Installation

2TR-FE LUBRICATION: OIL PUMP:

INSTALLATION

1. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (Replacement)

2. INSTALL THERMOSTAT (Installation)

3. INSTALL WATER INLET (Installation)

4. INSTALL OIL PUMP





(a) Apply adhesive to the head straight screw plug.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Using a 10 mm socket hexagon wrench, install the head straight screw plug.
Torque: 17 Nm (170 kgf-cm, 12 ft-lbf)





(c) Install 4 new O-rings onto the oil pump as shown in the illustration.
(d) Apply continuous beads of seal packing to the places shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal width::





NOTICE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.
- Do not start the engine for at least 4 hours after installation.









(e) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover onto the crankshaft.
(f) Loosely install the oil pump with the 19 bolts and 2 nuts, but do not tighten the bolts and nuts yet.





(g) Provisionally install the oil pump with the 19 bolts and 2 nuts.

NOTE: If the vehicle is equipped with air conditioning, install bolts A' and B' when installing the idle pulley with bracket since they are for this purpose.

HINT: Bolt length:

75 mm (2.95 in.) for bolt A, B

87 mm (3.43 in.) for bolt C

95 mm (3.74 in.) for bolt D

35 mm (1.37 in.) for bolt E

(h) Fully tighten the bolts and nuts, except bolts A, in the following order: Area 1, Area 3 and then Area 2.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(i) Fully tighten the bolts A in the following order: Area 2 and then Area 3.
Torque: 46 Nm (469 kgf-cm, 34 ft-lbf)
(j) Fully tighten the bolts E in Area 4.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)









(k) Install a new gasket, then install the water by-pass pipe No. 1 with the 2 nuts.
Torque: 18 Nm (178 kgf-cm, 13 ft-lbf)
5. INSTALL OIL PAN SUB-ASSEMBLY

6. INSTALL OIL STRAINER SUB-ASSEMBLY (Installation)

7. INSTALL OIL PAN SUB-ASSEMBLY NO.2 (Installation)

8. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
9. INSTALL CRANKSHAFT PULLEY (Installation)

10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (Installation)

11. INSTALL INTAKE MANIFOLD TO HEAD GASKET NO. 1 (Installation)

12. INSTALL CAMSHAFT POSITION SENSOR (Installation)

13. INSTALL CRANKSHAFT POSITION SENSOR (Installation)

14. INSTALL IDLE PULLEY ASSEMBLY W/BRACKET (w/ Air Conditioning System) (Installation)

15. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1 (Installation)

16. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (Installation)

17. INSTALL GENERATOR ASSEMBLY (Service and Repair)

18. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY (Installation)

19. INSTALL INTAKE AIR CONNECTOR (Installation)

20. INSTALL REAR END PLATE (Installation)

21. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transmission) (Installation)

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

23. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)





24. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)





25. INSTALL ENGINE ASSEMBLY (Installation)

26. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY ()

27. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY





28. INSTALL EXHAUST PIPE ASSEMBLY FRONT (Installation)

29. INSTALL EXHAUST PIPE ASSEMBLY TAIL (Installation)

30. CONNECT ENGINE WIRE
31. CONNECT AIR INJECTION SYSTEM NO.1 HOSE (Installation)

32. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY (Installation)

33. CONNECT FUEL HOSE NO.2 (Installation)

34. CONNECT FUEL HOSE (Installation)

35. INSTALL WATER HOSE SUB-ASSEMBLY (Installation)

36. INSTALL RADIATOR HOSE INLET
37. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System) (Installation)

38. INSTALL RADIATOR HOSE NO.2
39. INSTALL VANE PUMP ASSEMBLY (Installation)

40. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
41. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
42. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (Installation)

43. INSTALL FAN SHROUD (Installation)

44. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH (Installation)

45. INSTALL BATTERY TRAY
46. INSTALL BATTERY
47. ADD ENGINE OIL (Installation)

48. ADD ENGINE COOLANT (Service and Repair)

49. CHECK ENGINE OIL LEVEL
50. CHECK FUEL LEAK
51. CHECK ENGINE COOLANT LEAKAGE (Testing and Inspection)

52. CHECK OIL LEAKAGE
53. CHECK EXHAUST GAS LEAKAGE
54. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1 (for Pre Runner and 4WD Type)
(a) Install the engine under cover No. 1 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
55. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.2 (for Pre Runner and 4WD Type, Regular Cab)
(a) Install the engine under cover No. 2 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
56. INSTALL HOOD SUB-ASSEMBLY