Oil Pump Installation

Install a new gasket and the oil pump with the 3 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Set the crankshaft key in the left horizontal position.

Turn the cutout of the drive shaft so that it faces upward.

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

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

Temporarily tighten the oil pump drive shaft sprocket with the nut.

Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

Torque:

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

Align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.

Insert a 4 mm diameter bar into the adjusting hole on the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

Torque:

30 N*m{301 kgf*cm, 22 ft.*lbf}

Install the crankshaft timing gear or sprocket to the crankshaft.

Install the No. 1 chain vibration damper with the 2 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Set the No. 1 cylinder to TDC/compression.

1. Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks on the camshaft timing gear with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.
   





2. Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.
   

Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

Using SST and a hammer, tap in the crankshaft timing sprocket.

SST

09309-37010

Align the gold or yellow links with the timing marks located on the camshaft timing gear and sprocket, then install the chain.

Install the chain tensioner slipper with the bolt.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the timing chain guide with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the sensor plate with the "F" mark facing forward.

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

SST

09223-22010

NOTICE:

1. Keep the lip free from foreign matter.
   
2. Do not tap the oil seal at an angle.
   

Apply MP grease to the lip of the oil seal.

Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the chain cover within 3 minutes of applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installing the chain cover.
   

Apply a continuous bead of seal packing as shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the chain cover within 3 minutes of applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installing the chain cover.
   

Apply adhesive to the threads of the bolt A.

Seal packing:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Temporarily install the timing chain cover with the 12 bolts and 2 nuts.

Bolt length:

Item	Length
Bolt A	30 mm (1.18 in.) length for 10 mm head
Bolt B	30 mm (1.18 in.) length for 12 mm head
Bolt C	40 mm (1.57 in.) length for 14 mm head

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

Fully tighten the timing chain cover with the 15 bolts and 2 nuts as shown in the illustration.

Torque:

Bolt A:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Bolt B:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Bolt C:

55 N*m{561 kgf*cm, 41 ft.*lbf}

Nut:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.

Torque:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Release the ratchet pawl, then fully push in the plunger and set the hook to the pin so that the plunger is in the position shown in the illustration.

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

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

NOTICE:

When installing the chain tensioner, set the hook again if the hook releases the plunger.

Temporarily install the V-ribbed belt tensioner assembly with the nut.

Slightly push down on the V-ribbed belt tensioner assembly at part (A) to align the holes of the engine and tensioner as shown in the illustration, and temporarily install the bolt .

Tighten the bolt and nut to install the V-ribbed belt tensioner.

Torque:

60 N*m{612 kgf*cm, 44 ft.*lbf}

NOTICE:

1. When replacing the V-ribbed belt tensioner with a new one, do not pull out the pin.
   
2. The pin will be removed in a later step.
   

Using SST, fix the crankshaft pulley in place and tighten the bolt.

SST

09213-54015(91651-60855)
09330-00021

Torque:

180 N*m{1835 kgf*cm, 133 ft.*lbf}

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 to 4.5 mm (0.158 to 0.177 in.)) as shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the oil pan within 3 minutes of applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the oil pan onto the cylinder block.

Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Place a wooden block between a floor jack and the engine, then support the engine using the floor jack.

Remove the chain block and sling device.

Remove the 2 bolts and engine hangers.

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

Install the crank position sensor with the bolt.

Torque:

9.0 N*m{90 kgf*cm, 80 in.*lbf}

NOTICE:

Do not twist the O-ring.

Install the wire harness and crank position sensor connector clamp.

Connect the crank position sensor connector.

Install the idler pulley sub-assembly with the 2 bolts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Install the engine mounting insulator sub-assembly RH with the 4 bolts and 2 nuts.

Torque:

Bolt A:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Bolt B:

95 N*m{969 kgf*cm, 70 ft.*lbf}

Nut A:

95 N*m{969 kgf*cm, 70 ft.*lbf}

Nut B:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Install a new gasket.

Install the exhaust manifold converter sub-assembly with the 5 nuts in the order shown in the illustration.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

Torque:

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

Install the No. 2 manifold stay with the bolt and nut.

