OIL PUMP INSTALLATION


  1. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

      A015CZ2E01
      Text in Illustration
      *a Cylinder Head and Cylinder Block Side *b Timing Chain Cover Side
      A0155U9 Clean and degrease - -

      Note

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

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

    3. Install the oil pump gasket.

    4. A015DBDE01
      Text in Illustration
      *1 Seal Diameter
      A015DIT Seal Packing

      Apply seal packing 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.)

    5. Apply seal packing to the timing chain cover in a continuous line as shown in the following illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      A015A4GE04
      Text in Illustration
      *a 3.0 to 4.0 mm *b 2.0 to 3.0 mm
      *c Be sure to apply seal packing *d Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *e Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent) *f Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *g Diagonal line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) - -

      Note


      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover 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
      Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Diagonal Line Area 6.0 mm (0.236 in.) or more 5.0 mm (0.197 in.)
    6. A015ACVE01
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft

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

    7. Install the timing chain cover with the 26 bolts, labeled A, B, C and D, and the 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 35 mm (1.38 in.)
      Bolt D 65 mm (2.56 in.)
      A015DBVE01
      Text in Illustration
      *1 Nut - -
      *a Area 1 *b Area 2
      *c Area 3 *d Area 4

      Note

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

    8. Tighten the bolts in area 1.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

      Tech Tips

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

    9. Tighten the bolts in area 2.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    10. Tighten the bolts in area 3.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Tech Tips

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

    11. Tighten the bolts in area 4.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Note


      • 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 and head cover and make sure that there is no seal packing seeping out around the edges.

      Tech Tips

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

  2. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A01559IE01

      Apply MP grease to the lip of a new oil seal.

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

      SST
      09226-10010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  3. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

    2. Install 3 new O-rings to the timing chain cover.

    3. A0155CPE01
      Text in Illustration
      *1 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 within 3 minutes after applying seal packing.

    4. A015A1VE01
      Text in Illustration
      *1 Nut

      Install the oil pan with the 17 bolts (A, B, C, D and E) and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Torque:
      for bolt A, B, C, E, and nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 60 mm (2.36 in.)
      Bolt B 45 mm (1.77 in.)
      Bolt C 25 mm (0.984 in.)
      Bolt D 16 mm (0.630 in.)
      Bolt E 70 mm (2.76 in.)

      Note

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

  4. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install the oil strainer with the 2 nuts.

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

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A015ATYE02
      Text in Illustration
      *1 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 within 3 minutes after applying seal packing.

    2. A0156ZE

      Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      A015DIT Bolt
      A015CC1 Nut

      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.

  6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the camshaft housing, timing chain cover and cylinder head cover.

    2. A015E8A

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Text in Illustration
      A015DIT Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. Install 3 new gaskets.

    4. Install a new gasket to the cylinder head cover.

    5. Install new seal washers to the bolts.

    6. A015AMTE01

      Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A and D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B and C
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Standard Bolt
      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 65 mm (2.56 in.)
      D 60 mm (2.36 in.)
      Text in Illustration
      A015DIT Bolt A
      A015CC1 Bolt B
      A0158FK Bolt C
      A015719 Bolt D

      Note

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

  7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the camshaft housing, timing chain cover and cylinder head cover.

    2. A0155II

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Text in Illustration
      A015DIT Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. Install 3 new gaskets.

    4. Install a new gasket to the cylinder head cover.

    5. Install new seal washers to the bolts.

    6. A0156B3E01

      Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A and D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B and C
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Standard Bolt
      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 70 mm (2.76 in.)
      D 60 mm (2.36 in.)
      Text in Illustration
      A015DIT Bolt A
      A015CC1 Bolt B
      A0158FK Bolt C
      A015719 Bolt D

      Note

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

  8. CONNECT FUEL PIPE SUB-ASSEMBLY


    1. Connect the fuel pipe with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  9. INSTALL NO. 2 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.

    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

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

    4. 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.

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

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

  10. 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.

    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

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

    4. 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.

