Installation

2ZR-FXE LUBRICATION: OIL PUMP: INSTALLATION

1. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

2. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

(b) Apply a continuous bead of seal packing (diameter 4.0 mm (0.157 in.)) as shown in the illustration.

Text in Illustration

Seal packing:

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

NOTICE:
* Remove any oil from the contact surfaces.
* Install the oil pan within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installing the oil pan.

(c) Install the No. 2 oil pan with the 10 bolts and 2 nuts.

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

3. INSTALL OIL PAN DRAIN PLUG Reassembly

4. INSTALL CRANKSHAFT TIMING GEAR KEY Reassembly

5. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE Reassembly

6. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

(a) Temporarily install the crankshaft pulley bolt.

(b) Turn the crankshaft counterclockwise to position the timing gear key at the 9 o'clock position.

(c) Turn the drive shaft so that the cutout faces the 12 o'clock position.

(d) Align the yellow mark links with the timing marks of each gear as shown in the illustration.

Text in Illustration

HINT
Be sure to position the mark plates at the front of the engine.

(e) Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.

(f) Temporarily tighten the oil pump drive shaft gear with the nut.

(g) Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

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

(h) Temporarily tighten the crankshaft pulley with the bolt.

(i) Using SST, install the oil pump drive shaft gear nut while holding the crankshaft pulley.

SST : 09213-58014

91551-80840

SST : 09330-00021

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

(j) Remove the crankshaft pulley and bolt.

7. INSTALL CRANKSHAFT TIMING SPROCKET

(a) Install the crankshaft timing sprocket.

8. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation

9. SET NO. 1 CYLINDER TO TDC / COMPRESSION Installation

10. INSTALL CHAIN SUB-ASSEMBLY Installation

11. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION Installation

12. INSTALL CHAIN TENSIONER SLIPPER Installation

13. INSTALL NO. 2 CHAIN VIBRATION DAMPER Installation

14. INSTALL TIMING CHAIN COVER 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

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.

HINT
Tap in the oil seal so that it is positioned within 1.0 mm (0.0394 in.) from the edge of the timing chain case.

(b) Apply MP grease to the lip of the oil seal.

15. 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

(b) Install 3 new O-rings.

Seal packing:

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

Seal diameter:

5.0 mm (0.197 in.)

NOTICE:
* Remove any oil from the contact surfaces.
* Install the chain cover within 3 minutes of applying seal packing.
* Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.

(d) Apply seal packing to the timing chain cover in a line as shown in the following illustration.

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 of applying seal packing.
* Do not start the engine for at least 2 hours after installation.

Seal Packing:

Application Specification:

NOTICE:
* When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the timing chain cover within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
* After applying seal packing to the timing chain cover, install the engine mounting bracket and oil filter bracket within 10 minutes.
* Do not add engine oil for at least 2 hours after installation.

(e) Clean the bolt and fitting hole.

(f) Install the timing chain cover.

(g) Temporarily tighten the engine mounting bracket RH with the 3 bolts.

NOTICE:
* Install the mounting bracket within 10 minutes of installing the chain cover.
* Do not start the engine for at least 2 hours after installation.

Bolt Length:

(h) Install 2 new O-rings.

(i) Temporarily tighten the oil filter bracket with the 4 bolts.

NOTICE:
* Install the oil filter bracket within 10 minutes of installing the chain cover.
* Do not start the engine for at least 2 hours after installation.

Bolt Length:

(j) Install the timing chain cover with the 25 bolts and seal washer as shown in the illustration.

Text in Illustration

Bolt A, E, F - Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

Bolt B, C - Torque : 51 Nm (520 kgf-cm, 38 ft-lbf)

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

NOTICE:
* Apply adhesive 1324 to the threads of the bolt F.
* 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 of applying the seal packing.
* Do not add engine oil for at least 2 hours after installing the chain cover.
* Do not start the engine for at least 2 hours after installing the chain cover.

Bolt Length:

16. INSTALL CRANKSHAFT PULLEY Installation

17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation

18. INSTALL SPARK PLUG TUBE GASKET Reassembly

19. INSTALL CYLINDER HEAD COVER GASKET Reassembly

20. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly

21. INSTALL IGNITION COIL ASSEMBLY Installation

22. INSTALL FUEL INJECTOR ASSEMBLY Installation

23. INSTALL NO. 1 DELIVERY PIPE SPACER Installation

24. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

25. INSTALL FUEL VAPOR FEED PIPE Installation

26. INSTALL INTAKE MANIFOLD Installation

27. INSTALL EGR COOLER SUB-ASSEMBLY Installation

28. INSTALL EGR VALVE ASSEMBLY Installation

29. INSTALL EGR PIPE ASSEMBLY Installation

30. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

31. INSTALL THROTTLE BODY ASSEMBLY Installation

32. INSTALL ENGINE HANGERS Installation

33. REMOVE ENGINE STAND Installation

34. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

Installation