Torque:

44 N*m{449 kgf*cm, 33 ft.*lbf}

Install the manifold stay with the bolt and nut.

Torque:

44 N*m{449 kgf*cm, 33 ft.*lbf}

Install the No. 1 intake manifold insulator onto the cylinder block.

Install a new gasket into the intake manifold.

Install the intake manifold with the 5 bolts and 2 nuts.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Fit the union to connector tube hose into the vacuum hose clamp.

Install the wire harness clamp.

Connect the camshaft timing oil control valve connector.

Connect the union to connector tube hose to the No. 2 hose to hose tube.

Apply a light coat of engine oil to a new O-ring and install it onto the camshaft timing oil control valve assembly.

Install the camshaft timing oil control valve assembly with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Connect the camshaft timing oil control valve connector.

Install the vacuum hose clamp with the bolt.

Install 4 new insulators to the cylinder head.

Install the 2 delivery pipe spacers onto the cylinder head.

Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 2 bolts.

NOTICE:

Be careful not to drop the fuel injectors when installing the fuel delivery pipe.

Check that the fuel injector rotates smoothly.
If the fuel injector does not rotate smoothly, replace the O-ring.

Tighten the 2 bolts to the specified torque.

Torque:

20 N*m{205 kgf*cm, 15 ft.*lbf}

Connect the 4 fuel injector connectors.

Install the 2 wire harness clamps.

Connect the fuel main tube.

Push the fuel tube connector until it makes a "click" sound.

Install the fuel pipe clamp.

Install the fuel tube to the fuel hose clamp.

Apply a light coat of engine oil to a new O-ring and install it onto the engine oil level dipstick guide.

Install the engine oil level dipstick guide with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Remove any old packing material from the contact surface.

Apply seal packing to the 2 locations shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan within 3 minutes of applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the cylinder head cover gasket and sub-assembly with the 8 bolts and 2 nuts.

Torque:

Bolt A:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Bolt B:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Nut:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Install the 2 engine wire harness brackets with the 2 bolts.

Torque:

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

Connect the 2 ventilation hoses to the cylinder head cover.

Install the 4 spark plugs.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the 4 ignition coils with the 4 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Connect the 4 ignition coil connectors.

Install a new gasket onto the intake manifold.

Install the throttle body assembly with the 4 bolts.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Connect the throttle body connector.

Connect the 2 water by-pass hoses.

Install the air cleaner cap sub-assembly with hose and lock the 3 clamps.

Tighten the air cleaner hose clamp.

Connect the ventilation hose.

Connect the 2 vacuum hoses and No. 1 vacuum switching valve connector.

Connect the 2 wire harness clamps and the mass air flow meter connector.

Install the radiator reserve tank assembly with the 3 bolts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Connect the inlet heater water hose with the clamp.

Connect the outlet heater water hose with the clamp.

Connect the No. 1 radiator hose with the clamp.

Install the wire harness clamp bracket with the bolt.

Install the generator assembly with the 2 bolts.

Torque:

Bolt A:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Bolt B:

21 N*m{215 kgf*cm, 16 ft.*lbf}

Install the wire harness to terminal B with the nut.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Attach the clamp and connect the generator connector to the generator.

Install the 2 wire harness clamps.

Using SST, slowly turn the V-ribbed belt tensioner clockwise and install the V-ribbed belt.

SST

09216-42010(09216-04010)

NOTICE:

1. Make sure that SST and other tools are set to the tensioner securely.
   
2. When compressing the V-ribbed belt tensioner, slowly turn the tensioner.
   

Using a vernier caliper, measure the free length of the compression springs.

HINT:

If the free length is less than the minimum, replace the compression spring.

Remove the remains of exhaust manifold converter with wire brash.

Fully insert a new gasket to the exhaust manifold.

NOTICE:

1. Be sure to install the gasket in the correct direction.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   

Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.

Torque:

43 N*m{440 kgf*cm, 32 ft.*lbf}

Connect the heated oxygen sensor connector.

Using a vernier caliper, measure the free length of the compression springs.

HINT:

If the free length is less than the minimum, replace the compression spring.

Fully insert a new gasket to the center exhaust pipe assembly.

