Oil Pump Installation

Install a new gasket and the engine water pump with the 8 bolts.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Install 3 new O-rings to the timing chain cover as shown in the illustration.

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

Seal packing:

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

Application Specification:

Area	Seal Packing Diameter	Distance from Edge of Cover to Center of Seal Packing	Seal Packing Application Length	Protrusion from Cylinder Head
A - A (Dashed line)	2.5 to 4.0 mm (0.0984 to 0.157 in.)	2.0 mm (0.0787 in.)	-	-
B - B (Continuous line)	10 to 14 mm (0.394 to 0.551 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick	6.0 mm (0.236 in.)	46 mm (1.81 in.) from top of bolt hole	-
C - C (Continuous line)	10 to 14 mm (0.394 to 0.551 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick	6.0 mm (0.236 in.)	54 mm (2.13 in.) from top of bolt hole	-
D - D (Continuous line)	9.0 to 13 mm (0.354 to 0.512 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick	-	13 mm (0.512 in.) from top of bolt hole	-
E - E (Continuous line)	9.0 to 13 mm (0.354 to 0.512 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick	-	13 mm (0.512 in.) from top of bolt hole	-
I - I (Continuous line)	8.0 mm (0.315 in.)	-	56.5 mm (2.22 in.) from bottom of cylinder head	2.0 to 3.0 mm (0.0787 to 0.118 in.)
J	10 mm (0.394 in.)	-	20 mm (0.787 in.)	-

NOTICE:

1. Remove any oil from the contact surface.
   
2. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   
3. Install the timing chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
4. Do not start the engine for at least 4 hours after the installation.
   

Align the drive rotor spline of the oil pump and crankshaft timing gear as shown in the illustration.

Temporarily install the timing chain cover with the 19 bolts and 2 nuts.

Bolt Length:

Item	Length	Thread Diameter
Bolt A	75 mm (2.95 in.)	10 mm (0.394 in.)
Bolt B	75 mm (2.95 in.)	8 mm (0.315 in.)
Bolt C	90 mm (3.54 in.)	8 mm (0.315 in.)
Bolt D	95 mm (3.74 in.)	8 mm (0.315 in.)
Bolt E	35 mm (1.38 in.)	8 mm (0.315 in.)
Bolt F	75 mm (2.95 in.)	10 mm (0.394 in.)

Excluding the bolts labeled A and F, tighten the bolts and nuts in this order: Area 1, Area 3, Area 2.

Torque:

for bolt C:

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

for bolt B, D and nut:

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

Tighten the bolts labeled A in this order: Area 2 and Area 3.

Torque:

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

Tighten the bolts labeled F.

Torque:

46 N*m{469 kgf*cm, 34 ft.*lbf}

Tighten the bolts labeled E in Area 4.

Torque:

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

Apply adhesive to the timing chain cover plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using a 10 mm socket hexagon wrench, install the timing chain cover plug.

Torque:

17 N*m{169 kgf*cm, 12 ft.*lbf}

Temporarily install the belt tensioner with the 3 bolts.

HINT:

Make sure the flanges of the bolts are contacting the tensioner surface.

Install the tensioner with the 3 bolts.

Torque:

for bolt A:

43 N*m{438 kgf*cm, 32 ft.*lbf}

for bolt B:

40 N*m{408 kgf*cm, 30 ft.*lbf}

for bolt C:

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

Text in Illustration

	Bolt A
	Bolt B
	Bolt C

Apply MP grease to the lip of a new oil seal.

NOTICE:

1. Do not allow foreign matter to contact the lip of the oil seal.
   
2. Do not allow MP grease to contact the dust seal.
   

Temporarily install the oil seal to the timing chain cover.

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

SST

09223-75010
09950-70010(09951-07100)

NOTICE:

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

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

Install the sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

NOTICE:

Make sure that the O-ring is not cracked or jammed when installing.

Install the connector to the connector bracket.

Attach the harness clamp.

Connect the sensor connector.

Install a new O-ring.

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

Seal packing:

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

Application Specification:

Area	Seal Packing Diameter	Distance from Edge of Cover or Center of Bolt Hole to Center of Seal Packing
A - A and C - C	2.0 to 3.0 mm (0.0787 to 0.118 in.)	8.0 mm (0.315 in.)
B - B	2.0 to 3.0 mm (0.0787 to 0.118 in.)	6.5 mm (0.256 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 4 hours after the installation.
   

Temporarily install the oil pan with the 16 bolts and 2 nuts.

Bolt Length:

Item	Length
Bolt A	20 mm (0.787 in.)
Bolt B	40 mm (1.57 in.)

Text in Illustration

	Bolt A
	Bolt B
	Nut

Uniformly tighten the 16 bolts and 2 nuts in the order shown in the illustration.

Torque:

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

Install a new gasket and the oil strainer with the bolt and 2 nuts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

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

Seal packing:

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

Application Specification:

Seal Packing Diameter	Distance from Edge of Cover or Center of Bolt Hole to Center of Seal Packing
2.5 to 3.5 mm (0.0984 to 0.138 in.)	6.0 mm (0.236 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 4 hours after the installation.
   

Temporarily install the No. 2 oil pan with the 20 bolts and 2 nuts.

