OIL PUMP INSTALLATION

Tech Tips

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.


  1. INSTALL WATER INLET PIPE


    1. A01GY03

      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. A01GW7S

      Install a new oil pump gasket.

    2. A01GZLH

      Install a new O-ring.

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

      A01GY9KE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A01H1XPE03
        Apply Seal Packing as Follows
        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 0.5 mm (0.0197 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.

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

    4. A01GW1X

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

    5. A01H1IOE02

      Temporarily install the timing chain cover with the 30 bolts and nut.

      Bolt Length
      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.

    6. A01GYCF

      Tighten the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    7. A01GYJT

      Install the belt tensioner with the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    8. A01GXF1E01

      Tighten the 10 bolts in several steps, in the sequence shown in the illustration.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    9. A01GZTJE01

      Tighten the 19 bolts and nut in several steps, in the sequence shown in the illustration.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Note

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

      A01H1RZE01
    10. A01H0LK

      Install 2 new gaskets and the 2 plugs.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01GZM6

      Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3 and No. 7).

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

      Note

      Remove any oil from the contact surface.

    3. A01H0L9E01

      Apply seal packing as shown the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      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.

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

    4. A01GXUAE01

      Install the cylinder head cover and 2 new seal washers with the 15 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    5. Install the fuel pump spacer.

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01H1IN

      Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 1, No. 3 and No. 6).

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

      Note

      Remove any oil from the contact surface.

    3. A01GWURE01

      Apply seal packing as shown the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      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.

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

    4. A01GZSWE01

      Install the cylinder head cover and 2 new seal washers with the 15 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    5. Install the fuel pump spacer.

  5. INSTALL FRONT CRANKSHAFT OIL SEAL

    A01GYB3E02

    1. Apply MP grease to the lip of a new oil seal.

    2. Using SST and a hammer, tap in the oil seal to a depth between 0 to 1.0 mm (0 to 0.0394 in.) from the timing chain cover edge.

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  6. INSTALL CRANKSHAFT TIMING GEAR KEY

    A01GWH0E01

    1. Install the crankshaft timing gear key to the crankshaft.

  7. INSTALL IGNITION COIL ASSEMBLY

    A01GZU7

    1. Install the 8 ignition coils with the 8 bolts.

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

  8. INSTALL CRANKSHAFT PULLEY


    1. A01GX5JE01

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

    2. Using SST, install the pulley bolt.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  9. INSTALL OIL FILTER BRACKET


    1. A01GYZS

      Install 2 new gaskets and the filter bracket with the 3 bolts.

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

  10. INSTALL OIL FILTER ELEMENT


    1. Clean the inside of the oil filter cap, its threads and O-ring groove.

    2. A01GYR8E01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

      Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

      Note


      • Be sure to install the O-ring in the proper location, otherwise oil may leak.

      • Do not twist the O-ring.

    3. Set a new oil filter element to the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

    6. A01H13BE01
      Text in Illustration
      *1 Oil Filter Bracket Clip
      *2 Oil Filter Cap
      *3 O-Ring
      *4 Oil Filter Bracket
      *a No Clearance

      Using SST, tighten the oil filter cap.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note


      • Do not remove the oil filter bracket clip.

      • Make sure that the oil filter is installed securely as shown in the illustration.

      • Be careful that the O-ring does not get caught between any surrounding parts.

    7. A01H1MRE02
      Text in Illustration
      *1 O-Ring

      Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

      Note

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

    8. Install the oil filter drain plug.

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

      Note

      Be careful that the O-ring does not get caught between any surrounding parts.

  11. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH


    1. A01H1MBE01

      Turn the camshaft timing gear assembly's intermediate shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position.

      Tech Tips


      • When the cam of the camshaft lifts the valve, the intermediate shaft becomes difficult to turn.

      • The position where the intermediate shaft stops is the maximum retard angle.

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

    3. A01GW8R

      Align the joint of the camshaft timing control motor and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts.

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

      Note


      • Check that [R] is printed on the label of the camshaft timing control motor.

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor (connecting surface with timing chain cover sub-assembly).

      • When installing the camshaft timing control motor, do not use excessive force.

      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor.

      • Install the camshaft timing control motor with the arrow facing upward, as shown in the illustration.

      • Do not drop the camshaft timing control motor. If dropped, replace it.

      • Do not disassemble the camshaft timing control motor assembly. If disassembled, replace it.

  12. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH


    1. A01H0K3E01

      Turn the camshaft timing gear assembly's intermediate shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position.

      Tech Tips


      • When the cam of the camshaft lifts the valve, the intermediate shaft becomes difficult to turn.

      • The position where the intermediate shaft stops is the maximum retard angle.

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

    3. A01GYDHE02

      Align the joint of the camshaft timing control motor and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts.

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

      Note


      • Check that [L] is printed on the label of the camshaft timing control motor.

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor (connecting surface with timing chain cover sub-assembly).

      • When installing the camshaft timing control motor, do not use excessive force.

      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor.

