OIL PUMP > INSTALLATION |
| 1. INSTALL OIL PUMP ASSEMBLY |
Install the oil pump with the 3 bolts.
| 2. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY |
Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
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Apply a continuous bead of seal packing (diameter 4.0 mm (0.157 in.)) as shown in the illustration.
| *1 | Seal Packing |
Install the No. 2 oil pan with the 10 bolts and 2 nuts.
| 3. INSTALL OIL PAN DRAIN PLUG |
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Install a new gasket and the drain plug.
| 4. INSTALL CRANKSHAFT TIMING GEAR KEY |
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Using a plastic-faced hammer, tap in the 2 crankshaft timing gear keys.
| 5. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE |
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Install the crankshaft position sensor plate with the "F" mark facing forward.
| 6. INSTALL NO. 2 CHAIN SUB-ASSEMBLY |
Temporarily install the crankshaft pulley bolt.
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Turn the crankshaft counterclockwise to position the timing gear key at the 9 o'clock position.
Turn the drive shaft so that the cutout faces the 12 o'clock position.
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Align the yellow mark links with the timing marks of each gear as shown in the illustration.
| *1 | Front |
| *2 | Mark Plate (Yellow) |
| *3 | Timing Mark |
| *4 | Oil Pump Drive Gear |
| *5 | Oil Pump Drive Shaft Gear |
Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.
Temporarily tighten the oil pump drive shaft gear with the nut.
Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.
Temporarily tighten the crankshaft pulley with the bolt.
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Using SST, install the oil pump drive shaft gear nut while holding the crankshaft pulley.
Remove the crankshaft pulley and bolt.
| 7. INSTALL CRANKSHAFT TIMING SPROCKET |
Install the crankshaft timing sprocket.
| 8. INSTALL NO. 1 CHAIN VIBRATION DAMPER |
Install the chain vibration damper with the 2 bolts.
| 9. SET NO. 1 CYLINDER TO TDC / COMPRESSION |
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Temporarily install the crankshaft pulley bolt.
| *1 | Timing Gear Key |
Turn the crankshaft to position the timing gear key to the top.
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Check that the timing marks on the camshaft timing gear and camshaft timing sprocket are aligned as shown in the illustration.
| *1 | Timing Mark |
Remove the crankshaft pulley bolt.
| 10. INSTALL CHAIN SUB-ASSEMBLY |
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Align the mark plate (orange) with the timing mark as shown in the illustration and install the chain.
| *1 | Mark Plate (Orange) |
| *2 | Timing Mark |
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to align the mark plate (orange) and timing mark, and then install the chain.
Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear clockwise.
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Align the mark plate (yellow) and timing mark and install the chain to the crankshaft timing gear.
| *1 | Mark Plate (Yellow) |
| *2 | Timing Mark |
| 11. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION |
Check each timing mark at TDC/compression.

| *1 | Timing Mark | *2 | Mark Plate (Orange) |
| *3 | Mark Plate (Yellow) | - | - |
| 12. INSTALL CHAIN TENSIONER SLIPPER |
Install the chain tensioner slipper to the cylinder block.
| 13. INSTALL NO. 2 CHAIN VIBRATION DAMPER |
Install the No. 2 chain vibration damper with the 2 bolts.
| 14. INSTALL TIMING CHAIN COVER OIL SEAL |
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Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
Apply MP grease to the lip of the oil seal.
| 15. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY |
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.

| *a | Clean and degrease | - | - |
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Install 3 new O-rings.
Apply seal packing as shown in the illustration.

