OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

      B001X2GE01
      Text in Illustration
      *a Cylinder Head and Cylinder Block Side *b Timing Chain Cover Side
      B001YD9 Clean and degrease - -

      Note

      Be sure to clean and degrease the contact surfaces, especially the surfaces indicated in the illustration.

    2. Apply a light coat of engine oil to a new oil pump gasket.

    3. Install the oil pump gasket.

    4. B001YUWE01
      Text in Illustration
      *1 Seal Diameter
      B001XPG Seal Packing

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      B001Y9QE07
      Text in Illustration
      *a 3.0 to 4.0 mm *b 2.0 to 3.0 mm
      *c Be sure to apply seal packing *d Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *e Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent) *f Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *g Diagonal line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) - -

      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.

      Application Specification
      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Diagonal Line Area 6.0 mm (0.236 in.) or more 5.0 mm (0.197 in.)
    6. B001W5SE04
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft

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

    7. Install the timing chain cover with the 26 bolts, labeled A, B, C and D, and the 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 35 mm (1.38 in.)
      Bolt D 65 mm (2.56 in.)
      B001WF0E01
      Text in Illustration
      *1 Nut - -
      *a Area 1 *b Area 2
      *c Area 3 *d Area 4

      Note

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

    8. Tighten the bolts in area 1.

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

      Tech Tips

      Tighten the bolts from bottom to top as shown in the illustration.

    9. Tighten the bolts in area 2.

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

    10. Tighten the bolts in area 3.

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

      Tech Tips

      Tighten the bolts and nuts from top to bottom as shown in the illustration.

    11. Tighten the bolts in area 4.

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

      Note


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

      • Wipe off any seal packing that seeped out around the surfaces of the oil pan and head cover and make sure that there is no seal packing seeping out around the edges.

      Tech Tips

      Tighten the bolts from bottom to top as shown in the illustration.

  2. INSTALL FRONT CRANKSHAFT OIL SEAL

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  3. 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 cylinder block, rear oil seal retainer and oil pan.

    2. Install 3 new O-rings to the timing chain cover.

    3. B001ZPPE01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes after applying seal packing.

    4. B001VV6E04
      Text in Illustration
      *1 Nut

      Install the oil pan with the 17 bolts (A, B, C, D and E) and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Torque:
      for bolt A, B, C, E, and nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 60 mm (2.36 in.)
      Bolt B 45 mm (1.77 in.)
      Bolt C 25 mm (0.984 in.)
      Bolt D 16 mm (0.630 in.)
      Bolt E 70 mm (2.76 in.)

      Note

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

  4. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install the oil strainer with the 2 nuts.

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

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. B001ZF2E02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan within 3 minutes after applying seal packing.

    2. B001WJD

      Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      B001XPG Bolt
      B001WGT Nut

      Note


      • Tighten the nuts first. After tightening the bolts, check that the nuts and bolts are tightened to the specified torque.

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

  6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the camshaft housing, timing chain cover and cylinder head cover.

    2. B001WNS

      Apply seal packing as shown in 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.)
      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.

    3. Install 3 new gaskets.

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

    5. Install new seal washers to the bolts.

    6. B002060E05

      Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A and D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B and C
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Standard Bolt
      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 65 mm (2.56 in.)
      D 60 mm (2.36 in.)
      Text in Illustration
      B001XPG Bolt A
      B001WGT Bolt B
      B001X9H Bolt C
      B001ZHB Bolt D

      Note

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

  7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the camshaft housing, timing chain cover and cylinder head cover.

    2. B001WXE

      Apply seal packing as shown in 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.)
      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.

    3. Install 3 new gaskets.

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

    5. Install new seal washers to the bolts.

    6. B001ZKXE04

      Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A and D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B and C
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Standard Bolt
      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 70 mm (2.76 in.)
      D 60 mm (2.36 in.)
      Text in Illustration
      B001XPG Bolt A
      B001WGT Bolt B
      B001X9H Bolt C
      B001ZHB Bolt D

      Note

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

  8. CONNECT FUEL PIPE SUB-ASSEMBLY


    1. Connect the fuel pipe with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  9. INSTALL NO. 2 OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

      Note

      Do not touch the mesh when installing the oil control valve filter.

    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

    3. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the cylinder head cover side).

    4. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

    5. Tighten the oil pipe union (on the cylinder head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  10. INSTALL NO. 1 OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

      Note

      Do not touch the mesh when installing the oil control valve filter.

    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

    3. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the cylinder head cover side).

    4. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

    5. Tighten the oil pipe union (on the cylinder head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  11. INSTALL CRANKSHAFT PULLEY


    1. B001VNFE07

      Using SST, install the crankshaft pulley with the pulley set bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      260 N*m  { 2651 kgf*cm, 192 ft.*lbf }

  12. INSTALL OIL FILTER BRACKET


    1. Install the oil filter bracket and a new gasket with the 2 nuts and bolt.

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

  13. INSTALL OIL FILTER ELEMENT

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  14. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. B001XVQE04

      Temporarily install the V-ribbed belt tensioner with the 5 bolts.

      Standard Bolt
      Item Length
      A 70 mm (2.76 in.)
      B 33 mm (1.30 in.)
      Text in Illustration
      B001XPG Bolt A
      B001WGT Bolt B

    2. Tighten bolts 1 and 2 in numerical order.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    3. Tighten the other bolts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  15. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

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  16. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. B001XVIE07
      Text in Illustration
      *1 DOUBLE

      Install the No. 1 idler pulley with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

      Tech Tips

      "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.

  17. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B00201WE05
      Text in Illustration
      *a Upward
      *b Rearward

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

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

    2. Connect the 2 hoses.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  18. INSTALL WATER INLET HOUSING

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  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B001WURE01
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Push the engine oil level dipstick guide end into the guide hole.

    4. Install the engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.

  20. INSTALL IGNITION COIL ASSEMBLY

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  21. INSTALL NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)

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  22. INSTALL NO. 1 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)

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  23. INSTALL AIR TUBE (w/ Secondary Air Injection System)

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  24. INSTALL ENGINE ASSEMBLY

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