OIL PUMP INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

PROCEDURE


  1. INSTALL WATER INLET PIPE


    1. A000Z9O

      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. A000Y7A

      Install a new oil pump gasket.

    2. A000Y5R

      Install a new O-ring.

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

      A000Y5LE03
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A000UAQE18
        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 0.5 mm (0.0197 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.

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

    4. A000Y1C

      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. A000ZF4E06
      *1 Nut

      Temporarily install 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 (2.17 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.

    6. A000YB4

      Tighten the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    7. A000YHB

      Install the belt tensioner with the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    8. A000VTCE03

      Tighten the 10 bolts in several steps, in the sequence shown in the illustration.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    9. A000WV8E03
      *a Nut

      Tighten the 19 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.

      A000Y7NE02
    10. A00104G

      Install 2 new gaskets and the 2 plugs.

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

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A000TBS

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

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

      Note

      Remove any oil from the contact surface.

    3. A000ZL3E03
      *1 Seal packing

      Apply seal packing as shown 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.)

      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. A000YKLE06

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

    5. Install the fuel pump spacer.

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A000ZL2

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

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

      Note

      Remove any oil from the contact surface.

    3. A000U30E03
      *1 Seal packing

      Apply seal packing as shown 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.)

      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. A000XCXE04

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

    5. Install the fuel pump spacer.

  5. INSTALL FRONT CRANKSHAFT OIL SEAL

    Click here

  6. INSTALL CRANKSHAFT TIMING GEAR KEY

    Click here

  7. INSTALL IGNITION COIL ASSEMBLY

    Click here

  8. INSTALL CRANKSHAFT PULLEY


    1. A000UMBE02
      *1 Hold
      *2 Turn

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

    2. Using SST, install the pulley bolt.

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

  9. INSTALL OIL FILTER BRACKET


    1. A000TQT

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

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

  10. INSTALL OIL FILTER ELEMENT

    Click here

  11. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH


    1. A000WR0E08
      *1 Index Slot

      Turn the camshaft timing gear assembly's intermediate shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position.

      Tech Tips


      • When the cam of the camshaft lifts the valve, the intermediate shaft becomes difficult to turn.

      • The position where the intermediate shaft stops is the maximum retard angle.

    2. Install a new O-ring to the timing chain cover.

    3. A000WG0

      Align the joint of the camshaft timing control motor and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts.

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

      Note


      • Check that [R] is printed on the label of the camshaft timing control motor.

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor (connecting surface with timing chain cover sub-assembly).

      • When installing the camshaft timing control motor, do not use excessive force.

      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor.

      • Install the camshaft timing control motor with the arrow facing upward, as shown in the illustration.

      • Do not drop the camshaft timing control motor. If dropped, replace it.

      • Do not disassemble the camshaft timing control motor assembly. If disassembled, replace it.

  12. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH


    1. A000WXLE08
      *1 Index Slot

      Turn the camshaft timing gear assembly's intermediate shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position.

      Tech Tips


      • When the cam of the camshaft lifts the valve, the intermediate shaft becomes difficult to turn.

      • The position where the intermediate shaft stops is the maximum retard angle.

    2. Install a new O-ring to the timing chain cover.

    3. A000XGW

      Align the joint of the camshaft timing control motor and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts.

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

      Note


      • Check that [L] is printed on the label of the camshaft timing control motor.

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor (connecting surface with timing chain cover sub-assembly).

      • When installing the camshaft timing control motor, do not use excessive force.

      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor.

      • Install the camshaft timing control motor with the arrow facing upward, as shown in the illustration.

      • Do not drop the camshaft timing control motor. If dropped, replace it.

      • Do not disassemble the camshaft timing control motor assembly. If disassembled, replace it.

  13. INSTALL FRONT WATER BY-PASS JOINT

    Click here

  14. INSTALL WATER PUMP PULLEY

    Click here

  15. INSTALL WATER INLET HOUSING


    1. A000YRE

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

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

    2. Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the water inlet hose.

  16. INSTALL FUEL PUMP ASSEMBLY (for Bank 2)

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  17. INSTALL FUEL PUMP ASSEMBLY (for Bank 1)

    Click here

  18. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

    Click here

  19. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

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  20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

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  21. INSTALL INTAKE MANIFOLD ASSEMBLY

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  22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

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  23. INSTALL HEATER WATER PUMP ASSEMBLY

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  24. INSTALL PURGE VSV

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  25. INSTALL NO. 1 ENGINE COVER

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  26. INSTALL INJECTOR DRIVER

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  27. INSTALL ENGINE WIRE

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  28. INSTALL NO. 5 COVER SUB-ASSEMBLY

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  29. INSTALL ENGINE COVER SUB-ASSEMBLY RH

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  30. INSTALL NO. 6 COVER SUB-ASSEMBLY

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  31. INSTALL ENGINE COVER SUB-ASSEMBLY LH

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  32. INSTALL WITH MOTOR COMPRESSOR ASSEMBLY

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  33. INSTALL V-RIBBED BELT

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  34. INSTALL ENGINE ASSEMBLY

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