Installation

2UR-FSE LUBRICATION: OIL PUMP: INSTALLATION

INSTALLATION
HINT: When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

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) Install a new oil pump gasket.

(b) Install a new O-ring.
(c) 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.

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

(e) Temporarily install the timing chain cover with the 30 bolts and nut.
Bolt length:

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

(f) Tighten the bolt.
Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)

(g) Install the belt tensioner with the bolt.
Torque: 23 Nm (235 kgf-cm, 17 ft-lbf)

(h) Tighten the 10 bolts in several steps, in the sequence shown in the illustration.
Torque: 47 Nm (479 kgf-cm, 35 ft-lbf)
(i) Tighten the 19 bolts and nut 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.

(j) Install 2 new gaskets and the 2 plugs.
Torque: 46 Nm (469 kgf-cm, 34 ft-lbf)
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3 and No. 7).
(b) Install a new gasket to the cylinder head cover.
NOTE: Remove any oil from the contact surface.

(c) Apply seal packing as shown 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.)
- 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 2 new seal washers with the 15 bolts in the order shown in the illustration.
for bolt A - Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
for except bolt A - Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
(e) Install the fuel pump spacer.
4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 1, No. 3 and No. 6).
(b) Install a new gasket to the cylinder head cover.
NOTE: Remove any oil from the contact surface.

(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST: 09213-54015
90119-08216
SST: 09330-00021
Torque: 300 Nm (3059 kgf-cm, 221 ft-lbf)
9. INSTALL OIL FILTER BRACKET

(a) Install 2 new gaskets and the filter bracket with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
10. INSTALL OIL FILTER ELEMENT Replacement

11. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH

(a) Turn the camshaft timing gear assembly's intermediate shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position.
- When the cam of the camshaft lifts the valve, the intermediate shaft becomes difficult to turn.
- The position where the intermediate shaft stops is the maximum retard angle.

(b) Install a new O-ring to the timing chain cover.

(c) Align the joint of the camshaft timing control motor and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
- Check that [R] is printed on the label of the camshaft timing control motor.
- Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor (connecting surface with timing chain cover sub-assembly).
- When installing the camshaft timing control motor, do not use excessive force.
- Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor.
- Install the camshaft timing control motor with the arrow facing upward, as shown in the illustration.
- Do not drop the camshaft timing control motor. If dropped, replace it.
- Do not disassemble the camshaft timing control motor assembly. If disassembled, replace it.

12. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH

(c) Align the joint of the camshaft timing control motor and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
- Check that [L] is printed on the label of the camshaft timing control motor.
- Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor (connecting surface with timing chain cover sub-assembly).
- When installing the camshaft timing control motor, do not use excessive force.
- Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor.
- Install the camshaft timing control motor with the arrow facing upward, as shown in the illustration.
- Do not drop the camshaft timing control motor. If dropped, replace it.
- Do not disassemble the camshaft timing control motor assembly. If disassembled, replace it.

13. INSTALL FRONT WATER BY-PASS JOINT Reassembly

14. INSTALL WATER PUMP PULLEY Installation

15. INSTALL WATER INLET HOUSING

(a) Install a new gasket and the inlet housing with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the water inlet hose.
16. INSTALL FUEL PUMP ASSEMBLY (for Bank 2) Installation

17. INSTALL FUEL PUMP ASSEMBLY (for Bank 1) Installation

18. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY Installation

19. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY Installation

20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY Installation

21. INSTALL INTAKE MANIFOLD ASSEMBLY Installation

22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY Installation

23. INSTALL HEATER WATER PUMP ASSEMBLY Installation

24. INSTALL PURGE VSV Installation

25. INSTALL NO. 1 ENGINE COVER Installation

26. INSTALL INJECTOR DRIVER Installation

27. INSTALL ENGINE WIRE Installation

28. INSTALL NO. 5 COVER SUB-ASSEMBLY Installation

29. INSTALL ENGINE COVER SUB-ASSEMBLY RH Installation

30. INSTALL NO. 6 COVER SUB-ASSEMBLY Installation

31. INSTALL ENGINE COVER SUB-ASSEMBLY LH Installation

32. INSTALL WITH MOTOR COMPRESSOR ASSEMBLY Installation

33. INSTALL V-RIBBED BELT Installation

34. INSTALL ENGINE ASSEMBLY
(a) Install the engine Installation.
35. INSTALL SERVICE PLUG GRIP Installation

36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.