Oil Pump: Installation

INSTALL WATER INLET PIPE
1. Apply soapy water to 2 new O-rings and install them to the inlet pipe.
2. Install the inlet pipe to the No. 1 heat exchanger cover.
  
  Fig 1: Identifying Water Inlet Pipe O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Apply a light coat of engine oil to a new oil pump gasket.
Install the oil pump gasket.

Fig 2: Identifying Oil Pump Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to a new O-ring.
Install the O-ring.

Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Fig 3: Identifying Oil Pan O-Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 4: Identifying Seal Packing Applying Area

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 (0.118 to 0.157 in.)	2.5 mm (0.0984 in.)
Dashed Line Area	6.4 mm (0.252 in.) or more, or within OK area shown in illustration	7.0 mm (0.276 in.)
Diagonal Line Area	3.0 to 4.0 mm (0.118 to 0.157 in.)	5.5 mm (0.217 in.)

Fig 5: Identifying Seal Packing Width And Thickness

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 start the engine for at least 2 hours after installing.

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

Fig 6: Aligning Oil Pump Drive Rotor Spline And Crankshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily install the timing chain cover with the 28 bolts and nut.

Standard Bolt

STANDARD BOLT LENGTH AND THREAD DIAMETER SPECIFICATION

Item	Length	Thread Diameter
Bolt A	25 mm (0.984 in.)	8 mm (0.315 in.)
Bolt B	55 mm (2.17 in.)	8 mm (0.315 in.)
Bolt C	70 mm (2.76 in.)	8 mm (0.315 in.)
Bolt D	35 mm (1.38 in.)	10 mm (0.394 in.)
Bolt E	55 mm (2.17 in.)	10 mm (0.394 in.)
Bolt F	80 mm (3.15 in.)	10 mm (0.394 in.)

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

Fig 7: Locating Timing Chain Cover Bolts And Nut

Tighten the 3 bolts in several steps in the sequence shown in the illustration.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)

Fig 8: Identifying Timing Chain Cover Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily install the fluid coupling bracket with the 4 bolts.

Standard Bolt

STANDARD BOLT LENGTH AND THREAD DIAMETER SPECIFICATION

Item	Length	Thread Diameter
Bolt A	70 mm (2.76 in.)	8 mm (0.315 in.)
Bolt B	80 mm (3.15 in.)	10 mm (0.394 in.)

Fig 9: Locating Fluid Coupling Bracket Bolts

Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

Fig 10: Locating Hexagon Wrench Bolt And Belt Tensioner
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)

Fig 11: Locating Timing Chain Cover Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)

Fig 12: Locating Tightening Sequence Of Timing Chain Cover Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSTALL SPARK PLUG TUBE GASKET (See REASSEMBLY )

Fig 13: Identifying Seal Packing Applying Area
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).
2. Install the gasket to the cylinder head cover.
  NOTE: Remove any oil from the contact surface.
  
  Fig 14: Identifying Camshaft Bearing Caps Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing as 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 cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after the installation.
    
    Fig 15: Identifying Seal Packing Applying Area To Cylinder Head Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the cylinder head cover and the seal washer with the 14 bolts in the order shown in the illustration.
  Torque: for bolt A
  
  21 N*m (214 kgf*cm, 15 ft.*lbf) except bolt A
  
  12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 16: Identifying Cylinder Head Cover Bolts Tightening Sequence (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
1. Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).
2. Install the gasket to the cylinder head cover.
  NOTE: Remove any oil from the contact surface.
  
  Fig 17: Locating Camshaft Bearing Caps Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing as 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 cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
  - Do not start the engine for at least 2 hours after the installation.
    
