OIL PUMP INSTALLATION

PROCEDURE


  1. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any remaining seal packing material and be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head LH, cylinder head sub-assembly and cylinder block sub-assembly.

      B003T97C01
      *a Cylinder Head and Cylinder Block Side *b Timing Chain Cover Side
      B003UDQ Clean and Degrease - -

      Note

      Be sure to clean and degrease the contact surfaces, especially the surfaces indicated area A in the illustration.

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

    3. Install the oil pump gasket.

    4. B003TL9C03
      *a Seal Diameter
      B003WAF Seal Packing

      Apply seal packing in a continuous line to the engine unit as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note

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

    5. Apply seal packing to the timing chain cover sub-assembly as shown in the illustration.

      B003SZLC01
      *a

      Dashed Line Area

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

      		 *b

      Continuous Line Area

      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *c

      Alternate Long and Short Dashed Line Area

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

      		 *d

      Dashed Line Area

      (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)
      *e 9.0 mm (0.354 in.) *f 3.0 mm (0.118 in.)
      *g 6.0 mm (0.236 in.) or more - -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • When the contact surfaces are wet, 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 after applying seal packing.

      Application Specification
      Area Seal Packing Diameter Application Position from Inside Seal Line

      Dashed Line Area

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

      		 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.157 in.)

      Continuous Line Area

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

      		 6.0 mm (0.236 in.) or more 1.0 to 2.0 mm (0.0394 to 0.0787 in.)

      Alternate Long and Short Dashed Line Area

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

      		 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.157 in.)

      Dashed Line Area

      (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)

      		 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.0787 to 0.118 in.)
    6. B003WTFC04
      *1 Crankshaft
      *a Drive Rotor Spline
      *b 15°

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

    7. Temporarily install the timing chain cover assembly with the 2 nuts and 26 bolts.

      B003UBGC06
      *1 Nut - -
      *a Types of nut and bolt *b Tightening Order
      Bolt Length
      Item Length
      Bolt A 28 mm (1.10 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 60 mm (2.36 in.)
      Bolt D 40 mm (1.57 in.)

      Note


      • Make sure that there is no oil on the bolt threads.

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

      • Wipe off any seal packing that seeped out around the surfaces of the oil pan sub-assembly and cylinder head cover sub-assembly and make sure that there is no seal packing seeping out around the edges.

    8. Tighten the 26 bolts and 2 nuts in several steps, in the sequence shown in the illustration.

      Torque:
      Bolts A, B and nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt C and D
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  2. INSTALL TIMING CHAIN CASE OIL SEAL


    1. B003VC6E06

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

      SST
      09223-22010
      09506-35010
      Oil Seal Protrusion Height
      0 to 1.0 mm (0 to 0.0394 in.)

      Note


      • Keep the lip free from foreign matter.

      • Do not tap on the oil seal at an angle.

      • Make sure that the oil seal edge does not protrude from the timing chain cover sub-assembly.

  3. INSTALL TIMING CHAIN COVER PLATE

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  4. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer sub-assembly with the 3 nuts.

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

  5. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any remaining seal packing material and be careful not to drop any oil on the contact surfaces of the cylinder block sub-assembly, rear oil seal retainer and oil pan sub-assembly.

    2. B003V2W

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

    3. B003U5OC01
      *a Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan sub-assembly within 3 minutes after applying seal packing.

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

      • Do not start the engine within 2 hours after installation.

    4. B003TE0C01
      *a Types of nut and bolt
      *b Tightening Order
      B003WAF Bolt
      B003U82 Nut

      Install the oil pan sub-assembly with the 16 bolts and 2 nuts.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B, C, D and Nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 16 mm (0.630 in.)
      Bolt B 25 mm (0.984 in.)
      Bolt C 45 mm (1.77 in.)
      Bolt D 70 mm (2.76 in.)
    5. B003SXZC03
      B003V9P Wipe off the Seal Packing

      After tightening the oil pan bolts and nuts, wipe off the seal packing material that has seeped out from between the contact surfaces of the cylinder block sub-assembly and oil pan sub-assembly.

  6. INSTALL OIL LEVEL SENSOR BRACKET

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  7. INSTALL ENGINE OIL LEVEL SENSOR

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  8. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. B003UL9C01
      *a Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.

    2. B003WKSC02
      B003WAF Bolt
      B003U82 Nut

      Install the No. 2 oil pan sub-assembly with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

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

      Note


      • Tighten the nuts first. After tightening the bolts, check that the nuts and bolts are tightened to the specified torque.

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

  9. INSTALL SPARK PLUG TUBE GASKET

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  10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any remaining seal packing material and be careful not to drop any oil on the contact surfaces of the camshaft housing sub-assembly RH, timing chain cover sub-assembly and cylinder head cover sub-assembly.

