OIL PUMP INSTALLATION


  1. INSTALL TIMING CHAIN COVER OIL SEAL


    1. A01J4MWE01

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver with its tip taped, pry out the oil seal.

    3. A01J6U0E01

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

      SST
      09223-75010
      09950-70010   ( 09951-07150 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

      Tech Tips

      When installing the crankshaft pulley, check the shape of the pulley. The correct pulley has a groove Click here.

    4. Apply a light coat of MP grease to a new oil seal lip.

  2. INSTALL WATER PUMP


    1. A01J78NE01

      Install a new gasket and the water pump with the 8 bolts.

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

  3. INSTALL TIMING CHAIN COVER


    1. A01J398E01

      Install 3 new O-rings to the timing chain cover as shown in the illustration.

    2. A01J6CDE06

      Apply adhesive to the timing gear case plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A01J4UEE01

      Using a 10 mm socket hexagon wrench, install the timing gear case plug.

      Torque:
      16.6 N*m  { 169 kgf*cm, 12 ft.*lbf }

    4. 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
      Position Specified Condition
      A - A, C - C 2.5 to 3.0mm (0.098 to 0.118 in.)
      B - B, D - D 4.0 to 4.5 mm (0.157 to 0.177 in.)
      E 3.0 to 3.5 mm (0.118 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

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

      • Do not start the engine for at least 4 hours after the installation.

      A01J6PVE02
    5. A01J524E02

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

    6. Loosely install the timing chain cover with the 19 bolts and 2 nuts, but do not tighten the bolts and nuts yet.

    7. Excluding the bolts labeled A and C, tighten the bolts and nuts in this order: Area 1, Area 2 and Area 3.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Length Thread Diameter
      Bolt A 75 mm (2.95 in.) 10 mm (0.394 in.)
      Bolt B 75 mm (2.95 in.) 8 mm (0.315 in.)
      Bolt C 90 mm (3.54 in.) 8 mm (0.315 in.)
      Bolt D 95 mm (3.74 in.) 8 mm (0.315 in.)
      Bolt E 35 mm (1.38 in.) 8 mm (0.315 in.)
      Bolt F 75 mm (2.95 in.) 10 mm (0.394 in.)

    8. Excluding the bolts labeled A, E and F, tighten the bolts and nuts in this order: Area 1, Area 3, Area 2.

      Torque:
      for bolt C
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      for bolt B, D and nut
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    9. Tighten the bolts labeled A in this order: Area 2 and Area 3.

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

    10. Tighten the bolt labeled F.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

    11. Tighten the bolts labeled E in Area 4.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      A01J4JHE09

  4. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01J3TTE04

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

    2. Install the sensor with the bolt.

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

    3. Install the connector to the connector bracket.

    4. Attach the harness clamp.

    5. Connect the sensor connector.

  5. INSTALL NO. 1 OIL PAN


    1. A01J5CEE03

      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
      2 to 3 mm (0.079 to 0.118 in.)

      Note


      • Remove any oil from the contact surface.

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

      • Do not start the engine for at least 4 hours after the installation.

    2. A01J4CXE03

      Temporarily install the oil pan with the 16 bolts and 2 nuts.

      Tech Tips

      Bolt length:

      20 mm (0.79 in.) for bolt A

      40 mm (1.57 in.) for bolt B

    3. Uniformly tighten the 16 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  6. INSTALL OIL STRAINER


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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  7. INSTALL NO. 2 OIL PAN

    A01J4NME04

    1. 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
      2.5 to 3.5 mm (0.098 to 0.138 in.)

      Note


      • Remove any oil from the contact surface.

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

      • Do not start the engine for at least 4 hours after the installation.

    2. A01J3BYE03

      Temporarily install the oil pan with the 20 bolts and 2 nuts.

    3. Uniformly tighten the 20 bolts and 2 nuts in the order shown in the illustration.

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

    4. Install a new gasket and the drain plug.

      Torque:
      37.5 N*m  { 382 kgf*cm, 28 ft.*lbf }

  8. CHECK CRANKSHAFT PULLEY


    1. Check that the crankshaft pulley matches the pulley labeled A in the illustration.

      A01J6Z2E01

      Note

      If the crankshaft pulley matches the pulley labeled B, replace the crankshaft pulley.

  9. INSTALL CRANKSHAFT PULLEY


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

    2. A01J63RE02

      Using SST, install a new crankshaft pulley bolt.

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

      Note

      Do not reuse the pulley bolt.

  10. INSTALL CAMSHAFT POSITION SENSOR


    1. Apply a coat of engine oil to a new O-ring.

    2. Install the sensor with the bolt.

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

  11. INSTALL CYLINDER HEAD COVER


    1. Install the 2 cover gaskets to the head cover.

    2. A01J45ZE03

      Apply seal packing to the places 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 head cover within 3 minutes after applying seal packing.

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

    3. A01J3L7E01

      Temporarily install the head cover with the 19 bolts and 2 nuts.

