OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL TIMING CHAIN COVER ASSEMBLY


    1. Remove any old seal packing remaining on the sealing surfaces.

    2. Clean the contact surfaces of the timing chain cover assembly, cylinder head sub-assembly and cylinder block sub-assembly and confirm that there is no oil, moisture or other foreign matter on the surfaces.

      A01OBRGC02
      *a Engine Side *b Timing Chain Cover Assembly Side
      B004FVZ Area to be Cleaned and Degreased - -

      Note

      Be sure to clean the contact surfaces, especially the surfaces shown in the illustration.

    3. Apply a light coat of engine oil to a new oil pump gasket and a new oil pipe gasket.

    4. Install the oil pipe gasket to the oil strainer sub-assembly.

    5. Install the oil pump gasket to the stiffening crankcase assembly.

    6. Install a new water outlet gasket to the cylinder head sub-assembly.

    7. A01ODFNC04
      *1 Crankshaft Timing Sprocket
      *a Oil Pump Drive Rotor Spline

      Align the oil pump drive rotor spline with crankshaft timing sprocket as shown in the illustration.

    8. Apply seal packing as shown in the illustration.

      A01OAESC03
      *a 28 mm (1.102 in.) *b 25 mm (0.984 in.)
      *c 26 mm (1.024 in.) *d 2.5 mm (0.0984 in.)
      *e 3.0 mm (0.118 in.) *f 7.0 mm (0.276 in.) or more
      *g 5.0 mm (0.197 in.) *h 13 mm (0.512 in.) or more
      *i 3.0 mm (0.118 in.) or more *j 7.0 mm (0.276 in.)
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Application Specification
      Area Seal Packing Diameter Seal Packing Width Seal Packing Height Application Position from Inside Seal Line
      Dashed line area 3.0 mm (0.118 in.) - - 2.5 mm (0.0984 in.)
      A - A 3.0 mm (0.118 in.) - - 2.5 mm (0.0984 in.)
      B - B 5.0 mm (0.197 in.) 7.0 mm (0.276 in.) or more 3.0 mm (0.118 in.) or more 3.0 mm (0.118 in.)
      C - C 7.0 mm (0.276 in.) 13 mm (0.512 in.) or more 3.0 mm (0.118 in.) or more 5.0 mm (0.197 in.)
      D - D 5.0 mm (0.197 in.) 7.0 mm (0.276 in.) or more 3.0 mm (0.118 in.) or more 3.0 mm (0.118 in.)
      E 3.0 mm (0.118 in.) - - 3.0 mm (0.118 in.)

      Note


      • Install the timing chain cover assembly within 3 minutes and tighten the bolts and nuts within 10 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    9. Temporarily install the timing chain cover assembly with the 19 bolts and 3 nuts.

      A01O9O1C03
      *a Torque *b Tightening Order
      B004FMB Bolt B004EIV Nut
      Bolt Dimension
      Item Length Diameter
      Bolt (A) 30 mm (1.18 in.) 8.0 mm (0.315 in.)
      Bolt (B) 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt (C) 45 mm (1.77 in.) 8.0 mm (0.315 in.)

      Note

      Make sure that there is no oil on the threads of the bolt (B).

    10. Tighten the 19 bolts and 3 nuts in the order shown in the illustration.

      Torque:
      Bolt (A), (C) and Nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt (B)
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  2. INSTALL TIMING CHAIN COVER OIL SEAL

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  3. INSTALL WATER OUTLET SUB-ASSEMBLY


    1. Install a new O-ring to the timing chain cover assembly.

    2. Install the water outlet sub-assembly to the timing chain cover assembly with the 2 bolts and nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  4. INSTALL NO. 11 WATER BY-PASS HOSE


    1. A01OAYJC03
      *a Paint Mark (White)
      *b Paint Mark (Yellow)
      *c Rear of Engine
      *d Up

      Install the No. 11 water by-pass hose and slide the 2 clips to secure it.

