Oil Pump: Installation

1. Apply soapy water to 2 new O-rings and install them to the inlet water pipe.
2. Install the inlet pipe to the heat exchanger assembly.

Fig 1: Identifying Inlet Water Pipe O-Ring

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1. Remove any old packing material remaining on the sealing surfaces before applying seal packing
2. Clean and degrease the contact surfaces of the timing chain cover, cylinder head, and cylinder block and confirm that no oil, moisture, or other foreign matter remains on the surfaces.
   Fig 2: Identifying Timing Chain Cover Old Packing Area

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3. Install a new oil pump gasket.
   Fig 3: Identifying Oil Pump Gasket

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4. Install a new O-ring.
   Fig 4: Identifying Cylinder Block O-Ring

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5. Apply seal packing in a continuous line to the timing chain cover as shown in the illustration
   Fig 5: Identifying Seal Packing Applying Area

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   Seal packing: 

   Toyota Genuine Seal Packing Black, Three 

   Bond 1207B or equivalent 

   Apply seal packing as follows 

   SEAL PACKING DIAMETER SPECIFICATION
   
   

   Area	Seal Packing Diameter	Application Position from Inside Edge of Cover
   Continuous Line Area	3 0 to 4 0 mm (01181 to 0 1575 in.)	2 5 mm (0 098 in.)
   Dashed Line Area	6.4 mm (0.2520 in.) or more, or within OK area shown in illustration	0.5 mm (0.020 in.)
   Diagonal Line Area	3.0 to 4.0 mm (0.1181 to 0.1575 in.)	5 5 mm (0 217 in)

   Fig 6: FIPG Thickness Graph

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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.
   • Do not add engine oil for at least 2 hours after installing the chain cover.
   • Do not start the engine for at least 2 hours after installing the chain cover.
6. Align the oil pump drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.
   Fig 7: Aligning Oil Pump Drive Rotor Spline And Crankshaft

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7. Temporarily install the timing chain cover with the 30 bolts and nut.

   Bolt Length 

   BOLT LENGTH SPECIFICATION
   
   

   Item	Length	Thread Diameter
   Bolt A	25 mm (0.984 in.)	8 mm (0.315 in.)
   Bolt B	55 mm (2.165 in.)	8 mm (0.315 in.)
   Bolt C	70 mm (2.756 in.)	8 mm (0 315 in.)
   Bolt D	35 mm (1.378 in.)	10 mm (0 394 in.)
   Bolt E	80 mm (3.150 in.)	10 mm (0.394 in.)
   Bolt F	80 mm (3 150 in.)	10 mm (0.394 in)
   Bolt G	80 mm (3.150 in)	8 mm (0.315 in.)

   NOTE: Make sure that there is no oil on the bolt threads.
   Fig 8: Locating Timing Chain Cover Bolts

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8. Tighten the 11 bolts in several steps, in the sequence shown in the illustration.

   Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf) 

   Fig 9: Identifying Timing Chain Cover Bolts Tightening Sequence

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9. Temporarily install the belt tensioner with the standard bolt and hexagon bolt.
   Fig 10: Locating Belt Tensioner Bolt

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10. Tighten the 21 bolts and nut in several steps, in the sequence shown in the illustration.

    HINT.

    Use a 6 mm socket hexagon wrench to tighten the bolt numbered 22 in the illustration.

    Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 

    Fig 11: Identifying Timing Chain Cover Bolts Tightening Sequence

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11. After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

Fig 12: Identifying Seal Packing

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1. Install 2 new gaskets to the oil filter bracket sub-assembly.
2. Install the oil filter bracket sub-assembly with the 2 bolts and 2 nuts

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 13: Locating Oil Filter Bracket Sub-Assembly Bolts And Nuts

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3. Install the oil filter bracket stay with the 2 bolts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

Fig 14: Locating Oil Filter Bracket Stay Bolts

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1. Temporarily install the oil pump drive shaft pulley with the 4 bolts.
2. Using SST, hold the oil pump drive shaft pulley and tighten the 4 bolts.

   SST 09960-10010 (09962-01000, 09963-00600) 

   Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 

Fig 15: Locating Oil Pump Drive Shaft Pulley Bolts

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(See INSTALLATION )

(See INSTALLATION )

1. Connect the ground wire with the bolt and clamp

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 16: Locating Ground Wire Bolt

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2. Connect the ground cable with the bolt.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   Fig 17: Locating Ground Cable Bolt

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3. Connect the 7 clamps and connect the 5 connectors.
4. Install the 2 ground wires with the 2 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

   Fig 18: Locating No. 1 Engine Room Relay Block Cover Connectors And Clamps

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5. Connect the 3 clamps and 8 connectors.
   Fig 19: Locating Connectors And Clamps

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6. Connect the 5 connectors and grommet to the engine room ECU box
   Fig 20: Locating Engine Room ECU Box Connectors And Grommet

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7. Engage the claw and connect the No. 4 connector holder to the engine room ECU box
   Fig 21: Connecting No. 4 Connector Holder

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8. Connect the 3 connectors and connector clamp.

Fig 22: Locating Connector And Clamps

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(See INSTALLATION )