OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL WATER INLET PIPE


    1. B001A09

      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. B00189Z

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

    2. Install the oil pump gasket.

    3. B001A3F

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

    4. Install the O-ring.

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

      B00190FE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • B00196WE16
        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 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.

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

    6. B0019V5

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

    7. B0018PNE03
      *1 Nut

      Temporarily install the timing chain cover with the 28 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. B0018ZNE07

      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. B00197IE08

      Temporarily install the fluid coupling bracket with the 4 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.)
    10. B001A8F

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

    11. B00190UE01

      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. B001AF5E08

      Tighten the 23 bolts and nut labeled 12 to 35 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.

      B001B2EE01

  3. INSTALL SPARK PLUG TUBE GASKET

    Click here

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B001ATL

      Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).

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

      Note

      Remove any oil from the contact surface.

    3. B0019Z2E01
      *1 Seal Packing

      Apply seal packing as shown in the illustration.

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

      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. B0019BHE08

      Install the cylinder head cover and a new seal washer with the 14 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 CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. B001A91

      Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).

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

      Note

      Remove any oil from the contact surface.

    3. B0019B8E01
      *1 Seal Packing

      Apply seal packing as shown in the illustration.

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

      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. B0018DZE08

      Install the cylinder head cover and a new seal washer with the 14 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. B0019BN

      Install the noise filter to the cylinder head cover with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  6. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 8 ignition coils with the 8 bolts.

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

  7. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. B0018E2

      Install the crankshaft timing gear key to the crankshaft.

  8. CONNECT WIRE HARNESS CLAMP BRACKET


    1. B001AUD

      Connect the bracket to the timing chain cover with the bolt.

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

  9. INSTALL CRANKSHAFT PULLEY


    1. B001A26E02
      *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 set bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  10. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. B001A1Z

      Install the idler pulley with the bolt.

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

  11. INSTALL WATER PUMP PULLEY


    1. B0018T8E01

      Temporarily install the pulley with the 4 bolts.

    2. Using SST, hold the pulley and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  12. INSTALL WATER INLET HOUSING


    1. B001A3CE01
      *1 Gasket

      Install a new gasket to the timing chain cover.

    2. B001AUN

      Install the water inlet with the 3 bolts.

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

  13. INSTALL AIR PIPE SUB-ASSEMBLY (w/ Secondary Air Injection System)


    1. B0018FI

      Connect the 2 hoses.

    2. Install the air pipe with the bolt.

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

  14. INSTALL NO. 1 ENGINE COVER

    Click here

  15. INSTALL NO. 2 ENGINE COVER

    Click here

  16. INSTALL FRONT WATER BY-PASS JOINT


    1. B001B1E

      Install 2 new gaskets and the water by-pass joint with the 4 nuts.

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

    2. Connect the No. 2 water by-pass hose to the water by-pass joint.

  17. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Connect the 2 hoses.

    2. B0019VQ

      Install the water by-pass pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B001A10

      w/ Secondary Air Injection System:

      Connect the air tube with the bolt.

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

  18. INSTALL NO. 1 WATER BY-PASS HOSE


    1. B0019LA

      Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.

  19. INSTALL GENERATOR ASSEMBLY


  20. CONNECT OIL COOLER PIPE ASSEMBLY

    Click here

  21. CONNECT VANE PUMP ASSEMBLY

    Tech Tips

    B0019M5E16
    *1 Spacer

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


    1. B00184F

      Connect the vane pump to the timing chain cover with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. B0019IP

      Connect the 2 clamps and power steering oil pressure switch connector.

  22. INSTALL INTAKE MANIFOLD

    Click here

  23. INSTALL OIL FILTER BRACKET (w/o Oil Cooler)


    1. B00192X

      Apply a light coat of engine oil to 2 new O-rings.

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

    3. B001AC8

      Install the oil filter bracket with the 2 bolts and 2 nuts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  24. INSTALL OIL FILTER BRACKET (w/ Oil Cooler)

    Click here

  25. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)

    Click here

  26. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)


    1. Connect the 4 hoses.

    2. B001A2C

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

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

  27. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

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  28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  29. INSTALL OIL FILTER ELEMENT

    Click here

  30. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. B0019PCE14
      *1 LH Side:
      *2 RH Side:

      Connect the fuel tube with the 2 bolts.

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

  31. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. B0019X2E01

      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.

  32. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY


    1. B00197U

      Connect the hose and install the water pipe and hose sub-assembly with the 2 bolts.

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

    2. Connect the 3 hoses.

  33. CONNECT AIR PUMP HOSE AND WIRE HARNESS (w/ Secondary Air Injection System)


    1. B001AJSE06
      *1 No. 3 Air Hose
      *2 No. 2 Air Hose

      Connect the No. 2 and No. 3 air hoses.

    2. Connect the 2 clamps and air pump wire harness.

  34. CONNECT ENGINE WIRE


    1. B0019CT

      Engine Room RH Side:


      1. Connect the 5 clamps.

      2. Connect the throttle position sensor and throttle control motor connector.

      3. w/ Secondary Air Injection System:

        Connect the 2 air pump connectors.

      4. Install the ground wire with the 2 bolts.

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

      5. Connect the noise filter connector.

      6. Connect the 2 VVT sensor connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

      7. Connect the injector connector.

      8. Connect the 4 ignition coil connectors.

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

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

    2. B00194G

      Engine Room LH Side:


      1. Connect the cooler compressor connector.

      2. Connect the 3 clamps.

      3. Connect the camshaft position sensor connector.

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

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

      5. Connect the engine coolant temperature sensor connector.

      6. B001AMJ

        Connect the 4 clamps.

      7. Install the ground wire with the 2 bolts.

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

      8. Connect the noise filter connector.

      9. Connect the 2 VVT sensor connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

      10. Connect the 4 ignition coil connectors.

      11. Connect the injector connector.

      12. B0019WU

        w/ Secondary Air Injection System:

        Connect the wire harness clamp and 4 air injection control driver connectors.

      13. B0019ZK

        Connect the 2 connectors and 2 clips to the engine room junction block.

      14. Install the engine room relay block cover.

  35. INSTALL RADIATOR ASSEMBLY

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  36. INSTALL AIR CLEANER ASSEMBLY

    Click here

  37. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  38. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  39. ADD ENGINE OIL

    Click here

  40. ADD ENGINE COOLANT

    Click here

  41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  42. INSPECT FOR OIL LEAK

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  43. INSPECT FOR COOLANT LEAK

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  44. INSPECT ENGINE OIL LEVEL

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  45. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  46. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  47. INSTALL FRONT FENDER APRON SEAL FRONT RH

    Click here

  48. INSTALL FRONT FENDER APRON SEAL FRONT LH

    Click here

  49. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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  50. CONNECT RADIATOR SIDE DEFLECTOR LH

    Click here

  51. INSTALL TRANSMISSION OIL COOLER AIR DUCT

    Click here

  52. INSTALL FRONT BUMPER COVER

    Click here