OIL PUMP INSTALLATION

Tech Tips

Check whether the engine is TMC made or not by referring to the following illustration.

A01CE8JE01
Text in Illustration
*A for TMC Made Engine *B except TMC Made Engine
*1 Engine Oil Level Dipstick Guide *2 Water Inlet Housing
*3 Water Inlet Housing Drain Cock Assembly - -

  1. INSTALL OIL PUMP ASSEMBLY


    1. Install a new gasket and the oil pump with the 3 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  2. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. A01CCV9

      Set the crankshaft key into the left horizontal position.

    2. Turn the oil pump drive shaft so that the cutout faces upward.

    3. A01CBW3E11
      Text in Illustration
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *3 Mark Link
      *4 Timing Mark

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

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

    5. Temporarily tighten the oil pump drive shaft gear with the nut.

    6. A01CF6FE09
      Text in Illustration
      *1 Spring
      *2 Chain Tensioner Plate
      *3 Bolt

      Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    7. A01CG5DE09
      Text in Illustration
      *1 Groove

      Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.

    8. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    9. A01CFYZ

      Rotate the crankshaft 90° clockwise, and position the crankshaft key to face up as shown in the illustration.

  3. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A01CC5L

      Install the crankshaft timing gear or sprocket to the crankshaft.

  4. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A01CF5G

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

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

  5. INSTALL CHAIN SUB-ASSEMBLY


    1. Set the No. 1 cylinder to TDC/compression.


      1. A01CEAGE02
        Text in Illustration
        *1 Timing Mark

        Turn the camshafts with a wrench (using the hexagonal lobe) to align the timing marks on the camshaft timing gear with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.

      2. A01CFKIE01

        Using the crankshaft pulley bolt, turn the crankshaft to position the key on the crankshaft upward.

    2. A01CCHVE05
      Text in Illustration
      *1 Timing Mark
      *2 Mark Link

      Install the chain onto the crankshaft timing sprocket with the gold or orange mark link aligned with the timing mark on the crankshaft.

    3. A01CEW2E01

      Using SST and a hammer, tap in the crankshaft timing sprocket.

      SST
      09309-37010
    4. A01CDZKE04
      Text in Illustration
      *1 Mark Link
      *2 Timing Mark

      Align the gold or yellow links with the timing marks located on the camshaft timing gear and sprocket, then install the chain.

  6. INSTALL CHAIN TENSIONER SLIPPER


    1. A01CAWPE05
      Text in Illustration
      *a Hold

      Install the chain tensioner slipper with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  7. INSTALL TIMING CHAIN GUIDE


    1. A01CFN4E01

      Install the timing chain guide with the bolt.

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

  8. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01CFA0

      Install the sensor plate with the "F" mark facing forward.

  9. INSTALL TIMING CHAIN COVER OIL SEAL


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

    2. A01CFXVE01

      Using SST and a hammer, tap in the front crankshaft oil seal until its surface is flush with the front oil seal retainer edge.

      SST
      09223-22010

      Note


      • Keep the lip free from foreign matter.

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

  10. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


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

    2. A01CB3QE05

      Apply seal packing (Diameter 4.0 to 4.5 mm (0.157 to 0.177 in.)) as shown in the illustration.

      Text in Illustration
      A01CFEA Seal Packing
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the chain cover within 3 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the chain cover.

    3. Apply a continuous bead of seal packing as shown in the illustration.

      A01CD1NE10
      Text in Illustration
      *1 Seal Packing - -
      *a Seal Diameter: 2.5 to 3.0 mm (0.0984 to 0.118 in.) *b Seal Diameter: 3.0 mm (0.118 in.)
      *c Seal Diameter: 4.0 mm (0.157 in.) *d Seal Diameter: 4.0 to 4.5 mm (0.157 to 0.177 in.)
      *e Seal Diameter: 4.5 to 5.0 mm (0.177 to 0.197 in.) *f Seal Diameter: 5.5 to 6.0 mm (0.217 to 0.236 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surfaces.

      • Install the chain cover within 3 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the chain cover.

    4. Apply adhesive to the threads of the bolt A.

      Seal packing
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A01CFL9E10
      Text in Illustration
      *1 Nut

      Temporarily install the timing chain cover with the 12 bolts and 2 nuts.

