Oil Pump - Installation

1. Install oil pump assembly

2. Install transverse engine engine mounting bracket

3. Install water pump assembly

4. Install water pump pulley

5. Install camshaft timing oil control valve assembly (for unleaded gasoline specification vehicle)

6. Install crankshaft position sensor

7. Install crankshaft damper sub-assembly

8. Install engine mounting insulator sub-assembly rh (for hatchback)

9. Install engine mounting insulator sub-assembly rh (for sedan)

10. Install cylinder head cover sub-assembly (for rhd)

11. Install cylinder head cover sub-assembly (for lhd)

12. Install ventilation hose no. 2

13. Install ventilation hose

14. Install ignition coil no. 1

15. Install generator assembly

16. Install fan & generator v belt

17. Adjust fan & generator v belt

18. Inspect fan & generator v belt

19. Connect cable to negative battery terminal

20. Add engine oil

21. Add engine coolant

22. Check engine oil level

23. Check for engine oil leakage

24. Check for engine coolant leakage

25. Install cylinder head cover no. 2

26. Install engine under cover rh

27. Install engine under cover sub-assembly (for rough road area specification vehicles)

28. Install front wheel rh

​

1. Install 2 new O-rings onto the 2 locations shown in the illustration.

2. Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration.
   

   
   
   
   

   Seal packing:

   Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Other part Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent
   

   NOTICE:

   1. Remove any oil from the contact surfaces.
      
   2. Install the oil pump assembly within 3 minutes and tighten the bolts and nut within 15 minutes of applying the seal packing.
      
   3. Do not expose the seal to engine oil for at least 2 hours after installation.
      

3. Align the keyway of the oil pump rotor with the rectangular portion of the crankshaft, and slide the oil pump into place.

4. Install the oil pump assembly with the 15 bolts and the nut. Tighten the bolts and nut uniformly in several steps.

   Torque:

   Bolt A:

   32 N*m{326 kgf*cm, 24 ft.*lbf}

   Bolt B:

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}

   Bolt C:

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}

   Nut D:

   24 N*m{245 kgf*cm, 18 ft.*lbf}

   Bolt E:

   24 N*m{245 kgf*cm, 18 ft.*lbf}

   NOTICE:

   After installing the oil pump assembly, install the mounting bracket and water pump within 15 minutes.

   HINT:

   Each bolt length is as follows.

   A: 30 mm (1.181 in.)

   B: 35 mm (1.378 in.)

   C: 20 mm (0.787 in.)

   E: 14 to 20 mm (0.551 to 0.787 in.), Double ended bolt

1. Install the transverse engine engine mounting bracket with the 4 bolts.

   Torque:

   55 N*m{561 kgf*cm, 41 ft.*lbf}

1. Install the water pump assembly through a new gasket with the 3 bolts and 2 nuts.

   Torque:

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}

1. Provisionally install the water pump pulley with the 3 bolts.

2. Using SST, hold the water pump pulley.

   SST

   09960-10010 (09962-01000, 09963-00700)
   

3. Tighten the 3 bolts to the specified torque.

   Torque:

   15 N*m{153 kgf*cm, 11 ft.*lbf}

1. Apply a light coat of engine oil to a new O-ring and install it onto the camshaft timing oil control valve assembly.

   NOTICE:

   Do not twist the O-ring.

2. Install the camshaft timing oil control valve assembly with the bolt.

   Torque:

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

3. Connect the camshaft timing oil control valve assembly connector.

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

2. Install the crankshaft position sensor with the bolt.

   Torque:

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

   NOTICE:

   Do not twist the O-ring.

3. Connect the crankshaft position sensor connector.

1. Align the pin hole of the crankshaft damper with the pin and install the crankshaft damper sub-assembly.

2. Provisionally install the bolt.

3. Using 2 SSTs, tighten the bolt while holding the crankshaft damper sub-assembly.

   SST

   09213-14010 (91651-60865)
   09330-00021
   

   Torque:

   128 N*m{1,305 kgf*cm, 95 ft.*lbf}

   NOTICE:

   Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.

1. Install the engine mounting insulator sub-assembly RH with the 5 bolts and nut.

   Torque:

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

   52 N*m{530 kgf*cm, 38 ft.*lbf} for bolt B and nut

1. Install the engine mounting insulator sub-assembly RH with the 5 bolts and nut.

   Torque:

   52 N*m{530 kgf*cm, 38 ft.*lbf}

1. Apply seal packing to the cylinder head as shown in the illustration.

   Seal Packing:

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

   NOTICE:

   1. Remove any oil from the contact surface.
      
   2. Install the cylinder head cover sub-assembly within 3 minutes of applying seal packing.
      
   3. Do not start the engine within 2 hours of installation.
      

2. Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.

3. Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.

   Torque:

   10 N*m{102 kgf*cm, 7.0 ft.*lbf}

4. Connect the connector and wire harness clamp shown in the illustration and connect the engine wire harness.

5. Connect the fuel injector connectors.

1. Apply seal packing to the cylinder head as shown in the illustration.

   Seal Packing:

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

   NOTICE:

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

2. Install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 seal washers.

3. Tighten the 9 bolts and 2 nuts in the sequence shown in the illustration.

   Torque:

   10 N*m{102 kgf*cm, 7.0 ft.*lbf}

4. Install the wire harness bracket with the bolt.

   Torque:

   13 N*m{133 kgf*cm, 9.6 ft.*lbf}

5. Connect the connector and wire harness clamp shown in the illustration and connect the engine wire harness.

6. Connect the fuel injector connectors.

1. Connect ventilation hose No. 2.

1. Connect the ventilation hose.

1. Install the 4 ignition coils with the 4 bolts.

   Torque:

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

2. Connect the 4 ignition coil connectors.

1. Provisionally install the generator with fixing bolt B.

2. Provisionally install the fan belt adjusting slider with fan belt adjusting slider fixing bolts A and B, then move the generator toward the cylinder block and tighten bolt B.

