Installation
1GR-FE LUBRICATION: OIL PUMP: INSTALLATION
1. INSTALL FRONT CRANKSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST : 09223-22010
SST : 09506-35010
NOTICE:
* Keep the lip free from foreign matter.
* Do not tap on the oil seal at an angle.
* Make sure that the oil seal edge does not protrude from the timing chain case.
2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) 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 and cylinder block.
NOTICE:
Be sure to clean and degrease the contact surfaces, especially the surfaces indicated in the illustration.
(b) Apply a light coat of engine oil to a new oil pump gasket.
(c) Install the oil pump gasket.
(d) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
(e) 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
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
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.
Application Specification:
(f) Align the oil pump drive rotor spline and crankshaft as shown in the illustration. Install the drive rotor and chain cover to the crankshaft.
(g) Install the timing chain cover with the 26 bolts, labeled A, B, C and D, and the 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Standard Bolt:
NOTICE:
Make sure that there is no oil on the bolt threads.
(h) Tighten the bolts in area 1.
Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)
HINT
Tighten the bolts from bottom to top as shown in the illustration.
(i) Tighten the bolts in area 2.
Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)
(j) Tighten the bolts in area 3.
Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)
HINT
Tighten the bolts and nuts from top to bottom as shown in the illustration.
(k) Tighten the bolts in area 4.
Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)
HINT
Tighten the bolts from bottom to top as shown in the illustration.
NOTICE:
* Do not start the engine for at least 2 hours after installation.
* Wipe off any seal packing that seeped out around the surfaces of the oil pan and head cover and make sure that there is no seal packing seeping out around the edges.
3. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.
(b) Install a new 3 O-rings to the timing chain cover.
(c) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the oil pan within 3 minutes after applying seal packing.
(d) Install the oil pan with the 17 bolts (A, B, C, D and E) and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
for bolt A, B, C and E, and nut - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
for bolt D - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Standard Bolt:
NOTICE:
Do not start the engine for at least 2 hours after installing.
4. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the 2 nuts.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
(a) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.0 to 4.0 mm (0.118 to 0.157 in.)
NOTICE:
* Remove any oil from the contact surface.
* Install the No. 2 oil pan within 3 minutes after applying seal packing.
(b) Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
* Tighten the nuts first. After tightening the bolts, check that the nuts and bolts are tightened to the specified torque.
* Do not start the engine for at least 2 hours after the installation.
6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
(b) 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:
* 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.
(c) Install 3 new gaskets.
(d) Install a new gasket to the cylinder head cover.
(e) Install the seal washers to the bolts.
(f) Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.
for bolt A and D - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for bolt B and C - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Standard Bolt:
NOTICE:
Do not start the engine for at least 2 hours after installation.
7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
(b) 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:
* 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.
(c) Install 3 new gaskets.
(d) Install a new gasket to the cylinder head cover.
(e) Install the seal washers to the bolts.
(f) Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.
for bolt A and D - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for bolt B and C - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Standard Bolt:
NOTICE:
Do not start the engine for at least 2 hours after installation.
8. CONNECT FUEL PIPE SUB-ASSEMBLY
(a) Connect the fuel pipe with the 2 bolts.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
9. INSTALL REAR CYLINDER HEAD COVER Installation
10. INSTALL NO. 2 OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
NOTICE:
Do not touch the mesh when installing the oil control valve filter.
(b) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
(c) Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
(d) Tighten the oil pipe union (on the cylinder head side).
Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)
NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
(e) Tighten the oil pipe union (on the head cover side).
Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)
11. INSTALL NO. 1 OIL PIPE
(a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
NOTICE:
Do not touch the mesh when installing the oil control valve filter.
(b) Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
(c) Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
(d) Tighten the oil pipe union (on the cylinder head side).
Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)
NOTICE:
If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.
(e) Tighten the oil pipe union (on the head cover side).
Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)
12. INSTALL CRANKSHAFT PULLEY
(a) Using SST, install the crankshaft pulley with the pulley set bolt.
SST : 09213-54015
91651-60855
SST : 09330-00021
Torque : 260 Nm (2651 kgf-cm, 192 ft-lbf)
13. INSTALL OIL FILTER BRACKET
(a) Install the oil filter bracket and a new gasket with the 2 nuts and bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
14. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner with the 5 bolts.
Standard Bolt:
(b) Tighten bolts 1 and 2 in numerical order.
Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)
(c) Tighten the other bolts.
Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)
15. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Installation
16. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Install the No. 1 idler pulley with the bolt.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
HINT
"DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.
17. INSTALL WATER INLET HOUSING
(a) Install the 3 water by-pass hoses.
(b) Apply soapy water to a new O-ring and install the O-ring to the water outlet pipe.
(c) Install a new O-ring to the water outlet pipe.
(d) Install a new gasket to the water pump.
(e) Install the water inlet with the 5 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(f) Connect the 3 water by-pass hoses.
18. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Install the water by-pass pipe with the 3 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the 2 hoses.
HINT
The direction of the hose clamp is indicated in the illustration.
19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
(a) Install a new O-ring to the dipstick guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push the dipstick guide end into the guide hole.
(d) Install the dipstick guide with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(e) Install the dipstick.
20. INSTALL IGNITION COIL ASSEMBLY Installation
21. INSTALL ENGINE ASSEMBLY
(a) Install the engine assembly Installation.