NOTICE:

1. Be sure to install the gasket in the correct direction.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   

Install a new gasket to the front exhaust pipe assembly.

Connect the center exhaust pipe assembly to the 2 exhaust pipe supports.

Install the center exhaust pipe assembly with the 4 bolts and 2 compression springs.

Torque:

43 N*m{440 kgf*cm, 32 ft.*lbf}

Add fresh engine oil and install the oil filler cap.

Tighten the lower radiator drain cock plug.

Tighten the cylinder block drain cock plug.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Loosen the upper radiator drain cock plug.

Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Standard Capacity:

Item	Capacity
Engine coolant	5.7 liters (6.0 US qts, 5.0 lmp. qts)

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   
2. Contact your TOYOTA dealer for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.

Tighten the upper radiator drain cock plug.

Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

Install the radiator cap sub-assembly and reservoir tank cap.

Start the engine and warm it up.

Bleed air from the cooling system.

NOTICE:

1. Before starting the engine, turn the A/C switch off.
   
2. Adjust the air conditioning temperature setting to MAX (HOT).
   
3. Adjust the air conditioning blower setting to LO.
   

1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
   

   HINT:

   Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

   CAUTION:

   When squeezing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

Stop the engine, and wait until the engine coolant cools down.

Add engine coolant to the FULL line on the radiator reservoir.

Check fuel pump operation.

1. Connect the Techstream to the DLC3.
   

2. Turn the ignition switch to ON and turn the Techstream on.
   

   NOTICE:

   Do not start the engine.

3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
   

4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.
   

Check for fuel leaks.

1. There is no fuel leakage after performing maintenance anywhere on the fuel system. If there is a fuel leak, repair or replace parts as necessary.
   

Turn the ignition switch off.

Disconnect the Techstream from the DLC3.

Fill the radiator assembly with engine coolant, then attach a radiator cap tester.

Pump the tester to 118 kPa (1.2 kgf/cm², 17.1 psi), then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and water pump assembly for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

Warm up and stop the engine.

When using the Techstream:

1. Connect the Techstream to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Turn the Techstream on.
   

4. Enter the following menus: Power Train / Engine and ECT / Data List / IGN Advance
   

5. Start the engine.
   

6. According to the display on the Techstream, read the Data List.
   

   Standard ignition timing:

   5 to 15° BTDC at idle
   

7. Check that the ignition timing advances immediately when the engine speed is increased.
   

8. Turn the ignition switch off.
   

9. Disconnect the Techstream from the DLC3.
   

When not using the Techstream:

1. Remove the No. 1 engine cover sub-assembly (COROLLA_ZRE142 RM000001BC301CX_01_0101.html).
   





2. Open the ignition cover located to the right of the No. 4 ignition coil.
   

3. Pull the wire harness out from the IG cover.
   

4. Connect the timing light to the wire harness.
   

   NOTICE:

   Use a timing light that detects the primary signal.





5. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
   

   SST

   09843-18040
   

6. Allow the engine to idle and check the ignition timing.
   

   Standard ignition timing:

   8 to 12° BTDC at idle
   

   HINT:

   Run the engine at 1000 to 1300 rpm for 5 seconds, then check that the engine speed returns to idle speed.

7. Disconnect SST from terminals 13 (TC) and 4 (CG) of the DLC3.
   

8. Allow the engine to idle and check the ignition timing.
   

   Standard ignition timing:

   5 to 15° BTDC at idle
   

9. Check that the ignition timing advances immediately when the engine speed is increased.
   

10. Turn the ignition switch off.
    

11. Remove the timing light.
    

12. Close the IG cover.
    

13. Install the No. 1 engine cover sub-assembly (COROLLA_ZRE142 RM000001BC101CX_01_0268.html).
    

Warm up and stop the engine.

