Oil Pump: Installation

1. INSTALL OIL PUMP ASSEMBLY 
   1. Install the oil pump with the 3 bolts.

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

2. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
   1. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
      Fig 1: Locating Oil Pump Assembly Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Apply a continuous bead of seal packing (Diameter 4.0 mm (0.157 in.)) as shown in the illustration.

      Seal packing: 

      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

      NOTE:

      • Remove any oil from the contact surfaces.
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing the oil pan.
      Fig 2: Identifying Seal Packing Applying Areas

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Install the No. 2 oil pan with the 10 bolts and 2 nuts.

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

3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE  (See REASSEMBLY )
   Fig 3: Locating No. 2 Oil Pan Sub-Assembly Bolts And Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL NO. 2 CHAIN SUB-ASSEMBLY 
   1. Set the crankshaft key as shown in the illustration.
   2. Turn the drive shaft so that the cutout faces the right horizontal position.
      Fig 4: Setting Crankshaft Key

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Align the yellow mark links with the timing marks of each gear as shown in the illustration.
   4. Install the sprockets onto the crankshaft and oil pump shaft with the chain on the gears.
   5. Temporarily tighten the oil pump drive shaft sprocket with the nut.
      Fig 5: Aligning Yellow Mark Links With Timing Marks Of Gear

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   6. Insert the damper spring into the adjusting hole, and then install the chain tensioner plate with the bolt.

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

      Fig 6: Identifying Bolt, Chain Tensioner Plate And Spring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   7. Align the adjusting hole of the oil pump drive shaft sprocket with the groove of the oil pump.
      Fig 7: Aligning Adjusting Hole Of Oil Pump Drive Shaft Sprocket

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   8. Insert a pin punch (3 mm) into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then tighten the nut.

   Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

   Fig 8: Inserting Pin Punch Into Adjusting Hole Of Oil Pump Drive Shaft Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL CRANKSHAFT TIMING SPROCKET 
   1. Install the crankshaft timing sprocket.
6. INSTALL NO. 1 CHAIN VIBRATION DAMPER  (See INSTALLATION )
   Fig 9: Locating Crankshaft Timing Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL NO. 2 CHAIN VIBRATION DAMPER 
   1. Install the No. 2 chain vibration damper with the 2 bolts.

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

8. INSTALL CHAIN SUB-ASSEMBLY  (See INSTALLATION )
9. INSTALL CHAIN TENSIONER SLIPPER  (See INSTALLATION )
   Fig 10: Locating No. 2 Chain Vibration Damper Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL TIMING CHAIN COVER OIL SEAL 
    1. Using SST, tap in a new oil seal until its surface is flush with the timing chain cover sub-assembly edge.
       Fig 11: Tapping Timing Chain Cover Oil Seal

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       SST 09223-22010 

       NOTE:

       • Keep the lip free of foreign matter.
       • Do not tap the oil seal at an angle.
    2. Apply MP grease to the lip of the oil seal.
11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head, and cylinder block.
       Fig 12: Identifying Clean And Degrease Area On Timing Chain Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 3 new O-rings.
       Fig 13: Locating Timing Chain O-Rings

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply seal packing as shown in the illustration.
       Fig 14: Identifying Seal Packing Applying Location

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Seal packing: 

       Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 

       Seal diameter: 

       5.0 mm (0.197 in.) 

       NOTE:

       • Remove any oil from the contact surfaces.
       • Install the chain cover within 3 minutes after applying seal packing.
       • Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.
    4. Apply seal packing to the timing chain cover sub-assembly in a continuous bead as shown in the following illustration.
       NOTE:

       • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
       • Install the timing chain cover sub-assembly 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 installation.
       Fig 15: Seal Packing Applying Location On Timing Chain Cover Sub-Assembly With Torque Specifications

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Apply Seal Packing as Follows 

       SEAL PACKING AREAS REFERENCE CHART
       
       

       Area	Seal Packing Diameter	Application Position from Inside Seal Line	Seal Packing
       Continuous Line Area	3.0 mm (0.118 in.)	2.5 mm (0.0984 in.)	Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
       Dashed Line Area	4.0 mm (0.157 in.)	3.0 mm (0.118 in.)	Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

    5. Apply adhesive to the threads of the bolt E.

       Adhesive: 

       Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    6. Temporarily install the timing chain cover sub-assembly with the 19 bolts.
       NOTE:

       • Remove any oil from the contact surfaces.
       • Install the chain cover within 3 minutes after applying seal packing.
       • Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.

