GSIC - Global Service Information Center

# OIL PUMP > INSTALLATION

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1. INSTALL TIMING CHAIN COVER OIL SEAL

1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.

   SST
     09223-78010

1. Apply MP grease to the oil seal lip.

2. INSTALL OIL FILTER BRACKET

1. Install a new gasket and the oil filter bracket with the 3 bolts and 2 nuts.

   Torque:
     19 N*m{ 194 kgf*cm , 14 ft.*lbf }

3. INSTALL VVT SENSOR

1. Install the sensor with the bolt.

   Torque:
     8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

1. Connect the sensor connector.

1. Connect the No. 4 and No. 5 water by-pass hoses.

4. INSTALL CYLINDER HEAD COVER LH

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

1. Apply adhesive on the threads of the ventilation valve.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1324 or equivalent

1. Install the ventilation valve to the cylinder head cover.

   Torque:
     27 N*m{ 275 kgf*cm , 20 ft.*lbf }

1. Install the gasket to the cylinder head cover.

1. Apply a continuous bead of the seal packing to the cylinder head and timing chain cover as shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:
     2 to 3 mm (0.08 to 0.12 in.)

   NOTICE:
     Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

1. Install the seal washers to the bolts.

1. Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

5. INSTALL CYLINDER HEAD COVER RH

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

1. Install the gasket to the cylinder head cover.

1. Apply a continuous bead of the seal packing to the cylinder head and timing chain cover as shown in the illustration.

   Seal packing:
     Part No. 0882-00080 or equivalent

   Seal diameter:
     2 to 3 mm (0.08 to 0.12 in.)

   NOTICE:
     Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

1. Install the seal washers to the bolts.

1. Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

6. INSTALL IGNITION COIL

1. Install the ignition coil with the bolt.

   Torque:
     10 N*m{ 102 kgf*cm , 7 ft.*lbf }

7. INSTALL NO. 1 OIL PAN

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

1. Install a new O-ring to the oil pump.

1. Apply seal packing in a continuous line as shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:
     3 to 4 mm (0.12 to 0.16 in.)

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts must be tightened within 15 minutes.
   3. Do not start the engine for at least 4 hours after the installation.

1. Install the oil pan with the 17 bolts and 2nuts. Uniformly tighten the bolts and nuts in several passes.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolt A
     21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolt B
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf } for bolt C
     21 N*m{ 214 kgf*cm , 15 ft.*lbf } for nuts

   HINT:
     Each bolt length is as follows:
     A = 25 mm (0.98 in.)
     B = 45 mm (1.77 in.)
     C = 14 mm (0.55 in.)

   NOTICE:
     The bolts indicated by stars in the illustration are precoated parts. When reusing them, apply adhesive to 2 or 3 threads before installation.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1324 or equivalent.

8. INSTALL OIL STRAINER

1. Install a new gasket and the oil strainer with bolt and 2 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

9. INSTALL NO. 2 OIL PAN

1. Remove any old packing (FIPG) material and be careful not to drop nay oil on the contact surfaces of the oil pan and No. 2 oil pan.

1. Apply seal packing in a continuous line as shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:
     3 to 4 mm (0.12 to 0.16 in.)

   NOTICE:
   1. Remove the oil from the contact surface.
   2. Install the No. 2 oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts packing must be removed and reapplied.
   3. Do not start the engine for at least 4 hours after the installation.

1. Install the No. 2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf } for bolts
     10 N*m{ 102 kgf*cm , 7 ft.*lbf } for nuts

10. INSTALL CRANKSHAFT PULLEY

1. Using SST, install the pulley set bolt.

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

   Torque:
     250 N*m{ 2,549 kgf*cm , 184 ft.*lbf }

11. INSTALL NO. 1 IDLER PULLEY

1. Install the idler pulley with the bolt.

   Torque:
     54 N*m{ 551 kgf*cm , 40 ft.*lbf }

   HINT:
     "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No.2 idler pulley.

