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Oil Pump: Installation

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  1. INSTALL TIMING CHAIN CASE OIL SEAL 
    1. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
      Fig 1: Identifying Timing Chain Case Oil Seal
      G04057863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09223-22010, 09506-35010 

      NOTE:
      • Keep the lip free of foreign matter.
      • Do not tap on the oil seal at an angle.
      • Make sure that the oil seal edge does not stick out of the timing chain case.
  2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line to the engine unit as shown in the following illustration.
      Fig 2: Applying Seal Packing In Continuous Line To Engine Unit
      G04057864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: Part No. Seal Packing Black (FIPG) or 

      equivalent 

      Seal diameter: 5.0 to 5.5 mm (0.197 to 0.217 in.) 

      NOTE:
      • Be sure to clean and degrease the contact surfaces, especially indicated by C in the illustration.
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • Install the chain cover within 3 minutes.
      • Do not start the engine for at least 2 hours after installing.
    2. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.
      Fig 3: Applying Seal Packing In Continuous Line To Timing Chain Cover
      G04057865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: 

      • 08826-00080 or equivalent 
      • 08826-00100 or equivalent 
      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 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.

      Apply seal packing as follows 

      SEAL PACKING DIAMETER SPECIFICATION

      Area Seal Packing Diameter Application Position from Inside Seal Line
      Continuous Line Area 4.5 to 5.0 mm (0.177 to 0.197 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Alternate Long and Dashed Line Area 4.5 to 5.0 mm (0.177 to 0.197 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.)
      Dashed Line Area 3.5 to 4.5 mm (0.138 to 0.158 in.) 1.0 to 2.0 mm (0.039 to 0.079 in.)
      Diagonal Line Area 6.0 to 6.5 mm (0.236 to 0.256 in.) 4.5 mm (0.177 in.)
    3. Install a new gasket.
      Fig 4: Locating Gasket
      G04057866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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 5: Aligning Oil Pump's Drive Rotor Spline And Crankshaft
      G04057867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

      Bolt length 

      BOLT LENGTH SPECIFICATION

      Item Length
      Bolt A 50 mm (1.97 in.)
      Bolt B 25 mm (0.98 in.)
      Bolt C 55 mm (2.17 in.)
      NOTE: Make sure that there is no oil on the bolt threads.
      Fig 6: Identifying Timing Chain Cover With Bolts And Nuts
      G04057868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Fully tighten the 3 bolts as shown in the illustration.

      Torque: 

      • 43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A 
      • 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A 
      Fig 7: Identifying Bolts
      G04057869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Fully tighten the 3 bolts as shown in the illustration.

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

      Fig 8: Identifying Bolts
      G04057870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Fully tighten the 7 bolts and 2 nuts as shown in the illustration.

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

      HINT:

      Tighten the bolts and nuts in the order of upper to lower as shown in the illustration.

      Fig 9: Identifying Bolts And Nuts
      G04057871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Fully tighten the 12 bolts as shown in the illustration.

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

      HINT:

      Tighten the bolts in the order of lower to upper as shown in the illustration.

      Fig 10: Identifying Bolts
      G04057872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the bolt and wiring harness bracket.

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

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1) (See  REASSEMBLY  ) 
  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) (See  REASSEMBLY  ) 
    Fig 11: Identifying Bolt And Wiring Harness Bracket
    G04057873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 2 OIL PIPE (See  REASSEMBLY  ) 
  6. INSTALL NO. 1 OIL PIPE (See  REASSEMBLY  ) 
  7. INSTALL IGNITION COIL ASSEMBLY (See  INSTALLATION  ) 
  8. INSTALL NO. 2 FUEL PIPE (See  INSTALLATION  ) 
  9. INSTALL FUEL PUMP ASSEMBLY (See  INSTALLATION  ) 
  10. CONNECT NO. 2 FUEL PIPE (See  INSTALLATION  ) 
  11. INSTALL NO. 1 FUEL PIPE (See  INSTALLATION  ) 
  12. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See  INSTALLATION  ) 
  13. INSTALL OIL STRAINER SUB-ASSEMBLY (See  REASSEMBLY  ) 
  14. INSTALL OIL PAN SUB-ASSEMBLY (See  REASSEMBLY  ) 
  15. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (See  REASSEMBLY  ) 
  16. INSTALL WATER INLET (See  INSTALLATION  ) 
  17. INSTALL CRANKSHAFT PULLEY (See  INSTALLATION  ) 
  18. INSTALL WATER HOSE JOINT (See  INSTALLATION  ) 
  19. INSTALL NO. 2 SURGE TANK STAY (See  INSTALLATION  ) 
  20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    (See INSTALLATION )

