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. A01KD3MC03
      *1 Seal Packing
      *a 3.0 to 4.5 mm (0.118 to 0.177 in.)
      *b 6.0 mm (0.236 in.)

      Remove any old packing material and be careful not to drop any oil on the contact surfaces of the stiffening crankcase 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 after applying seal packing.

      • Do not add engine oil 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 NO. 2 CHAIN SUB-ASSEMBLY


    1. A01KC32

      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. A01KC0TC01
      *1 Timing Mark
      *2 Mark Plate (Yellow)
      *3 Oil Pump Drive Gear
      *4 Oil Pump Drive Shaft Gear
      A01KBXM Front

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

    6. Install the gears onto the crankshaft and oil pump shaft with the chain on the gears.

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

    8. Install the chain damper 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. A01KCG4E01

      Temporarily install the crankshaft pulley with the pulley bolt.

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

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

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

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

  4. INSTALL CRANKSHAFT TIMING SPROCKET


    1. A01KBM6C02
      *a Front

      Install the crankshaft timing sprocket as shown in the illustration.

  5. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  6. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  7. INSTALL CHAIN SUB-ASSEMBLY

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  8. INSTALL CHAIN TENSIONER SLIPPER

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  9. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

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  10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Install a new gasket to the timing chain cover sub-assembly.

      Note

      Remove any oil from the contact surface.

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

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

    3. Remove any remaining seal packing material.

    4. Clean the contact surfaces of the timing chain cover sub-assembly, camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.

      A01KAKMC01
      A01KCAQ Clean and Degrease - -

    5. Install 3 new O-rings.

    6. A01KBTW

      Apply seal packing as shown in the illustration.

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

      Note

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

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

      A01KBSBC01
      *a 2.5 mm (0.0984 in.) *b 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *c 5.0 mm (0.197 in.) *d 4.5 to 5.5 mm (0.177 to 0.217 in.)
      *e 7.5 mm (0.295 in.) *f 7.0 to 8.0 mm (0.276 to 0.315 in.)
      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 3.5 mm (0.0984 to 0.138 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.) - 15.8 mm (0.622 in.) 50.1 mm (1.97 in.)
      G 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 155.1 mm (6.11 in.)
      H 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 165.4 mm (6.51 in.)
      I 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (1.31 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.) 133.9 mm (5.27 in.)
      L 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 159.2 mm (6.28 in.)
      M 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.0 mm (0.197 in.) 185.0 mm (7.28 in.)
      N 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (1.31 ft.)
      O 4.0 mm (0.157 in.)

      Center of seal packing

      3.0 mm (0.118 in.)

      		 - -

      Note

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

    8. Clean the bolts and their installation holes.

    9. Apply adhesive to 5 and a half threads or more of the end of bolt C.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    10. A01KB3JC01
      *1 Seal Washer

      Temporarily install the timing chain cover sub-assembly with the 19 bolts and a new seal washer.

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

      Note

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

    11. Temporarily install the engine mounting bracket RH to the timing chain cover sub-assembly with the 3 bolts.

      Bolt Length
      Length Thread Diameter
      80 mm (3.15 in.) 10 mm (0.394 in.)

      Note

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

    12. Install 2 new O-rings to the timing chain cover sub-assembly.

    13. Temporarily install the oil filter bracket to the timing chain cover sub-assembly with the 4 bolts.

      Bolt Length
      Length Thread Diameter
      35 mm (1.38 in.) 8 mm (0.315 in.)

      Note

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

    14. Tighten the 26 bolts in the order shown in the illustration.

      A01KBDFC01
      *a Torque *b Bolt Tightening Order
      Torque:
      for bolt A, C
      25.5 N*m  { 260 kgf*cm, 19 ft.*lbf }
      for bolt B, E
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • Tighten the bolts within 10 minutes of applying seal packing.

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

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

  11. INSTALL TIMING CHAIN COVER OIL SEAL

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  12. INSTALL OIL FILTER CAP ASSEMBLY

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  13. INSTALL ENGINE MOUNTING BRACKET STUD BOLT

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  14. INSTALL CRANKSHAFT PULLEY

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  15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  16. INSTALL CYLINDER HEAD COVER GASKET

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  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  19. INSTALL NO. 1 VACUUM PUMP BRACKET

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  20. INSTALL IGNITION COIL ASSEMBLY

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  21. INSTALL THERMOSTAT

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  22. INSTALL WATER INLET

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  23. CONNECT WATER INLET HOSE

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  24. INSTALL WATER BY-PASS HOSE

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  25. CONNECT NO. 3 WATER BY-PASS HOSE

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  26. INSTALL PCV HOSE

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  27. INSTALL VACUUM PUMP ASSEMBLY

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  28. INSTALL EXHAUST MANIFOLD

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  29. INSTALL MANIFOLD STAY

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  30. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  31. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  32. INSTALL FUEL INJECTOR ASSEMBLY

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  33. INSTALL NO. 1 DELIVERY PIPE SPACER

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  34. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  35. INSTALL FUEL TUBE SUB-ASSEMBLY

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  36. INSTALL WIRE HARNESS CLAMP BRACKET

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  37. INSTALL INTAKE MANIFOLD

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  38. INSTALL AIR TUBE

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  39. INSTALL THROTTLE BODY ASSEMBLY

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  40. REMOVE ENGINE STAND

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  41. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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