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

| Item | Seal Packing |
| Dashed line | Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Continuous line | |
| Alternate long and short dashed line | Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent |
| Area | Seal Packing Diameter | Distance from Edge of Cover to: | Seal Packing Application Length | Distance from Top of Cover to Top of Seal Packing |
| Dashed line | 2.5 to 3.0 mm (0.0984 to 0.118 in.) | Center of seal packing 2.5 mm (0.0984 in.) | - | - |
| Continuous line | 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) | - | - | - |
| Alternate long and short dashed line | 4.0 mm (0.157 in.) | Center of seal packing 3.0 mm (0.118 in.) | - | - |
| A - A | 2.5 to 3.5 mm (0.0984 to 0.138 in.) | Center of seal packing 2.5 mm (0.0984 in.) | - | - |
| B - B | 4.5 to 5.5 mm (0.177 to 0.217 in.) | Opposite edge of seal packing 5.0 mm (0.197 in.) | - | - |
| C - C | 7.0 to 8.0 mm (0.276 to 0.315 in.) | Opposite edge of seal packing 7.5 mm (0.295 in.) | - | - |
| F | 4.5 to 5.5 mm (0.177 to 0.217 in.) | - | 15.5 mm (0.610 in.) | 50.4 mm (1.98 in.) |
| G | 4.5 to 5.5 mm (0.177 to 0.217 in.) | - | 10.3 mm (0.406 in.) | 143.1 mm (5.63 in.) |
| H | 7.0 to 8.0 mm (0.276 to 0.315 in.) | - | 19.5 mm (0.768 in.) | 153.4 mm (6.04 in.) |
| I | 4.5 to 5.5 mm (0.177 to 0.217 in.) | - | 16.0 mm (0.630 in.) | 385.8 mm (1.27 ft.) |
| J | 4.5 to 5.5 mm (0.177 to 0.217 in.) | - | 18.6 mm (0.732 in.) | 51.4 mm (2.02 in.) |
| K | 4.5 to 5.5 mm (0.177 to 0.217 in.) | - | 25.3 mm (0.996 in.) | 121.9 mm (4.80 in.) |
| L | 7.0 to 8.0 mm (0.276 to 0.315 in.) | - | 25.8 mm (1.02 in.) | 147.2 mm (5.80 in.) |
| M | 4.5 to 5.5 mm (0.177 to 0.217 in.) | - | 5.1 mm (0.201 in.) | 173.0 mm (6.81 in.) |
| N | 4.5 to 5.5 mm (0.177 to 0.217 in.) | - | 14.6 mm (0.575 in.) | 385.8 mm (1.27 ft.) |
| O | 4.0 mm (0.157 in.) | Center of seal packing 3.0 mm (0.118 in.) | - | - |
Clean the bolt and fitting hole.
Install the timing chain cover.
Temporarily tighten the engine mounting bracket RH with the 3 bolts.
| Item | Length |
| Bolt | 80 mm (3.15 in.) |
Install 2 new O-rings.
Temporarily tighten the oil filter bracket with the 4 bolts.
| Item | Length |
| Bolt | 35 mm (1.38 in.) |
Install the timing chain cover with the 25 bolts and seal washer as shown in the illustration.

