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Oil Pump: Installation

  1. INSTALL OIL PUMP SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.

      SST 09223-00010 

      Fig 1: Installing Oil Pump Seal
      G04088245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to tap the oil seal at an angle.
      • Keep the lip free of foreign objects.
    2. Apply MP grease to the oil seal lip.
  2. INSTALL OIL PUMP ASSEMBLY 
    1. Remove any old seal packing material from the contact surface.
    2. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.
      Fig 2: Removing Seal Packing Material From Contact Surface
      G04088246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration.
      Fig 3: Applying Seal Packing
      G04088247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing : 

      Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from contact surface.
      • Apply seal packing to the inner side of the bolt holes.
      • Install the oil pump within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    4. Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.
      Fig 4: Aligning Key Of Oil Pump Drive Gear
      G04088248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
    Fig 5: Installing Oil Pump With Bolts
    G04088249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: Bolt A 

    8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    Bolt B 

    20 N*m (199 kgf*cm, 14 ft.*lbf) 

    Bolt C 

    43 N*m (439 kgf*cm, 32 ft.*lbf) 

  3. INSTALL CRANKSHAFT POSITION SENSOR 

    Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf) 

  4. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Remove any old seal packing from the contact surface.
    2. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
      Fig 6: Applying Seal Packing
      G04088250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing : 

      Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Apply seal packing to the outer side of the bolt holes in the region "X".
      • Apply seal packing to the inner side of the bolt holes in the region "Y".
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    3. Install oil pan No. 1 with the 17 bolts and 2 nuts.

      Tighten the bolts uniformly in several steps. 

      Torque: 10 mm head 

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

      12 mm head 

      20 N*m (199 kgf*cm, 14 ft.*lbf) 

      14 mm head 

      37 N*m (379 kgf*cm, 27 ft.*lbf) 

    4. Install the flywheel housing under cover with the 2 bolts.

    Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

  5. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Install a new gasket and the oil strainer with the bolt and 2 nuts.

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

  6. INSTALL OIL PAN SUB-ASSEMBLY NO. 2 
    1. Remove any old seal packing from the contact surface.
    2. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown in the illustration.
      Fig 7: Applying Seal Packing
      G04088251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing : 

      Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Apply seal packing to the inner side of the bolt holes.
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    3. Install the oil pan No. 2 with the 10 bolts and 2 nuts.

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

  7. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the 4 bolts and nut and engine mounting bracket RH.
    Fig 8: Installing Engine Mounting Bracket RH
    G04088252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: Bolt A 

    54 N*m (551 kgf*cm, 40 ft.*lbf) 

    Nut B 

    54 N*m (551 kgf*cm, 40 ft.*lbf) 

    Bolt C 

    43 N*m (439 kgf*cm, 32 ft.*lbf) 

  8. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the 4 nuts and nut and engine mounting insulator RH.
    Fig 9: Installing Engine Mounting Insulator RH
    G04088253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: Nut A 

    95 N*m (969 kgf*cm, 70 ft.*lbf) 

    Nut B 

    87 N*m (887 kgf*cm, 64 ft.*lbf) 

  9. INSTALL ENGINE MOUNTING INSULATOR FR 
    1. Install the 4 nuts and engine mounting insulator FR.
      Fig 10: Installing Engine Mounting Insulator FR
      G04088254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Nut A 

      87 N*m (887 kgf*cm, 64 ft.*lbf) Nut B 

      52 N*m (530 kgf*cm, 38 ft.*lbf) 

  10. INSTALL ENGINE MOUNTING INSULATOR RR 
    1. Install the 2 nuts and engine insulator RR.

    Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

  11. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 
    Fig 11: Installing Compressor Mounting Bracket
    G04088255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

  12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 
    1. Install the compressor with the 3 bolts.

      Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

    2. Install the adjusting bar bracket with the bolt and nut.
    Fig 12: Installing Compressor And Magnetic Clutch
    G04088256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: Bolt 

    25 N*m (250 kgf*cm, 18 ft.*lbf) 

    Nut 

    26 N*m (265 kgf*cm, 19 ft.*lbf) 

  13. INSTALL GENERATOR BELT ADJUSTING BAR 
    1. Install the adjusting bar with the 2 bolts and 2 nuts.

    Torque: Nut A 

    43 N*m (438 kgf*cm, 32 ft.*lbf) 

    Torque: Bolt B 

    18 N*m (184 kgf*cm, 13 ft.*lbf) 

    Bolt C 

    8.4 N*m (85 kgf*cm, 74 in.*lbf) 

  14. INSTALL OIL LEVEL GAGE GUIDE 
    Fig 13: Installing Oil Level Gage Guide
    G04088257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY NO. 2 
    1. Install the exhaust manifold converter sub-assembly No. 2 (See INSTALLATION ).
  16. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2 
    1. Install the exhaust manifold heat insulator No. 2 (See INSTALLATION ).
  17. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3 
    1. Install the manifold converter insulator No. 3 (See INSTALLATION ).
  18. INSTALL EXHAUST PIPE SUPPORT BRACKET NO. 1 
    1. Install the exhaust pipe support bracket No. 1 (See INSTALLATION ).
  19. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See  INSTALLATION  ) 
  20. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3 (See  INSTALLATION  ) 
  21. INSTALL CRANKSHAFT TIMING PULLEY 
    1. Install the crankshaft timing pulley (See INSTALLATION ).
  22. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 1 (See  INSTALLATION  ) 
  23. INSTALL TIMING BELT NO. 3 COVER 
    1. Install the timing belt No. 3 cover (See INSTALLATION ).
  24. INSTALL CAMSHAFT TIMING PULLEY 
    1. Install the camshaft timing pulley (See INSTALLATION ).

    SST 09960-10010 (09962-01000, 09963-01000),09249-63010 

  25. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2 
    1. Install the timing belt idler sub-assembly No. 2 (See INSTALLATION ).
  26. INSPECT TIMING BELT 
    1. Inspect timing belt (See INSPECTION ).
  27. INSTALL TIMING BELT 
    1. Install the timing belt (See INSTALLATION ).

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

  28. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1 
    1. Install the chain tensioner assembly No. 1 (See INSTALLATION ).
  29. INSTALL TIMING BELT GUIDE NO.2 
    1. Install the timing belt guide No. 2 (See INSTALLATION ).
  30. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket RH (See INSTALLATION ).
  31. INSTALL TIMING BELT NO. 2 COVER 
    1. Install the timing belt No. 2 cover (See INSTALLATION ).
  32. INSTALL TIMING BELT NO. 1 COVER 
    1. Install the timing belt No. 1 cover (See INSTALLATION ).
  33. INSTALL CRANKSHAFT PULLEY 
    1. Install the crankshaft pulley (See INSTALLATION ).

    SST 09213-54015 (91651-60855), 09330-00021 

  34. INSTALL GENERATOR BRACKET NO. 2 
    1. Install the generator bracket No. 2 (See INSTALLATION ).
  35. INSTALL ENGINE MOUNTING STAY NO. 2 RH 
    1. Install the engine mounting stay No. 2 RH (See INSTALLATION ).
  36. INSTALL ENGINE MOVING CONTROL ROD 
    1. Install the engine moving control rod (See INSTALLATION ).
  37. INSTALL VANE PUMP V BELT 
    1. Install the vane pump V belt (See INSTALLATION ).
  38. INSTALL GENERATOR ASSEMBLY 
    1. Install the generator assembly (See INSTALLATION ).
  39. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 
    1. Install V (cooler compressor to crankshaft pulley) belt No. 1 (See INSTALLATION ).
  40. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE) 
    1. Inspect drive belt deflection and tension (reference) (See ENGINE ).
  41. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER (See  INSTALLATION  ) 
  42. INSTALL WINDSHIELD WIPER LINK ASSEMBLY (See  INSTALLATION  ) 
  43. INSTALL FR WIPER ARM LH (See  INSTALLATION  ) 
  44. INSTALL FR WIPER ARM RH (See  INSTALLATION  ) 
  45. INSTALL FRONT WHEEL RH 
  46. ADD ENGINE OIL (See  REPLACEMENT   ) 
  47. CHECK FOR ENGINE OIL LEAKS 
  48. CHECK FOR EXHAUST GAS LEAKS 
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