When using the Techstream:

1. Connect the Techstream to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Turn the Techstream on.
   

4. Enter the following menus: Power Train / Engine and ECT / Data List / Engine Speed
   

5. Start the engine.
   

6. According to the display on the Techstream, read the Data List.
   

   Standard idle speed:

   600 to 700 rpm
   

7. Turn the ignition switch off.
   

8. Disconnect the Techstream from the DLC3.
   

When not using the Techstream:

1. Turn off all the accessories and air conditioning.
   

2. Move the shift lever to P or neutral.
   





3. Connect SST to 9 (TAC) of the DLC3 terminal, and then connect a tachometer to SST.
   

   SST

   09843-18030
   

4. Start the engine.
   

5. Check the idle speed with the cooling fan off.
   

   Standard idle speed:

   600 to 700 rpm
   

6. Turn the ignition switch off.
   

7. Remove the tachometer and disconnect SST from the DLC3.
   

Warm up and stop the engine.

Remove the 4 ignition coils and spark plugs (COROLLA_ZRE142 RM000001QVM03MX.html).

Disconnect the 4 fuel injector connectors.

Insert the compression gauge into the spark plug hole.

Fully open the throttle.

While cranking the engine, measure the compression pressure.

Standard compression pressure:

1300 kPa (13.3 kgf/cm², 189 psi)

Minimum compression pressure:

1000 kPa (10.0 kgf/cm², 145 psi)

Standard difference between each cylinder:

100 kPa (1.0 kgf/cm², 15 psi) or less

NOTICE:

1. Always use a fully-charged battery to obtain an engine speed of 250 rpm or more.
   
2. Check the other cylinders in the same way.
   
3. This measurement must be done as quickly as possible.
   

HINT:

1. If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
   
2. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket.
   

Connect the 4 fuel injector connectors.

Install the 4 spark plugs and ignition coils (COROLLA_ZRE142 RM000001QVK03PX.html).

Start and warm up the engine.

Run the engine at 2500 rpm for approximately 180 seconds.

Insert the CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe while idling.

Inspect the CO/HC concentration during idle at 2500 rpm.
If the CO/HC concentration does not comply with local regulations, troubleshoot in the order given below.

1. Check the A/F sensor and heated oxygen sensor operation.
   

2. See the table below for possible causes, then inspect the applicable parts and repair them if necessary.
   
   

   
   

   CO	HC	Problem	Possible Cause
   Normal	High	Rough idle	1. Faulty ignition: - Incorrect timing - Plugs are contaminated, shorted, or gaps are defective 2. Incorrect valve clearance 3. Leaks in intake and exhaust valve 4. Leaks in cylinders
   Low	High	Rough idle (Fluctuating HC reading)	1. Vacuum leakage: - Ventilation hoses - Intake manifold - Throttle body - Brake booster line 2. Lean mixture causing misfire
   High	High	Rough idle (Black smoke from exhaust)	1. Restricted air filter 2. Plugged PCV valve 3. Faulty EFI system: - Faulty pressure regulator - Faulty engine coolant temperature sensor - Faulty mass air flow meter - Faulty ECM - Faulty injectors - Faulty throttle body

Fully tighten the 2 nuts.

Torque:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Install the outer cowl top panel with the 12 bolts.

Torque:

8.8 N*m{90 kgf*cm, 78 in.*lbf}

Engage the clamp.

Bend the water guard plate RH as shown in the illustration, and engage the clamp.

Bend the No. 1 heater air duct splash shield seal as shown in the illustration, and engage the clamp.

Install the windshield wiper motor and link assembly with the 2 bolts.

Torque:

5.5 N*m{56 kgf*cm, 49 in.*lbf}

Connect the connector.

Engage the clip and 8 claws to install the cowl top ventilator louver LH.

Engage the clip and 14 claws to install the center No. 1 cowl top ventilator louver.

Engage the 7 clips to install the hood to cowl top seal.

Operate the front wipers and stop the windshield wiper motor at the automatic stop position.

Clean the wiper arm serrations.

When reinstalling:

1. Clean the wiper pivot serrations with a wire brush.
   

Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

HINT:

Hold the arm hinge by hand while fastening the nut.

Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body.

Operate the wiper and stop the windshield wiper motor at the automatic stop position.

Clean the wiper arm serrations.

When reinstalling:

1. Clean the wiper pivot serrations with a wire brush.
   

Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

HINT:

Hold the arm hinge by hand while fastening the nut.

Install the 2 front wiper arm head caps.

Install the No. 1 engine cover sub-assembly with the 2 nuts.