  21. INSTALL INJECTOR DRIVER (See  INSTALLATION  ) 
  22. INSTALL ENGINE WIRE (See  INSTALLATION  ) 
  23. INSTALL WATER PUMP PULLEY (See  INSTALLATION  ) 
  24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See  INSTALLATION  ) 
  25. INSTALL ENGINE MOUNTING BRACKET LH (See  INSTALLATION  ) 
  26. INSTALL ENGINE MOUNTING BRACKET RH (See  INSTALLATION  ) 
  27. CONNECT COOLER COMPRESSOR ASSEMBLY (See  INSTALLATION  ) 
  28. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
  29. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (See  INSTALLATION  ) 
  30. INSTALL NO. 1 ENGINE COVER (See  INSTALLATION  ) 
  31. INSTALL NO. 2 ENGINE COVER (See  INSTALLATION  ) 
  32. INSTALL V-RIBBED BELT (See  INSTALLATION  ) 
  33. INSTALL ENGINE HANGERS (See  INSTALLATION  ) 
  34. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY (See  INSTALLATION  ) 
  35. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (See  INSTALLATION  ) 
  36. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 

    (See INSTALLATION )

  37. INSTALL STARTER ASSEMBLY (See  INSTALLATION  ) 
  38. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (See  INSTALLATION  ) 
  39. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See  INSTALLATION  ) 
  40. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (See  INSTALLATION  ) 
  41. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (See  INSTALLATION  ) 
  42. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (See  INSTALLATION  ) 
  43. CONNECT POWER STEERING LINK WIRE HARNESS (See  INSTALLATION  ) 
  44. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (See  INSTALLATION  ) 
  45. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (See  INSTALLATION  ) 
  46. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (See  INSTALLATION  ) 
  47. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (See  INSTALLATION  ) 
  48. CONNECT HEIGHT CONTROL SENSOR LINK (See  INSTALLATION  ) 
  49. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (See  INSTALLATION  ) 
  50. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR (See  INSTALLATION  ) 
  51. CONNECT FUEL TUBE SUB-ASSEMBLY (See  INSTALLATION  ) 
  52. CONNECT NO. 3 FUEL HOSE (See  INSTALLATION  ) 
  53. CONNECT FUEL MAIN TUBE 

    (See FUEL SYSTEM )

  54. CONNECT ENGINE WIRE (See  INSTALLATION  ) 
  55. INSTALL ECM COVER (See  INSTALLATION  ) 
  56. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (See  INSTALLATION  ) 
  57. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (See  INSTALLATION  ) 
  58. CONNECT INLET HEATER WATER HOSE (See  INSTALLATION  ) 
  59. CONNECT OUTLET HEATER WATER HOSE (See  INSTALLATION  ) 
  60. CONNECT INLET RADIATOR HOSE (See  INSTALLATION  ) 
  61. CONNECT OUTLET RADIATOR HOSE (See  INSTALLATION  ) 
  62. CONNECT RADIATOR RESERVOIR TANK HOSE (See  INSTALLATION  ) 
  63. CONNECT NO. 2 FUEL VAPOR FEED HOSE (See  INSTALLATION  ) 
  64. CONNECT UNION TO CHECK VALVE HOSE (See  INSTALLATION  ) 
  65. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (See  INSTALLATION  ) 
  66. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See  INSTALLATION  ) 
  67. INSTALL NO. 1 INLET AIR CLEANER (See  INSTALLATION  ) 
  68. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY 

    (See INSTALLATION )

  69. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    (See INSTALLATION )

  70. ADD ENGINE OIL (See  ON-VEHICLE INSPECTION   ) 
  71. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See  INSTALLATION  ) 
  72. ADD ENGINE COOLANT (See  COOLANT  ) 
  73. CHARGE REFRIGERANT (See  REPLACEMENT  ) 
  74. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  75. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
  76. CHECK FOR ENGINE OIL LEAKS 
  77. CHECK FOR EXHAUST GAS LEAKS 
  78. CHECK FOR LEAKAGE OF REFRIGERANT (See  REPLACEMENT  ) 
  79. INSTALL FRONT WHEEL 

    Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

  80. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  81. ADJUST SHIFT LEVER POSITION (See  ADJUSTMENT  ) 
  82. CHECK SHIFT LEVER POSITION (See  ADJUSTMENT  ) 
  83. CHECK AND ADJUST FRONT WHEEL ALIGNMENT 

    (See ADJUSTMENT )

  84. CHECK IGNITION TIMING (See  ON-VEHICLE INSPECTION  ) 
  85. CHECK IDLE SPEED (See  ON-VEHICLE INSPECTION  ) 
  86. CHECK CO/HC (See  ON-VEHICLE INSPECTION  ) 
  87. CHECK ENGINE OIL LEVEL (See  ON-VEHICLE INSPECTION   ) 
  88. INSTALL ENGINE UNDER COVER REAR LH (See  INSTALLATION  ) 
  89. INSTALL ENGINE UNDER COVER REAR RH (See  INSTALLATION  ) 
  90. INSTALL NO. 2 ENGINE UNDER COVER 
  91. INSTALL ENGINE UNDER COVER 
  92. INSTALL V-BANK COVER SUB-ASSEMBLY (See  INSTALLATION  ) 
  93. INSTALL ENGINE ROOM SIDE COVER LH (See  INSTALLATION  ) 
  94. INSTALL ENGINE ROOM COVER SIDE RH (See  INSTALLATION  ) 
  95. INSTALL COOL AIR INTAKE DUCT SEAL (See  INSTALLATION  ) 
  96. PERFORM INITIALIZATION 
    1. Perform initialization (See REPAIR INSTRUCTION )
      NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.
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