    Fig 18: Locating Seal Packing Applying Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the cylinder head cover and the seal washer with the 14 bolts in the order shown in the illustration.
  Torque: for bolt A
  
  21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  except bolt A
  
  12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 19: Identifying Cylinder Head Cover Bolts Tightening Sequence (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the noise filter to the cylinder head cover with the bolt.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
INSTALL IGNITION COIL ASSEMBLY
1. Install the 8 ignition coils with the 8 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 20: Identifying Cylinder Head Cover Sub-Assembly Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT TIMING GEAR KEY
1. Install the crankshaft timing gear key to the crankshaft.
  
  Fig 21: Identifying Crankshaft Timing Gear Key
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT WIRE HARNESS CLAMP BRACKET
1. Connect the bracket to the timing chain cover with the bolt.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 22: Locating Wire Harness Clamp Bracket Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
2. Using SST, install the pulley set bolt.
  SST 09213-70011 (09213-70020), 09330-00021
  
  Torque: 300 N*m (3059 kgf*cm, 221 ft.*lbf)
  
  Fig 23: Installing Pulley Set Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley with the bolt.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
  
  Fig 24: Locating Idler Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER PUMP PULLEY
1. Temporarily install the pulley with the 4 bolts.
2. Using SST, hold the pulley and tighten the 4 bolts.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 25: Tightening Water Pump Pulley Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER INLET HOUSING
1. Install a new gasket to the timing chain cover.
  
  Fig 26: Identifying Timing Chain Cover Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water inlet with the 3 bolts.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 27: Locating Water Inlet Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR TUBE SUB-ASSEMBLY
1. Connect the 2 hoses.
2. Install the air tube with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL NO. 1 ENGINE COVER (See INSTALLATION )
INSTALL NO. 2 ENGINE COVER (See INSTALLATION )

Fig 28: Locating Air Tube Bolt And Hoses
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT WATER BY-PASS JOINT
1. Install 2 new gaskets and the water by-pass joint with the 4 nuts.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. Connect the No. 2 water by-pass hose to the water by-pass joint.
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Connect the 2 hoses.
  
  Fig 29: Locating Water By-Pass Joint Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the water by-pass pipe with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 30: Locating Water By-Pass Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the air tube with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 31: Locating Air Tube Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 WATER BY-PASS HOSE
1. Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.
INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
CONNECT OIL COOLER PIPE ASSEMBLY (See INSTALLATION )

Fig 32: Locating Water By-Pass Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT VANE PUMP ASSEMBLY
HINT:

Before performing the following procedures, move the spacer until the vane pump can be installed.

Fig 33: Moving Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Connect the vane pump to the timing chain cover with the 2 bolts.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 34: Locating Vane Pump Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 2 clamps and power steering oil pressure switch connector.
INSTALL INTAKE MANIFOLD (See INSTALLATION )

Fig 35: Identifying Clamps And Power Steering Oil Pressure Switch Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER BRACKET (w/o Oil Cooler)
1. Apply a light coat of engine oil to 2 new O-rings.
2. Install the 2 O-rings to the timing chain cover.
  
  Fig 36: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil filter bracket with the 2 bolts and 2 nuts.
  Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
INSTALL OIL FILTER BRACKET (w/ Oil Cooler) (See INSTALLATION )
INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See INSTALLATION )
INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)
1. Connect the 4 hoses.
2. Install the water by-pass pipe with the 3 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 37: Locating Oil Filter Bracket Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (See INSTALLATION )
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (See INSTALLATION )
INSTALL OIL FILTER ELEMENT (See REPLACEMENT )

Fig 38: Locating Water Bypass Pipe Bolts And Hoses
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY
1. Connect the fuel tube with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 39: Locating Fuel Tube Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT COOLER COMPRESSOR ASSEMBLY
1. Install the cooler compressor with the stud bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Install the 3 bolts and nut.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
  
  NOTE: Tighten the bolts and nut in the order shown in the illustration to install the cooler compressor.
  
  Fig 40: Identifying Cooler Compressor Assembly Bolts And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 WATER BY-PASS PIPE
1. Connect the No. 2 water by-pass pipe to the cylinder head cover with the 3 bolts.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
2. Connect the 3 hoses.
  