| *1 | Seal Washer | - | - |
| *a | Torque | *b | Bolt Torque Order |
| Item | Length |
| Bolt A, F | 35 mm (1.38 in.) |
| Bolt B | 55 mm (2.16 in.) |
| Bolt C | 80 mm (3.15 in.) |
| Bolt D | 40 mm (1.57 in.) |
| Bolt E | 55 mm (2.16 in.) |
| 16. INSTALL CRANKSHAFT PULLEY |
Align the pulley set key with the key groove of the pulley.
Install the crankshaft pulley to the crankshaft.
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Using SST, hold the pulley in place and tighten the bolt.
| *a | Hold |
| *b | Turn |
| 17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY |
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Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.
| *1 | Cam |
| *2 | Pin |
| *3 | Hook |
| *a | Push |
| *b | Raise |
| *c | CORRECT |
| *d | INCORRECT |
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Install a new gasket, the bracket and chain tensioner with the 2 nuts.
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Rotate the crankshaft counterclockwise slightly and check that the hook is released.
| *1 | Pin |
| *2 | Hook |
| *a | Push |
| *b | Turn |
| *c | Disconnect |
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Turn the crankshaft clockwise and check that the plunger is extended.
| *1 | Plunger |
| *a | Turn |
| *b | Plunger Extended |
| 18. INSTALL SPARK PLUG TUBE GASKET |
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Using a cutter knife, cut off the seal part of the removed gasket.
![]() | Part to Cut Off |
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Using a hammer and the plug tube gasket which has had the sealing part cut off, uniformly tap in a new plug tube gasket all the way.
| *1 | Plug Tube Gasket without Sealing Part |
| *2 | New Plug Tube Gasket |
Return the claws of the ventilation baffle plate to their original positions.
| 19. INSTALL CYLINDER HEAD COVER GASKET |
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Install a new cylinder head cover gasket to the cylinder head cover.
| *1 | Cylinder Head Cover |
| *2 | Cylinder Head Cover Gasket |
| 20. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY |
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Install 2 new gaskets to the camshaft bearing cap.
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Apply seal packing as shown in the illustration.
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Install the cylinder head cover with a new seal washer and the 13 bolts.
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| *1 | Timing Chain Cover |
| *2 | Camshaft Housing |
| *3 | Cylinder Head Cover Gasket |
| 21. INSTALL IGNITION COIL ASSEMBLY |
Install the 4 ignition coils with the 4 bolts.
Connect the 4 ignition coil connectors.
| 22. INSTALL FUEL INJECTOR ASSEMBLY |
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Install a new insulator and O-ring to each fuel injector assembly.
| *1 | O-ring |
| *2 | Insulator |
Apply a light coat of gasoline or spindle oil to the contact surfaces of the new O-ring on each fuel injector assembly.
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While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe sub-assembly.
| 23. INSTALL NO. 1 DELIVERY PIPE SPACER |
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Install the 2 No. 1 delivery pipe spacers onto the cylinder head.
| *a | Delivery Pipe Side |
| *b | Cylinder Head Side |
| 24. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY |
Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts.
Install the bolt to secure the fuel delivery pipe sub-assembly.
| 25. INSTALL FUEL VAPOR FEED PIPE |
Install the fuel vapor feed pipe with the bolt.
| 26. INSTALL INTAKE MANIFOLD |
Install a new No. 1 intake manifold to head gasket to the intake manifold.
Install the intake manifold with the 2 bolts and 2 nuts.
Connect the fuel vapor feed hose and ventilation hose.
Install a new O-ring to the engine oil level dipstick guide sub-assembly.
Apply a light coat of engine oil to the O-ring.
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Install the engine oil level dipstick guide sub-assembly with the 2 bolts and connect the wire harness clamp.
Install the engine oil level dipstick.
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Connect the 2 wire harness clamps and 3 connectors.
| 27. INSTALL EGR COOLER SUB-ASSEMBLY |
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Temporarily install a new gasket and the EGR cooler sub-assembly with the 2 nuts (A).
| *A | Nut (C), Type A |
| *B | Nut (C), Type B |
| *1 | Bolt |
| *2 | Stud Bolt and Nut |
Install 2 new gaskets and set the EGR valve with cooler assembly in place.
Using an E8 "TORX" socket wrench, install the 4 stud bolts.
Temporarily install the 4 nuts (B and C) and bolt.
Tighten the 2 nuts (A).
Tighten the 2 nuts (B) and bolt.
Tighten the 2 nuts (C).
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Connect the connector, wire harness clamp and 4 water hoses.
| 28. INSTALL EGR VALVE ASSEMBLY |
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Temporarily install a new gasket and the EGR valve assembly with the 2 nuts (A).
| *A | Nut (C), Type A |
| *B | Nut (C), Type B |
| *1 | Bolt |
| *2 | Stud Bolt and Nut |
Install 2 new gaskets and set the EGR valve with cooler assembly in place.
Using an E8 "TORX" socket wrench, install the 4 stud bolts.
Temporarily install the 4 nuts (B and C) and bolt.
Tighten the 2 nuts (A).
Tighten the 2 nuts (B) and bolt.
Tighten the 2 nuts (C).
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Connect the connector, wire harness clamp and 4 water hoses.
| 29. INSTALL EGR PIPE ASSEMBLY |
Install 2 new gaskets and EGR pipe assembly with the 4 bolts.
Install the wire harness support with the bolt.
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Connect the 2 wire harness clamps.
| 30. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE |
Apply a light coat of engine oil to a new O-ring.
Install the O-ring to the engine oil level dipstick guide.
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Install the engine oil level dipstick guide with the 2 bolts.
Connect the clamp to the engine oil level dipstick guide.
Install the oil dipstick.
| 31. INSTALL THROTTLE BODY ASSEMBLY |
Install a new gasket onto the intake manifold.
Install the throttle body assembly with the 2 bolts and 2 nuts.
Connect the 2 water by-pass hoses and throttle body connector.
| 32. INSTALL ENGINE HANGERS |
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Install the 2 engine hangers with the 2 bolts.
| Part Name | Part No. |
| No. 1 engine hanger | 12281-37021 |
| No. 2 engine hanger | 12282-37011 |
| Bolt | 91552-81050 |
| 33. REMOVE ENGINE STAND |
Remove the engine from the engine stand.
| 34. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE |