GSIC - Global Service Information Center

# OIL PUMP > INSTALLATION

## for Preparation Click here

1. INSTALL WATER PUMP

1. Install a new gasket and the water pump with the 8 bolts.

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

2. INSTALL TIMING CHAIN COVER

1. Install 3 new O-rings to the timing chain cover as shown in the illustration.

1. Apply adhesive to the timing gear case plug.

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

1. Using a 10 mm socket hexagon wrench, install the timing gear case plug.

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

   Seal packing:
     Part No. 08826-00080 or equivalent

   Seal diameter:

     Position | Specified Condition
     A - A, C - C | 2.5 to 3.0 mm (0.098 to 0.118 in.)
     B - B, D - D | 4.0 to 4.5 mm (0.157 to 0.177 in.)
     E | 3.0 to 3.5 mm (0.118 to 0.138 in.)

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the timing chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   3. Do not start the engine for at least 4 hours after the installation.

1. Align the oil pump's drive rotor spline and crankshaft as shown in the illustration. Install the spline and chain cover plate to the crankshaft.

1. Temporarily install the timing chain cover with the 19 bolts and 2 nuts.

1. Excluding bolt A, tighten the bolts and nuts in this order: Area 1, Area 2, Area 3.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf }

   HINT:
     Bolt length:
     75 mm (2.95 in.) for bolt A
     75 mm (2.95 in.) for bolt B
     87 mm (3.43 in.) for bolt C
     95 mm (3.74 in.) for bolt D

1. Tighten the bolts labeled A in this order: Area 2 and Area 3.

   Torque:
     46 N*m{ 469 kgf*cm , 34 ft.*lbf }

1. Tighten the bolts labeled E for Area 4.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf }

   HINT:
     Bolt length:
     35 mm (1.37 in.) for bolt E

3. INSTALL CRANKSHAFT POSITION SENSOR

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

1. Install the sensor with the bolt.

   Torque:
     8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

1. Install the connector to the connector bracket.

1. Attach the harness clamp.

1. Connect the sensor connector.

4. INSTALL NO. 1 OIL PAN

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

   Seal packing:
     Part No. 0886-00080 or equivalent

   Seal diameter:
     2 to 3 mm (0.079 to 0.118 in.)

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the oil pan within 3 minutes after applying seal packing.
   3. Do not start the engine for at least 4 hours after the installation.

1. Temporarily install the oil pan with the 16 bolts and 2 nuts.

   HINT:
     Bolt length:
     20 mm (0.79 in.) for bolt A
     40 mm (1.57 in.) for bolt B

1. Uniformly tighten the 16 bolts and 2 nuts in the order shown in the illustration.

   Torque:
     26 N*m{ 265 kgf*cm , 19 ft.*lbf }

5. INSTALL OIL STRAINER

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

   Torque:
     20 N*m{ 204 kgf*cm , 15 ft.*lbf }

6. INSTALL 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:
     2.5 to 3.5 mm (0.098 to 0.138 in.)

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the oil pan within 3 minutes after applying seal packing.
   3. Do not start the engine for at least 4 hours after the installation.

1. Temporarily install the oil pan with the 20 bolts and 2 nuts.

1. Uniformly tighten the 20 bolts and 2 nuts in the order shown in the illustration.

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

1. Install a new gasket and the drain plug.

7. INSTALL CRANKSHAFT PULLEY

1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.

1. Using SST, install the crankshaft pulley bolt.

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

   Torque:
     260 N*m{ 2,651 kgf*cm , 192 ft.*lbf }

   NOTICE:
     Do not reuse the pulley bolt.

8. INSTALL CAMSHAFT POSITION SENSOR

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

1. Install the sensor with the bolt.

   Torque:
     8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

9. INSTALL CYLINDER HEAD COVER

1. Install the 2 cover gaskets to the head cover.

1. Apply seal packing to the places shown in the illustration.

   Seal packing:
     Part No. 08826-00080 or equivalent

   NOTICE:
   1. Remove any oil from the contact surface.
   2. Install the head cover within 3 minutes after applying seal packing.
   3. Do not start the engine for at least 2 hours after the installation.

1. Temporarily install the head cover with the 19 bolts and 2 nuts.

1. Uniformly tighten the 19 bolts and 2 nuts in the order shown in the illustration.

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

1. In numerical order, confirm that the bolts labeled 1 to 8 are tightened to the torque specification. Tighten the bolts as necessary.

10. INSTALL OIL FILLER CAP

11. INSTALL NO. 1 WATER BY-PASS PIPE

1. Install a new gasket and the water by-pass pipe with the 2 nuts.

   Torque:
     17.5 N*m{ 179 kgf*cm , 13 ft.*lbf }

12. INSTALL NO. 1 IDLER PULLEY

1. Install the spacer, idler pulley and pulley plate with the bolt.

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

13. INSTALL V-RIBBED BELT TENSIONER

1. Temporarily install the belt tensioner with the 3 bolts.

   HINT:
     Make sure that the flanges of the bolts are contacting the tensioner surface.

1. Install the tensioner by tightening the 3 bolts in the order shown in the illustration.

   Torque:
     40 N*m{ 408 kgf*cm , 30 ft.*lbf } for bolt 1
     21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolt 2
     43 N*m{ 438 kgf*cm , 32 ft.*lbf } for bolt 3

14. INSTALL THERMOSTAT

1. Install a new gasket to the thermostat.

   HINT:
     When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.

1. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.

   HINT:
     The jiggle valve may be set within 10°of either side of the prescribed position.

