OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL WATER INLET PIPE


    1. A001EMY

      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. A001B62

      Install a new oil pump gasket.

    2. A001CVF

      Install a new O-ring.

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

      A001DPHE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A001BDIE17
        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 (0.1181 to 0.1575 in.) 2.5 mm (0.098 in.)
        Dashed Line Area 6.4 mm (0.2520 in.) or more, or within OK area shown in illustration 0.5 mm (0.020 in.)
        Diagonal Line Area 3.0 to 4.0 mm (0.1181 to 0.1575 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. A001FHH

      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. A001EUZE01
      *1 Nut

      Temporarily tighten 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 (2.165 in.) 8 mm (0.315 in.)
      Bolt C 70 mm (2.756 in.) 8 mm (0.315 in.)
      Bolt D 35 mm (1.378 in.) 10 mm (0.394 in.)
      Bolt E 55 mm (2.165 in.) 10 mm (0.394 in.)
      Bolt F 80 mm (3.150 in.) 10 mm (0.394 in.)

      Note

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

    6. A001E3JE03

      Tighten the 11 bolts in several steps, in the sequence shown in the illustration.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    7. A0019UO

      Temporarily tighten the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

    8. A001AE1E03
      *a Nut

      Tighten the 21 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.

      A00192ZE01
    9. A001ABL

      Install the 2 new gaskets and the 2 plugs.

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

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)


    1. A0018YZ

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

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

      Note

      Remove any oil from the contact surface.

    3. A001FC0E01
      *1 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.

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

    4. A001BHZE04

      Install the cylinder head cover with 2 new seal washers and the 15 bolts.

      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 }

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A001ACI

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

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

      Note

      Remove any oil from the contact surface.

    3. A001B7IE01
      *1 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.

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

    4. A001EGQE05

      Install the cylinder head cover with 2 new seal washers and the 15 bolts.

      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 IGNITION COIL ASSEMBLY

    Click here

  6. INSTALL CRANKSHAFT PULLEY


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

    2. A001FHVE04
      *1 Hold
      *2 Turn

      Using SST, install the pulley bolt.

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

  7. INSTALL RESONATOR BRACKET SUB-ASSEMBLY

    Click here

  8. INSTALL OIL FILTER BRACKET


    1. A001EDT

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

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

  9. INSTALL OIL FILTER ELEMENT

    Click here

  10. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (for Bank 1)

    Click here

  11. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY (for Bank 2)

    Click here

  12. INSTALL FRONT WATER BY-PASS JOINT

    Click here

  13. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  14. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

    Click here

  15. INSTALL WATER PUMP PULLEY

    Click here

  16. INSTALL WATER INLET HOUSING


    1. A001BXB

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

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A001ARL

      Using needle-nose pliers, grip the claws of the clips and slide the clips to connect the water by-pass hoses and water inlet hose.

  17. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH

    Click here

  18. INSTALL NO. 3 ENGINE COVER

    Click here

  19. INSTALL INTAKE MANIFOLD

    Click here

  20. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  21. INSTALL GENERATOR ASSEMBLY

    Click here

  22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  23. CONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

  24. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  25. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  26. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  27. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS)

    Click here

  28. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS)

    Click here

  29. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  30. INSTALL FRONT STABILIZER BAR

    Click here

  31. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  32. CONNECT ENGINE WIRE


    1. A001CK8

      Connect the engine wire with the 4 nuts.

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

    2. Connect the clamp and install the 2 clamp brackets with the 2 bolts.

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

    3. Connect the intake air control valve actuator connector.

    4. Connect the No. 1 vacuum switching valve connector.

    5. A001FBT

      Connect the ground wire with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    6. A001E66

      for Engine Room RH Side:


      1. Connect the 2 clamps and install the 3 clamp brackets with the 3 bolts.

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

      2. Connect the engine oil level sensor connector.

      3. Connect the crankshaft position sensor connector.

      4. Connect the starter connector and starter wire with the nut.

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

      5. Connect the generator connector and generator wire with the nut.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      6. Connect the camshaft position sensor connector.

      7. Connect the engine wire connector.

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

      9. Connect the 2 VVT sensor connectors.

      10. Connect the 4 ignition coil connectors.

      11. Connect the camshaft timing control valve connector.

      12. A0019OP

        Connect the wires to the No. 1 engine room junction block with the 2 nuts.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      13. A001A27

        Connect the 3 connectors to the front controller with the clamp.

    7. A001C68

      for Engine Room LH Side:


      1. Install the clamp bracket with the bolt.

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

      2. Connect the 3 clamps and 3 ground wires with the 3 bolts.

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

      3. Attach the clamp and connect the cooler compressor connector.

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

      5. Connect the engine oil pressure sensor connector.

      6. Connect the engine coolant temperature sensor connector.

      7. A001BFP

        Connect the clamp and install the 2 clamp brackets with the 2 bolts.

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

      8. Connect the No. 8 engine wire connector.

      9. Connect the 2 VVT sensor connectors.

      10. Connect the 4 ignition coil connectors.

      11. Connect the camshaft timing control valve connector.

      12. A001EMF

        Connect the 3 ECT connectors and 4 ECM connectors.

      13. Install the ECM box cover (upper).

  33. INSTALL ENGINE ROOM ECU OUTLET DUCT

    Click here

  34. INSTALL SKID CONTROL ECU BRACKET

    Click here

  35. CONNECT NO. 2 RADIATOR HOSE

  36. CONNECT NO. 1 RADIATOR HOSE

  37. INSTALL V-RIBBED BELT

    Click here

  38. INSTALL RADIATOR RESERVOIR ASSEMBLY

    Click here

  39. INSTALL AIR CLEANER ASSEMBLY LH

    Click here

  40. INSTALL AIR CLEANER ASSEMBLY RH

    Click here

  41. INSTALL INTAKE AIR CONNECTOR PIPE

    Click here

  42. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  43. INSTALL ENGINE UNDER COVER REAR LH

    Click here

  44. INSTALL ENGINE UNDER COVER REAR RH

    Click here

  45. INSTALL BATTERY TRAY


    1. Install the battery tray with the 3 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    2. Install the battery and battery insulator.

  46. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Install the battery clamp and 2 clamp bolts with the nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  47. ADD ENGINE OIL

    Click here

  48. ADD ENGINE COOLANT

    Click here

  49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  50. INSPECT FOR OIL LEAK

    Click here

  51. INSPECT FOR COOLANT LEAK

    Click here

  52. INSPECT FOR EXHAUST GAS LEAK

    Click here

  53. CHECK ENGINE OIL LEVEL

    Click here

  54. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER

    Click here

  55. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  56. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  57. INSTALL ENGINE ROOM SIDE COVER RH

    Click here

  58. INSTALL ENGINE ROOM SIDE COVER LH

    Click here

  59. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY

    Click here

  60. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  61. INSTALL COWL TOP VENTILATOR LOUVER RH

    Click here