12. INSTALL NO. 2 IDLER PULLEY

1. Install the 2 idler pulleys with the 2 bolts.

   Torque:
     39 N*m{ 398 kgf*cm , 29 ft.*lbf }

13. INSTALL V-RIBBED BELT TENSIONER

1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

1. Install the V-ribbed belt tensioner by tightening bolt 1 and then bolt 2.

   Torque:
     36 N*m{ 367 kgf*cm , 27 ft.*lbf }

1. Tighten the other bolts.

   Torque:
     36 N*m{ 367 kgf*cm , 27 ft.*lbf }

   HINT:
     Each bolt length is as follows:
     A = 70 mm (2.76 in.)
     B = 33 mm (1.30 in.)

14. INSTALL GENERATOR

1. Install the generator and adjusting bar with the 2 bolts.

   Torque:
     43 N*m{ 438 kgf*cm , 32 ft.*lbf }

1. Install the generator wire with the nut.

   Torque:
     9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

1. Connect the generator connector.

15. INSTALL WATER INLET

1. Install a new gasket to the water inlet housing with thermostat.

1. Install the water inlet housing with thermostat with the 3 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

16. INSTALL OIL DIPSTICK GUIDE

1. Install a new O-ring to the oil dipstick guide.

1. Apply a light coat of engine oil to the O-ring.

1. Push in the oil dipstick guide end into the guide hole of the oil pan.

1. Install the oil dipstick guide with the bolt.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

1. Install the dipstick.

17. REMOVE ENGINE ASSEMBLY FROM STAND

18. INSTALL FLYWHEEL (for Manual Transmission)

1. Using SST, hold the crankshaft.

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

1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1324 or equivalent

1. Install the flywheel.

1. Install and tighten the 8 mounting bolts uniformly in several steps.

   Torque:
     83 N*m{ 846 kgf*cm , 61 ft.*lbf }

19. INSTALL DRIVE PLATE AND RING GEAR ASSEMBLY (for Automatic Transmission)

1. Using SST, hold the crankshaft.

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

1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1324 or equivalent

1. Install the front spacer, drive plate and rear spacer on the crankshaft.

1. Install and uniformly tighten the 8 mounting bolts in several passes in the sequence as shown in the illustration.

   Torque:
     83 N*m{ 846 kgf*cm , 61 ft.*lbf }

20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

21. PERFORM INITIALIZATION

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to e initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

22. ADD ENGINE OIL

1. Clean and install the oil drain plug with a new gasket.

   Torque:
     40 N*m{ 408 kgf*cm , 30 ft.*lbf }

1. Add fresh engine oil.

   Standard capacity:

     Item | Capacity
     Drain and refill with oil filter change | 5.5 liters (5.8 US qts, 4.8 Imp. qts)
     Drain and refill without oil filter change | 5.2 liters (5.5 US qts, 4.6 Imp. qts)
     Dry fill | 6.6 liters (7.0 US qts, 5.8 Imp. qts)

1. Install the oil filler cap.

23. ADD ENGINE COOLANT

1. Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

   Torque:
     24.5 N*m{ 250 kgf*cm , 18 ft.*lbf } for cylinder block drain cock plug

   Standard capacity:

     Item | Specified Condition
     A/T | 9.8 liters (10.4 US qts, 8.6 lmp. qts)
     M/T | 8.5 liters (9.0 US qts, 7.5 lmp. qts)

   HINT:
   1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic and technology consists of a combination of low phosphates and organic acids).
   2. Please contact your TOYOTA dealer for further details.

   NOTICE:
     Never use water as a substitute for engine coolant.

1. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

1. Install the radiator cap.

1. Bleed air from the cooling system.

   1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

   2. Maintain the engine speed at 2,000 to 2,500 rpm.

   3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

      CAUTION:
      When pressing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fan.

1. Stop the engine and wait until the coolant cools down to ambient temperature.

   CAUTION:
     Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

1. Check the coolant level in the radiator reservoir.
   If the coolant level is low, add SLLC to the reservoir F line.

24. CHECK FOR ENGINE COOLANT LEAKS

CAUTION:

  Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

1. Fill the radiator with coolant and attach a radiator cap tester.

1. Warm up the engine.

1. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.
   If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the cylinder block and head.