      • Install the camshaft timing control motor with the arrow facing upward, as shown in the illustration.

      • Do not drop the camshaft timing control motor. If dropped, replace it.

      • Do not disassemble the camshaft timing control motor assembly. If disassembled, replace it.

  13. INSTALL FRONT WATER BY-PASS JOINT


    1. A01H0BH

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

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

  14. INSTALL WATER PUMP PULLEY


    1. A01GXZLE01

      Temporarily install the pulley with the 4 bolts.

    2. Using SST, hold the pulley and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  15. INSTALL WATER INLET HOUSING


    1. A01H0SI

      Install a new gasket and the inlet housing with the 3 bolts.

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

    2. Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the water inlet hose.

  16. INSTALL FUEL PUMP ASSEMBLY (for Bank 2)

    A01GZ5FE01

    1. Turn the camshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.

      Tech Tips

      By not using the camshaft lobe to push up the pump lifter surface, it is easier to install the fuel pump and No. 2 fuel pipe later.

    2. Pour 30 cc (1.8 cu. in.) of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.

    3. A01GZCJE04

      Apply a coat of engine oil to the pump activation cam and pump lifter.

    4. A01H11LE03

      Install a new fuel pump insulator to the cylinder head cover. Then pass the 2 stud bolts through the holes of the fuel pump and set it on the insulator.

      Note

      Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.

    5. A01H1U0E01

      Install the fuel pump with the 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    6. Connect the No. 1 fuel hose.

      Tech Tips

      As shown in the illustration.

    7. Connect the fuel pump connector.

  17. INSTALL FUEL PUMP ASSEMBLY (for Bank 1)

    A01GYKJE02

    1. Turn the camshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.

      Tech Tips

      By not using the camshaft lobe to push up the pump lifter surface, it is easier to install the fuel pump and No. 3 fuel pipe later.

    2. Pour 30 cc (1.8 cu. in.) of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.

    3. A01GZCJE04

      Apply a coat of engine oil to the pump activation cam and pump lifter.

    4. A01H11LE03

      Install a new fuel pump insulator to the cylinder head cover. Then pass the 2 stud bolts through the holes of the fuel pump and set it on the insulator.

      Note

      Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.

    5. A01H1S1E02

      Install the fuel pump with the 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    6. Connect the No. 2 fuel hose.

      Tech Tips

      As shown in the illustration.

    7. Connect the fuel pump connector.

  18. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Install a new O-ring, new No. 1 backup ring, new No. 2 backup ring and a new E-ring to the No. 3 fuel pipe sub-assembly as shown in the illustration.

      A01GYGIE03
      Text in Illustration
      *1 No. 1 Backup Ring *2 No. 2 Backup Ring
      *3 O-Ring *4 E-Ring
      *a Alignment Opening *b Overlapped
      *c Stretched *d CORRECT
      *e INCORRECT - -

      Note


      • Check that there is no foreign matter or damaged areas in the No. 3 fuel pipe sub-assembly O-ring groove.

      • Check that the No. 1 backup ring and No. 2 backup ring are installed in the correct direction.

      • Make sure that the backup rings and O-ring are installed in the correct order.

      • Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.

      • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

    2. A01H06J

      Apply engine oil to the O-ring.

      Note

      Make sure there is no gasoline on the O-ring and inside the installation hole.

    3. Temporarily install the No. 3 fuel pipe sub-assembly to the delivery pipe with the 2 bolts.

    4. A01GX2G

      Temporarily install the No. 3 fuel pipe sub-assembly to the fuel pump.

      Note

      Be careful not to damage the sealing surface of the No. 3 fuel pipe sub-assembly when temporarily installing the No. 3 fuel pipe sub-assembly.

    5. Tighten the 2 bolts in several passes.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    6. A01GXVSE01
      Text in Illustration
      *1 Union Nut Wrench

      Using a 19 mm union nut wrench, tighten the union nut.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note


      • There must be absolutely no free play in the union on the fuel pump side. If the union on the fuel pump side has free play, replace the fuel pump.

      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

      Tech Tips

      Make sure use the union nut wrench and torque wrench are connected in a straight line.

    7. Connect the fuel pump connector.

  19. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

    Tech Tips

    The installation procedures are the same as for the No. 3 fuel pipe sub-assembly.

  20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY


    1. Apply a light coat of engine oil to the threads and gasket seating surfaces of the 2 fuel pressure pulsation damper assemblies.

    2. A01GWT5E02

      Temporarily install each dampers together with 2 new gaskets and the fuel pipe to the fuel pump.

    3. A01GY7X

      Install the 2 clamp bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A01GWUPE03

      Using SST, tighten the 2 dampers.

      SST
      09612-24014   ( 09617-24011 )
      Torque:
      without SST
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      with SST
      31 N*m  { 313 kgf*cm, 23 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the torque wrench are connected in a straight line.

    5. A01GYHSE01

      Connect the 3 fuel hoses.

    6. A01GYCME03

      Connect the 2 delivery pipe connectors to the delivery pipe.