    2. B003TJRC02
      *a Mark
      *b Seal Packing (Diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.))
      *c Seal Packing (Diameter 5.0 to 7.0 mm (0.197 to 0.276 in.))
      B003WAF 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 sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. B003WT4

      Install a new camshaft bearing cap oil hole gasket RH to the camshaft housing sub-assembly RH.

    4. Install 2 new gaskets and a new cylinder head cover gasket.

    5. Temporarily install the VVT sensor (for intake side of bank 1) to the cylinder head cover sub-assembly.

      Click here

    6. Temporarily install the VVT sensor (for exhaust side of bank 1) to the cylinder head cover sub-assembly.

      Click here

    7. B003X6HC03
      B003WAF Bolt A
      B003U82 Bolt B

      Temporarily install the cylinder head cover sub-assembly with the 15 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 23.5 mm (0.925 in.)

      Note

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

  11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Remove any remaining seal packing material and be careful not to drop any oil on the contact surfaces of the camshaft housing sub-assembly LH, timing chain cover sub-assembly and cylinder head cover sub-assembly LH.

    2. B003VLDC02
      *a Mark
      *b Seal Packing (Diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.))
      *c Seal Packing (Diameter 5.0 to 7.0 mm (0.197 to 0.276 in.))
      B003WAF 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 sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. B003WBA

      Install a new camshaft bearing cap oil hole gasket to the camshaft housing sub-assembly LH.

    4. Install 2 new gaskets and a new cylinder head cover gasket.

    5. Temporarily install the VVT sensor (for intake side of bank 2) to the cylinder head cover sub-assembly LH.

      Click here

    6. Temporarily install the VVT sensor (for exhaust side of bank 2) to the cylinder head cover sub-assembly LH.

      Click here

    7. B003UF9C03
      B003WAF Bolt A
      B003U82 Bolt B

      Temporarily install the cylinder head cover sub-assembly LH with the 16 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 23.5 mm (0.925 in.)

      Note

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

  12. INSTALL IGNITION COIL ASSEMBLY

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  13. INSTALL CRANKSHAFT PULLEY


    1. B003W2RC03
      *a Hold
      B003WAF Turn

      Using SST, install the crankshaft pulley with the pulley set bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      260 N*m  { 2651 kgf*cm, 192 ft.*lbf }

  14. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Install the oil filter bracket sub-assembly and a new gasket with the 2 nuts and 2 bolts.

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

  15. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the timing chain cover sub-assembly with the nut.

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

    2. Install the wire harness clamp bracket to the timing chain cover sub-assembly with the bolt.

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

    3. Install the wire harness clamp bracket to the cylinder head cover sub-assembly LH with the nut.

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

    4. Install the wire harness clamp bracket to the oil filter bracket sub-assembly with the nut.

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

  16. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

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  17. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

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  18. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

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  19. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

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  20. INSTALL WATER OUTLET SUB-ASSEMBLY

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  21. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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  22. INSTALL NO. 2 WATER BY-PASS HOSE ASSEMBLY

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  23. INSTALL NO. 3 WATER BY-PASS HOSE

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  24. INSTALL NO. 2 WATER BY-PASS HOSE

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  25. INSTALL NO. 6 WATER BY-PASS HOSE

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  26. INSTALL NO. 1 WATER BY-PASS PIPE (w/ Oil Cooler)

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  27. INSTALL WATER PUMP PULLEY

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  28. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

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  29. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  30. INSTALL INTAKE MANIFOLD

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  31. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

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  32. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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  33. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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  34. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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  35. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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  36. CONNECT WIRE HARNESS


    1. for Bank 2:


      1. Engage the claw and connect the No. 8 engine wire to the No. 7 engine wire.

      2. Engage the clamp.

      3. Engage the claw and connect the No. 7 engine wire to the cylinder head cover sub-assembly LH.

    2. for Bank 1:


      1. Engage the claw and connect the No. 5 engine wire to the No. 6 engine wire.

      2. Engage the claw and connect the No. 6 engine wire to the cylinder head cover sub-assembly.

  37. INSTALL NO. 1 FUEL TUBE SUB-ASSEMBLY

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  38. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. for Bank 1:

      Install the No. 1 engine cover to the cylinder head cover sub-assembly with the 2 clips.

    2. for Bank 2:

      Install the No. 1 engine cover to the cylinder head cover sub-assembly LH with the clip.

  39. INSTALL NO. 2 FUEL TUBE SUB-ASSEMBLY

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  40. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

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  41. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  42. INSTALL ENGINE WIRE

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  43. INSTALL ENGINE ASSEMBLY

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