OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL TIMING CHAIN COVER 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 assembly, camshaft housing sub-assembly, stiffening crankcase assembly, cylinder block sub-assembly and cylinder head sub-assembly.

      Note

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

      A000QUPE01
      Text in Illustration
      *a Engine Side *b Timing Chain Cover Assembly Side
      B002BPS Clean and degrease - -

    2. Apply a light coat of engine oil to 2 new gaskets.

    3. Install the 2 gaskets to the stiffening crankcase assembly and oil strainer sub-assembly.

    4. Install a water outlet gasket to the cylinder head sub-assembly.

    5. A000QGLE02
      Text in Illustration
      *1 Oil Pump Drive Rotor Spline
      *2 Crankshaft Timing Sprocket

      Align the oil pump drive rotor spline and crankshaft timing sprocket as shown in the illustration.

    6. Apply seal packing as shown in the illustration.

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

      Note


      • Install the timing chain cover assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

      Application Specification
      Area Seal Packing Diameter Seal Packing Width Seal Packing Height Application Position from Inside Seal Line
      Dashed line area 3.0 mm (0.118 in.) - - 2.5 mm (0.0984 in.)
      A - A 3.0 mm (0.118 in.) - - 2.5 mm (0.0984 in.)
      B - B 5.0 mm (0.197 in.) 7.0 mm (0.276 in.) or more 3.0 mm (0.118 in.) or more 3.0 mm (0.118 in.)
      C - C 7.0 mm (0.276 in.) 13 mm (0.512 in.) or more 3.0 mm (0.118 in.) or more 5.0 mm (0.197 in.)
      D - D 5.0 mm (0.197 in.) 7.0 mm (0.276 in.) or more 3.0 mm (0.118 in.) or more 3.0 mm (0.118 in.)
      E 3.0 mm (0.118 in.) - - 3.0 mm (0.118 in.)
      A000N06E02
      Text in Illustration
      *a 28 mm (1.102 in.) *b 25 mm (0.984 in.)
      *c 26 mm (1.024 in.) *d 2.5 mm (0.0984 in.)
      *e 3.0 mm (0.118 in.) *f 7.0 mm (0.276 in.) or more
      *g 5.0 mm (0.197 in.) *h 13 mm (0.512 in.) or more
      *i 3.0 mm (0.118 in.) or more *j 7.0 mm (0.276 in.)

    7. Temporarily install the timing chain cover assembly with the 19 bolts (A, B and C) and 2 nuts.

      Standard Bolt
      Item Length Bolt Diameter
      Bolt A 30 mm (1.18 in.) 8.0 mm (0.315 in.)
      Bolt B 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt C 45 mm (1.77 in.) 8.0 mm (0.315 in.)

      Note

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

    8. Tighten the 19 bolts and 3 nuts in the order shown in the illustration.

      Torque:
      Bolt A, C and Nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt B
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      A000R5QE02
      Text in Illustration
      B002B6O Bolt B002BBR Nut

  2. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

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  3. INSTALL WATER OUTLET SUB-ASSEMBLY


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

    2. Install the water outlet sub-assembly with the 2 bolts and nut.

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

  4. INSTALL NO. 11 WATER BY-PASS HOSE


    1. Install the No. 11 water by-pass hose to the water outlet housing sub-assembly and No. 5 water by-pass pipe, and slide the 2 clamps to secure the 2 hoses.

  5. INSTALL NO. 13 WATER BY-PASS HOSE


    1. Install the No. 13 water by-pass hose to the water outlet housing sub-assembly and No. 3 water by-pass pipe, and slide the 2 clamps to secure the 2 hoses.

  6. INSTALL CRANKSHAFT PULLEY ASSEMBLY

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  7. INSTALL CRANKSHAFT POSITION SENSOR

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  8. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  9. INSTALL ENGINE OIL LEVEL DIPSTICK

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  10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to 3 new gaskets.

    2. Install the 3 gaskets to the camshaft bearing caps.

    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

    4. A000PXZE02
      Text in Illustration
      *1 Timing Chain Cover Assembly
      *2 Camshaft Housing Sub-assembly
      *a 5.0 mm (0.197 in.)
      B002B6O 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 6.0 mm (0.118 to 0.236 in.)

      Note


      • Be sure to clean and degrease the contact surfaces.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

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

    5. A000RXSE02
      Text in Illustration
      *a Pin A
      *b Pin B
      B002B6O Bolt A
      B002BBR Bolt B

      Align the pin holes in the cylinder head cover sub-assembly with pin A and pin B in this order, and then install the cylinder head cover sub-assembly.

    6. Temporarily install 3 new seal washers and the 3 bolts labeled B.

    7. Temporarily install the 13 bolts labeled A.

    8. Tighten the 16 bolts in the order shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 35 mm (1.38 in.)

  11. INSTALL IGNITION COIL ASSEMBLY

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  12. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 2 wire harness clamp brackets to the timing chain cover assembly with the 2 bolts.

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

  13. CONNECT ENGINE WIRE


    1. Attach the wire harness clamp.

    2. Connect the 2 ground wires to the timing chain cover assembly with the 2 bolts.

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

    3. Install the wire harness clamp bracket to the timing chain cover assembly with the bolt.

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

    4. Install the wire harness clamp bracket to the timing chain cover assembly with the 2 bolts.

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

    5. Connect the engine coolant temperature sensor connector.

    6. Connect the 4 wire harness clamps.

    7. Install the wire harness clamp bracket to the cylinder head cover sub-assembly with the bolt.

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

    8. Attach the 2 wire harness clamps to the wire harness clamp bracket.

    9. Connect the engine wire with the 5 nuts.

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

    10. Connect the engine oil pressure switch connector.

    11. Connect the 4 ignition coil connectors.

    12. Connect the 2 VVT sensor connectors.

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

    14. Attach the 3 wire harness clamps.

  14. CONNECT PCV HOSE ASSEMBLY


    1. Connect the PCV hose assembly to the PCV valve sub-assembly, and slide the clamp to secure the hose.

  15. CONNECT OIL COOLER TUBE SUB-ASSEMBLY


    1. Connect the oil cooler tube sub-assembly with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. Attach the engine ground wire clamp to the oil cooler tube sub-assembly.

  16. CONNECT NO. 1 HV WATER PUMP OUTLET PIPE


    1. Connect the No. 1 HV water pump outlet pipe to the stiffening crankcase with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  17. INSTALL FAN AND GENERATOR V BELT

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  18. INSTALL ENGINE MOTOR CABLE CLAMP BRACKET (for LHD)

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  19. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

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  20. INSPECT ENGINE OIL LEVEL

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  21. INSPECT FOR OIL LEAK

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  22. INSTALL NO. 2 ENGINE UNDER COVER

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  23. INSTALL FRONT SUSPENSION MEMBER BRACE

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  24. INSTALL ENGINE UNDER COVER

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