Diesel Data: Automotive Repair
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Installation








2ZR-FE LUBRICATION: OIL PUMP: INSTALLATION

INSTALLATION

1. INSTALL OIL PUMP ASSEMBLY





(a) Install the oil pump with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 15 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.
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 after 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 NO. 1 CRANKSHAFT POSITION SENSOR PLATE Reassembly
4. INSTALL NO. 2 CHAIN SUB-ASSEMBLY





(a) Set the crankshaft key as shown in the illustration.
(b) Turn the drive shaft so that the cutout faces the right horizontal position.





(c) Align the yellow mark links with the timing marks of each gear as shown in the illustration.
(d) Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.
(e) Temporarily tighten the oil pump drive shaft sprocket with the nut.





(f) 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)





(g) Align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.





(h) Insert a pin punch (3 mm) into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
5. INSTALL CRANKSHAFT TIMING SPROCKET





(a) Install the crankshaft timing sprocket.
6. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
7. INSTALL NO. 2 CHAIN VIBRATION DAMPER





(a) Install the No. 2 chain vibration damper with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
8. INSTALL CHAIN SUB-ASSEMBLY Installation
9. INSTALL CHAIN TENSIONER SLIPPER Installation
10. INSTALL TIMING CHAIN COVER OIL SEAL





(a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover sub-assembly edge.
SST: 09223-22010

NOTICE:
- Keep the lip free of foreign matter.
- Do not tap the oil seal at an angle.

(b) Apply MP grease to the lip of the oil seal.
11. 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 sub-assembly, cylinder head, and cylinder block.









(b) Install 3 new O-rings.
(c) Apply seal packing as shown in the illustration.





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 after 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 sub-assembly in a continuous bead as shown in the following illustration.
NOTICE:
- When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
- Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.





Apply Seal Packing as Follows:






(e) Apply adhesive to the threads of the bolt E.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent





(f) Temporarily install the timing chain cover sub-assembly with the 19 bolts.

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

Bolt Length:










(g) Install a new gasket.
NOTE: Remove any oil from the contact surfaces.





(h) Install the water pump with the 3 bolts.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)





(i) Temporarily install the engine mounting bracket with the 3 bolts.

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

Bolt Length:










(j) Install 2 new O-rings.





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

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

Bolt Length:






(l) Fully tighten the timing chain cover sub-assembly with the 26 bolts as shown in the illustration.





Bolt A, E - Torque: 26 Nm (260 kgf-cm, 19 ft-lbf)
Bolt B, C - Torque: 51 Nm (520 kgf-cm, 37 ft-lbf)
Bolt D - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
- When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
- Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying the seal packing.
- Do not start the engine for at least 2 hours after installing.

12. INSTALL CRANKSHAFT PULLEY Installation
13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Reassembly
14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly
15. INSTALL RADIO SETTING CONDENSER Installation
16. INSTALL THERMOSTAT Installation
17. INSTALL INLET WATER Installation
18. INSTALL INLET WATER HOSE Installation
19. INSTALL WATER BY-PASS HOSE Installation
20. INSTALL NO. 1 WATER BY-PASS PIPE Installation
21. INSTALL NO. 3 WATER BY-PASS HOSE Installation
22. INSTALL VENTILATION HOSE Installation
23. INSPECT EXHAUST MANIFOLD Engine Unit
24. INSTALL EXHAUST MANIFOLD Installation
25. INSTALL MANIFOLD STAY Installation
26. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
27. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY Installation
28. INSTALL IGNITION COIL ASSEMBLY Installation
29. INSTALL FUEL INJECTOR ASSEMBLY Installation
30. INSTALL NO. 1 DELIVERY PIPE SPACER Installation
31. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
32. INSTALL FUEL TUBE SUB-ASSEMBLY Installation
33. INSTALL INTAKE MANIFOLD Installation
34. REMOVE ENGINE STAND Installation
35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT: Installation.
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