  21. INSTALL INTAKE MANIFOLD ASSEMBLY

    A01H0CLE01

    1. Install 2 new gaskets to the intake manifold.

    2. Temporarily install the intake manifold with the 2 nuts and 8 bolts. Then tighten the 2 nuts and 8 bolts uniformly in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A01GY12

      Connect the No. 1 ventilation hose and 2 water by-pass hoses as shown in the illustration.

  22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

    A01GW3G

    1. Slide the clamp to connect the water inlet hose to the front water by-pass joint.

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

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

  23. INSTALL HEATER WATER PUMP ASSEMBLY

    A01GWJJ

    1. Install the heater water pump with the bolt.

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

    2. Slide the 2 clamps to connect the 2 hoses to the water by-pass pipe and water inlet housing.

  24. INSTALL PURGE VSV

    A01GWF6

    1. Install the purge VSV with the bolt.

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

    2. Connect the purge line hose to the intake manifold.

  25. INSTALL NO. 1 ENGINE COVER

    A01GWY7

  26. INSTALL INJECTOR DRIVER

    Note


    • Be careful not to drop or strike the injector driver.

    • The injector driver is grounded at the bolt and nut. To ensure that it is grounded, clean all oil and foreign matter from the installation areas of the injector driver and engine before installing the injector driver.


    1. A01H028E01

      Temporarily install the 2 injector drivers with the 2 bolts and 2 nuts.

    2. Tighten the 2 bolts and 2 nuts in the order shown in the illustration.

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

  27. INSTALL ENGINE WIRE


    1. Engine Upper Side:


      1. A01GZB4

        Connect the engine wire with the 4 nuts.

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

      2. Install the 2 clamp brackets with the 2 bolts and connect the 2 clamps.

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

      3. Connect the intake air control valve actuator connector.

      4. Connect the purge VSV connector.

      5. Connect the 2 clamps.

      6. A01H1TME01

        Connect the 8 injector driver connectors as shown in the illustration.

    2. A01H04L

      Engine Rear Side:


      1. Connect the 2 ground wires with the 2 bolts.

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

      2. Connect the 8 clamps.

      3. Connect the fuel relief valve connector.

      4. Connect the engine wire connector.

    3. A01GZMK

      Engine RH Side:


      1. Connect the 4 clamps.

      2. Connect the fuel injector connector.

      3. Connect the camshaft position sensor connector.

      4. Connect the engine wire connector.

      5. Connect the fuel pump connector (for high pressure).

      6. Connect the 2 VVT sensor connectors.

      7. Connect the 4 ignition coil connectors.

      8. Connect the camshaft timing control valve connector.

    4. A01H0HT

      Engine Front Side:


      1. Connect the 3 ground wires with the 3 bolts.

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

      2. Connect the clamp.

      3. Connect the 2 camshaft timing control motor connectors (for Bank 2).

      4. Connect the 2 camshaft timing control motor connectors (for Bank 1).

      5. Connect the engine coolant temperature sensor connector.

    5. A01H1Y9

      Engine LH Side:


      1. Connect the 4 clamps.

      2. Connect the fuel injector connector.

      3. Connect the fuel pump connector (for high pressure).

      4. Connect the 2 VVT sensor connectors.

      5. Connect the 4 ignition coil connectors.

      6. Connect the camshaft timing control valve connector.

  28. INSTALL NO. 5 COVER SUB-ASSEMBLY


    1. Install the No. 5 cover.

  29. INSTALL ENGINE COVER SUB-ASSEMBLY RH


    1. A01GXYYE01

      Install the engine cover RH with the 4 nuts.

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

  30. INSTALL NO. 6 COVER SUB-ASSEMBLY


    1. Install the No. 6 cover.

  31. INSTALL ENGINE COVER SUB-ASSEMBLY LH


    1. A01GZYBE01

      Install the engine cover LH with the 4 nuts.

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

  32. INSTALL WITH MOTOR COMPRESSOR ASSEMBLY


    1. A01GZLEE01

      Using an E8 ''TORX'' socket wrench, install the with motor compressor assembly with the 2 stud bolts

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

    2. Install the 2 bolts and 2 nuts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the nuts and bolts in the order shown in the illustration to install the cooler compressor.

    3. Connect the connector.

  33. INSTALL V-RIBBED BELT


    1. A01H0Q6E01

      Install the V-ribbed belt as shown in the illustration.

      Note

      Check that the V-ribbed belt is properly set to each pulley.


      1. Rotate the tensioner pulley counterclockwise, and then remove the bar.

    2. A01H0W4E01

      After installing the belt, check that it fits properly in the ribbed grooves.

    3. Check by hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley.

    4. A01GZ5XE01

      Check that the alignment mark on the belt tensioner is within area "A".

      If it is outside area "A", replace the V-ribbed belt.

      Tech Tips

      When a new belt is installed, the alignment mark should be within area "B". If not, the V-ribbed belt is not installed correctly.

  34. INSTALL ENGINE ASSEMBLY

    Click here