Uniformly tighten the 20 bolts and 2 nuts in the order shown in the illustration.

Torque:

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

Text in Illustration

	Bolt
	Nut

Install a new gasket and the drain plug.

Torque:

38 N*m{382 kgf*cm, 28 ft.*lbf}

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

Using SST, install the crankshaft pulley bolt.

SST

09213-54015(91651-60855)
09330-00021

Torque:

260 N*m{2651 kgf*cm, 192 ft.*lbf}

NOTICE:

Do not reuse the pulley bolt.

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

Install the sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

NOTICE:

Make sure that the O-ring is not cracked or jammed when installing.

Connect the sensor connector.

Install 2 new cover gaskets to the head cover.

Apply seal packing to the places shown in the illustration.

Seal packing:

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

Seal packing diameter:

4.0 mm (0.157 in.)

Text in Illustration

Seal Packing

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the head cover within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 4 hours after the installation.
   

Temporarily install the cylinder head cover with the 19 bolts and 2 nuts.

Uniformly tighten the 19 bolts and 2 nuts in the order shown in the illustration.

Torque:

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

In numerical order, confirm that the bolts labeled 1 to 8 are tightened to the specified torque. Tighten the bolts as necessary.

Install the gasket to the oil filler cap.

Install the oil filler cap.

Install a new gasket and the water by-pass pipe with the 2 nuts.

Torque:

18 N*m{178 kgf*cm, 13 ft.*lbf}

Install the spacer and pulley with the bolt.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Install a new gasket to the thermostat.

HINT:

When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket as shown in the illustration.

Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.

HINT:

The jiggle valve may be set within 10° of either side of the prescribed position.

Install a new gasket and the water inlet with the 2 nuts and bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the power steering pump connector.

Temporarily install the mounting bracket with the 3 bolts labeled A.

HINT:

Make sure the flanges of the bolts are contacting the bracket surface.

Make sure there is no clearance between the cylinder block and bracket as shown in the illustration. Then install the bolt labeled B.

Torque:

for bolt B:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Tighten the bolts labeled A and install the bolt labeled C.

Torque:

for bolt A:

45 N*m{459 kgf*cm, 33 ft.*lbf}

for bolt C:

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

Install the generator with the 2 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Connect the generator connector.

Install the generator wire with the bolt and nut.

Torque:

for nut:

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

for bolt:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Attach the terminal cap.

Install the purge line hose to the intake manifold.

Install the 2 wire harness clamp brackets to the intake manifold with the 2 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Apply gasoline to 4 new O-rings. Then install the 4 O-rings to the No. 1 fuel pipe sub-assembly.

Set the No. 1 fuel pipe sub-assembly against the 4 protrusions and install it with the 4 bolts.

Torque:

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

NOTICE:

1. Set the areas of the fuel pipe marked with white paint marks against the protrusions of the intake manifold from the directions indicated by the arrows in the illustration.
   
2. Make sure the fuel pipe does not become deformed when installing it.
   

Install a new gasket to the intake manifold.

Install the intake manifold with the 5 bolts and 2 nuts, and tighten the bolts and nuts in the sequence shown in the illustration.

Torque:

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

Text in Illustration

	Bolt
	Nut

Connect the No. 3 PCV hose and vacuum hose to the intake manifold.

Attach the No. 2 water by-pass hose.

Attach the No. 1 fuel hose to the intake manifold.

Install the clamp.

Attach the 3 wire harness clamps to the 2 wire harness clamp brackets.

Install a new insulator to the fuel injector.

Apply a light coat of grease or gasoline to a new O-ring and install it to the fuel injector.

Apply a light coat of grease or gasoline on the place where the delivery pipe touches the O-ring.

Text in Illustration

	Turn
	Push

To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back and forth.

NOTICE:

1. Be careful not to twist the O-ring.
   
2. After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
   

Position the fuel injector connector so that it faces downward.

Apply a light coat of gasoline or spindle oil to new O-rings, and then install one to each spacer.

Install the 4 spacers to the cylinder head.

Install 4 new injector vibration insulators to the cylinder head.

Install the 2 No. 1 delivery pipe spacers to the cylinder head.

Install the fuel delivery pipe together with the 4 fuel injectors with the 2 bolts.

Torque:

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

NOTICE:

Do not drop the fuel injectors when installing the fuel delivery pipe.

Connect the 4 injector connectors.

Connect the 4 clamps and wire harness to the delivery pipe.

Connect the vacuum hose.

Install a new gasket on the intake manifold.

HINT:

Align the protrusion of the gasket with the groove of the intake manifold.

Install the throttle body with motor the 2 bolts and 2 nuts.

Torque:

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

Connect the 2 water by-pass hoses to the throttle body with motor.

Connect the throttle position sensor and control motor connector.

Install the PCV pipe with the bolt.

Torque:

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

Connect the PCV hose to the PCV valve sub-assembly and intake manifold.

Using a 16 mm plug wrench, install the 4 spark plugs.

Torque:

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

Install the 4 ignition coils with the 4 bolts.

Torque:

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

Connect the ignition coil connector.

Attach an engine sling device and hang the engine with a chain block.

NOTICE:

Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

Lift the engine and remove it from the engine stand.

NOTICE:

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

Place the engine onto a workbench.