OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL OIL PUMP ASSEMBLY


    1. Install the oil pump assembly with the 3 bolts.

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

  2. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. B0043I1C03
      *a Seal Packing Black

      Remove any remaining seal packing and be careful not to drop any oil on the contact surfaces of the cylinder block and No. 2 oil pan sub-assembly.

    2. Apply seal packing in a continuous line as shown in the illustration.

      Application Specification
      Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing
      A - A 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.)
      B - B -
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the No. 2 oil pan sub-assembly.

    3. B0042G1

      Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.

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

  3. INSTALL OIL PAN DRAIN PLUG

    Click here

  4. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. B0041X9

      Temporarily install the crankshaft pulley bolt.

    2. Set the crankshaft key as shown in the illustration.

    3. Turn the drive shaft so that the cutout faces upward.

    4. Remove the crankshaft pulley bolt.

    5. B0042IAC02
      *1 Yellow Mark Plate
      *2 Timing Mark
      *3 Oil Pump Drive Gear
      *4 Oil Pump Drive Shaft Gear
      B0042CO Engine Front

      Align the yellow mark plates with the timing mark of each oil pump drive gear as shown in the illustration.

    6. Install the oil pump drive gear onto the crankshaft and oil pump shaft with the No. 2 chain sub-assembly on the oil pump shaft gears.

    7. Temporarily install the oil pump drive shaft gear with the nut.

    8. B0044ZF

      Install the spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. B0043CZE01

      Temporarily install the crankshaft pulley with the pulley bolt.

    10. Using SST, hold the crankshaft. Then tighten the drive shaft gear nut.

      for 86 mm (3.39 in.) Bolt Pitch Type:

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

    11. Remove SST, the crankshaft pulley bolt and crankshaft pulley.

  5. INSTALL CRANKSHAFT TIMING SPROCKET


    1. B0042F6C01
      B0042CO Engine Front

      Install the crankshaft timing sprocket as shown in the illustration.

  6. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  7. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  8. INSTALL CHAIN SUB-ASSEMBLY

    Click here

  9. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  10. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Install a new gasket.

      Note

      Remove any oil from the contact surface.

    2. Install the water pump assembly with the 3 bolts.

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

    3. Remove any remaining packing (FIPG) material.

      Note

      Be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head sub-assembly, camshaft housing sub-assembly, stiffening crankcase and cylinder block.

      B0043OFC01
      *a Engine Side *b Timing Chain Cover Side
      B0042HX Surface to be cleaned - -

    4. Install 3 new O-rings.

    5. Apply seal packing as shown in the illustration.

      B0042B3N01
      *1 5.0 mm
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the timing chain cover sub-assembly.

    6. Apply seal packing to the timing chain cover sub-assembly in a continuous line as shown in the following illustration.

      B00434UE01
      Seal Packing
      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Application Specification
      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.0 mm (0.0984 to 0.118 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -
      A - A 2.5 to 3.0 mm (0.0984 to 0.118 in.)

      Center of seal packing

      2.5 mm (0.0984 in.)

      		 - -
      B - B 4.5 to 5.5 mm (0.177 to 0.217 in.)

      Opposite edge of seal packing

      5.0 mm (0.197 in.)

      		 - -
      C - C 7.0 to 8.0 mm (0.276 to 0.315 in.)

      Opposite edge of seal packing

      7.5 mm (0.295 in.)

      		 - -
      F 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.5 mm (0.610 in.) 50.4 mm (1.98 in.)
      G 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 143.1 mm (5.63 in.)
      H 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 153.4 mm (6.04 in.)
      I 4.5 to 5.5 mm (0.177 to 0.217 in.) - 16.0 mm (0.630 in.) 385.8 mm (1.27 ft.)
      J 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      K 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 121.9 mm (4.80 in.)
      L 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 147.2 mm (5.80 in.)
      M 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.1 mm (0.201 in.) 173.0 mm (6.81 in.)
      N 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 385.8 mm (1.27 ft.)
      O 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -

      Note


      • If there is oil on the contact surfaces, wipe them with oil-free cloth before applying seal packing.

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

      • After applying seal packing to the timing chain cover sub-assembly, install the engine mounting bracket and oil filter bracket within 10 minutes.

      • Do not add engine oil for at least 2 hours after installation.

    7. Clean the bolts and their installation holes.

    8. Install the timing chain cover sub-assembly.

    9. Temporarily install the engine mounting bracket RH with the 3 bolts.

      Note


      • Install the engine mounting bracket RH within 10 minutes of installing the timing chain cover sub-assembly.

      • Do not add engine oil for at least 2 hours after installation.

    10. Install 2 new O-rings.

    11. Temporarily tighten the oil filter bracket with the 4 bolts.

      Note


      • Install the oil filter bracket within 10 minutes of installing the timing chain cover sub-assembly.

      • Do not add engine oil for at least 2 hours after installation.

    12. B0041QEC34
      *1 Adhesive

      Apply adhesive to 5 and half threads or more of the end of the bolt (E).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the timing chain cover sub-assembly with the 26 bolts and a new seal washer in the order shown in the illustration.

      B0043RXC01
      *a Torque *b Bolt Tightening Order
      *1 Seal Washer - -
      Torque:
      Bolt A, E
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      Bolt B
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      Bolt C
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      Bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • If there is oil on the contact surfaces, wipe them with oil-free cloth before applying seal packing.

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

      Bolt Length
      Item Length Thread Diameter
      Bolt A, E 35 mm (1.38 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt C 80 mm (3.15 in.) 10 mm (0.394 in.)
      Bolt D 40 mm (1.57 in.) 6 mm (0.236 in.)

      Tech Tips

      Apply adhesive to the bolt (E) before installing it.

  12. INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

  13. INSTALL CRANKSHAFT PULLEY

    Click here

  14. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  15. INSTALL SPARK PLUG TUBE GASKET

    Click here

  16. INSTALL CYLINDER HEAD COVER GASKET

    Click here

  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  18. INSTALL IGNITION COIL ASSEMBLY

    Click here

  19. CONNECT NO. 3 WATER BY-PASS HOSE


    1. Connect the No. 3 water by-pass hose to the water inlet housing.

  20. INSTALL WATER INLET HOSE

    Click here

  21. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  22. INSTALL DUTY VACUUM SWITCHING VALVE

    Click here

  23. INSTALL INTAKE MANIFOLD

    Click here

  24. INSTALL THROTTLE BODY ASSEMBLY

    Click here

  25. INSTALL ENGINE HANGER

    Click here

  26. REMOVE ENGINE FROM ENGINE STAND

    Click here