Oil Pump: Installation

HINT.

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

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 O-Rings From Water Inlet Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Install a new oil pump gasket.

Fig 2: Identifying Oil Pump Gasket From Cylinder Block
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install a new O-ring

Fig 3: Identifying O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 4: Applying Seal Packing In Continuous Line To Timing Chain Cover

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

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	0.5 mm (0.0197 in.)
Diagonal Line Area	3.0 to 4.0 mm (0.118 to 0.157 in.)	5.5 mm (0.217 in.)

Fig 5: Seal Packing Thickness Chart

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

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

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 (2.17 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)

Fig 7: Locating Timing Chain Cover With Bolts

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

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

Fig 8: Locating Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the belt tensioner with the bolt.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)

Fig 9: Locating Belt Tensioner With Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tighten the 10 bolts in several steps, in the sequence shown in the illustration.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)

Fig 10: Identifying Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tighten the 19 bolts and nut in several steps, in the sequence shown in the illustration.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)

Fig 11: Identifying Bolts Tightening Sequence
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.

Fig 12: Identifying Label
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install 2 new gaskets and the 2 plugs.
Torque: 46 N*m (469 kgf*cm, 34 ft.*lbf)

Fig 13: Locating Timing Chain Cover Plugs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3 and No. 7)
2. Install a new gasket to the cylinder head cover.
  NOTE: Remove any oil from the contact surface.
  
  Fig 14: Locating Camshaft Bearing Caps Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply seal packing as shown 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.)
  
  Fig 15: Identifying Seal Packing Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
4. Install the cylinder head cover and 2 new seal washers with the 15 bolts in the order shown in the illustration.
  Torque:
  
  for bolt A
  
  21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for except bolt A
  
  12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 16: Identifying Cylinder Head Cover With Bolt Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the fuel pump spacer.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
1. Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No 1, No 3 and No 6)
2. Install a new 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 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.)
  
  Fig 18: Identifying Seal Packing Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
4. Install the cylinder head cover and 2 new seal washers with the 15 bolts in the order shown in the illustration.
  Torque:
  
  for bolt A
  
  21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  for except bolt A
  
  12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 19: Locating Cylinder Head Cover Bolt Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the fuel pump spacer.
INSTALL FRONT CRANKSHAFT OIL SEAL (See REASSEMBLY )
INSTALL CRANKSHAFT TIMING GEAR KEY (See REASSEMBLY )
INSTALL IGNITION COIL ASSEMBLY (See INSTALLATION )
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 bolt
  SST 09213-54015 (90119-08216), 09330-00021
  
  Torque: 300 N*m (3059 kgf*cm, 221 ft.*lbf)
INSTALL OIL FILTER BRACKET
1. Install 2 new gaskets and the filter bracket with the 3 bolts
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 21: Locating Filter Bracket And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL FILTER ELEMENT (See REPLACEMENT )
INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH
1. Turn the camshaft timing gear assembly's intermediate shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position.
  
  Fig 22: Turning Camshaft Timing Gear Assembly's Intermediate Shaft Index Slot RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT.
  - When the cam of the camshaft lifts the valve, the intermediate shaft becomes difficult to turn.
  - The position where the intermediate shaft stops is the maximum retard angle
2. Install a new O-ring to the timing chain cover
3. Align the joint of the camshaft timing control motor and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 23: Locating Camshaft Timing Control Motor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Check that [R] is printed on the label of the camshaft timing control motor.
  - Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor (connecting surface with timing chain cover sub-assembly).
  - When installing the camshaft timing control motor, do not use excessive force.
  - Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor.
  - Install the camshaft timing control motor with the arrow facing upward, as shown in the illustration.
  - Do not drop the camshaft timing control motor. If dropped, replace it.
  - Do not disassemble the camshaft timing control motor assembly. If disassembled, replace it.
INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH
1. Turn the camshaft timing gear assembly's intermediate shaft index slot in the counterclockwise direction by hand, and set it to the maximum retard angle position
  
  Fig 24: Turning Camshaft Timing Gear Assembly's Intermediate Shaft Index Slot LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT.
  - When the cam of the camshaft lifts the valve, the intermediate shaft becomes difficult to turn
  - The position where the intermediate shaft stops is the maximum retard angle
2. Install a new O-ring to the timing chain cover
3. Align the joint of the camshaft timing control motor and the keyway of the camshaft timing gear assembly, and install the motor with the 3 bolts
  
  Fig 25: Locating Camshaft Timing Control Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  NOTE:
  - Check that [L] is printed on the label of the camshaft timing control motor.
  - Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor (connecting surface with timing chain cover sub-assembly).
  - When installing the camshaft timing control motor, do not use excessive force.
  - Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor.
  - Install the camshaft timing control motor with the arrow facing upward, as shown in the illustration.
  - Do not drop the camshaft timing control motor. If dropped, replace it.
  - Do not disassemble the camshaft timing control motor assembly. If disassembled, replace it.
INSTALL FRONT WATER BY-PASS JOINT (See REASSEMBLY )
INSTALL WATER PUMP PULLEY (See INSTALLATION )
INSTALL WATER INLET HOUSING
1. Install a new gasket and the inlet housing with the 3 bolts.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 26: Locating Water Inlet Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the water inlet hose
INSTALL FUEL PUMP ASSEMBLY (for Bank 2) (See INSTALLATION )
INSTALL FUEL PUMP ASSEMBLY (for Bank 1) (See INSTALLATION )
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION )
INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION )
INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See INSTALLATION )
INSTALL INTAKE MANIFOLD ASSEMBLY (See INSTALLATION )
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (See INSTALLATION )
INSTALL HEATER WATER PUMP ASSEMBLY (See INSTALLATION )
INSTALL PURGE VSV (See INSTALLATION )
INSTALL NO. 1 ENGINE COVER (See INSTALLATION )
INSTALL INJECTOR DRIVER (See INSTALLATION )
INSTALL ENGINE WIRE (See INSTALLATION )
INSTALL NO. 5 COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL ENGINE COVER SUB-ASSEMBLY RH (See INSTALLATION )
INSTALL NO. 6 COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL ENGINE COVER SUB-ASSEMBLY LH (See INSTALLATION )
INSTALL WITH MOTOR COMPRESSOR ASSEMBLY (See INSTALLATION )
INSTALL V-RIBBED BELT (See INSTALLATION )
INSTALL ENGINE ASSEMBLY
1. Install the engine (see INSTALLATION )
INSTALL SERVICE PLUG GRIP (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).