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, 16 ft.*lbf }

  2. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any remaining seal packing.

      Note

      Be careful not to drop any oil on the contact surfaces of the cylinder block sub-assembly and No. 2 oil pan sub-assembly.

    2. A01KU19C05
      *a Seal Packing

      Apply a continuous bead of seal packing (diameter 4.0 mm (0.157 in.)) as shown in the illustration.

      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 of applying seal packing.

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

    3. 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 CRANKSHAFT TIMING GEAR KEY

    Click here

  5. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  6. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. Temporarily install the crankshaft pulley bolt.

    2. A01KSU7

      Turn the crankshaft counterclockwise to position the crankshaft timing gear key at the 9 o'clock position.

    3. Turn the drive shaft so that the flat surface faces the 12 o'clock position.

    4. A01KRUSC06
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *a Mark Plate (Yellow)
      *b Timing Mark
      A01KRLR Engine Front

      Align mark plate (yellow) with the timing mark as shown in the illustration.

      Tech Tips

      Be sure to position the mark plates at the front of the engine.

    5. Install the sprockets onto the crankshaft and oil pump shaft with the No. 2 chain sub-assembly on the gears.

    6. Temporarily tighten the oil pump drive shaft gear with the nut.

    7. Insert the chain damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

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

    8. Temporarily tighten the crankshaft pulley with the bolt.

    9. A01KRPSN01

      Using SST, install the oil pump drive shaft gear nut while holding the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    10. Remove the crankshaft pulley and bolt.

  7. INSTALL CRANKSHAFT TIMING SPROCKET


    1. Install the crankshaft timing sprocket.

  8. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  9. SET NO. 1 CYLINDER TO TDC / COMPRESSION

    Click here

  10. INSTALL CHAIN SUB-ASSEMBLY

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  11. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION

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  12. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  13. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    Click here

  14. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A01KTV7N03

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

      SST
      09223-22010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap in the timing chain cover oil seal at an angle.

      • Make sure that the timing chain cover oil seal edge does not stick out of the timing chain cover sub-assembly.

      Tech Tips

      Tap in the timing chain cover oil seal so that it is positioned within 1.0 mm (0.0394 in.) from the edge of the timing chain cover sub-assembly.

    2. Apply MP grease to the lip of the timing chain cover oil seal.

  15. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any remaining seal packing (FIPG).

      Note

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

      A01KTH7C03
      *a Engine Side *b Timing Chain Cover Side
      A01KR3W Surface to be cleaned - -
    2. A01KSYJ

      Install 3 new O-rings.

    3. Apply seal packing as shown in the illustration.

      A01KTNDN01
      *1 5.0 mm
      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal Diameter
      5.0 mm (0.197 in.)

      Note


      • Remove any oil from the contact surfaces.

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

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

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

      Note


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

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

      A01KRLAN02
      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 3.5 mm (0.0984 to 0.138 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 an 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.

    5. Clean the bolt and fitting hole.

    6. Install the timing chain cover sub-assembly.

    7. 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 start the engine for at least 2 hours after installation.

      Bolt Length
      Item Length
      Bolt 80 mm (3.15 in.)

    8. Install 2 new O-rings.

    9. 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 start the engine for at least 2 hours after installation.

      Bolt Length
      Item Length
      Bolt 35 mm (1.38 in.)

    10. Install the timing chain cover sub-assembly with the 25 bolts and seal washer as shown in the illustration.

      A01KS26C03
      *1 Seal Washer - -
      *a Torque *b Bolt Tightening Order
      Torque:
      Bolt A, D, E
      25.5 N*m  { 260 kgf*cm, 19 ft.*lbf }
      Bolt B, F
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      Bolt C
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • Apply adhesive 1324 to the threads of the bolt (E).

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

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.

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

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

      Bolt Length
      Item Length
      Bolt A, F 35 mm (1.38 in.)
      Bolt B 55 mm (2.16 in.)
      Bolt C 80 mm (3.15 in.)
      Bolt D 40 mm (1.57 in.)
      Bolt E 55 mm (2.16 in.)

    11. Using an 8 mm socket wrench, install the stud bolt to the engine mounting bracket RH.

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

  16. INSTALL CRANKSHAFT PULLEY

    Click here

  17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01KR69C06
      *a Push
      *b Raise
      *c Correct
      *d Incorrect
      *e Cam
      *f Pin
      *g Hook

      Release the cam, and then fully push in the plunger and engage the hook to the pin so that the plunger is in the position shown in the illustration.

      Note

      Make sure that the cam engages the first tooth of the plunger to allow the hook to pass over the pin.

    2. A01KR9H

      Install a new gasket, the bracket and No. 1 chain tensioner assembly with the 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, engage the hook again.

    3. A01KRK1C03
      *a Push
      *b Turn
      *c Release
      *d Pin
      *e Hook

      Rotate the crankshaft counterclockwise slightly and check that the hook is released.

    4. A01KRYOC01
      *a Turn
      *b Plunger is extended
      *c Plunger

      Turn the crankshaft clockwise and check that the plunger is extended.

  18. INSTALL SPARK PLUG TUBE GASKET

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  19. INSTALL CYLINDER HEAD COVER GASKET

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  20. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  21. INSTALL IGNITION COIL ASSEMBLY

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  22. INSTALL NO. 3 WATER BY-PASS HOSE

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  23. INSTALL FUEL VAPOR FEED PIPE

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  24. INSTALL INTAKE MANIFOLD

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  25. INSTALL EGR VALVE WITH COOLER ASSEMBLY

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  26. INSTALL EGR PIPE ASSEMBLY

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  27. INSTALL THROTTLE BODY ASSEMBLY

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  28. INSTALL ENGINE HANGERS

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  29. REMOVE ENGINE FROM ENGINE STAND

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  30. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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