      Note


      • Install the clips so that they are positioned as shown in the illustration.

      • Install the No. 11 water by-pass hose so that the white paint mark and yellow paint mark are positioned as shown in the illustration.

  5. INSTALL NO. 13 WATER BY-PASS HOSE


    1. A01ODDDC03
      *a Paint Mark (Yellow)
      *b Paint Mark (White)
      *c Up
      *d Front of Engine

      Install the No. 13 water by-pass hose and slide the 2 clips to secure it.

      Note


      • Install the clips so that they are positioned as shown in the illustration.

      • Install the No. 13 water by-pass hose so that the white paint mark and yellow paint mark are positioned as shown in the illustration.

  6. INSTALL CRANKSHAFT PULLEY ASSEMBLY

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  7. INSTALL CRANKSHAFT POSITION SENSOR

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  8. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  9. INSTALL ENGINE OIL LEVEL DIPSTICK

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  10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to 3 new camshaft bearing cap oil hole gaskets.

    2. Install the 3 camshaft bearing cap oil hole gaskets to the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.

    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

    4. A01OBP8C02
      *1 Timing Chain Cover Assembly
      *2 Camshaft Housing Sub-assembly
      *a 5.0 mm (0.197 in.)
      B004FMB Seal Packing

      Apply seal packing as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Standard Seal Packing Diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)

      Note


      • Be sure to clean the contact surfaces.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

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

    5. A01O9TVC02
      *a Pin (A)
      *b Pin (B)
      B004FMB Bolt (A)
      B004EIV Bolt (B)

      Align the pin holes in the cylinder head cover sub-assembly with the pin (A) and pin (B) in this order, and then install the cylinder head cover sub-assembly to the camshaft housing sub-assembly.

    6. Temporarily install 3 new seal washers and the 3 bolts (B).

    7. Temporarily install the 13 bolts (A).

    8. Tighten the 16 bolts in the order shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Bolt Dimension
      Item Length
      Bolt (A) 25 mm (0.984 in.)
      Bolt (B) 35 mm (1.38 in.)

  11. INSTALL IGNITION COIL ASSEMBLY

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  12. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the 2 wiring harness clamp brackets to the timing chain cover assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  13. CONNECT ENGINE WIRE


    1. Engage the wire harness clamp.

    2. Connect the 2 ground wires to the timing chain cover assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the wire harness clamp bracket to the timing chain cover assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Install the wire harness clamp bracket to the timing chain cover assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    5. Connect the engine coolant temperature sensor connector.

    6. Engage the 4 wire harness clamps.

    7. Install the wire harness clamp bracket to the cylinder head cover sub-assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    8. Engage the 2 wire harness clamps to the wire harness clamp bracket.

    9. Connect the engine wire with the 5 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    10. Connect the engine oil pressure switch assembly connector.

    11. Connect the 4 ignition coil assembly connectors.

    12. Connect the 2 VVT sensor connectors.

    13. Connect the 2 camshaft timing oil control valve assembly connectors.

    14. Engage the 3 wire harness clamps.

  14. CONNECT VENTILATION HOSE ASSEMBLY


    1. Connect the ventilation hose assembly to the ventilation valve sub-assembly and slide the clip to secure it.

  15. INSTALL OIL COOLER TUBE SUB-ASSEMBLY


    1. Install the oil cooler tube sub-assembly to the stiffening crankcase assembly with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. Connect the No. 3 engine wire clamp to the oil cooler tube sub-assembly.

  16. INSTALL OUTLET NO. 1 HV WATER PUMP PIPE


    1. Install the outlet No. 1 HV water pump pipe to the stiffening crankcase assembly with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  17. INSTALL V-RIBBED BELT

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  18. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

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  19. CHECK ENGINE OIL LEVEL

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  20. INSPECT FOR ENGINE OIL LEAK

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  21. INSTALL NO. 2 ENGINE UNDER COVER

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  22. INSTALL FRONT SUSPENSION MEMBER BRACE

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  23. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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