OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL OIL PUMP ASSEMBLY


    1. Install the oil pump with the 3 bolts.

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

  2. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. B002AOPC03
      *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 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. Temporarily install the crankshaft pulley bolt.

    2. B002ALD

      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. B0029TAC01
      *1 Timing Mark
      *2 Mark Plate (Yellow)
      *3 Oil Pump Drive Gear
      *4 Oil Pump Drive Shaft Gear
      B0029FL 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. Temporarily install the crankshaft pulley with the pulley bolt.

    10. B002AFQE01

      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 installationbolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

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

  4. INSTALL CRANKSHAFT TIMING SPROCKET


    1. B002ABZC02
      *a Front

      Install the crankshaft timing sprocket as shown in the illustration.

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  6. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  7. INSTALL CHAIN SUB-ASSEMBLY

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  8. INSTALL CHAIN TENSIONER SLIPPER

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  9. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. Install the No. 2 chain vibration damper with the 2 bolts.

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

  10. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

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  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Install a new gasket.

      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 old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head, camshaft housing, stiffening crankcase and cylinder block.

      B0029D5C01
      B0029XJ Clean and Degrease - -

    4. Install 3 new O-rings.

    5. Apply seal packing as shown in the illustration.

      B002A5JC01
      *a 5.0 mm (0.197 in.) - -
      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 after 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.

      B0029O2C01
      *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


      • When the contact surfaces are wet, 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 after 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.

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

      Note


      • Install the mounting bracket within 10 minutes after 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 install the oil filter bracket with the 4 bolts.

      Note


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

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

    12. Apply adhesive to 5 and a half threads or more of the end of bolt E.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the timing chain cover with the 26 bolts and seal washer in the order shown in the illustration.

      B002AG9C01
      *1 Seal Washer - -
      *a Torque Specification *b Bolt Tightening Order
      Torque:
      for bolt A, E
      25.5 N*m  { 260 kgf*cm, 19 ft.*lbf }
      for bolt B
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt C
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
      for bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • When the contact surfaces are wet, 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 after applying the 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 bolt E before installing it.

  12. INSTALL OIL FILTER

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  13. INSTALL TIMING CHAIN COVER OIL SEAL

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  14. INSTALL ENGINE MOUNTING BRACKET STUD BOLT

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  15. INSTALL CRANKSHAFT PULLEY

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  16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  17. INSTALL CYLINDER HEAD COVER GASKET

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  18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  19. INSTALL THERMOSTAT

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  20. INSTALL WATER INLET

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  21. CONNECT WATER INLET HOSE

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  22. INSTALL WATER BY-PASS HOSE

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  23. INSTALL NO. 1 WATER BY-PASS PIPE

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  24. INSTALL NO. 3 WATER BY-PASS HOSE

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  25. INSTALL PCV HOSE

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  26. INSTALL EXHAUST MANIFOLD

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  27. INSTALL MANIFOLD STAY

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  28. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  29. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  30. INSTALL IGNITION COIL ASSEMBLY

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  31. INSTALL FUEL INJECTOR ASSEMBLY

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  32. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  33. INSTALL FUEL TUBE SUB-ASSEMBLY

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  34. INSTALL INTAKE MANIFOLD

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  35. INSTALL VACUUM SURGE TANK

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  36. INSTALL THROTTLE BODY ASSEMBLY

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  37. REMOVE ENGINE STAND

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  38. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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