OIL PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click here

PROCEDURE


  1. INSTALL NO. 6 ENGINE COVER

    Click here

  2. INSTALL TIMING CHAIN COVER ASSEMBLY

    Click here

  3. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

    Click here

  4. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    Click here

  5. INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  6. INSTALL IDLE SPROCKET ASSEMBLY

    Click here

  7. INSTALL NO. 1 CHAIN SUB-ASSEMBLY

    Click here

  8. INSTALL CHAIN TENSIONER SLIPPER

    Click here

  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  10. INSPECT VALVE TIMING

    Click here

  11. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY


    1. B006B4FC02
      *1 Oil Pump Drive Sprocket
      *2 Oil Pump Drive Shaft Sprocket
      *3 Oil Pump Drive Chain Sub-assembly
      *a Mark Plate
      *b Timing Mark
      *c D Cut Plane

      Rotate the crankshaft timing gear key position 30° counterclockwise as shown in the illustration.

    2. Set the D cut plane of the oil pump shaft at the position shown in the illustration.

    3. Align the mark plates (yellow) on the oil pump drive sprocket, oil pump drive shaft sprocket and oil pump drive chain sub-assembly with the timing marks.

    4. Install them to the oil pump shaft and crankshaft.

    5. Temporarily install the oil pump drive shaft gear nut.

    6. While pushing the chain damper spring, install the chain tensioner plate and chain damper spring.

    7. Using the hexagonal portion of the camshaft, secure the camshaft.

    8. Tighten the oil pump drive shaft gear nut.

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

  12. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. Remove any old packing remaining on the sealing surfaces before applying seal packing.

    2. Clean the contact surfaces of the timing chain cover assembly, timing chain or belt cover sub-assembly and confirm that there is no oil, moisture or other foreign matter on the surfaces.

      B006FQHC01
      *a Timing Chain Cover Assembly Side *b Timing Chain or Belt Cover Sub-assembly Side
      B006FQ2 Clean and Degrease - -

      Note


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

      • Check the bolts and bolt holes, and clean and degrease them.

    3. Install 2 new water pump gaskets to the timing chain cover assembly.

    4. B006E7GC01
      *a 3.0 to 4.0 mm (0.118 to 0.157 in.)
      B006ECJ Seal Packing

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

      Note


      • Using non-residue solvent, clean and remove any oil from the installation surface.

      • Check the bolts and bolt holes, and clean and degrease them.

      • Install the timing chain or belt cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

      • Do not start the engine for at least 2 hours after installing the timing chain cover assembly.

    5. Temporarily install the timing chain or belt cover sub-assembly with the 27 bolts.

      B006B2ZC01
      *a Type of bolt *b Tightening Order
      Bolt Length
      Item Length
      A 35 mm (1.38 in.)
      B 80 mm (3.15 in.)
      C 90 mm (3.54 in.)
      D 55 mm (2.17 in.)

      Note

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

    6. Tighten the 27 bolts in several steps, in the sequence shown in the illustration.

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

  13. INSTALL TIMING CHAIN CASE OIL SEAL

    Click here

  14. INSTALL CRANKSHAFT PULLEY

    Click here

  15. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  16. INSTALL CRANKSHAFT PULLEY COVER

    Click here

  17. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY LH

    Click here

  18. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY RH

    Click here

  19. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY LH

    Click here

  20. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY RH

    Click here

  21. INSTALL SPARK PLUG TUBE GASKET

    Click here

  22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. Install a new No. 1 cylinder head cover gasket RH to the cylinder head cover sub-assembly RH.

    2. Install 6 new No. 2 cylinder head cover gasket RH to the cylinder head cover sub-assembly RH.

    3. Before applying seal packing black, cleanly remove any old sealant sticking to the part to be sealed.

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

    5. 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 6.0 mm (0.118 to 0.236 in.)

      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.

      B006B5QC01
      *a Application Width 20 to 30 mm (0.787 to 1.181 in.) *b Application Range
    6. B006GCR

      Install a new camshaft bearing cap oil hole gasket RH to the camshaft bearing cap.

    7. B006BUQC01
      B006AHR Bolt A
      B006EC9 Bolt B

      Degrease the threads of the 14 cylinder head cover installation bolts (A).

