Installation

3UR-FE LUBRICATION: OIL PUMP: INSTALLATION

INSTALLATION

1. INSTALL WATER INLET PIPE

(a) Apply soapy water to 2 new O-rings and install them to the inlet pipe.
(b) Install the inlet pipe to the No. 1 heat exchanger cover.
2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Apply a light coat of engine oil to a new oil pump gasket.
(b) Install the oil pump gasket.

(c) Apply a light coat of engine oil to a new O-ring.
(d) Install the O-ring.
(e) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
- Apply seal packing as follows:

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

(f) Align the oil pump drive rotor spline and crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

(g) Temporarily install the timing chain cover with the 28 bolts and nut.
Standard Bolt:

NOTE: Make sure that there is no oil on the bolt threads.

(h) Tighten the 3 bolts in several steps in the sequence shown in the illustration.
Torque: 47 Nm (479 kgf-cm, 35 ft-lbf)

(i) Temporarily install the fluid coupling bracket with the 4 bolts.
Standard Bolt:

(j) Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

(k) Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.
Torque: 47 Nm (479 kgf-cm, 35 ft-lbf)
(l) Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.

Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)
NOTE: After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

3. INSTALL SPARK PLUG TUBE GASKET Reassembly

4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).
(b) Install the gasket to the cylinder head cover.
NOTE: Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
- Remove any oil from the contact surface.
- Install the cylinder head cover 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.

(d) Install the cylinder head cover and the seal washer with the 14 bolts in the order shown in the illustration.
for bolt A - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
except bolt A - Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

(a) Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).
(b) Install the gasket to the cylinder head cover.
NOTE: Remove any oil from the contact surface.

(e) Install the noise filter to the cylinder head cover with the bolt.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
6. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 8 ignition coils with the 8 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
7. INSTALL CRANKSHAFT TIMING GEAR KEY

(a) Install the crankshaft timing gear key to the crankshaft.
8. CONNECT WIRE HARNESS CLAMP BRACKET

(a) Connect the bracket to the timing chain cover with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
9. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
(b) Using SST, install the pulley set bolt.
SST: 09213-70011
09213-70020
SST: 09330-00021
Torque: 300 Nm (3059 kgf-cm, 221 ft-lbf)
10. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
11. INSTALL WATER PUMP PULLEY

(a) Temporarily install the pulley with the 4 bolts.
(b) Using SST, hold the pulley and tighten the 4 bolts.
SST: 09960-10010
09962-01000
09963-01000
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
12. INSTALL WATER INLET HOUSING

(a) Install a new gasket to the timing chain cover.

(b) Install the water inlet with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
13. INSTALL AIR TUBE SUB-ASSEMBLY

(a) Connect the 2 hoses.
(b) Install the air tube with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
14. INSTALL NO. 1 ENGINE COVER Installation

15. INSTALL NO. 2 ENGINE COVER Installation

16. INSTALL FRONT WATER BY-PASS JOINT

(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Connect the No. 2 water by-pass hose to the water by-pass joint.
17. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Connect the 2 hoses.
(b) Install the water by-pass pipe with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)

(a) Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.
19. INSTALL GENERATOR ASSEMBLY

20. CONNECT OIL COOLER PIPE ASSEMBLY Installation

21. CONNECT VANE PUMP ASSEMBLY

HINT: Before performing the following procedures, move the spacer until the vane pump can be installed.

(a) Connect the vane pump to the timing chain cover with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
22. INSTALL INTAKE MANIFOLD Installation

23. INSTALL OIL FILTER BRACKET (w/o Oil Cooler)

(a) Apply a light coat of engine oil to 2 new O-rings.
(b) Install the 2 O-rings to the timing chain cover.

(c) Install the oil filter bracket with the 2 bolts and 2 nuts.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
24. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) Installation

25. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) Installation

26. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)

(a) Connect the 4 hoses.
(b) Install the water by-pass pipe with the 3 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
27. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY Installation

28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

29. INSTALL OIL FILTER ELEMENT Replacement

30. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
31. CONNECT COOLER COMPRESSOR ASSEMBLY

(a) Install the cooler compressor with the stud bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Install the 3 bolts and nut.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
NOTE: Tighten the bolts and nut in the order shown in the illustration to install the cooler compressor.

32. CONNECT NO. 2 WATER BY-PASS PIPE

(a) Connect the No. 2 water by-pass pipe to the cylinder head cover with the 3 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
(b) Connect the 3 hoses.
33. CONNECT AIR PUMP HOSE AND WIRE HARNESS

(a) Connect the No. 2 and No. 3 air hoses.
(b) Connect the 2 clamps and air pump wire harness.
34. CONNECT ENGINE WIRE
(a) Engine Room RH Side:

(1) Connect the 5 clamps.
(2) Connect the throttle position sensor and throttle control motor connector.
(3) Connect the 2 air pump connectors.
(4) Install the ground wire with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(5) Connect the noise filter connector.
(6) Connect the 2 VVT sensor connectors.
(7) Connect the injector connector.
(8) Connect the 4 ignition coil connectors.
(9) Connect the 2 camshaft timing oil control valve connectors.

(10) Connect the 2 clamps and power steering oil pressure switch connector.

(b) Engine Room LH Side:
(1) Connect the cooler compressor connector.
(2) Connect the 3 clamps.
(3) Connect the camshaft position sensor connector.
(4) Connect the 2 camshaft timing oil control valve connectors.
(5) Connect the engine coolant temperature sensor connector.

(6) Connect the 4 clamps.
(7) Install the ground wire with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(8) Connect the noise filter connector.
(9) Connect the 2 VVT sensor connectors.
(10) Connect the 4 ignition coil connectors.
(11) Connect the injector connector.

(12) Connect the wire harness clamp and 4 air injection control driver connectors.

(13) Connect the 2 connectors and 2 clips to the engine room junction block.
(14) Install the engine room relay block cover.
35. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator Installation.
36. INSTALL AIR CLEANER ASSEMBLY Installation

37. INSTALL AIR CLEANER HOSE ASSEMBLY Installation

38. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

39. ADD ENGINE OIL Replacement

40. ADD ENGINE COOLANT Service and Repair

41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
42. INSPECT FOR OIL LEAK Replacement

43. INSPECT FOR COOLANT LEAK Testing and Inspection

44. INSPECT ENGINE OIL LEVEL Testing and Inspection

45. INSTALL NO. 2 ENGINE UNDER COVER Installation

46. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Installation

47. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

48. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

49. INSTALL FRONT FENDER APRON SEAL FRONT RH Installation

50. INSTALL FRONT FENDER APRON SEAL LH Installation

51. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
(a) Install the cowl top ventilator louver .
52. CONNECT RADIATOR SIDE DEFLECTOR LH Installation

53. CONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) Installation

54. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler) Installation

55. INSTALL FRONT BUMPER COVER

56. INSTALL RADIATOR GRILLE

57. INSTALL UPPER RADIATOR SUPPORT SEAL