OIL PUMP INSTALLATION

PROCEDURE

  1. INSTALL WATER INLET PIPE

    1. Apply soapy water to 2 new O-rings and install them to the inlet pipe.

    2. Install the inlet pipe to the No. 1 heat exchanger cover.

  2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    1. Apply a light coat of engine oil to a new gasket.

    2. Install the gasket to the cylinder block.

    3. Apply a light coat of engine oil to a new O-ring.

    4. Install the O-ring to the oil pan.

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

      A273567C01

      *1

      Continuous Line Area

      *2

      Dashed Line Area

      *3

      Diagonal Line Area

      -

      -

      Seal packing

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

      • A229741C01

        *1

        Seal Packing Thickness mm (in.)

        *2

        Seal Packing Width mm (in.)

        *3

        Seal Packing Thickness

        *4

        Seal Packing Width

        *a

        OK Area

        Application Specification

        Area

        Seal Packing Diameter

        Application Position from Inside Edge of Cover

        Continuous line area

        3.0 to 4.0 mm (0.118 to 0.157 in.)

        2.5 mm (0.0984 in.)

        Dashed line area

        6.4 mm (0.252 in.) or more, or within OK area shown in illustration

        7.0 mm (0.276 in.)

        Diagonal line area

        3.0 to 4.0 mm (0.118 to 0.157 in.)

        5.5 mm (0.217 in.)
      Note:

      • 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.

    6. A210031

      Align the oil pump drive rotor spline and crankshaft as shown in the illustration and install the chain cover.

    7. A273556C01

      *1

      Nut

      Temporarily install the 26 bolts and nut.

      Standard Bolt

      Item

      Length

      Thread Diameter

      Bolt A

      25 mm (0.984 in.)

      8 mm (0.315 in.)

      Bolt B

      55 mm (2.17 in.)

      8 mm (0.315 in.)

      Bolt C

      70 mm (2.76 in.)

      8 mm (0.315 in.)

      Bolt D

      35 mm (1.38 in.)

      10 mm (0.394 in.)

      Bolt E

      55 mm (2.17 in.)

      10 mm (0.394 in.)

      Bolt F

      80 mm (3.15 in.)

      10 mm (0.394 in.)
      Note:

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

    8. A273557E02

      Tighten the 3 bolts in several steps in the sequence shown in the illustration.

      47 N*m

      479 kgf*cm

      35 ft.*lbf

    9. A273685E02

      Temporarily install the fan bracket with the 5 bolts.

      Standard Bolt

      Item

      Length

      Thread Diameter

      Bolt A

      70 mm (2.76 in.)

      8 mm (0.315 in.)

      Bolt B

      80 mm (3.15 in.)

      10 mm (0.394 in.)
    10. A229736C01

      *1

      Bolt

      *2

      6 mm Hexagon Bolt

      Temporarily install the belt tensioner with the bolt and 6 mm hexagon bolt.

    11. A273558E01

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

      47 N*m

      479 kgf*cm

      35 ft.*lbf

    12. A273560E01

      Tighten the 22 bolts and nut labeled 12 to 34 in several steps in the sequence shown in the illustration.

      23 N*m

      235 kgf*cm

      17 ft.*lbf

      Note:

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

      A210033C01

      *a

      Labeled A
      Note:

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

    13. Check the torque of each bolt and nut again.

  3. INSTALL FRONT CRANKSHAFT OIL SEAL

    Click here

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

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

    2. Install the cover gasket to the cylinder head cover.

      Note:

      Remove any oil from the contact surface.

    3. A229737C01

      *a

      Seal Packing

      Apply seal packing as shown in the illustration.

      Seal packing

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

      Note:

      • 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.

    4. Install a new seal washer to the bolt.

    5. A273561C01

      *1

      Bolt A

      Temporarily install the cylinder head cover with the 14 bolts. Tighten the bolts uniformly in several steps.

      for bolt A

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      for bolt B

      12 N*m

      122 kgf*cm

      9 ft.*lbf

      Standard Bolt

      Item

      Length

      Thread Diameter

      Bolt A

      70 mm (2.76 in.)

      8 mm (0.315 in.)

      except Bolt A

      25 mm (0.984 in.)

      6 mm (0.236 in.)
      Note:

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

  5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

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

    2. Install the cover gasket to the cylinder head cover.

      Note:

      Remove any oil from the contact surface.

    3. A229738C01

      *a

      Seal Packing

      Apply seal packing as shown in the illustration.

      Seal packing

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

      Note:

      • 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.

    4. Install a new seal washer to the bolt.

    5. A273562C01

      *1

      Bolt A

      Temporarily install the cylinder head cover with the 14 bolts. Tighten the bolts uniformly in several steps.

      for bolt A

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      for bolt B

      12 N*m

      122 kgf*cm

      9 ft.*lbf

      Standard Bolt

      Item

      Length

      Thread Diameter

      Bolt A

      70 mm (2.76 in.)

      8 mm (0.315 in.)

      except Bolt A

      25 mm (0.984 in.)

      6 mm (0.236 in.)
      Note:

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

  6. INSTALL IGNITION COIL ASSEMBLY

    Click here

  7. INSTALL NO. 3 AIR TUBE

    1. Install a new gasket to the No. 3 air tube.

    2. A229749C01

      *1

      No. 3 Air Tube

      *2

      Claw

      *3

      Exhaust Manifold

      Install the No. 3 air tube with the 2 stud bolts, 2 nuts and bolt.

      for bolt and nut

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      for stud bolt

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

      Note:

      Make sure the claws of the gasket are not caught between the No. 3 air tube and exhaust manifold.

