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 oil pump gasket.

    2. Install the oil pump gasket.

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

    4. Install the O-ring.

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

      B001YUGE02
      Text in Illustration
      *1 Continuous line area *2 Dashed line area
      *3 Diagonal line area - -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • B001XUVE15
        Text in Illustration
        *1 Seal Packing Thickness mm (in.)
        *2 Seal Packing Width mm (in.)
        *3 Seal Packing Thickness
        *4 Seal Packing Width
        *5 OK Area
        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 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. B001YXI

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

    7. B001VOWE02
      Text in Illustration
      *1 Nut

      Temporarily install the timing chain cover with the 28 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. B001VTXE06

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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    9. B001ZTIE07

      Temporarily install the fluid coupling bracket with the 4 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. B001WHE

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

    11. B001WEKE01

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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    12. B001ZHVE07

      Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.

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

      Note


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

      • B001W8IE05

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

  3. INSTALL SPARK PLUG TUBE GASKET

    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 a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    3. B001Z87

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      B001XPG Seal Packing

      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. B001W0TE07

      Install the cylinder head cover and a new seal washer with the 14 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 }

      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 a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    3. B001VVI

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      B001XPG Seal Packing

      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. B00203VE07

      Install the cylinder head cover and a new seal washer with the 14 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 }

      Note

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

    5. Install the noise filter to the cylinder head cover with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  6. INSTALL IGNITION COIL ASSEMBLY


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

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

  7. INSTALL CRANKSHAFT TIMING GEAR KEY


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

  8. CONNECT WIRE HARNESS CLAMP BRACKET


    1. Connect the bracket to the timing chain cover with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  9. INSTALL CRANKSHAFT PULLEY


    1. B001Y52E08
      Text in Illustration
      *a Hold
      B001XPG Turn

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

    2. Using SST, install the pulley set bolt.

      SST
      09213-70011
      09330-00021
      Torque:
      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.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  11. INSTALL WATER PUMP PULLEY


    1. B001VTPE05

      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 }

  12. INSTALL WATER INLET HOUSING


    1. B001WYME08
      Text in Illustration
      *1 Gasket

      Install a new gasket to the timing chain cover.

    2. Install the water inlet with the 3 bolts.

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

  13. INSTALL NO. 1 ENGINE COVER

  14. INSTALL NO. 2 ENGINE COVER

  15. INSTALL FRONT WATER BY-PASS JOINT


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

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

    2. Connect the No. 2 water by-pass hose to the water by-pass joint.

  16. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Connect the 2 hoses.

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

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

  17. INSTALL NO. 1 WATER BY-PASS HOSE


    1. Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.

  18. INSTALL GENERATOR ASSEMBLY

    Click here

  19. CONNECT OIL COOLER PIPE ASSEMBLY

    Click here

  20. CONNECT VANE PUMP ASSEMBLY

    B001X8EE15

    Tech Tips

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

    Text in Illustration
    *1 Spacer

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

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

  21. INSTALL INTAKE MANIFOLD

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  22. INSTALL OIL FILTER BRACKET

    Click here

  23. INSTALL NO. 1 OIL COOLER BRACKET

    Click here

  24. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Connect the 4 hoses.

    2. Install the water by-pass pipe with the 3 bolts.

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

  25. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

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  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  27. INSTALL OIL FILTER ELEMENT

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  28. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. B001Z7AE11
      Text in Illustration
      *A LH Side
      *B RH Side

      Connect the fuel tube with the 2 bolts.

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

  29. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. B001XQME01

      Install the cooler compressor with the stud bolt.

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

    2. Install the 3 bolts and nut.

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

      Note

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

  30. CONNECT WATER PIPE AND HOSE SUB-ASSEMBLY


    1. Connect the water pipe and hose to the cylinder head cover with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Connect the 3 hoses.

  31. CONNECT ENGINE WIRE


    1. Connect the 2 clamps and power steering oil pressure switch connector.

    2. Engine Room RH Side:


      1. Connect the 5 clamps.

      2. Connect the throttle position sensor and throttle control motor connector.

      3. Install the ground wire with the 2 bolts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      4. Connect the noise filter connector.

      5. Connect the 2 VVT sensor connectors.

      6. Connect the injector connector.

      7. Connect the 4 ignition coil connectors.

      8. Connect the 2 camshaft timing oil control valve connectors.

    3. Engine Room LH Side:


      1. Connect the cooler compressor connector.

      2. Connect the 3 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 4 clamps.

      7. Install the ground wire with the 2 bolts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      8. Connect the noise filter connector.

      9. Connect the 2 VVT sensor connectors.

      10. Connect the 4 ignition coil connectors.

      11. Connect the injector connector.

      12. Connect the 2 connectors and 2 clips to the engine room junction block.

      13. Install the engine room relay block cover.

  32. INSTALL RADIATOR ASSEMBLY

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  33. INSTALL AIR CLEANER ASSEMBLY

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  34. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  35. INSTALL V-BANK COVER SUB-ASSEMBLY

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  36. ADD ENGINE OIL

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  37. ADD ENGINE COOLANT

    Click here

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  39. INSPECT FOR OIL LEAK

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  40. INSPECT FOR COOLANT LEAK

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  41. INSPECT ENGINE OIL LEVEL

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  42. INSTALL NO. 2 ENGINE UNDER COVER

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  43. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

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  44. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

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  45. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

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  46. INSTALL FRONT FENDER APRON SEAL FRONT RH

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  47. INSTALL FRONT FENDER APRON SEAL LH

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  48. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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  49. CONNECT RADIATOR SIDE DEFLECTOR LH

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  50. INSTALL TRANSMISSION OIL COOLER AIR DUCT

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  51. INSTALL FRONT BUMPER COVER

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  52. INSTALL RADIATOR GRILLE

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  53. INSTALL UPPER RADIATOR SUPPORT SEAL

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