Installation

4GR-FSE LUBRICATION: OIL PUMP: INSTALLATION

1. INSTALL TIMING CHAIN CASE OIL SEAL

(a) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

SST : 09223-22010

SST : 09506-35010

NOTICE:
* Keep the lip free of foreign matter.
* Do not tap on the oil seal at an angle.
* Make sure that the oil seal edge does not stick out of the timing chain case.

2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing:

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

Seal diameter:

A
3.0 to 4.0 mm (0.118 to 0.158 in.)

B
3.0 mm (0.118 in.)

NOTICE:
* Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
* When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes.
* Do not start the engine for at least 2 hours after installing.

(b) 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

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 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

Seal Packing Application Chart:

(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 tighten the timing chain cover with the 25 bolts and 2 nuts.

Bolt length:

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

(f) Fully tighten the 3 bolts as shown in the illustration.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf) for bolt A

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for bolts except A

(g) Fully tighten the 3 bolts as shown in the illustration.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(h) Fully tighten the 7 bolts and 2 nuts as shown in the illustration.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

HINT
Tighten the bolts and nuts in order from upper to lower as shown in the illustration.

(i) Fully tighten the 12 bolts as shown in the illustration.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

HINT
Tighten the bolts in order from lower to upper as shown in the illustration.

(j) Install the wiring harness bracket with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH Reassembly

4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Reassembly

5. INSTALL NO. 2 OIL PIPE Reassembly

6. INSTALL NO. 1 OIL PIPE Reassembly

7. INSTALL IGNITION COIL ASSEMBLY Installation

8. INSTALL NO. 2 FUEL PIPE Installation

9. INSTALL FUEL PUMP ASSEMBLY Installation

10. CONNECT NO. 2 FUEL PIPE Installation

11. INSTALL NO. 1 FUEL PIPE Installation

12. INSTALL FUEL PRESSURE PULSATION DAMPER Installation

13. INSTALL OIL STRAINER SUB-ASSEMBLY Reassembly

14. INSTALL OIL PAN SUB-ASSEMBLY Reassembly

15. INSTALL OIL WITH STRAINER PIPE SUB-ASSEMBLY (for 4WD) Reassembly

16. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Reassembly

17. INSTALL CRANKSHAFT PULLEY Installation

18. INSTALL WATER INLET Installation

19. INSTALL WATER HOSE JOINT Installation

20. INSTALL NO. 2 SURGE TANK STAY Installation

21. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

Installation

22. INSTALL INJECTOR DRIVER Installation

23. INSTALL ENGINE WIRE Installation

24. INSTALL WATER PUMP PULLEY Installation

25. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) Installation

26. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation

27. INSTALL ENGINE MOUNTING BRACKET LH Installation

28. INSTALL ENGINE MOUNTING BRACKET RH Installation

29. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (for 2WD) Installation

30. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH (for 4WD) Installation

31. INSTALL OIL FILTER BRACKET (for 4WD) Installation

32. FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH (for 4WD) Installation

33. INSTALL GENERATOR ASSEMBLY Installation

34. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Installation

35. INSTALL NO. 1 ENGINE COVER Installation

36. INSTALL NO. 2 ENGINE COVER Installation

37. INSTALL V-RIBBED BELT Installation

38. INSTALL ENGINE HANGERS Installation

39. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) Installation

40. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) Installation

41. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD) Installation

42. INSTALL FRONT FRAME ASSEMBLY (for 4WD) Installation

43. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) Installation

44. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD) Installation

45. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

46. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

A960E:

A760H: Installation

47. INSTALL STARTER ASSEMBLY Installation

48. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

49. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

50. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 2WD) Installation

51. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 4WD) Installation

52. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) Installation

53. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 2WD) Installation

54. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 4WD) Installation

55. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)

56. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD) Installation

57. CONNECT POWER STEERING LINK WIRE HARNESS (for 2WD) Installation

58. CONNECT POWER STEERING LINK WIRE HARNESS (for 4WD) Installation

59. INSTALL FRONT AXLE ASSEMBLY LH (for 4WD) Installation

60. INSTALL FRONT AXLE ASSEMBLY RH (for 4WD) Installation

61. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD) Installation

62. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD) Installation

63. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD) Installation

64. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD) Installation

65. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD) Installation

66. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD) Installation

67. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD) Installation

68. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD) Installation

69. CONNECT HEIGHT CONTROL SENSOR LINK (for 2WD) Installation

70. CONNECT HEIGHT CONTROL SENSOR LINK (for 4WD) Installation

71. INSTALL TIE ROD ASSEMBLY LH (for 4WD) Installation

72. INSTALL TIE ROD ASSEMBLY LH (for 4WD) Installation

73. INSTALL FRONT AXLE SHAFT LH NUT (for 4WD) Installation

74. INSTALL FRONT AXLE SHAFT RH NUT (for 4WD) Installation

75. INSTALL FRONT SPEED SENSOR LH (for 4WD) Installation

76. INSTALL FRONT SPEED SENSOR RH (for 4WD) Installation

77. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD) Installation

78. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) Installation

79. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD) Installation

80. CONNECT NO. 3 FUEL HOSE Installation

81. CONNECT FUEL MAIN TUBE

Service Precautions

82. CONNECT ENGINE WIRE Installation

83. INSTALL ECM COVER Installation

84. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

85. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation

86. CONNECT INLET HEATER WATER HOSE Installation

87. CONNECT OUTLET HEATER WATER HOSE Installation

88. CONNECT INLET RADIATOR HOSE Installation

89. CONNECT OUTLET RADIATOR HOSE Installation

90. CONNECT RADIATOR RESERVOIR TANK HOSE Installation

91. CONNECT NO. 2 FUEL VAPOR FEED HOSE Installation

92. CONNECT UNION TO CHECK VALVE HOSE Installation

93. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

94. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE Installation

95. INSTALL NO. 1 INLET AIR CLEANER Installation

96. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

Installation

97. INSTALL FRONT EXHAUST PIPE ASSEMBLY

Installation

98. ADD FRONT DIFFERENTIAL OIL (for 4WD) Adjustments

99. ADD ENGINE OIL (for 2WD) Replacement

100. ADD ENGINE OIL (for 4WD) Replacement

101. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

102. ADD ENGINE COOLANT Testing and Inspection

103. CHARGE REFRIGERANT Service and Repair

104. CHECK FOR FUEL LEAKS Fuel System

105. CHECK FOR ENGINE COOLANT LEAKS Testing and Inspection

106. CHECK FOR ENGINE OIL LEAKS

107. CHECK FOR EXHAUST GAS LEAKS

108. CHECK FOR LEAKAGE OF REFRIGERANT Service and Repair

109. INSTALL FRONT WHEEL

Torque : 103 Nm (1,050 kgf-cm, 76 ft-lbf)

110. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

111. ADJUST SHIFT LEVER POSITION

112. CHECK SHIFT LEVER POSITION

113. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

Front Wheel Alignment

114. CHECK IGNITION TIMING Engine

115. CHECK ENGINE IDLE SPEED Engine

116. CHECK CO/HC Engine

117. CHECK ENGINE OIL LEVEL Testing and Inspection

118. CHECK FRONT DIFFERENTIAL OIL LEVEL (for 4WD) Adjustments

119. INSTALL ENGINE UNDER COVER REAR LH (for 2WD) Installation

120. INSTALL ENGINE UNDER COVER REAR RH (for 2WD) Installation

121. INSTALL NO. 2 ENGINE UNDER COVER (for 2WD)

122. INSTALL ENGINE UNDER COVER

123. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

124. INSTALL ENGINE ROOM SIDE COVER LH Installation

125. INSTALL ENGINE ROOM SIDE COVER RH Installation

126. INSTALL COOL AIR INTAKE DUCT SEAL Installation