Oil Pump Installation

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

Torque:

8.9 N*m{91 kgf*cm, 79 in.*lbf}

Install 3 new O-rings to the timing chain cover sub-assembly.

Clean and degrease the contact surfaces of the timing chain cover sub-assembly, cylinder head sub-assembly and cylinder block.

Apply 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. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   
3. Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
4. Do not start the engine for at least 4 hours after the installation.
   

Align the width of the joint portion of the oil pump drive rotor and the crankshaft timing gear, and then install the timing chain cover sub-assembly.

Temporarily install the timing chain cover sub-assembly with the 16 bolts and nut.

Text in Illustration

*a	Types of nut and bolt	*b	Tightening Order
	Bolt		Nut

Torque:

for bolt A:

57 N*m{581 kgf*cm, 42 ft.*lbf}

for bolt B and nut:

23 N*m{235 kgf*cm, 17 ft.*lbf}

for bolt C:

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

for bolt D:

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

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.)	8.0 mm (0.315 in.)
Bolt C	40 mm (1.57 in.)	8.0 mm (0.315 in.)
Bolt D	90 mm (3.54 in.)	8.0 mm (0.315 in.)

NOTICE:

1. Make sure that there is no oil on the threads of bolts.
   
2. Check the bolts and bolt holes, and clean and degrease them.
   

Remove the seal packing from the 2 bolt holes for the No. 1 compressor mounting bracket.

NOTICE:

Do not use any cleaners to remove the seal packing.

Temporarily install the V-ribbed belt tensioner assembly with the 2 bolts.

HINT:

Make sure that the V-ribbed belt tensioner assembly is in contact with the timing chain cover sub-assembly.

Install the V-ribbed belt tensioner assembly by tightening the 2 bolts in the order shown in the illustration.

Torque:

for bolt 1:

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

for bolt 2:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Install a new gasket to the oil strainer sub-assembly.

Clean and degrease the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not start the engine for at least 4 hours after the installation.
   

Install a new gasket to the oil strainer sub-assembly.

Temporarily install the oil pan sub-assembly 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}

Clean and degrease the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.

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

Seal packing:

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

Seal packing diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 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 sub-assembly with the 16 bolts and 2 adjusting screws, 2 nuts.

Text in Illustration

	Bolt
	Nut
	Adjusting Screw

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

Torque:

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

Install a new gasket and the oil pan drain plug.

Torque:

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

Install the oil pan cover silencer with the 2 No. 1 oil pan plugs.

Torque:

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

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

NOTICE:

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

Temporarily install the timing chain case oil seal to the timing chain cover sub-assembly.

Using SST and a hammer, tap in the timing chain case 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 timing chain case oil seal at an angle.
   

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

Using SST, install a new crankshaft pulley bolt.

SST

09213-54015(91651-60855)
09330-00021

Torque:

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

Text in Illustration

*a	Hold
	Turn

NOTICE:

Do not reuse the pulley bolt.

Clean and degrease the contact surfaces of the cylinder head cover sub-assembly, timing chain cover sub-assembly and cylinder head sub-assembly.

Apply seal packing as 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. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
2. Do not add the engine oil for at least 4 hours after the installation.
   
3. Do not start the engine for at least 4 hours after the installation.
   

Install a new No. 1 camshaft bearing cap oil hole gasket to the cylinder head cover spacer.

Install a new gasket to the cylinder head cover sub-assembly.

Install the cylinder head cover sub-assembly, 2 plate washers and 2 seal washers with the 21 bolts and 2 nuts, and tighten the 21 bolts and 2 nuts in the sequence shown in the illustration.

Torque:

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

Text in Illustration

*1	Plate Washer and Seal Washer
	Seal Packing
	Nut

NOTICE:

Make sure that the metal face of the seal washer is facing upward.

Connect the PCV hose to the PCV valve sub-assembly and slide the clip to secure the hose.

Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.

Torque:

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

w/ Engine Oil Cooler:
Connect the No. 6 water by-pass hose to the No. 1 water by-pass pipe and slide the clip to secure the hose.

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

Install the crankshaft position sensor with the bolt.

Torque:

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

NOTICE:

1. When reusing the crankshaft position sensor, inspect the O-ring.
   
2. Make sure that the O-ring is not cracked or jammed when installing the crankshaft position senor.
   

Connect the crankshaft position sensor connector and attach the wire harness clamp.

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

NOTICE:

Do not damage the O-ring when installing.

HINT:

An O-ring is already installed in a new camshaft timing oil control valve assembly. So, the O-ring only needs to be coated with engine oil when the assembly is replaced with a new one.

Install the camshaft timing oil control valve assembly to the cylinder head cover sub-assembly with the bolt.

Torque:

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

NOTICE:

1. Replace with a new part if it is dropped or if it receives a strong impact.
   
2. Make sure that the O-ring is not cracked or jammed when installing.
   

Connect the camshaft timing oil control valve connector.

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

Install the camshaft position sensor with the bolt.

Torque:

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

NOTICE:

1. When reusing the camshaft position sensor, inspect the O-ring.
   
2. Make sure that the O-ring is not cracked or jammed when installing the camshaft position sensor.
   

Connect the camshaft position sensor connector.

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

Install the camshaft position sensor with the bolt.

Torque:

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

NOTICE:

1. When reusing the camshaft position sensor, inspect the O-ring.
   
2. Make sure that the O-ring is not cracked or jammed when installing the camshaft position sensor.
   

Connect the camshaft position sensor connector.

Install the spacer and No. 1 idler pulley sub-assembly with the bolt.

Torque:

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

Install a new gasket to the thermostat.

Install the thermostat with the jiggle valve upward.

HINT:

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

Install a new gasket and the water inlet to the timing chain cover sub-assembly with the bolt and 2 nuts.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Temporarily install the No. 1 compressor mounting bracket with the 3 bolts.

HINT:

Temporarily install the No. 1 compressor mounting bracket with the 3 bolts so that the bracket can be moved by hand.

Push the No. 1 compressor mounting bracket toward the cylinder block as shown in the illustration and tighten bolt B.

Torque:

for bolt B:

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

HINT:

Make sure there is no clearance between the cylinder block and No. 1 compressor mounting bracket as shown in the illustration.

Uniformly tighten the 4 bolts in the order shown in the illustration.

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}

Text in Illustration

	Bolt A
	Bolt C

Install the generator assembly with the 3 bolts.

Torque:

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

Connect the wire harness to terminal B with the nut.

Torque:

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

Install the terminal cap.

Connect the connector to the generator assembly.

Install the 4 ignition coil assemblies with the 4 bolts.

Torque:

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

Connect the 4 ignition coil connectors.