  Fig 41: Locating Water By-Pass Pipe And Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT AIR PUMP HOSE AND WIRE HARNESS
1. Connect the No. 2 and No. 3 air hoses.
2. Connect the 2 clamps and air pump wire harness.
  
  Fig 42: Locating No. 2 And No. 3 Air Hoses Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT ENGINE WIRE
1. Engine Room RH Side:
  1. Connect the 5 clamps.
  2. Connect the throttle position sensor and throttle control motor connector.
  3. Connect the 2 air pump connectors.
  4. Install the ground wire with the 2 bolts.
    Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  5. Connect the noise filter connector.
  6. Connect the 2 VVT sensor connectors.
    HINT:
    
    The wire harnesses on the exhaust side are wrapped with white tape.
    
    Fig 43: Locating Injector Connector, VVT Sensor Connectors And Ignition Coil Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Connect the injector connector.
  8. Connect the 4 ignition coil connectors.
  9. Connect the 2 camshaft timing oil control valve connectors.
    HINT:
    
    The wire harnesses on the exhaust side are wrapped with white tape.
2. Engine Room LH Side:
  1. Connect the cooler compressor connector.
  2. Connect the 3 clamps.
  3. Connect the camshaft position sensor connector.
  4. Connect the 2 camshaft timing oil control valve connectors.
    HINT:
    
    The wire harnesses on the exhaust side are wrapped with white tape.
  5. Connect the engine coolant temperature sensor connector.
  6. Connect the 4 clamps.
    
    Fig 44: Locating Engine Coolant Temperature Sensor Connector And Clamps
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Install the ground wire with the 2 bolts.
    Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  8. Connect the noise filter connector.
  9. Connect the 2 VVT sensor connectors.
    HINT:
    
    The wire harnesses on the exhaust side are wrapped with white tape.
  10. Connect the 4 ignition coil connectors.
  11. Connect the injector connector.
    
    Fig 45: Locating Injector Connector, Ignition Coil Connectors And VVT Sensor Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Connect the wire harness clamp and 4 air injection control driver connectors.
    
    Fig 46: Locating Air Injection Control Driver Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. Connect the 2 connectors and 2 clips to the engine room junction block.
  14. Install the engine room relay block cover.
INSTALL RADIATOR ASSEMBLY
1. Install the radiator (See INSTALLATION ).
INSTALL AIR CLEANER ASSEMBLY (See INSTALLATION )
INSTALL AIR CLEANER HOSE ASSEMBLY (See INSTALLATION )
INSTALL V-BANK COVER SUB-ASSEMBLY (See INSTALLATION )

Fig 47: Identifying Connectors And Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADD ENGINE OIL (See REPLACEMENT )
ADD ENGINE COOLANT (See REPLACEMENT )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
INSPECT FOR OIL LEAK (See REPLACEMENT )
INSPECT FOR COOLANT LEAK (See COOLING SYSTEM )
INSPECT ENGINE OIL LEVEL (See ON-VEHICLE INSPECTION )
INSTALL NO. 2 ENGINE UNDER COVER (See INSTALLATION )
INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See INSTALLATION )
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See INSTALLATION )
INSTALL FRONT FENDER APRON SEAL FRONT RH (See INSTALLATION )
INSTALL FRONT FENDER APRON SEAL LH (See INSTALLATION )
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
1. Install the cowl top ventilator louver (See INSTALLATION ).
CONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) (See LUBRICATION SYSTEM )
CONNECT RADIATOR SIDE DEFLECTOR LH (See LUBRICATION SYSTEM )
INSTALL RADIATOR GRILLE (See INSTALLATION )
INSTALL UPPER RADIATOR SUPPORT SEAL (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER RH (See INSTALLATION )
INSTALL ENGINE ROOM SIDE COVER LH (See INSTALLATION )