OIL PUMP INSTALLATION


  1. INSTALL TIMING CHAIN CASE OIL SEAL


    1. A01G83UE04

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

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

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

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

      Tech Tips

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

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

  2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

      A01G889E12
      Text in Illustration
      *a Seal Packing Diameter: 3.0 mm (0.118 in.) or more A01G8AH Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      3.0 mm (0.118 in.)

      Note


      • Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.

      • 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.

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

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

      A01G6B2E01
      Text in Illustration
      *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 1282B, Three Bond 1282B or equivalent)

      		 *d

      Diagonal Line Area

      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      A01G8AH Be sure to apply seal packing - -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      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 after applying seal packing.

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

      Seal Packing Application Chart
      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 mm or more (0.177 in.) 1.0 to 2.0 mm (0.0394 to 0.0787 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm or more (0.138 in.) 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm or more (0.138 in.) 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Diagonal Line Area 6.0 mm or more (0.236 in.) 5.0 mm (0.197 in.)
    3. A01G8BM

      Install a new gasket.

    4. A01G626E07
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft

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

    5. A01G5DDE01
      Text in Illustration
      *1 Nut

      Temporarily tighten the timing chain cover sub-assembly with the 23 bolts and 2 nuts.

      Bolt Length
      Item Length
      Bolt A 40 mm (1.57 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 25 mm (0.984 in.)

      Note

      Make sure that there is no oil on the threads of bolt B and C.

    6. Fully tighten the bolts in Area 1.

    7. A01G4VME01
      Text in Illustration
      *a Area 1
      *b Area 2
      *c Area 3
      *d Area 4

      Fully tighten the bolts in Area 2.

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

    8. Fully tighten the bolts and nuts in Area 3.

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

      Tech Tips

      Tighten the bolts and nuts from top to bottom as shown in the illustration.

    9. Fully tighten the bolts in Area 4.

      Torque:
      Bolt A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Torque:
      Except bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Tighten the bolts from bottom to top as shown in the illustration.

  3. INSTALL OIL PAN SUB-ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

      A01G7KQE01
      Text in Illustration
      *A w/ Oil Cooler - -
      *a Lower Cylinder Block *b Timing Chain Cover
      *c Oil Pan LH Side - -
      Torque:
      Bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    2. A01G76L

      Install 2 new O-rings.

    3. A01G59RE01
      Text in Illustration
      *a Seal Diameter

      Apply seal packing in a continuous line 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


      • Remove any oil from the contact surface.

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

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

    4. A01G7EWE02
      Text in Illustration
      *1 Nut

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

      Torque:
      Bolts A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Except bolts A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  4. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01G5U8E07
      Text in Illustration
      *a Timing Chain Cover

      Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01G751E02
      Text in Illustration
      *1 Nut

      Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts.

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

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01G68HE02

      Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01G8R6E01
      Text in Illustration
      *a Seal Diameter

      Apply seal packing in a continuous line 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


      • Remove any oil from the contact surface.

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

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

    3. A01G5WAE02
      Text in Illustration
      *1 Nut

      Install the No. 2 oil pan sub-assembly with the 16 bolts and 2 nuts.

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

  6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01G93C

      Apply seal packing as shown in the illustration.

      Text in Illustration
      A01G8AH Seal Packing
      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 after applying seal packing.

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

    2. A01G6GM

      Install 3 new gaskets as shown in the illustration.

    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

    4. A01G5LGE04
      Text in Illustration
      *1 Seal Washer

      Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.

      Torque:
      Bolts A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolts A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

  7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01G7R7

      Apply seal packing as shown in the illustration.

      Text in Illustration
      A01G8AH Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the cylinder head cover sub-assembly LH within 3 minutes after applying seal packing.

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

    2. A01G4HP

      Install 3 new gaskets as shown in the illustration.

    3. Install a new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly LH.

    4. A01G5VNE08
      Text in Illustration
      *1 Seal Washer

      Install the cylinder head cover sub-assembly LH with the 12 bolts and a new seal washer.

      Torque:
      Bolts A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolts A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      After tightening all bolts, check the tightening torque of 1 and 10. Retighten the bolt if necessary.

  8. INSTALL WATER INLET HOUSING


    1. A01G4OHE01

      Install 2 new O-rings.

      Tech Tips

      Apply a small amount of water or soapy water to O-ring (A) shown in the illustration before installation.

    2. A01G97IE02

      Install the 2 stud bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A01G9QHE03
      Text in Illustration
      *1 Nut
      *2 Bolt

      Install the water inlet housing with the 2 bolts and nut.

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

      Note

      Be careful that the O-ring does not get caught between the parts.

    4. Connect the No. 1 water by-pass hose.

    5. Apply adhesive around the drain cock assembly.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the drain cock assembly to the water inlet housing.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    7. Install the drain cock plug to the drain cock assembly.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    8. Install a new gasket to the thermostat.

    9. A01G6JTE01

      Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

      Tech Tips

      The jiggle valve may be set within 10° of either side of the prescribed position.

    10. A01G540

      Install the water inlet with the 2 nuts.

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

  9. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01G69ZE04
      Text in Illustration
      *1 Stud Bolt

      Using an E8 "TORX" socket wrench, install the 2 stud bolts.

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

    2. Install the No. 1 front engine mounting bracket LH with the 6 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

      Note


      • Install the water inlet and No. 1 front engine mounting bracket LH within 15 minutes after installing the timing chain cover sub-assembly.

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

  10. INSTALL CRANKSHAFT PULLEY


    1. Align the pulley set key with the key groove of the crankshaft pulley, and slide on the crankshaft pulley.

    2. A01G6SXE03
      Text in Illustration
      *a Hold
      A01G8AH Turn

      Using SST, install the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      250 N*m  { 2549 kgf*cm, 184 ft.*lbf }

  11. INSTALL NO. 1 OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

      Note

      Do not touch the mesh when installing the oil control valve filter LH.