25. CHECK FOR FUEL LEAKS

1. Connect the intelligent tester to the DLC3.

   1. Turn the ignition switch ON.

      NOTICE:
        Do not start the engine.

   2. Push the intelligent tester main switch ON.

   3. Select Active Test and enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

1. Check for fuel leaks.

   1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system.

26. CHECK FOR ENGINE OIL LEAKS

1. Start the engine, and check that there are no oil leaks after performing maintenance.

27. INSTALL V-BANK COVER

1. Install the V-back cover with the 2 nuts.

   Torque:
     7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

28. INSPECT IGNITION TIMING

1. When using intelligent tester:
   Check the ignition timing.

   1. Connect the intelligent tester to the DLC3.

      HINT:
        Please refer to the intelligent tester operator's manual for further details.

      Ignition timing:
        7 to 24°BTDC @ idle
        (Transmission in neutral position)

   2. Disconnect the intelligent tester from the DLC3.

1. When not using intelligent tester.
   Check the ignition timing.

   1. Remove the air cleaner cap.

   2. Connect the tester probe of a timing light to the green-red read wire of the ignition coil connector for the No.1 cylinder.

   3. Using SST, connect terminals TC and CG of the DLC3.

      SST
        09843-18040

   4. Using the timing light, check the ignition timing.

      Ignition timing:
        10 +- 2° BTDC @ idle
        (Transmission in neutral position)

   5. Remove the SST from the DLC3.

   6. Check the ignition timing.

      Ignition timing:
        7 to 24° BTDC @ idle
        (Transmission in neutral position)

   7. Disconnect the timing light from the engine.

   8. Install the air cleaner cap.

29. INSPECT IDLE SPEED

1. When using intelligent tester:
   Check the idle speed.

   1. Connect the intelligent tester to the DLC3.

      HINT:
        Please refer to the intelligent tester operator's manual for further details.

   2. Switch the air conditioning OFF.

   3. Race the engine at 2,500 rpm for approximately 90 seconds.

   4. Check the idle speed.

      Idle speed:
        700 +- 50 rpm
        (Transmission in neutral position)
      If the idle speed is not as specified, check the air intake system

   5. Disconnect the intelligent tester from the DLC3.

1. When not using intelligent tester:
   Check the idle speed.

   1. Using SST, connect tachometer probe to terminal TAC of the DLC3.

      SST
        09843-18030

   2. Switch the air conditioning OFF.

   3. Race the engine speed at 2,500 rpm for approximately 90 seconds.

   4. Check the idle speed.

      Idle speed:
        700 +- 50 rpm
        (Transmission in neutral position)
      If the idle speed is not as specified, check the air intake system.

   5. Disconnect the tachometer from the DLC3.

30. INSPECT CO/HC

HINT:

  This check is for determining whether or not the idle CO/HC complies with regulations.

1. Start the engine.

1. Keep the engine speed at 2,500 rpm for approximately 180 seconds.

1. Insert CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe during idling.

1. Immediately check CO/HC concentration at idle and/or 2,500 rpm.

   HINT:
     When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.
     If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

   1. Check the A/F sensor operation and heated oxygen sensor operation.

   2. See the table below for possible causes, then inspect and correct the applicable causes if necessary.

      CO | HC | Symptom | Causes

      Normal

      High

      Rough idle

      1. Faulty ignitions:
      1. Incorrect timing
      2. Fouled, shorted or improperly gapped plugs
      2. Incorrect valve clearance
      3. Leaky intake and exhaust valves
      4. Leaky cylinder

      Low

      High

      Rough idle
      (Fluctuating HC reading)

      1. Vacuum leaks:
      1. PCV hose
      2. Intake manifold
      3. Throttle body
      2. Lean mixture causing misfire.

      High

      High

      Rough idle
      (Black smoke from exhaust)

      1. Restricted air filter
      2. Faulty SFI system:
      1. Faulty pressure regulator
      2. Defective ECT sensor
      3. Faulty ECM
      4. Faulty injector
      5. Faulty throttle position sensor
      6. Faulty MAF sensor