after installing the chain cover.
Do not start the engine for at least 2 hours after installing the chain cover.
| Bolt Length | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
INSTALL CRANKSHAFT PULLEY
Align the pulley set key with the key groove of the pulley.
| *a | Hold |
| *b | Turn |
Using SST, hold the pulley in place and tighten the bolt.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
| *1 | Cam |
| *2 | Pin |
| *3 | Hook |
| *a | Push |
| *b | Raise |
| *c | CORRECT |
| *d | INCORRECT |
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.
Install a new gasket, the bracket and chain tensioner with the 2 nuts.
Note
If the hook releases the plunger while the chain tensioner is being installed, set the hook again.
| *1 | Pin |
| *2 | Hook |
| *a | Push |
| *b | Turn |
| *c | Disconnect |
Rotate the crankshaft counterclockwise slightly and check that the hook becomes released.
| *1 | Plunger |
| *a | Turn |
| *b | Plunger Extended |
Turn the crankshaft clockwise and check that the plunger is extended.
INSTALL SPARK PLUG TUBE GASKET
Using a cutter knife, cut off the seal part of the removed gasket.
|
Part to Cut Off |
| *1 | Plug Tube Gasket without Sealing Part |
| *2 | New Plug Tube Gasket |
Using a hammer and the plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.
Note
Keep the lip free of foreign matter.
Do not tap in the plug tube gasket.
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.
Return the claws of the ventilation baffle plate to their original positions.
INSTALL CYLINDER HEAD COVER GASKET
| *1 | Cylinder Head Cover |
| *2 | Cylinder Head Cover Gasket |
Install a new cylinder head cover gasket to the cylinder head cover.
Note
Remove any oil from the contact surfaces.
Misalignment between the center of the cylinder head cover rib and the center of the cylinder head gasket tab is within 4 mm (0.157 in.).
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Install 2 new gaskets to the camshaft bearing cap.
Apply seal packing as shown 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 of applying seal packing.
Do not start the engine for at least 2 hours after the installation.
| *1 | Timing Chain Cover |
| *2 | Camshaft Housing |
| *3 | Cylinder Head Cover Gasket |
Install the cylinder head cover with a new seal washer and the 13 bolts.
Note
Misalignment between the contact surfaces of the timing chain cover and the camshaft housing and the center of the cylinder head gasket tab is within 4 mm (0.157 in.).
INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
Install a new gasket on the water inlet with thermostat sub-assembly.
Install the water inlet with thermostat sub-assembly with the 2 nuts and bolt.
| *1 | No. 2 Radiator Hose |
| *2 | No. 3 Water By-pass Hose |
Connect the No. 2 radiator hose and No. 3 water by-pass hose.
INSTALL FUEL INJECTOR ASSEMBLY
| *1 | O-ring |
| *2 | Insulator |
Install a new insulator and O-ring to each fuel injector assembly.
Apply a light coat of gasoline or spindle oil to the contact surfaces of the new O-ring on each fuel injector assembly.
While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe sub-assembly.
Note
Do not damage the fuel injector assembly or O-ring.
Do not twist the O-ring.
After installing each fuel injector, check that it turns smoothly. If not, replace the O-ring with a new one.
INSTALL NO. 1 DELIVERY PIPE SPACER
| *a | Delivery Pipe Side |
| *b | Cylinder Head Side |
Install the 2 No. 1 delivery pipe spacers onto the cylinder head.
Note
Install the No. 1 delivery pipe spacers in the correct direction.
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts.
Note
Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.
Install the bolt to secure the fuel delivery pipe sub-assembly.
INSTALL FUEL VAPOR FEED PIPE
Install the fuel vapor feed pipe with the bolt.
INSTALL INTAKE MANIFOLD
Install a new No. 1 intake manifold to head gasket to the intake manifold.
Install the intake manifold with the 2 bolts and 2 nuts.
Connect the fuel vapor feed hose and ventilation hose.
Install a new O-ring to the engine oil level dipstick guide sub-assembly.
Apply a light coat of engine oil to the O-ring.
Install the engine oil level dipstick guide sub-assembly with the 2 bolts and connect the wire harness clamp.
Install the engine oil level dipstick.
Connect the 2 wire harness clamps and 3 connectors.
INSTALL EGR COOLER SUB-ASSEMBLY
| *A | Nut (C), Type A |
| *B | Nut (C), Type B |
| *1 | Bolt |
| *2 | Stud Bolt and Nut |
Temporarily install a new gasket and the EGR cooler sub-assembly with the 2 nuts (A).
Install 2 new gaskets and set the EGR valve with cooler assembly in place.
Using an E8 "TORX" wrench, install the 4 stud bolts.
Temporarily install the 4 nuts (B and C) and bolt.
Tighten the 2 nuts (A).
Tighten the 2 nuts (B) and bolt.
Note
Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.
Tighten the 2 nuts (C).
Connect the connector, wire harness clamp and 4 water hoses.
INSTALL EGR VALVE ASSEMBLY
| *A | Nut (C), Type A |
| *B | Nut (C), Type B |
| *1 | Bolt |
| *2 | Stud Bolt and Nut |
Temporarily install a new gasket and the EGR valve assembly with the 2 nuts (A).
Install 2 new gaskets and set the EGR valve with cooler assembly in place.
Using an E8 "TORX" wrench, install the 4 stud bolts.
Temporarily install the 4 nuts (B and C) and bolt.
Tighten the 2 nuts (A).
Tighten the 2 nuts (B) and bolt.
Note
Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.
Tighten the 2 nuts (C).
Connect the connector, wire harness clamp and 4 water hoses.
INSTALL EGR PIPE ASSEMBLY
Install 2 new gaskets and EGR pipe assembly with the 4 bolts.
Note
Make sure to tighten the 4 bolts evenly until the flanges of the EGR pipe assembly contact with the installation surfaces.
Install the wire harness support with the bolt.
Connect the 2 wire harness clamps.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Apply a light coat of engine oil to a new O-ring.
Install the O-ring to the engine oil level dipstick guide.
Install the engine oil level dipstick guide with the 2 bolts.
Connect the clamp to the engine oil level dipstick guide.
Install the oil dipstick.
INSTALL THROTTLE BODY ASSEMBLY
Install a new gasket onto the intake manifold.
Install the throttle body assembly with the 2 bolts and 2 nuts.
Connect the 2 water by-pass hoses and throttle body connector.
INSTALL ENGINE HANGERS
Install the 2 engine hangers with the 2 bolts.
| Part Name | Part No. |
|---|---|
| No. 1 engine hanger | 12281-37021 |
| No. 2 engine hanger | 12282-37011 |
| Bolt | 91552-81050 |
REMOVE ENGINE ON ENGINE STAND
Remove the bolts and engine on engine stand.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE