Oil Pump Installation

Install the oil pump with the 3 bolts.

Torque:

21 N*m{214 kgf*cm, 15 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 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

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the oil pan within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installing the oil pan.
   

Install the No. 2 oil pan with the 10 bolts and 2 nuts.

Torque:

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

Temporarily install the crankshaft pulley bolt.

Set the crankshaft key as shown in the illustration.

Turn the drive shaft so that the cutout faces upward.

Remove the crankshaft pulley bolt.

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

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

Temporarily install the oil pump drive shaft gear with the nut.

Install the 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}

Temporarily install the crankshaft pulley with the pulley bolt.

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

SST

09213-58014(91551-80840)
09330-00021

Torque:

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

Remove SST, the crankshaft pulley bolt and crankshaft pulley.

Install the crankshaft timing sprocket as shown in the illustration.

Install the chain vibration damper with the 2 bolts.

Torque:

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

Temporarily install the crankshaft pulley bolt.

Turn the crankshaft counterclockwise to position the timing gear key at the top.

Check that the timing marks on the camshaft timing gears are aligned as shown in the illustration.

Remove the crankshaft pulley bolt.

Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.

HINT:

1. Be sure to position the mark plate at the front of the engine.
   
2. The mark plate on the camshaft side is colored orange.
   
3. Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket.
   
4. Pass the chain through the No. 1 vibration damper.
   

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.

HINT:

To tension the chain, slowly turn the camshaft timing gear clockwise to prevent the chain from being misaligned.

Align the mark plates (yellow) and timing marks and install the chain to the crankshaft timing gear.

HINT:

The mark plates on the crankshaft side are colored yellow.

Install the chain tensioner slipper to the cylinder block.

Check each timing mark at TDC/compression.

Install a new gasket.

NOTICE:

Remove any oil from the contact surface.

for Type A:
Install the water pump with the 3 bolts.

Torque:

24 N*m{241 kgf*cm, 17 ft.*lbf}

for Type B:
Install the water pump with the 3 bolts.

Torque:

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

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.

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

Standard seal packing diameter:

5.0 mm (0.197 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installing the timing chain cover sub-assembly.
   

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

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.)	-	15.8 mm (0.622 in.)	50.1 mm (1.97 in.)
G	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	10.3 mm (0.406 in.)	155.1 mm (6.11 in.)
H	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	19.5 mm (0.768 in.)	165.4 mm (6.51 in.)
I	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	14.6 mm (0.575 in.)	397.8 mm (1.31 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.)	133.9 mm (5.27 in.)
L	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	25.8 mm (1.02 in.)	159.2 mm (6.28 in.)
M	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	5.0 mm (0.197 in.)	185.0 mm (7.28 in.)
N	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	14.6 mm (0.575 in.)	397.8 mm (1.31 ft.)
O	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-

NOTICE:

1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
   
2. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.
   
4. Do not add engine oil for at least 2 hours after installation.
   

Clean the bolts and their installation holes.

Install the timing chain cover.

Temporarily install the engine mounting bracket with the 3 bolts.

NOTICE:

1. Install the mounting bracket within 10 minutes after installing the timing chain cover.
   
2. Do not add engine oil for at least 2 hours after installation.
   

Install 2 new O-rings.

Temporarily install the oil filter bracket with the 4 bolts.

NOTICE:

1. Install the oil filter bracket within 10 minutes after installing the timing chain cover.
   
2. Do not add engine oil for at least 2 hours after installation.
   

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

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

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}

NOTICE:

1. When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
   
2. Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes after applying the seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   

Bolt Length:

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.)

HINT:

Apply adhesive to bolt E before installing it.

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.
   

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

SST

09223-22010

NOTICE:

1. Wipe off any extra grease from the crankshaft.
   
2. Do not tap in the oil seal at an angle.
   

Align the key groove of the pulley with the pulley set key.

Temporarily install the pulley with the pulley bolt.

Using SST, hold the pulley in place and tighten the pulley bolt.

SST

09330-00021
09213-58014(91551-80840)

Torque:

190 N*m{1940 kgf*cm, 140 ft.*lbf}

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.

NOTICE:

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 chain tensioner and bracket with the 2 nuts.

Torque:

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

NOTICE:

If the hook releases the plunger while the chain tensioner is being installed, set the hook again.

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

Turn the crankshaft clockwise and check that the plunger is extended.

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

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.

HINT:

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.

NOTICE:

1. Keep the lip free of foreign matter.
   
2. Do not tap in the plug tube gasket at an angle.
   

Return the claws of the ventilation baffle plate to their original positions.

Install a new cylinder head cover gasket to the cylinder head cover.

NOTICE:

Remove any oil from the contact surfaces.

Install 3 new gaskets to the camshaft bearing cap.

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.)

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after the installation.
   

Install the cylinder head cover with a new seal washer and the 13 bolts.

Torque:

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

Install the setting condenser with the bolt.

Torque:

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

Install the 4 ignition coils with the 4 bolts.

Torque:

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

NOTICE:

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.

Connect the 4 ignition coil connectors.

Install a new gasket on the thermostat.

Install the thermostat to the water inlet housing.

NOTICE:

The jiggle valve must be set within 10° on either side of the position shown in the illustration.

Install the water inlet with the 2 nuts.

Torque:

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

Connect the water inlet hose to the water inlet housing.

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

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

Install the O-ring to the dipstick guide.

Install the dipstick guide with the bolt.

Torque:

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

Install the engine oil level dipstick.

Install the engine assembly with transaxle (RAV4_ACA30 RM000003PXK003X.html).