    4. Uniformly tighten the 19 bolts and 2 nuts in the order shown in the illustration.

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

    5. In numerical order, confirm that the bolts labeled 1 to 8 are tightened to the torque specification. Tighten the bolts as necessary.

  12. INSTALL OIL FILLER CAP

  13. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A01J4HW

      Install a new gasket and the water by-pass pipe with the 2 nuts.

      Torque:
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

  14. INSTALL NO. 1 IDLER PULLEY


    1. Install the spacer, idler pulley and pulley plate with the bolt.

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

  15. INSTALL V-RIBBED BELT TENSIONER


    1. Temporarily install the belt tensioner with the 3 bolts.

      Tech Tips

      Make sure that the flanges of the bolts are contacting the tensioner surface.

    2. A01J3ARE04

      Install the tensioner by tightening the 3 bolts in the order shown in the illustration.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf, for bolt 1 }
      21 N*m  { 214 kgf*cm, 15 ft.*lbf, for bolt 2 }
      43 N*m  { 438 kgf*cm, 32 ft.*lbf, for bolt 3 }

  16. INSTALL THERMOSTAT


    1. A01J6VUE02

      Install a new gasket to the thermostat.

      Tech Tips

      When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.

    2. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.

      Tech Tips

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

  17. INSTALL WATER INLET


    1. Install the inlet with the 2 nuts and bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the connector.

  18. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

    Note

    Install the compressor mounting bracket exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.


    1. A01J5YJ

      Temporarily install the compressor mounting bracket with the 3 bolts.

      Tech Tips

      Temporarily install the compressor mounting bracket with the 3 bolts so that the bracket can be moved by hand.

    2. Push the compressor mounting bracket toward the cylinder block as shown in the illustration and tighten bolt B.

      A01J35XE01
      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf, for bolt B }

      Tech Tips

      Make sure there is no clearance between the cylinder block and compressor mounting bracket as shown in the illustration.

    3. A01J3G8E01

      Uniformly tighten the 4 bolts in the order shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf, for bolt A }
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf, for bolt C }

  19. INSTALL GENERATOR


    1. A01J5WDE03

      Install the generator with the 2 bolts.

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

    2. Install the generator wire with the bolt and nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Attach the terminal cap.

    4. Connect the connector.

  20. INSTALL INTAKE MANIFOLD

    A01J5MAE01

    1. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.

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

    2. Connect the crankshaft position sensor to the clamp.

  21. INSTALL THROTTLE BODY


    1. A01J5FA

      Install a new gasket on the intake manifold.

      Tech Tips

      Align the protrusion of the gasket with the groove of the intake manifold.

    2. A01J53W

      Install the throttle body with the 4 bolts.

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

    3. Connect the water by-pass hose to the throttle body.

    4. Connector the throttle position sensor and control motor connector.

  22. INSTALL SPARK PLUG

  23. INSTALL IGNITION COIL


    1. Install the ignition coil with the bolt.

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

  24. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

  25. INSTALL ENGINE ASSEMBLY


    1. Install the engine to the vehicle Click here.

  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  27. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

  28. ADD ENGINE OIL


    1. Clean and install the oil drain plug with a new gasket.

      Torque:
      37.5 N*m  { 382 kgf*cm, 28 ft.*lbf }

    2. Add fresh engine oil.

      Standard capacity
      Item Specified Condition
      Drain and refill with oil filter change 5.6 liters (5.9 US qts, 4.9 Imp. qts)
      Drain and refill without oil filter change 5.3 liters (5.6 US qts, 4.6 Imp. qts)
      Dry fill 6.3 liters (6.7 US qts, 5.5 Imp. qts)

    3. Install the oil filler cap.

  29. ADD ENGINE COOLANT


    1. Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf, for cylinder block drain cock plug }
      Standard capacity
      Item Specified Condition
      A/T 8.1 liters (8.6 US qts, 7.1 Imp. qts)
      M/T 7.8 liters (8.2 US qts, 6.9 Imp. qts)

    2. Fill the radiator with TOYOTA SLLC to the F line.

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

      • Please contact your TOYOTA dealer for further details.

        Note

        Never use water as a substitute for engine coolant.

    3. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level drops below the F line, add TOYOTA SLLC to the F line.

    4. Install the radiator cap.

    5. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

      2. Maintain the engine speed at 2,000 to 2,500 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. Stop the engine and wait until the coolant cools down to ambient temperature.

      CAUTION:

      Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    7. A01J31CE01

      Check the coolant level in the radiator reservoir.

      If the coolant level is below the L line, add SLLC to the reservoir F line.

  30. CHECK FUEL FOR LEAKS


    1. Connect the intelligent tester to the DLC3.


      1. Turn the ignition switch ON.

        Note

        Do not start the engine.

      2. Push the intelligent tester main switch ON.

      3. Select the Active Test and enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

    2. Check for fuel leaks.


      1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system.

        If there are fuel leaks, repair or replace parts as necessary.

  31. CHECK FOR ENGINE OIL LEAKS


    1. Start the engine, and check that there are no oil leaks after performing maintenance.

  32. CHECK FOR COOLANT LEAKS


    1. Check for engine coolant leaks Click here.

  33. CHECK FUNCTION OF THROTTLE BODY


    1. A01J6NO

      Check the throttle control motor operating sound.


