Installation

3UR-FE LUBRICATION: OIL PUMP: INSTALLATION

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) Apply a light coat of engine oil to a new oil pump gasket.

(b) Install the oil pump gasket.

(c) Apply a light coat of engine oil to a new O-ring.

(d) Install the O-ring.

(e) 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.

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

(g) Temporarily install the timing chain cover with the 28 bolts and nut.

Standard Bolt:

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

(h) Tighten the 3 bolts in several steps in the sequence shown in the illustration.

Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)

(i) Temporarily install the fluid coupling bracket with the 4 bolts.

Standard Bolt:

(j) Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

(k) Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.

Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)

(l) Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.

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

NOTICE:
After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).

(b) Install the gasket to the cylinder head cover.

NOTICE:
Remove any oil from the contact surface.

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

Seal packing:

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

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.

(d) Install the cylinder head cover washer with a new seal and the 14 bolts.

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

except bolt A - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

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

4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

(a) Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).

(b) Install the gasket to the cylinder head cover.

NOTICE:
Remove any oil from the contact surface.

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

Install the noise filter to the cylinder head cover with the bolt.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

5. INSTALL IGNITION COIL ASSEMBLY

(a) Install the 8 ignition coils with the 8 bolts.

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

6. INSTALL CRANKSHAFT PULLEY

Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(a) Using SST, install the pulley set bolt.

SST : 09213-70011

SST : 09330-00021

Torque : 300 Nm (3059 kgf-cm, 221 ft-lbf)

7. CONNECT WIRE HARNESS CLAMP BRACKET

Connect the bracket to the timing chain cover with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

8. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

Install the idler pulley with the bolt.

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

9. INSTALL WATER PUMP PULLEY

Temporarily install the pulley with the 4 bolts.

(a) Using SST, hold the pulley and tighten the 4 bolts.

SST : 09960-10010

09962-01000

09963-01000

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

10. INSTALL WATER INLET HOUSING

Install a new gasket to the timing chain cover.

(a) Install the water inlet with the 3 bolts.

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

11. INSTALL AIR TUBE SUB-ASSEMBLY

Connect the 2 hoses.

(a) Install the air tube with the bolt.

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

12. INSTALL NO. 1 ENGINE COVER Installation

13. INSTALL NO. 2 ENGINE COVER Installation

14. INSTALL FRONT WATER BY-PASS JOINT

Install 2 new gaskets and the water by-pass joint with the 4 nuts.

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

(a) Connect the No. 2 water by-pass hose to the water by-pass joint.

15. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

Connect the 2 hoses.

(a) Install the water by-pass pipe with the 2 bolts.

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

Connect the air tube with the bolt.

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

16. INSTALL NO. 1 WATER BY-PASS HOSE

Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.

17. INSTALL GENERATOR ASSEMBLY

Install the 2 stud bolts.

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

(a) Install the generator with the 2 bolts and 2 nuts.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

Connect the generator connector.

(b) Connect the generator wire with the nut.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(c) Install the terminal cap.

Connect the wire harness bracket to the generator with the bolt.

Torque : 31 Nm (316 kgf-cm, 23 ft-lbf)

18. CONNECT VANE PUMP ASSEMBLY

HINT
Before performing the following procedures, move the spacer until the vane pump can be installed.

Connect the vane pump to the timing chain cover with the 2 bolts.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

20. INSTALL OIL FILTER BRACKET (w/o Oil Cooler)

Apply a light coat of engine oil to 2 new O-rings.

(a) Install the 2 O-rings to the timing chain cover.

Install the oil filter bracket with the 2 bolts and 2 nuts.

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

21. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) Installation

22. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) Installation

23. INSTALL NO. 2 WATER BY-PASS PIPE (w/ Oil Cooler)

Connect the 4 hoses.

(a) Install the water by-pass hose with the 3 bolts.

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

24. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY Installation

25. INSTALL OIL FILTER ELEMENT Replacement

26. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

Connect the fuel tube with the 2 bolts.

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

27. CONNECT COOLER COMPRESSOR ASSEMBLY

Install the cooler compressor with the 2 stud bolts.

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

(a) Install the 2 bolts and 2 nuts.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

NOTICE:
Tighten the bolts and nuts in the order shown in the illustration to install the cooler compressor.

28. CONNECT HEATER HOSE AND PIPE

Connect the 3 hoses.

(a) Install the 2 bolts.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

29. CONNECT AIR PUMP HOSE AND WIRE HARNESS

Connect the No. 2 and No. 3 air hoses.

(a) Connect the 2 clamps and air pump wire harness.

30. INSTALL INTAKE MANIFOLD

(a) Install the intake manifold Installation.

31. CONNECT ENGINE WIRE

(a) Engine Room RH Side:

(1) Connect the 5 clamps.

(2) Connect the throttle position sensor and throttle control motor connector.

(3) Connect the 2 air pump connectors.

(4) Install the ground wire with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(5) Connect the noise filter connector.

(6) Connect the 2 VVT sensor connectors.

(7) Connect the injector connector.

(8) Connect the 4 ignition coil connectors.

(9) Connect the 2 camshaft timing oil control valve connectors.

Connect the 2 clamps and power steering oil pressure switch connector.

(10) for 4WD:

Connect the clamp and junction connector.

Engine Room LH Side:

(1) Connect the cooler compressor connector.

(2) Connect the 3 clamps.

(3) Connect the camshaft position sensor connector.

(4) Connect the 2 camshaft timing oil control valve connectors.

(5) Connect the engine coolant temperature sensor connector.

Connect the 4 clamps.

(6) Install the ground wire with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(7) Connect the noise filter connector.

(8) Connect the 2 VVT sensor connectors.

(9) Connect the 4 ignition coil connectors.

(10) Connect the injector connector.

Connect the 2 wire harness clamps.

Connect the 4 air injection control driver connectors.

Connect the 2 connectors and attach the 2 clamps to the engine room junction block.

(11) Install the engine room relay block cover.

32. INSTALL AIR CLEANER ASSEMBLY Installation

33. INSTALL AIR CLEANER HOSE ASSEMBLY Installation

34. INSTALL RADIATOR ASSEMBLY

(a) Install the radiator Installation.

35. ADD ENGINE OIL Replacement

36. ADD ENGINE COOLANT Service and Repair

37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

38. INSPECT FOR OIL LEAK Replacement

39. INSPECT FOR COOLANT LEAK Testing and Inspection

40. CHECK ENGINE OIL LEVEL Testing and Inspection