OIL PUMP > INSTALLATION

for Preparation Click here



1. INSTALL WATER PUMP


A087223E01

  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


A097922E02

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



    A058128E05

  1. Apply adhesive to the timing gear case plug.

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



    G036021E01

  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.



    G038474E02



    G038475E01

  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



    G037337E02



3. INSTALL CRANKSHAFT POSITION SENSOR


    A099147E04

  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


G038861E01

  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.



    A099220E03

  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


A099221E02

  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.



    A099214E03

  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


A097885E02

  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


A099825E03

  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.



    A088646E01

  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


G035081E04

  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


    A110369E01

  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.



    A113390E01

  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



    A113788E01

  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


    A099681E03

  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


G036020E01

  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


    G036423E01

  1. Install a new gasket on the intake manifold.

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



    A086829E01

  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:
    Item
    		Specified Capacity
    A/T
    		7.3 liters (7.7 US qts, 6.4 lmp. qts)
    M/T
    		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.



    A112081E01

  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.



    A099675E01

  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. Check the idle speed control system.



      G039758E01

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

      SST
      09843-18040  

    2. Start the engine at idle.

      NOTICE:
      1. Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
      2. Turn off all electrical systems before connecting the terminals.
      3. When checking ISC function, the transmission should be in the neutral position.



      3. A099876E01

    3. After connecting terminals (TC and CG), check that the engine speed changes to approximately 1,000 to 1,500 rpm for 5 seconds, and then returns to idle speed.
      If the result is not as specified, check the throttle body, DTC (Click here) and wire harness.



31. CHECK CO (for Leaded Gasoline Specification Vehicle)

HINT:
This check is used only to determine whether or not the idle CO complies with regulations.

  1. Initial condition:

    1. Engine at normal operating temperature

    2. Air cleaner installed

    3. All pipes and hoses of air induction system connected

    4. All accessories switched OFF

    5. All vacuum lines properly connected

    6. SFI system wiring connectors fully seated

    7. Ignition timing set correctly

    8. Transmission in neutral position

    9. Tachometer and CO meter calibration at idle

      NOTICE:
      If a CO meter is not available, do not attempt to adjust the idle mixture. Always use a CO meter when adjusting the idle mixture. Use of the idle mixture screw for adjustments is typically not necessary if the vehicle is in good condition.

  1. Warm up the engine under constant speed (approximately 50 km/h (31 mph)). Close the throttle valve for 5 minutes after the engine coolant temperature becomes stable (80 to 90°C (176 to 194°F)) and idle the engine for 5 minutes.



    G037188E02

  1. Insert a tester probe at least 40 cm (1.3 ft.) into the tailpipe.

  1. Wait at least 1 minute before measuring to allow the concentration to stabilize. Complete the measuring within 3 minutes.

    Idle CO concentration:
    0 to 0.5 %



    A001435E03

  1. If the CO concentration does not conform to regulations, adjust by turning the idle mixture adjusting screw in the variable resistor with SST.

    SST
    09243-00020  



    A001434E02

  1. The idle mixture adjusting screw can be adjusted through an 180° angle range.
    If the CO concentration is within specification, this adjustment is complete.
    If the CO concentration cannot be corrected by idle mixture adjustment, see the table below for other possible causes.

    CO
    		Problems
    		Causes
    High
    		Rough idle
    (black smoke from exhaust)
    1. Clogged air filter
    2. Plugged ventilation valve
    3. Faulty SFI system
      1. Faulty fuel pressure regulator
      2. Clogged fuel pressure regulator
      3. Defective engine coolant temperature (ECT) sensor
      4. Faulty ECM
      5. Faulty injectors
      6. Faulty throttle position sensor
      7. Faulty MAF meter



32. CHECK CO/HC (for Unleaded Gasoline Specification Vehicle)

  1. Start and warm up the engine.

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



    G037188E01

  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



33. CHECK FUNCTION OF THROTTLE BODY


    A111693

  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.



    A099015E01

  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.



34. 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.