OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL WATER INLET PIPE


    1. Apply soapy water to 2 new O-rings and install them to the water inlet pipe.

    2. Install the water 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 gasket.

    2. Install the gasket to the cylinder block.

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

    4. Install the O-ring to the oil pan.

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

      B001VXFE01
      Text in Illustration
      *1 Continuous Line Area *2 Dashed Line Area
      *3 Diagonal Line Area - -
      *a 20.0 mm (0.787 in.) *b 26.0 mm (1.02 in.)
      *c 16.0 mm (0.630 in.) *d 18.0 mm (0.709 in.)
      *e 7.0 mm (0.276 in.) - -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • B001XDBE04
        Application Specification
        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. B001Y59

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

    7. B001VU5E02
      Text in Illustration
      *1 Nut

      Temporarily install the 26 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. B001YL7E04

      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. B001ZM7

      Temporarily install the fan bracket with the 5 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.)
      Text in Illustration
      B001XPG Bolt A
      B001WGT Bolt B
    10. B001WZI

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

      Text in Illustration
      B001XPG Bolt
      B001WGT 6 mm Hexagon Bolt
    11. B001WMLE01

      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. B001Z4YE04

      Tighten the 22 bolts and nut labeled 12 to 34 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 the installation.

      • B001YP5

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

      Text in Illustration
      B001YD9 Labeled A

    13. Check the torque of each bolt and nut again.

  3. INSTALL FRONT CRANKSHAFT OIL SEAL

    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 cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

      Note

      Remove any oil from the contact surface.

    3. B001WCZ

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      B001YW3 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. Install a new seal washer to the bolt.

    5. B001XYUE03

      Temporarily install the cylinder head cover sub-assembly LH with the 14 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Standard Bolt
      Item Length Thread Diameter
      Bolt A 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt B 25 mm (0.984 in.) 6 mm (0.236 in.)
      Text in Illustration
      B001XPG Bolt A
      B001WGT Bolt B

      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 cylinder head cover gasket RH to the cylinder head cover sub-assembly RH.

      Note

      Remove any oil from the contact surface.

    3. B001YNK

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      B001YW3 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. Install a new seal washer to the bolt.

    5. B001ZTLE03

      Temporarily install the cylinder head cover sub-assembly RH with the 14 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Standard Bolt
      Item Length Thread Diameter
      Bolt A 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt B 25 mm (0.984 in.) 6 mm (0.236 in.)
      Text in Illustration
      B001XPG Bolt A
      B001WGT Bolt B

      Note

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

  6. INSTALL IGNITION COIL ASSEMBLY

    Click here

  7. INSTALL CRANKSHAFT PULLEY


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

    2. B001Y52E05
      Text in Illustration
      *a Hold
      B001XPG Turn

      Using SST, install the pulley set bolt.

      SST
      09213-70011
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  8. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the No. 1 idler pulley with the bolt.

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

  9. INSTALL WATER PUMP PULLEY

    Click here

  10. 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 }

  11. INSTALL WATER INLET HOUSING

    Click here

  12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the water by-pass pipe sub-assembly with the 2 bolts.

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

    2. Connect the No. 2 water by-pass hose from the front water by-pass joint.

  13. CONNECT NO. 5 WATER BY-PASS HOSE

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

    Click here

  15. INSTALL NO. 1 WATER BY-PASS HOSE

  16. CONNECT WATER BY-PASS HOSE

  17. INSTALL NO. 1 WATER BY-PASS PIPE


    1. Connect the No. 1 water by-pass pipe with the 2 bolts.

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

    2. Connect the heater water hose.

  18. INSTALL NO. 3 AIR TUBE (w/ Secondary Air Injection System)


    1. Install a new gasket to the No. 3 air tube.

    2. B001WFJE01
      Text in Illustration
      *1 No. 3 Air Tube
      *2 Claw
      *3 Exhaust Manifold

      Install the No. 3 air tube with the 2 stud bolts, 2 nuts and bolt.

      Torque:
      for bolt and nut
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for stud bolt
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      Make sure the claws of the gasket are not caught between the No. 3 air tube and exhaust manifold.

  19. INSTALL NO. 4 AIR TUBE (w/ Secondary Air Injection System)


    1. Install a new gasket to the No. 4 air tube.

    2. B001W8QE02
      Text in Illustration
      *1 No. 4 Air Tube
      *2 Claw
      *3 Exhaust Manifold

      Install the No. 4 air tube with the 2 stud bolts, 2 nuts and bolt.

      Torque:
      for bolt and nut
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for stud bolt
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      Make sure the claws of the gasket are not caught between the No. 4 air tube and exhaust manifold.

    3. Install the wire harness clamp bracket with the bolt.

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

  20. INSTALL FUEL HOSE


    1. Install the fuel hose Click here.

    2. Install the fuel pipe clamp.

    3. Connect the 2 clamps.

  21. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. Install the fuel tube Click here.

    2. Install the 2 bolts.

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

  22. INSTALL NO. 3 ENGINE COVER

    Click here

  23. INSTALL NO. 4 ENGINE COVER

    Click here

  24. INSTALL GENERATOR ASSEMBLY

    Click here

  25. CONNECT OIL COOLER TUBE

    Click here

  26. CONNECT VANE PUMP ASSEMBLY

    B001VLT

    Tech Tips

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

    Text in Illustration
    B001YD9 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 }

  27. CONNECT POWER STEERING OIL PRESSURE SWITCH CONNECTOR

  28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  29. INSTALL OIL FILTER BRACKET

    Click here

  30. INSTALL NO. 1 OIL COOLER BRACKET

    Click here

  31. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  32. INSTALL OIL FILTER ELEMENT

    Click here

  33. CONNECT ENGINE WIRE


    1. Connect the clamp and engine wire with the bolt.

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

    2. for Engine Room RH Side:


      1. Connect the 6 clamps.

      2. Connect the noise filter connector.

      3. Connect the injector connector.

      4. Connect the 2 VVT sensor connectors.

      5. Connect the 4 ignition coil connectors.

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

    3. for Engine Room LH Side:


      1. Install the ground wire with the bolt.

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

      2. Connect the 8 clamps.

      3. Connect the noise filter connector.

      4. Connect the engine coolant temperature sensor connector.

      5. Connect the camshaft position sensor connector.

      6. Connect the 2 VVT sensor connectors.

      7. Connect the 4 ignition coil connectors.

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

      9. Connect the injector connector.

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


    1. Install the air tube with the 2 bolts.

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

    2. Connect the No. 3 air injection system hose.

    3. Attach the wire harness clamp.

  35. INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)


  36. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. B001XQME02

      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.

  37. INSTALL INTAKE MANIFOLD

    Click here

  38. INSTALL RADIATOR ASSEMBLY

    Click here

  39. INSTALL AIR CLEANER AND HOSE

    Click here

  40. INSTALL FRONT FENDER APRON TRIM PACKING A

    Click here

  41. ADD ENGINE OIL

    Click here

  42. ADD ENGINE COOLANT

    Click here

  43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  44. INSPECT ENGINE OIL LEVEL

    Click here

  45. INSPECT FOR OIL LEAK

    Click here

  46. INSPECT FOR COOLANT LEAK

    Click here

  47. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here