    2. A01G5QEE02
      Text in Illustration
      *1 Oil Pipe Union

      Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the No. 1 oil pipe (on the head cover side) with the union.

    3. Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head side) with the union.

    4. Tighten the oil pipe union (on the head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    5. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

  12. INSTALL OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

      Note

      Do not touch the mesh when installing the oil control valve filter RH.

    2. A01G79BE05
      Text in Illustration
      *1 Oil Pipe Union

      Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union.

    3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.

    4. Install the bolt (A) to the cylinder head.

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

    5. Tighten the oil pipe union (on the head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    6. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

  13. INSTALL CRANK POSITION SENSOR


    1. Clean and degrease the threads of the bolt for the crank position sensor.

    2. A01G8AJE02
      Text in Illustration
      *1 O-ring

      Apply a light coat of engine oil to the O-ring on the crank position sensor.

    3. Install the crank position sensor with the bolt.

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

      Note

      Make sure that the O-ring is not cracked or does not move out of place during installation.

    4. Connect the crank position sensor connector.

  14. INSTALL NO. 1 VACUUM SWITCHING VALVE


    1. Install the No. 1 vacuum switching valve with the bolt.

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

  15. INSTALL WATER PUMP PULLEY


    1. Temporarily install the water pump pulley with the 4 bolts.

    2. Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    3. Tighten the 4 bolts.

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

  16. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  17. INSTALL NO. 2 TIMING GEAR COVER


    1. Install the No. 2 timing gear cover with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  18. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01G587

      Apply a light coat of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

    2. A01G90F

      Install the engine oil level dipstick guide.

  19. INSTALL OIL COOLER PIPE (w/ Oil Cooler)


    1. A01G917

      Install a new gasket to the oil pan sub-assembly.

    2. Install the oil cooler pipe with the bolt and 2 nuts.

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

  20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01G4FIE01

      Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.

      Tech Tips

      Each bolt length is as follows:

      A: 70 mm (2.76 in.)

      B: 33 mm (1.30 in.)

    2. Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    3. Tighten the other bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01G4QR

      Install a new gasket as shown in the illustration.

      Text in Illustration
      A01G47H Engine Front
    2. A01G6LJE01

      Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.

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

  22. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  23. INSTALL NO. 2 MANIFOLD STAY


    1. A01G4BDE03

      Tighten the bolt and nut in the order shown in the illustration.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  24. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.

    4. Install the No. 2 engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.

  25. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01G7HT

      Install a new gasket as shown in the illustration.

      Text in Illustration
      A01G47H Engine Front
    2. A01G9M0E01

      Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.

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

  26. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 6 ignition coil assemblies with the 6 bolts.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing an ignition coil assembly Click here.

    2. Connect the 6 ignition coil assembly connectors.

    3. Connect the 2 wire harness clamps.

    4. Install the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  27. INSTALL THROTTLE BODY BRACKET

    Note

    Do not apply oil to the bolt as listed below:

    Oil Application Prohibited Bolt
    Bolt for throttle body bracket and cylinder head cover

    1. Install the throttle body bracket with the bolt.

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

  28. INSTALL NO. 1 SURGE TANK STAY

    Note

    Do not apply oil to the bolt as listed below:

    Oil Application Prohibited Bolt
    Bolt for No. 1 surge tank stay and cylinder head cover

    1. Install the No. 1 surge tank stay with the bolt.

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

  29. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    Do not apply oil to the bolts listed below

    Oil Application Prohibited Bolt
    Bolt for Intake Air Surge Tank Assembly and Intake Manifold
    Bolt for No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    Bolt for Throttle Body Bracket and Intake Air Surge Tank Assembly

    1. Install 3 new gaskets to the intake air surge tank assembly.

    2. Temporarily install the intake air surge tank assembly with the 4 bolts and 2 nuts.

    3. A01G57KE01

      Using a 5 mm hexagon socket wrench, in several steps, uniformly tighten the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

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

    5. Install the vacuum hose clamp with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      Install the vacuum hose clamp so that its tab is in contact with the No. 1 surge tank stay.

    6. Connect the connector to the intake air control valve assembly.

    7. Connect the 2 water by-pass hoses and fuel vapor feed hose.

    8. Connect the connector and wire harness clamp to the throttle body assembly.

    9. Connect the hose clamp and union to check valve hose.

    10. Connect the ventilation hose to the intake air surge tank assembly.

  30. INSTALL ENGINE HANGERS


    1. Install the 2 engine hangers with the 4 bolts.

      Part No.
      Item Part No.
      No. 1 Engine Hanger 12281-31120
      No. 2 Engine Hanger 12282-31100
      Bolt 91671-10825
      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

    2. Attach an engine sling device and hang the engine with a chain block.

  31. REMOVE ENGINE STAND

  32. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021

    2. Clean the 8 bolts and 8 bolt holes.

    3. A01G9KL

      Install the front drive plate spacer.

      Tech Tips

      Align the pin of the front drive plate spacer with the pin hole of the crankshaft.

    4. A01G7HUE03
      Text in Illustration
      *1 Drive Plate
      *2 Rear Spacer
      A01G8AH Transaxle Side

      Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft.

    5. A01G9NCE12
      Text in Illustration
      *1 Adhesive

      Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A01G6I0E01

      Install and uniformly tighten the 8 bolts in several steps in the sequence shown in the illustration.

      Torque:
      83 N*m  { 846 kgf*cm, 61 ft.*lbf }

      Note

      Do not start the engine for at least an hour after installing the drive plate and ring gear sub-assembly.

  33. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Click here