       Bolt Length 

       TIMING CHAIN COVER SUB-ASSEMBLY BOLT LENGTH
       
       

       Item	Length
       Bolt A, E	35 mm (1.38 in.)
       Bolt B	55 mm (2.17 in.)
       Bolt C	80 mm (3.15 in.)
       Bolt D	40 mm (1.57 in.)

       Fig 16: Locating Timing Chain Cover Sub-Assembly Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install a new gasket.
       NOTE: Remove any oil from the contact surfaces.
       Fig 17: Identifying Gasket

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the water pump with the 3 bolts.

       Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

       Fig 18: Locating Water Pump Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Temporarily install the engine mounting bracket with the 3 bolts.
       NOTE:

       • Install the mounting bracket within 10 minutes after installing the timing chain cover sub-assembly.
       • Do not start the engine for at least 2 hours after installation.
       Fig 19: Locating Engine Mounting Bracket Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Bolt Length 

       ENGINE MOUNTING BRACKET BOLT LENGTH
       
       

       Item	Length
       Bolt	80 mm (3.15 in.)

    10. Install 2 new O-rings.
        Fig 20: Locating O-Rings

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Temporarily tighten the oil filter bracket with the 4 bolts.
        NOTE:

        • Install the oil filter bracket within 10 minutes after installing the chain cover.
        • Do not start the engine for at least 2 hours after installation.
        Fig 21: Locating Oil Filter Bracket Mounting Bolts

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Bolt Length 

        OIL FILTER BRACKET BOLT LENGTH
        
        

        Item	Length
        Bolt	35 mm (1.38 in.)

    12. Fully tighten the timing chain cover sub-assembly with the 26 bolts as shown in the illustration.
    Fig 22: Locating Timing Chain Cover Sub-Assembly Bolts Tightening Sequence

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: Bolt A, E 

    26 N*m (260 kgf*cm, 19 ft.*lbf) 

    Bolt B, C 

    51 N*m (520 kgf*cm, 37 ft.*lbf) 

    Bolt D 

    10 N*m (102 kgf*cm, 7 ft.*lbf) 

    NOTE:

    • When the contact surfaces are wet, wipe them with oil-free cloth before applying seal packing.
    • Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying the seal packing.
    • Do not start the engine for at least 2 hours after installing.
12. INSTALL CRANKSHAFT PULLEY  (See INSTALLATION )
13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY  (See REASSEMBLY )
14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY  (See REASSEMBLY )
15. INSTALL RADIO SETTING CONDENSER  (See INSTALLATION )
16. INSTALL THERMOSTAT  (See INSTALLATION )
17. INSTALL WATER INLET  (See INSTALLATION )
18. INSTALL INLET WATER HOSE  (See INSTALLATION )
19. INSTALL WATER BY-PASS HOSE  (See INSTALLATION )
20. INSTALL NO. 1 WATER BY-PASS PIPE  (See INSTALLATION )
21. INSTALL NO. 3 WATER BY-PASS HOSE  (See INSTALLATION )
22. INSTALL VENTILATION HOSE  (See INSTALLATION )
23. INSPECT EXHAUST MANIFOLD  (See INSTALLATION )
24. INSTALL EXHAUST MANIFOLD  (See INSTALLATION )
25. INSTALL MANIFOLD STAY  (See INSTALLATION )
26. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
27. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY  (See INSTALLATION )
28. INSTALL IGNITION COIL ASSEMBLY  (See INSTALLATION )
29. INSTALL FUEL INJECTOR ASSEMBLY  (See INSTALLATION )
30. INSTALL NO. 1 DELIVERY PIPE SPACER  (See INSTALLATION )
31. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY  (See INSTALLATION )
32. INSTALL FUEL TUBE SUB-ASSEMBLY  (See INSTALLATION )
33. INSTALL INTAKE MANIFOLD  (See INSTALLATION )
34. REMOVE ENGINE STAND  (See INSTALLATION )
35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 

HINT:

(See INSTALLATION ).