OIL PUMP INSTALLATION


  1. INSTALL TIMING GEAR CASE ASSEMBLY (Oil Pump Assembly)


    1. A01KFLSE01
      Text in Illustration
      *1 New O-ring

      Install the 2 new O-rings to the cylinder block groove of the timing gear case.

    2. A01KI3LE01
      Text in Illustration
      *1 New Gasket

      Install a new gasket to the groove of the timing gear case.

    3. A01KIJHE01
      Text in Illustration
      *a Width: 3 - 5 mm

      Apply seal packing to the timing gear case as shown in the illustration.

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

      1. Install a nozzle that has been cut to a 3 - 5mm(0.16 - 0.20 in.) opening.

        Tech Tips

        Avoid applying an excessive amount to the surface.

      2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

      3. Immediately remove nozzle from the tube and reinstall cap.

    4. A01KFBW

      Install the timing gear case with the union bolt and 8 bolts.

      Torque:
      Union bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      Bolt
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }

  2. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and cylinder block.


      1. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.

      2. Thoroughly clean all components to remove all the loose material.

      3. Using a non-residue solvent, clean both sealing surfaces.

        Note

        Do not use a solvent which will affect the painted surfaces.

    2. A01KI1NE01
      Text in Illustration
      *a Width: 3 - 5 mm

      Apply seal packing to the oil pan as shown in the illustration.

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

      1. Install a nozzle that has been cut to a 3 - 5mm(0.12 - 0.20 in.) opening.

      2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

      3. Immediately remove nozzle from the tube and reinstall cap.

    3. Install the oil pan with the 22 bolts and 2 nuts.

      Torque:
      16 N*m  { 165 kgf*cm, 12 ft.*lbf }

    4. Remove the timing gear case plug.

    5. Fill the engine oil into the oil pump.


      1. A01KIBY

        Remove the timing gear case plug.

      2. A01KI67

        Pour in approx. 50 cc (3.15 cu in.) of engine oil into the oil pump.

    6. Reinstall a new gasket and the screw plug.

      Torque:
      41.5 N*m  { 423 kgf*cm, 31 ft.*lbf }

  3. INSTALL REAR END PLATE

  4. INSTALL CYLINDER BROCK INSULATOR NO.4

  5. INSTALL STIFFENER PLATE LH (MTM)

  6. INSTALL STIFFENER PLATE RH (MTM)

  7. INSTALL INJECTION GEAR


    1. Inserting a new O-ring in between, temporarily install the injection pump assembly with the 2 A nuts.

    2. Securely tighten the 2 A nuts of the injection pump assembly.

      Torque:
      21 N*m  { 215 kgf*cm, 15 ft.*lbf }

    3. Install a new O-ring to the injection gear.

    4. Install the injection gear set nut.

    5. A01KEWHE01

      Using SST, torque the nut.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  8. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A01KGEEE01

      Align the crankshaft timing gear with timing mark 1 facing the forward.

    2. Align the set key on the crankshaft with the key groove of the crankshaft timing gear.

    3. Using SST and a hammer, tap in the pulley.

      SST
      09223-00010

  9. INSTALL IDLE GEAR SHAFT NO.1


    1. A01KEV7E01
      Text in Illustration
      *1 Idler Gear Shaft

      Install the idler gear shaft.


      1. Coat the idler gear shaft with engine oil.

      2. Install the idler gear shaft to the cylinder block.

  10. INSTALL IDLE GEAR NO.1


    1. A01KFNE

      Align the idler gear assembly timing marks "5" and "4" with the crankshaft timing gear mark "5" and injection pump drive gear timing mark "4" respectively, and mesh the gears.

  11. INSTALL IDLE GEAR THRUST PLATE


    1. A01KEUA

      Align the thrust plate set bolt holes.

    2. Install the 2 bolts to the idle gear thrust plate.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    3. Remove the service bolt.

    4. A01KIQK

      Install the crank position sensor plate.

