Diesel Data: Automotive Repair
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Installation








2AZ-FE LUBRICATION: OIL PUMP: INSTALLATION

INSTALLATION

1. INSTALL OIL PUMP ASSEMBLY





(a) Install a new gasket and the oil pump with the 3 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
2. CONNECT INLET HEATER WATER HOSE Installation
3. CONNECT OUTLET HEATER WATER HOSE Installation
4. CONNECT NO. 1 RADIATOR HOSE Installation
5. INSTALL NO. 2 CHAIN SUB-ASSEMBLY Installation
6. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET Installation
7. INSTALL NO. 1 CHAIN VIBRATION DAMPER Installation
8. INSTALL CHAIN SUB-ASSEMBLY Installation
9. INSTALL CHAIN TENSIONER SLIPPER Installation
10. INSTALL TIMING CHAIN GUIDE Installation
11. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE Installation
12. 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 edge.
SST: 09223-22010

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

(b) Apply MP grease to the lip of the oil seal.
13. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Remove any old packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.





(b) Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 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 chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.

(c) Apply a continuous bead of 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 chain cover within 3 minutes of applying seal packing.
- Do not add engine oil for at least 2 hours after installing the chain cover.

(d) Apply adhesive to the threads of the bolt A.
Seal packing:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent





(e) Temporarily install the timing chain cover with the 12 bolts and 2 nuts.
Bolt Length:










(f) Temporarily install the transverse engine engine mounting bracket with the 3 bolts.
(g) Fully tighten the timing chain cover with the 15 bolts and 2 nuts as shown in the illustration.





Bolt A - Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
Bolt B - Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
Bolt C - Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
Nut - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)





(h) Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.
Torque: 22 Nm (220 kgf-cm, 16 ft-lbf)
14. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Installation
15. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
16. INSTALL CRANKSHAFT PULLEY Installation
17. INSTALL OIL PAN SUB-ASSEMBLY Installation
18. INSTALL CRANKSHAFT POSITION SENSOR Installation
19. INSTALL IDLER PULLEY SUB-ASSEMBLY Installation
20. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH Installation
21. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Installation
22. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
23. INSTALL NO. 2 MANIFOLD STAY Installation
24. INSTALL MANIFOLD STAY Installation
25. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR Installation
26. INSTALL INTAKE MANIFOLD Installation
27. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
28. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
29. CONNECT FUEL MAIN TUBE Installation
30. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation
31. INSTALL ENGINE OIL LEVEL DIPSTICK
32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Installation
33. INSTALL SPARK PLUG Installation
34. INSTALL IGNITION COIL ASSEMBLY Installation
35. INSTALL THROTTLE BODY ASSEMBLY Installation
36. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE Installation
37. INSTALL RADIATOR RESERVE TANK ASSEMBLY Installation
38. INSTALL GENERATOR ASSEMBLY Installation
39. INSTALL V-RIBBED BELT Installation
40. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
41. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2WD) Installation
42. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 4WD) Installation
43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
44. ADD ENGINE OIL Replacement
45. ADD ENGINE COOLANT Service and Repair
46. INSPECT FOR FUEL LEAK Testing and Inspection
47. INSPECT FOR COOLANT LEAK Testing and Inspection
48. INSPECT FOR OIL LEAK
49. INSPECT FOR EXHAUST GAS LEAK
50. INSPECT IGNITION TIMING Engine
51. INSPECT ENGINE IDLING SPEED Engine
52. INSPECT COMPRESSION Engine
53. INSPECT CO/HC Engine
54. INSTALL SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar) Installation
55. INSTALL OUTER COWL TOP PANEL Installation
56. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
57. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
58. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
59. INSTALL HOOD TO COWL TOP SEAL Installation
60. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
61. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
62. INSTALL FRONT WIPER ARM HEAD CAP Installation
63. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
64. INSTALL ENGINE UNDER COVER LH
65. INSTALL ENGINE UNDER COVER RH
66. INSTALL FRONT WHEEL RH
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