    8. Temporarily install the 2 VVT sensors with the 2 new bolts (B).

    9. Temporarily install the cylinder head cover sub-assembly RH with the 14 bolts (A).

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

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      Bolt Length
      Item Length
      Bolt A 23.5 mm (0.925 in.)
      Bolt B 30 mm (1.18 in.)

      Note

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

    11. Install the No. 1 intercooler air guide to the cylinder head cover sub-assembly RH.

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

  23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Install a new No. 1 cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

    2. Install 6 new No. 2 cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

    3. Before applying seal packing black, cleanly remove any old sealant sticking to the part to be sealed.

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

    5. 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 6.0 mm (0.118 to 0.236 in.)

      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.

      B006E3WC01
      *a Application Width 20 to 30 mm (0.787 to 1.181 in.) - -
    6. B006BM2

      Install a new camshaft bearing cap oil hole gasket LH to the camshaft bearing cap.

    7. B006B52C01
      B006AHR Bolt A
      B006EC9 Bolt B

      Degrease the threads of the 14 cylinder head cover installation bolts (A).

    8. Temporarily install the 2 VVT sensors with the 2 new bolts (B).

    9. Temporarily install the cylinder head cover sub-assembly RH with the 14 bolts (A).

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

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      Bolt Length
      Item Length
      Bolt A 23.5 mm (0.925 in.)
      Bolt B 30 mm (1.18 in.)

      Note

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

    11. Install the No. 1 intercooler air guide to the cylinder head cover sub-assembly LH.

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

  24. INSTALL NO. 2 ENGINE COVER RH

    Click here

  25. INSTALL NO. 2 ENGINE COVER LH

    Click here

  26. INSTALL SPARK PLUG

    Click here

  27. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Install 2 new gaskets to the timing chain cover assembly.

    2. Install the oil filter bracket sub-assembly with the 3 bolts.

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

  28. INSTALL IGNITION COIL ASSEMBLY

    Click here

  29. INSTALL GENERATOR BRACKET SUB-ASSEMBLY

    Click here

  30. INSTALL WATER INLET ASSEMBLY

    Click here

  31. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  32. INSTALL IDLER PULLEY SUB-ASSEMBLY

    Click here

  33. INSTALL WATER PUMP PULLEY

    Click here

  34. CONNECT NO. 4 RADIATOR HOSE

    Click here

  35. INSTALL WATER OUTLET PIPE WATER BY-PASS JOINT

    Click here

  36. INSTALL NO. 2 WATER OUTLET PIPE

    Click here

  37. INSTALL NO. 1 WATER OUTLET PIPE

    Click here

  38. INSTALL NO. 11 ENGINE WIRE

    Click here

  39. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  40. INSTALL WATER CONTROL VALVE

    Click here

  41. INSTALL INTAKE PIPE STAY

    Click here

  42. INSTALL NO. 1 TURBO PRESSURE SENSOR

    Click here

  43. CONNECT NO. 1 WATER BY-PASS PIPE


    1. Connect the No. 1 water by-pass pipe with the 3 bolts.

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

  44. CONNECT WATER HOSE

    Click here

  45. CONNECT NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. Connect the No. 1 turbo water pipe sub-assembly to the cylinder head cover sub-assembly RH with the bolt.

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

  46. INSTALL TURBO WATER PIPE STAY


    1. Install the turbo water pipe stay with the 2 bolts.

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

  47. INSTALL NO. 2 AIR INLET DUCT


    1. Connect the No. 2 air inlet duct to the compressor inlet elbow.

    2. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Install the bolt.

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

    4. Attach the 2 clamps and connect the vacuum hose.

  48. CONNECT NO. 2 PCV TUBE

    Click here

  49. INSTALL NO. 1 AIR HOSE


    1. Install the No. 1 air hose to the No. 1 compressor outlet elbow.

    2. Tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  50. INSTALL NO. 1 AIR INLET DUCT


    1. Connect the No. 1 air inlet duct to the compressor inlet elbow.

    2. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Install the bolt.

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

    4. Attach the 2 clamps and connect the vacuum hose.

  51. CONNECT NO. 1 PCV TUBE

    Click here

  52. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  53. INSTALL FUEL PUMP ASSEMBLY (for Bank 2)

    Click here

  54. INSTALL FUEL PUMP ASSEMBLY (for Bank 1)

    Click here

  55. INSTALL GENERATOR ASSEMBLY

    Click here

  56. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY