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 stick out of 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.

Text in Illustration

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.

Text in 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 in a continuous line to the timing chain cover as shown in the following illustration.

Text in 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 there is oil on the contact surfaces, 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 the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Text in Illustration

(g) Install the timing chain cover with the 26 bolts labeled A, B, C, D and the 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Text in Illustration

Bolt Length:

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

(h) Fully 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) Fully tighten the bolts in Area 2.

Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)

(j) Fully 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) Fully 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 installing it.
* 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 3 new O-rings to the timing chain cover.

(c) Apply seal packing in a continuous line as shown in the illustration.

Text in 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.

Text in Illustration

for bolt A, B, C, E and nut - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

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

Bolt Length:

NOTICE:
Do not start the engine for at least 2 hours after the installation.

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.

Text in 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.

Text in Illustration

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 or cylinder head cover.

(b) Apply seal packing as shown in the illustration.

Text in 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 as shown in the illustration.

(d) Install a new gasket to the cylinder head cover.

(e) Install a new seal washer to the bolt.

(f) Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

Text in Illustration

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)

Bolt Length:

NOTICE:
Do not start the engine for at least 2 hours after the 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 or cylinder head cover.

(b) Apply seal packing as shown in the illustration.

Text in Illustration

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)

Bolt Length:

NOTICE:
Do not start the engine for at least 2 hours after the 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 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.

Text in Illustration

Bolt Length:

(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

(a) for Cover Separate Type:

Install the 2 idler pulley cover plates, 2 No. 2 idler pulleys and 2 No. 2 idler pulley cover plates with the 2 bolts.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

(b) for Cover Integrated Type:

Install the 2 No. 2 idler pulleys with the 2 bolts.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

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, install it to the water outlet pipe.

(c) Install a new gasket to the water pump.

(d) Install the water inlet with the 5 bolts.

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

(e) Connect the 3 water by-pass hoses.

18. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Install a new O-ring to the dipstick guide.

Text in Illustration

(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.

19. INSTALL IGNITION COIL ASSEMBLY Installation

20. INSTALL ENGINE ASSEMBLY

(a) Install the engine assembly Installation.