      1. Turn the ignition switch ON.

      2. When pressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises emit from the motor.

        If friction noise is heard, replace the throttle body.

    2. A01J639E01

      Check the throttle position sensor.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch ON.

      3. Under Current Data, check that the throttle valve opening percentage (Throttle Pos) is within the standard.

        Standard throttle valve opening percentage
        60% or more

        Note

        When checking the standard throttle valve opening percentage, the shift lever should be in the N position.

        If the percentage is less than 60%, replace the throttle body.

  34. CHECK IGNITION TIMING


    1. Warm up the engine and stop the engine.

      Note

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.

    2. A01J4GEE03

      When using the intelligent tester:

      Check the ignition timing.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine at idle.

      3. Turn the intelligent tester main switch ON.

      4. Enter the following item: Powertrain / Engine and ECT / Data List / IGN Advance.

        Standard ignition timing
        0 to 20° BTDC @ idle

        Tech Tips

        Please refer to the intelligent tester operator's manual for further details.

    3. A01J4G5E01

      When not using the intelligent tester:

      Check the ignition timing.


      1. Using SST, connect tachometer probe to terminal TAC of the DLC3.

        SST
        09843-18030

        Note


        • Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.

        • Turn off all electrical systems before connecting the terminals.

      2. A01J79VE01

        Clamp the tester probe of a timing light to the 4 lead wires or green-red lead wire of the ignition coil connector for No. 1 cylinder.

      3. Start the engine.

      4. A01J6S2E01

        Using SST, connect terminals TC and CG of the DLC3.

        SST
        09843-18040

        Note

        When checking the ignition timing, the transmission should be in the neutral position.

        Tech Tips

        A01J7H2E01

        • After connecting terminals (TC and CG), engine rpm changes to approximately 1,000 to 1,500 rpm for 5 seconds, then returns to idle speed. Because the ECM checks that the ISC (idle speed control system) operates properly.

        • Perform the inspection of the ignition timing after engine rpm is returned to idle speed.

      5. A01J5FFE01

        Using a timing light, measure the ignition timing.

        Standard ignition timing
        3 to 7° BTDC @ idle

      6. Remove the SST from terminals 13 (TC) and 4 (CG) of the DLC3.

      7. Check the ignition timing.

        Standard ignition timing
        0 to 20° BTDC @ idle

      8. Confirm that ignition timing moves to the advanced angle side when the engine speed is increased.

      9. Remove the timing light.

  35. CHECK ENGINE IDLE SPEED


    1. Warm up and stop the engine.

      Note

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.

    2. When using the intelligent tester:

      Check the idle speed.


      1. A01J4GEE03

        Connect the intelligent tester to the DLC3.

        Tech Tips

        Please refer to the intelligent tester II operator's manual for further details.

      2. Start the engine at idle.

      3. Turn the intelligent tester main switch ON.

      4. Enter the following item: Powertrain / Engine and ECT / Data List / Engine SPD.

        Standard idle speed
        600 to 700 rpm

        Note


        • When checking the idle speed, the transmission should be in the neutral position.

        • Switch off all accessories and air conditioning before connecting the intelligent tester.

    3. A01J4G5E01

      When not using the intelligent tester:

      Check the idle speed.


      1. Using SST, connect tachometer tester probe to terminal 9 (TAC) of the DLC3.

        SST
        09843-18030

      2. Start the engine at idle.

      3. Check the idle speed.

        Standard idle speed
        600 to 700 rpm

  36. CHECK CO/HC


    1. Start and warm up the engine.

    2. Run the engine at 2,500 rpm for approximately 180 seconds and idle the engine.

    3. A01J60NE01

      Insert CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe.

    4. Check CO/HC concentration at idle.

      Idle CO concentration
      0 to 0.5%
      Idle HC concentration
      Applicable local regulation

    5. If the CO/HC concentration is not as specified, perform troubleshooting in the order given below.


      1. Check the heated oxygen sensor operation Click here.

      2. See the table below for possible causes, and then inspect and repair the applicable causes if necessary.

        CO HC Problems Causes
        Normal High Rough idle

        1. Faulty ignitions:


          • Incorrect timing

          • Plugs are contaminated, shorted or gaps are defective

        2. Incorrect valve clearance

        3. Leaks in intake and exhaust valves

        4. Leaks in cylinders
        Low High

        Rough idle

        (Fluctuating HC reading)

        1. Vacuum leaks:


          • Ventilation hoses

          • Intake manifold

          • Throttle body

          • Brake booster line

        2. Lean mixture causing misfire
        High High

        Rough idle

        (Black smoke from exhaust)

        1. Restricted air filter

        2. Plugged ventilation valve

        3. Faulty SFI system:


          • Faulty pressure regulator

          • Defective ECT sensor

          • Defective Mass Air Flow (MAF) meter

          • Faulty ECM

          • Faulty injectors

          • Faulty throttle position sensor