    3. Install the 2 wire harness clamp brackets with the 2 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

  8. INSTALL NO. 4 AIR TUBE

    1. Install a new gasket to the No. 4 air tube.

    2. A229750C01

      *1

      No. 4 Air Tube

      *2

      Claw

      *3

      Exhaust Manifold

      Install the No. 4 air tube with the 2 stud bolts, 2 nuts and bolt.

      for bolt and nut

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      for stud bolt

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

      Note:

      Make sure the claws of the gasket are not caught between the No. 4 air tube and exhaust manifold.

    3. Install the 2 wire harness clamp brackets with the 2 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

  9. INSTALL CRANKSAHFT PULLEY

    1. A164230C01

      *a

      Hold

      *b

      Turn

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

    2. Using SST, install the pulley set bolt.

      09213-70011

      09330-00021

      300 N*m

      3059 kgf*cm

      221 ft.*lbf

  10. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

    1. Install the idler pulley with the bolt.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

  11. INSTALL WATER PUMP PULLEY

    Click here

  12. INSTALL FRONT WATER BY-PASS JOINT

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

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  13. INSTALL WATER INLET HOUSING

    1. Install a new gasket to the timing chain cover.

    2. Install the water inlet housing with the 3 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  14. CONNECT NO. 5 WATER BY-PASS HOSE

    Click here

  15. CONNECT NO. 8 WATER BY-PASS HOSE

    Click here

  16. INSTALL NO. 3 WATER BY-PASS HOSE

    1. A232107C01

      *1

      Paint Mark

      *2

      Protrusion

      Install the hose.

      Tip:

      Align the paint mark on the hose with the protrusion of the front water by-pass joint, and then align the claw of the clip with the paint mark.

  17. INSTALL NO. 3 WATER BY-PASS PIPE

    1. A232108C01

      *a

      Upward

      *b

      LH Side

      Connect the hose.

    2. Install the water by-pass pipe with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Tip:

      The direction of the clip is indicated in the illustration.

  18. INSTALL NO. 1 WATER BY-PASS HOSE

    Click here

  19. INSTALL WATER BY-PASS HOSE

    1. A229711C01

      *1

      Paint Mark

      Install the water by-pass hose.

      Tip:

      Be sure to align the claw of the clip with the paint mark on the hose.

  20. CONNECT NO. 4 WATER BY-PASS PIPE

    1. Connect the No. 4 water by-pass pipe with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  21. CONNECT HEATER WATER HOSE

    1. A229709C01

      *a

      LH Side

      *b

      Rear Side

      Connect the 2 heater water hoses.

      Tip:

      The direction of the hose clamp is indicated in the illustration.

  22. INSTALL FUEL HOSE

    1. Install the fuel hose with the 2 clamps (Click here).

    2. Install the EFI fuel pipe clamp.

  23. INSTALL FUEL TUBE SUB-ASSEMBLY

    1. Install the fuel tube with the 2 bolts (Click here).

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    2. Install the EFI fuel pipe clamp.

  24. INSTALL NO. 3 ENGINE COVER

    Click here

  25. INSTALL NO. 4 ENGINE COVER

    Click here

  26. INSTALL GENERATOR ASSEMBLY

    Click here

  27. CONNECT VANE PUMP ASSEMBLY

    A229744C01

    *1

    Spacer
    Tip:

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

    1. A163289

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

      43 N*m

      438 kgf*cm

      32 ft.*lbf

  28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  29. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

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

    2. Install the 2 O-rings to the timing chain cover.

    3. A280696C01

      *1

      Bolt A

      *2

      Bolt B

      *3

      Nut

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

      35 N*m

      357 kgf*cm

      26 ft.*lbf

      Standard Bolt

      Item

      Length

      Bolt A

      30 mm (1.18 in.)

      Bolt B

      80 mm (3.15 in.)

  30. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  31. INSTALL OIL FILTER ELEMENT

    Click here

  32. CONNECT ENGINE WIRE

    1. A229704

      Connect the clamp and engine wire with the bolt.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    2. for Engine Room RH Side:

      1. A229755

        Connect the wire harness clamp bracket with the bolt.

        8.0 N*m

        82 kgf*cm

        71 in.*lbf

      2. Connect the wire harness clamp.

      3. A229703

        Connect the 6 clamps.

      4. Install the ground wire with the bolt.

        8.0 N*m

        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.

      10. Connect the power steering oil pressure switch connector and solenoid valve connector.

    3. A229702

      for Engine Room LH Side:

      1. Connect the cooler compressor connector.

      2. Connect the 6 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.

      6. Connect the noise filter connector.

      7. Connect the 2 VVT sensor connectors.

      8. Connect the 4 ignition coil connectors.

      9. Connect the injector connector.

  33. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 2)

    Click here

  34. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 1)

    Click here

  35. INSTALL AIR TUBE SUB-ASSEMBLY

    Click here

  36. INSTALL FRONT FENDER APRON SEAL RH

    Click here

  37. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  38. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  39. INSTALL AIR CLEANER CAP AND HOSE

    Click here

  40. INSTALL COOLER COMPRESSOR ASSEMBLY

    1. Install the cooler compressor (Click here).

  41. INSTALL INTAKE MANIFOLD

    1. Install the intake manifold (Click here).

  42. INSTALL RADIATOR ASSEMBLY

    1. Install the radiator (Click here).

  43. ADD ENGINE OIL

    Click here

  44. ADD ENGINE COOLANT

    Click here

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  46. INSPECT FOR OIL LEAK

    Click here

  47. INSPECT FOR COOLANT LEAK

    Click here

  48. CHECK ENGINE OIL LEVEL

    Click here