OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. B001HKZE05

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap on the oil seal at an angle.

      • Make sure that the oil seal edge does not protrude from the timing chain case.

  2. 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.

      B001EOPE04
      Text in Illustration
      *A Cylinder head and cylinder block side *B Timing chain cover side
      *a 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. B001D1XE01
      Text in Illustration
      *1 Seal Diameter
      B001CHY 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
      B001IJOE09
      Text in Illustration
      *a Be sure to apply seal packing *b Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *c Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) *d Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)
      *e 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. B001GFQE06
      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.)
      B001EK6E04
      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 }

      Tech Tips

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

      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.

  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 a new 3 O-rings to the timing chain cover.

    3. B001DCYE01
      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. B001G6IE05
      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 and 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 installing.

  4. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. B001EHZE02
      Text in Illustration
      *1 Groove
      *2 Protrusion

      Install a new gasket to the oil strainer.

      Tech Tips

      Align the protrusion of the gasket with the groove of the oil strainer.

    2. Install the oil strainer with the 2 nuts.

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

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. B001GNZE02
      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. B001CET

      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
      B001CHY Bolt
      B001DEF 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 cylinder head, timing chain cover and cylinder head cover.

    2. B001HDD

      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
      B001CHY 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 the seal washers to the bolts.

    6. B001GXRE06

      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
      B001CHY Bolt A
      B001DEF Bolt B
      B001HIB Bolt C
      B001HHG 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 cylinder head, timing chain cover and cylinder head cover.

    2. B001HAQ

      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
      B001CHY 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 the seal washers to the bolts.

    6. B001EIDE07

      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
      B001CHY Bolt A
      B001DEF Bolt B
      B001HIB Bolt C
      B001HHG 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 REAR CYLINDER HEAD COVER

    Click here

  10. 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 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 head cover side).

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

  11. 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 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 head cover side).

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

  12. INSTALL CRANKSHAFT PULLEY


    1. B001CPKE08

      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 }

  13. 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 }

  14. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. B001GGJE06

      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
      B001CHY Bolt A
      B001DEF 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

    Click here

  16. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. B001GHGE08
      *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 INLET HOUSING


    1. Install the 3 water by-pass hoses.

    2. Apply soapy water to a new O-ring and install the O-ring to the water outlet pipe.

    3. Install a new O-ring to the water outlet pipe.

    4. Install a new gasket to the water pump.

    5. Install the water inlet with the 5 bolts.

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

    6. Connect the 3 water by-pass hoses.

  18. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)


    1. B001FPOE04
      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.

  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B001GJKE04
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the dipstick guide.

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

    3. Push the dipstick guide end into the guide hole.

    4. Install the dipstick guide with the bolt.

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

    5. Install the dipstick.

  20. INSTALL IGNITION COIL ASSEMBLY

    Click here

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

    Click here

  22. INSTALL EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)

    Click here

  23. INSTALL ENGINE ASSEMBLY


    1. Install the engine assembly Click here.