OIL PUMP INSTALLATION
PROCEDURE
INSTALL FRONT CRANKSHAFT OIL SEAL
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Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
09223-22010
09506-35010
Note:Keep the lip free from foreign matter.
Do not tap on the oil seal at an angle.
Make sure that the oil seal edge does not protrude from the timing chain case.
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INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
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.
*a
Cylinder Head and Cylinder Block Side
*b
Timing Chain Cover Side
*c
Clean and Degrease
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-
Note:Be sure to clean and degrease the contact surfaces, especially the surfaces indicated in the illustration.
Apply a light coat of engine oil to a new oil pump gasket.
Install the oil pump gasket.
-
*1
Seal Diameter
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.)
Apply seal packing in a line to the timing chain cover 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
*a
Be sure to apply seal packing
*b
Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
*c
Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
*d
Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)
*e
Diagonal line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
*f
3.0 to 4.0 mm
*g
2.0 to 3.0 mm
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-
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.
Seal Packing Application Chart
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.)
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*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.
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.)
*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.
Tighten the bolts in area 1.
47 N*m
479 kgf*cm
35 ft.*lbf
Tip:Tighten the bolts from bottom to top as shown in the illustration.
Tighten the bolts in area 2.
23 N*m
235 kgf*cm
17 ft.*lbf
Tighten the bolts in area 3.
23 N*m
235 kgf*cm
17 ft.*lbf
Tip:Tighten the bolts and nuts from top to bottom as shown in the illustration.
Tighten the bolts in area 4.
23 N*m
235 kgf*cm
17 ft.*lbf
Tip:Tighten the bolts from bottom to top as shown in the illustration.
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.
INSTALL OIL PAN SUB-ASSEMBLY
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.
Install 3 new O-rings to the timing chain cover.
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*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.
-
*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.
for bolt A, B, C and 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.
INSTALL OIL STRAINER SUB-ASSEMBLY
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*1
Groove
*2
Protrusion
Install a new gasket to the oil strainer.
Tip:Align the protrusion of the gasket with the groove of the oil strainer.
Install the oil strainer with the 2 nuts.
9.0 N*m
92 kgf*cm
80 in.*lbf
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INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
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*1
Seal Packing
Apply seal packing in a continuous line as shown in the illustration.
Seal packing
Toyota Genuine Seal Packing Black, Three Bond
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.
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Bolt
Nut
Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
10 N*m
102 kgf*cm
7 ft.*lbf
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.
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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
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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
2.0 to 3.0 mm (0.0787 to 0.118 in.)
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.
Install 3 new gaskets.
Install a new gasket to the cylinder head cover.
Install the seal washers to the bolts.
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Bolt A
Bolt B
Bolt C
Bolt D
Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.
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.)
Note:Do not start the engine for at least 2 hours after installation.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
-
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
2.0 to 3.0 mm (0.0787 to 0.118 in.)
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.
Install 3 new gaskets.
Install a new gasket to the cylinder head cover.
Install the seal washers to the bolts.
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Bolt A
Bolt B
Bolt C
Bolt D
Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.
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.)
Note:Do not start the engine for at least 2 hours after installation.
CONNECT FUEL PIPE SUB-ASSEMBLY
Connect the fuel pipe with the 2 bolts.
9.0 N*m
92 kgf*cm
80 in.*lbf
INSTALL REAR CYLINDER HEAD COVER
INSTALL NO. 2 OIL PIPE
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.
Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
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).
Tighten the oil pipe union (on the cylinder head side).
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.
Tighten the oil pipe union (on the head cover side).
65 N*m
663 kgf*cm
48 ft.*lbf
INSTALL NO. 1 OIL PIPE
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.
Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.
Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).
Tighten the oil pipe union (on the cylinder head side).
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.
Tighten the oil pipe union (on the head cover side).
65 N*m
663 kgf*cm
48 ft.*lbf
INSTALL CRANKSHAFT PULLEY
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*a
Hold
Turn
Using SST, install the crankshaft pulley with the pulley set bolt.
09213-54015
91651-60855
09330-00021
260 N*m
2651 kgf*cm
192 ft.*lbf
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INSTALL OIL FILTER BRACKET
Install the oil filter bracket and a new gasket with the 2 nuts and bolt.
21 N*m
214 kgf*cm
15 ft.*lbf
INSTALL OIL FILTER ELEMENT
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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Bolt A
Bolt B
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.)
Tighten bolts 1 and 2 in numerical order.
36 N*m
367 kgf*cm
27 ft.*lbf
Tighten the other bolts.
36 N*m
367 kgf*cm
27 ft.*lbf
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INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
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Install the No. 1 idler pulley with the bolt.
54 N*m
551 kgf*cm
40 ft.*lbf
Tip:"DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.
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INSTALL WATER INLET HOUSING
Install the 3 water by-pass hoses.
Apply soapy water to a new O-ring and install the O-ring to the water outlet pipe.
Install a new O-ring to the water outlet pipe.
Install a new gasket to the water pump.
Install the water inlet with the 5 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
Connect the 3 water by-pass hoses.
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
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*a
Upward
*b
Rearward
Install the water by-pass pipe with the 3 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
Connect the 4 hoses.
Tip:The direction of the hose clamp is indicated in the illustration.
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INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
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*1
New O-Ring
Install a new O-ring to the dipstick guide.
Apply a light coat of engine oil to the O-ring.
Push the dipstick guide end into the guide hole.
Install the dipstick guide with the bolt.
10 N*m
102 kgf*cm
7 ft.*lbf
Install the dipstick.
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INSTALL IGNITION COIL ASSEMBLY
INSTALL ENGINE ASSEMBLY