OIL PUMP INSTALLATION


  1. INSTALL OIL PUMP ASSEMBLY


    1. A01ITKC

      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. A01ISFUE05

      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. A01IT5H

      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. A01ISIJ

      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. A01IROQE01

      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. A01IR8C

      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. A01INTIE01

      Temporarily install the crankshaft pulley with the pulley bolt.

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

      for 86 mm (3.39 in.) Bolt Pitch Type:

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      09330-00021
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

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

  4. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01IRR7E01

      Install the crankshaft timing sprocket as shown in the illustration.

  5. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01IOQ3

      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. A01IRSVE02
      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. A01IOS1E02
      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. A01IQZFE01
      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 plate (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. A01IN7UE03
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (Yellow or Pink)

      Align the mark plate (yellow or pink) and timing mark and install the chain to the crankshaft timing gear.

      Tech Tips

      The mark plate on the crankshaft side is colored yellow or pink.

  8. INSTALL CHAIN TENSIONER SLIPPER


    1. A01IP0L

      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.

      A01IO0KE02
      Text in Illustration
      *1 Timing Mark *2 Mark Plate (Orange)
      *3 Mark Plate (Yellow or Pink) - -

  10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01IOBZE03

      Install a new gasket.

      Note

      Remove any oil from the contact surface.

    2. A01IORK

      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.

      A01ISONE03
    4. A01IO6Z

      Install 3 new O-rings.

    5. Apply seal packing as shown in the illustration.

      A01IPIXE03
      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.

      A01IOERE04
      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. A01IU7T

      Temporarily install the engine mounting bracket with the 3 bolts.

      Note


      • Make sure that there is no oil on the threads of the bolts.

      • 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. A01ISTB

      Install 2 new O-rings.

    11. A01IPTE

      Temporarily install the oil filter bracket with the 4 bolts.

      Note


      • Make sure that there is no oil on the threads of the bolts.

      • 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. A01IRNAE07
      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

      Note

      Make sure that there is no oil on the threads of the bolts.

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

      A01IT15E01
      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


      • Make sure that there is no oil on the threads of the bolts.

      • 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.

      Standard Bolt
      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. A01IONUE01

      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. A01ITW6E01
      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.

      for 86 mm (3.39 in.) Bolt Pitch Type:

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      09330-00021
      Torque:
      190 N*m  { 1940 kgf*cm, 140 ft.*lbf }

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01IQX9E01

      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. A01IQBJ

      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. A01IOHLE01
      Text in Illustration
      *1 Release
      *2 Pin
      *3 Hook
      *4 Turn

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

    4. A01IRX6E01
      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. A01IP0ME01
      Text in Illustration
      *1 Part to Cut Off

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

    2. A01IS66E01
      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. A01IU5J

      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. A01IP7C

      Install 3 new gaskets to the camshaft bearing cap.

    2. A01IR75

      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. A01IUMW

      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 IGNITION COIL ASSEMBLY


    1. A01IRN7E01
      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. A01IO82

      Connect the 4 ignition coil connectors.

  18. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A01IO3SE05

      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.

  19. INSTALL WATER INLET


    1. A01IR3Q

      Install the water inlet with the 2 nuts.

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

  20. CONNECT WATER INLET HOSE


    1. A01IRVB

      Connect the water inlet hose to the water inlet housing.

  21. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A01IS6M

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

  22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01IU0I

      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.

  23. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine assembly with transaxle Click here.