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

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

  11. INSTALL CRANKSHAFT PULLEY


    1. A0159I5E03

      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 }

  12. INSTALL OIL FILTER BRACKET


    1. Install the oil filter bracket and a new gasket with the 2 nuts and bolt.

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

  13. INSTALL OIL FILTER ELEMENT


    1. Clean the inside of the oil filter cap, the threads and O-ring groove.

    2. A015AVFE01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

      Apply a light coat of engine oil to a new O-ring for the cap, and then install the O-ring to the groove of the oil filter cap.

      Note


      • Be sure to install the O-ring in the proper location, otherwise oil may leak.

      • Do not twist the O-ring.

    3. Set a new oil filter element in the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

      Note

      Do not pinch the O-ring for the cap.

    6. A015A81E01
      Text in Illustration
      *1 Oil Filter Cap
      *2 O-Ring
      *3 Oil Filter Bracket
      *a No Gap

      Using SST, tighten the oil filter cap.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      After tightening the oil filter cap, make sure that there is no gap and that the O-ring is not protruding.

    7. A0155YJE01
      Text in Illustration
      *1 O-Ring

      Apply a small amount of engine oil to a new drain plug O-ring and install the O-ring to the oil filter cap.

      Note

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

    8. Install the oil filter drain plug.

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

      Note

      Make sure that the O-ring does not get caught between the parts.

  14. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01573PE01

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

      Standard Bolt
      Item Length
      A 70 mm (2.76 in.)
      B 33 mm (1.30 in.)
      Text in Illustration
      A015DIT Bolt A
      A015CC1 Bolt B

    2. Tighten bolts 1 and 2 in numerical order.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    3. Tighten the other bolts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  15. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the 2 No. 2 idler pulleys with the 2 bolts.

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

  16. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A015DP2E02
      Text in Illustration
      *1 DOUBLE

      Install the No. 1 idler pulley with the bolt.

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

      Tech Tips

      "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.

  17. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A0156MBE01
      Text in Illustration
      *a Upward
      *b Rearward

      Install the water by-pass pipe with the 3 bolts.

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

    2. Connect the 2 hoses.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  18. INSTALL WATER INLET HOUSING

    A0159P9

    1. Install a new O-ring to the water outlet pipe.

    2. Install a new gasket to the water pump.

    3. Apply soapy water to the gasket of the water outlet pipe.

    4. Install the water inlet with the 5 bolts.

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

    5. Connect the 5 water by-pass hoses.

    6. Connect the oil cooler hose.

    7. Connect the No. 2 oil cooler hose.

    8. Connect the throttle body connector.

  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A015BW2E01
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the engine oil level dipstick guide.

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

    3. Push the engine oil level dipstick guide end into the guide hole.

    4. Install the engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.

  20. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 6 ignition coils with the 6 bolts.

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

    2. Connect the 6 ignition coil connectors.

  21. INSTALL NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. Install the No. 2 emission control valve set with the 3 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A015C4KE01
      Text in Illustration
      *1 Paint Mark
      *2 Rib
      *a Top
      *b LH Side

      Align the paint mark with the rib and connect the No. 1 air hose.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the No. 2 emission control valve set connector.

  22. INSTALL NO. 1 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. Install the No. 1 emission control valve set with the 3 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A015B8PE01
      Text in Illustration
      *1 Rib
      *2 Paint Mark
      *a RH Side
      *b Top

      Align the paint mark with the rib and connect the No. 1 air hose.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the No. 1 emission control valve set connector.

  23. INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. A0156MEE01
      Text in Illustration
      *1 Paint Mark
      *a Top
      *b RH Side

      for Bank 1 Side:

      Align the paint mark with the projection and connect the air tube assembly to the emission control valve set.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    2. A0159P0E01
      Text in Illustration
      *1 Paint Mark
      *a Top
      *b LH Side

      for Bank 2 Side:

      Align the paint mark with the projection and connect the air tube assembly to the No. 2 emission control valve set.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Install the 3 bolts.

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

    4. Connect the No. 3 air hose.

  24. INSTALL ENGINE ASSEMBLY

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