      Bolt Length
      Item Length
      Bolt A 30 mm (1.18 in.) length for 10 mm head
      Bolt B 30 mm (1.18 in.) length for 12 mm head
      Bolt C 40 mm (1.57 in.) length for 14 mm head
    6. A01CG6C

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

    7. Fully tighten the timing chain cover with the 15 bolts and 2 nuts as shown in the illustration.

      A01CFXOE01
      Torque:
      Bolt A
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      Bolt B
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Bolt C
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      Nut
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    8. Using an E10 "TORX" socket, install the stud bolt for the V-ribbed belt tensioner.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }

  11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01CGD9E07
      Text in Illustration
      *1 Pin
      *2 Hook
      *a Raise
      *b Push

      Release the ratchet pawl, then fully push in the plunger and set the hook to the pin so that the plunger is in the position shown in the illustration.

    2. A01CFT0

      Install a new gasket and the chain tensioner with the 2 nuts.

      Text in Illustration
      A01CFEA Engine Front
      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Note

      When installing the chain tensioner, set the hook again if the hook releases the plunger.

  12. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01CC9OE02
      Text in Illustration
      *1 Bolt
      *2 Nut

      Temporarily install the V-ribbed belt tensioner assembly with the nut.

      Note

      Do not lift the engine more than necessary.

    2. Slightly push down on the V-ribbed belt tensioner assembly at part (A) to align the holes of the engine and tensioner as shown in the illustration, and temporarily install the bolt.

    3. A01CFXPE03
      Text in Illustration
      *1 Pin

      Tighten the bolt and nut to install the V-ribbed belt tensioner.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note


      • When replacing the V-ribbed belt tensioner with a new one, do not pull out the pin.

      • The pin will be removed in a later step.

  13. INSTALL CRANKSHAFT PULLEY


    1. A01CC44E01

      Using SST, secure the pulley in place and tighten the bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      180 N*m  { 1835 kgf*cm, 133 ft.*lbf }
    2. A01CCT5E07
      Text in Illustration
      *1 Hook
      *2 Pin
      *a Disconnect

      Turn the crankshaft counterclockwise, then disconnect the hook from the pin.

    3. A01CF8EE11
      Text in Illustration
      *1 Plunger
      *a Extend
      *b Turn

      Turn the crankshaft clockwise, then check that the plunger is extended.

  14. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.

    2. A01CB5AE07
      Text in Illustration
      *1 Seal Packing
      *a Seal Diameter: 3.0 to 4.0 mm

      Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.118 to 0.157 in.)) as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan within 3 minutes of applying seal packing.

      • Do not add engine oil for at least 2 hours after installing the oil pan.

    3. Install the oil pan onto the cylinder block.

    4. A01CCAEE01

      Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.

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

  15. INSTALL CRANK POSITION SENSOR (for TMC Made Engine)


    1. A01CEJOE11
      Text in Illustration
      *1 New O-ring

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

    2. A01CCT1

      Install the crank position sensor with the bolt.

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

      Note

      Do not twist the O-ring.

    3. Install the 2 wire harness clamps.

    4. Install the connector to the connector bracket.

  16. INSTALL CRANK POSITION SENSOR (except TMC Made Engine)


    1. A01CEJOE12
      Text in Illustration
      *1 New O-ring

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

    2. A01CG06

      Install the crank position sensor with the bolt.

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

      Note

      Do not twist the O-ring.

    3. Install the wire harness clamp.

    4. Install the connector to the connector bracket.

  17. INSTALL IDLER PULLEY SUB-ASSEMBLY


    1. Install the idler pulley bracket with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing material from the contact surfaces.

    2. A01CARIE03
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the 2 locations shown in the illustration.

      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 within 3 minutes of applying seal packing.

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

    3. A01CD2IE04
      Text in Illustration
      *1 Nut

      Install the cylinder head cover with the 8 bolts and 2 nuts.

      Torque:
      Bolt A
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Bolt B
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Nut
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  19. INSTALL IGNITION COIL ASSEMBLY


    1. A01CC5A

      Install the 4 ignition coils with the 4 bolts.

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

    2. Connect the 4 ignition coil connectors.

  20. INSTALL ENGINE HANGERS


    1. A01CG33E08
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Part Name Part No.
      No. 1 engine hanger

      12281-28010 or

      12281-0H010
      No. 2 engine hanger

      12282-28010 or

      12282-0H010
      Bolt

      91552-B1020 or

      90105-C0076

  21. REMOVE ENGINE STAND

  22. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01CCOPE02

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01CDPS

      Install the front spacer.

      Tech Tips

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

    3. A01CD8VE01
      Text in Illustration
      *1 Drive Plate And Ring Gear Sub-Assembly
      *2 Rear Spacer
      A01CFEA Transaxle

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

    4. Clean the 8 bolts and 8 bolt holes.

    5. A01CBLRE13
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A01CFYUE02

      In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

      Note

      Do not start the engine for at least an hour after installing the drive plate.

  23. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

    Click here

  24. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here