15. INSTALL WATER INLET

1. Install the inlet with the 2 nuts and bolt.

   Torque:
     20 N*m{ 204 kgf*cm , 15 ft.*lbf }

1. Connect the connector.

16. INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning)

NOTICE:

  In order to prevent misalignment, which causes belt rattle, the 5 bolts must be tightened exactly as described in the procedures below.

1. Temporarily install the mounting bracket with the 3 bolts labeled A.

   HINT:
     Make sure the flanges of the bolts are contacting the bracket surface.

1. Make sure there is no clearance between the cylinder block and bracket as shown in the illustration. Then install the bolt labeled B.

   Torque:
     45 N*m{ 459 kgf*cm , 33 ft.*lbf } for bolt B

1. Tighten the bolts labeled A and install the bolt labeled C.

   Torque:
     45 N*m{ 459 kgf*cm , 33 ft.*lbf } for bolt A
     24.5 N*m{ 250 kgf*cm , 18 ft.*lbf } for bolt C

17. INSTALL GENERATOR

1. Install the generator with the 2 bolts.

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

1. Install the generator wire with the bolt and nut.

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

1. Connect the connector.

18. INSTALL INTAKE MANIFOLD

1. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.

   Torque:
     25 N*m{ 255 kgf*cm , 18 ft.*lbf }

1. Connect the crankshaft position sensor to the clamp.

19. INSTALL THROTTLE BODY

1. Install a new gasket on the intake manifold.

   HINT:
     Align the protrusion of the gasket with the groove of the intake manifold.

1. Install the throttle body with the 2 bolts and 2 nuts.

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

1. Connect the water by-pass hose to the throttle body.

1. Connector the throttle control motor & throttle position sensor connector.

20. INSTALL SPARK PLUG

21. INSTALL IGNITION COIL

1. Install the ignition coil with the bolt.

22. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

23. INSTALL ENGINE ASSEMBLY

1. Install the engine to the vehicle (Click here).

24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

25. ADD ENGINE OIL

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

   Torque:
     37.5 N*m{ 382 kgf*cm , 28 ft.*lbf }

1. Add fresh engine oil.

   Standard capacity:

     Item | Capacity
     Drain and refill with oil filter change | 5.6 liters (5.9 US qts, 4.9 lmp. qts)
     Drain and refill without oil filter change | 5.3 liters (5.6 US qts, 4.6 lmp. qts)
     Dry fill | 6.3 liters (6.7 US qts, 5.5 lmp. qts)

1. Install the oil filler cap.

26. 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:
     7.0 liters (7.4 US qts, 6.2 lmp. qts)

1. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the F line.

   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 acid 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.
   If the coolant level drops below the F line, add TOYOTA SLLC to the F line.

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.

27. CHECK FUEL FOR 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 the 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.

28. CHECK FOR OIL LEAKS

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

29. CHECK FOR 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.

30. CHECK IDLE SPEED AND IGNITION TIMING

1. Warm up and stop the engine.

   NOTICE:
     A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.

1. When using the 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. Start the engine at idle.

   3. Turn the intelligent tester main switch ON.

   4. Enter the following item:
      Powertrain / Engine and ECT / Data List / Engine SPD.

      Idle speed:
        650 to 750 rpm

      NOTICE:
      1. When checking the idle speed, the transmission should be in the neutral position.
      2. Switch off all accessories and air conditioning before connecting the intelligent tester.

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

   1. Using SST, connect tachometer tester probe to terminal 9 (TAC) of the DLC3.

      SST
        09843-18030

   2. Start the engine at idle.

   3. Check the idle speed.

      Idle speed:
        650 to 750 rpm

31. CHECK CO/HC

1. Start and warm up the engine.

1. Run the engine at 2,500 rpm for approximately 180 seconds and idle the engine.

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

1. Check CO/HC concentration at idle.

   Idle CO concentration:
     0 to 0.5%

   Idle HC concentration:
     Applicable local regulation

1. If the CO/HC concentration is not as specified, perform troubleshooting in the order given below.

   1. Check the heated oxygen sensor operation (Click here).

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

      CO | HC | Problems | Causes

      Normal

      High

      Rough idle

      1. Faulty ignitions:
      1. Incorrect timing
      2. Plugs are contaminated, shorted or gaps are defective
      2. Incorrect valve clearance
      3. Leaks in intake and exhaust valves
      4. Leaks in cylinders

      Low

      High

      Rough idle
      (Fluctuating HC reading)

      1. Vacuum leaks:
      1. PCV hoses
      2. Intake manifold
      3. Throttle body
      4. Brake booster line
      2. Lean mixture causing misfire

      High

      High

      Rough idle
      (Black smoke from exhaust)

      1. Restricted air filter
      2. Plugged PCV valve
      3. Faulty SFI system:
      1. Faulty pressure regulator
      2. Defective ECT sensor
      3. Defective Mass Air Flow (MAF) meter
      4. Faulty ECM
      5. Faulty injectors
      6. Faulty throttle position sensor

32. CHECK FUNCTION OF THROTTLE BODY

1. Check the throttle control motor operating sound.

   1. Turn the ignition switch ON.

   2. When pressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises emit from the motor.
      If friction noise is heard, replace the throttle body.

1. Check the throttle position sensor.

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch ON.

   3. Under Current Data, check that the throttle valve opening percentage (Throttle Pos) is within the standard.

      Standard throttle valve opening percentage:
        60% or more

      NOTICE:
        When checking the standard throttle valve opening percentage, the shift lever should be in the N position.
      If the percentage is less than 60%, replace the throttle body.

33. PERFORM INITIALIZATION

1. Perform initialization (Click here).

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