   Torque:

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}

3. Install the connector and wire harness clamp.

4. Install terminal B with the nut.

   Torque:

   9.8 N*m{100 kgf*cm, 7.2 ft.*lbf}

5. Install the terminal cap.

6. Close the terminal cap.

1. Provisionally install the fan and generator V belt onto each pulley.

   NOTICE:

   1. Make sure that there is no foreign matter or liquid, such as oil, on the belt and pulleys.
      
   2. Make sure that the V belt is securely fitted into the rib grooves of the pulley.
      

1. for Unleaded Gasoline Specification Vehicle:
   Insert an adjusting bar between the engine mounting bracket and generator assembly. Pull the adjusting bar towards the vehicle front to adjust the generator V belt tension.

   NOTICE:

   Do not insert the adjusting bar between the camshaft timing oil control valve assembly and generator assembly. It could damage the camshaft timing oil control valve assembly.

2. for Leaded Gasoline Specification Vehicle:
   Insert the adjusting bar between the engine mounting bracket and generator assembly. Pull the adjusting bar towards the vehicle front to adjust the generator V belt tension.

3. First tighten bolt A, then tighten bolt B.

   Torque:

   19 N*m{189 kgf*cm, 14 ft.*lbf} for bolt A

   54 N*m{551 kgf*cm, 40 ft.*lbf} for bolt B

1. Check the V belt deflection and tension.

   Deflection:

   Item	Specified Condition
   New belt	8.0 to 9.0 mm (0.31 to 0.35 in)
   Used belt	12.5 to 13.5 mm (0.49 to 0.53 in)

   Tension:

   Item	Specified Condition
   New belt	700 to 800 N (71 to 82 kg, 157 to 180 lb)
   Used belt	300 to 400 N (31 to 41 kg, 67 to 90 lb)

   If the belt deflection is not as specified, adjust it.
   

   HINT:

   1. Perform the V belt inspection and adjustment while the engine is cold.
      
   2. V-ribbed belt tension and deflection should be checked immediately after installation of a new belt, and after cranking the engine when inspecting a used belt.
      
   3. Check the V belt deflection at the point between the specified pulleys where the deflection is greatest.
      
   4. When installing a new belt, set its tension to the intermediate value of the specification.
      
   5. When inspecting a belt which has been used for over 5 minutes, apply the Used Belt specifications.
      
   6. When reinstalling a belt which has been used for over 5 minutes, adjust its deflection and tension to the intermediate values of each Used Belt specification.
      
   7. V-ribbed belt tension and deflection should be checked after 2 revolutions of engine cranking.
      
   8. When using a belt tension gauge, confirm its accuracy by using a master gauge first.
      

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

1. Tighten all the plugs.

2. Pour engine coolant into the radiator assembly until it overflows.

   Capacity:

   w/o Fan Shroud Ventilation Duct: M/T 4.9 liters (5.2 USqts, 4.6 lmp. qts)
   

   w/o Fan Shroud Ventilation Duct: A/T 4.8 liters (5.1 USqts, 4.5 lmp. qts)
   

   w/ Fan Shroud Ventilation Duct: M/T 5.1 liters (5.4 USqts, 4.7 lmp. qts)
   

   w/ Fan Shroud Ventilation Duct: A/T 5.0 liters (5.3 USqts, 4.6 lmp. qts)
   

   NOTICE:

   Do not substitute water for engine coolant.

   HINT:

   1. Use of improper engine coolant may damage the engine coolant system.
      
   2. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine 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).
      

3. Check the engine coolant level inside the radiator assembly by squeezing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

4. Install the radiator cap sub-assembly securely.

5. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

6. Warm up the engine until the cooling fan operates.
   

   1. Set the air conditioning as follows while warming up the engine.
      

      Item	Manual air conditioning system	Automatic air conditioning system
      Set control as follows	Fan speed - Any setting except "OFF" Temperature - Toward WARM Air conditioning switch "OFF"	Fan speed - Any setting except "OFF" Temperature - To the highest temperature Air conditioning switch "OFF" "AUTO" switch "OFF"

   2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates.

7. Stop the engine and wait until the coolant cools down.

8. If the engine coolant level is below the full level, perform steps (b) through (g) again and repeat the operation until the engine coolant level stays at the full level.

9. Recheck the engine coolant level inside the radiator reservoir tank assembly. If it is below the full level, add the engine coolant.

1. Warm up the engine, then stop the engine and wait for 5 minutes. Check that the engine oil level is between the low and full marks on the oil level gauge.
   If the engine oil level is low, check for oil leakage and add engine oil up to the full level mark.

   NOTICE:

   Do not add engine oil to above the full level mark.

CAUTION:

To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

1. Fill the radiator assembly with engine coolant, then attach a radiator cap tester.

2. Pump the tester to 137 kPa (1.4 kgf/cm², 19.9 psi), then check that the pressure does not drop.
   If the pressure drops, check the hoses, radiator assembly and water pump assembly for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

1. Tighten 2 A nuts, then 2 B nuts.

   Torque:

   7.0 N*m{71 kgf*cm, 62 in.*lbf}

Torque:

103 N*m{1050 kgf*cm, 76 ft.*lbf}