  12. INSTALL TIMING GEAR COVER OIL SEAL (Injection Pump)


    1. A01KI5WE01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

      SST
      09223-15020
      09502-12010
      09950-70010   ( 09951-07100 )

    2. Apply MP grease to the oil seal lip.

  13. INSTALL TIMING GEAR COVER OIL SEAL (Crankshaft Front)


    1. A01KGKBE01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

      SST
      09214-76011

    2. Apply MP grease to the oil seal lip.

  14. INSTALL TIMING GEAR CASE


    1. A01KI05E01
      Text in Illustration
      *1 O-ring

      Install a new O-ring to the timing gear case.

    2. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing gear cover and cylinder block.


      • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.

      • Thoroughly clean all components to remove all the loose material.

      • Using a non-residue solvent, clean both sealing surfaces.

    3. A01KIOQE01
      Text in Illustration
      *a Width: 2 - 3 mm

      Apply seal packing to the timing gear cover as shown in the illustration.

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

      1. Install a nozzle that has been cut to a 2 - 3mm(0.08 - 0.12 in.) opening.

      2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

      3. Immediately remove nozzle from the tube and reinstall cap.

    4. A01KGWV

      Install the timing gear cover with the 14 bolts and 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  15. INSTALL ENGINE OIL LEVEL SENSOR

    Torque:
    5 N*m  { 51 kgf*cm, 44 in.*lbf }

  16. INSTALL INJECTION PUMP ASSEMBLY

    Click here

  17. INSTALL CRANK POSITION NO.2 SENSOR

    Torque:
    8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  18. INSTALL CRANK POSITION SENSOR

    Torque:
    8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  19. INSTALL WATER PUMP ASSEMBLY


    1. A01KGOG

      Install a new gasket, and install the water pump, 5 bolts and 2 nuts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01KHKO

      Install the alternator with belt tensioner assembly and 5 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  21. INSTALL CRANKSHAFT PULLEY


    1. A01KF3DE01

      Align the pulley set key with the key groove of the pulley.

    2. Using SST and a hammer, tap in the pulley.

      SST
      09214-60010
    3. A01KHSEE01

      Using SST, install and torque the plate bolt.

      SST
      09213-58012
      09330-00021
      Torque:
      365 N*m  { 3,700 kgf*cm, 269 ft.*lbf }

  22. INSTALL VANE PUMP ASSEMBLY

    Click here

  23. INSTALL VACUUM PUMP ASSEMBLY


    1. A01KEI6E01
      Text in Illustration
      *1 New O-ring

      Install 2 new O-rings to the vacuum pump.

    2. A01KGGU

      Install the vacuum pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  24. INSTALL TIMING BELT COVER NO.2

  25. INSTALL CAMSHAFT TIMING PULLEY

    Click here

  26. INSTALL TIMING BELT

    Click here

  27. REPLACE ENGINE OIL

  28. CHECK ENGINE OIL LEAK

  29. REFILL ENGINE COOLANT

  30. CHECK ENGINE COOLANT LEAK

  31. REPLACE POWER STEERING FLUID

  32. BLEED POWER STEERING FLUID


    1. Check the fluid level.

    2. Jack up the front of the vehicle and support it with stands.

    3. Turn the steering wheel.


      1. With the engine stopped, turn the wheel slowly from lock to lock several times.

    4. Lower the vehicle.

    5. Start the engine.


      1. Run the engine at idle for a few minutes.

    6. Turn the steering wheel.


      1. With the engine idling, turn the wheel to the left or right full lock position and keep it there for 2 - 3 seconds. Then turn the wheel to the opposite full lock position and keep it there for 2 - 3 seconds (step A).

      2. Repeat step A several times.

    7. Stop the engine.

    8. A01KEKBE17
      Text in Illustration
      *a Normal
      *b Abnormal

      Check for foaming or emulsification.

      Especially, if the system has to be bled twice because of foaming or emulsification, check for fluid leakage in the system.

    9. Check the fluid level.

  33. CHECK POWER STEERING FLUID LEAKAGE