Oil Pump (For Hatchback) Installation

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

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 seal packing.
   
3. Do not expose the seal to engine oil for at least 2 hours after the installation.
   

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

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 ft.*lbf}

bolt C:

11 N*m{112 kgf*cm, 8 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

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

Torque:

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

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

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Provisionally install the water pump pulley with the 3 bolts.

Using SST, hold the water pump pulley.

SST

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

Tighten the 3 bolts to the specified torque.

Torque:

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

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.

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

Torque:

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

NOTICE:

1. If a component has been dropped or subjected to a strong impact, replace it.
   
2. Make sure that the O-ring is not damaged or does not jump out of position during installation.
   

Connect the camshaft timing oil control valve assembly connector.

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

NOTICE:

If reusing the camshaft position sensor, be sure to inspect the O-ring.

Install the crankshaft position sensor with the bolt.

Torque:

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

NOTICE:

1. If a component has been dropped or subjected to a strong impact, replace it.
   
2. Make sure that the O-ring is not damaged or does not jump out of position during installation.
   

Connect the crankshaft position sensor connector.

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

Provisionally install the bolt.

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

SST

09213-14010(91651-60865)
09330-00021

Torque:

128 N*m{1305 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.

Install the engine mounting insulator sub-assembly RH with the 4 bolts and 2 nuts.

Torque:

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

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 surfaces.
   
2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after the installation.
   

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

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

Torque:

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

Install the wire harness bracket with the bolt.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Connect the connector and 4 wire harness clamps and connect the engine wire harness.

Connect the 4 fuel injector connectors.

Connect fuel vapor feed hose assembly.

Connect the ventilation hose.

Add fresh engine oil.

Standard Oil Grade:

Oil Grade	Oil Viscosity (SAE)
API grade SL "energy-conserving", SM "energy-conserving" or ILSAC multigrade engine oil	0W-20 5W-20 5W-30 10W-30
API grade SL or SM multigrade engine oil	15W-40 20W-50

Oil capacity:

Item	Capacity
Drain and refill with oil filter change	3.7 liters (3.9 US qts, 3.3 Imp. qts)
Drain and refill without oil filter change	3.4 liters (3.6 US qts, 3.0 Imp. qts)
Dry fill	4.1 liters (4.3 US qts, 3.6 Imp. qts)

Tighten the cylinder block drain cock plug and the radiator drain cock plug.

Torque:

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

Pour engine coolant into the radiator assembly until it is full.

Standard capacity:

5.0 liters (5.3 US qts, 4.4 Imp. qts)

NOTICE:

Do not substitute water for 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).
   

Check the coolant level inside the radiator assembly by squeezing the No. 2 radiator hose and the No. 3 radiator hose several times by hand. If the coolant level goes down, add engine coolant.

Install the water filler cap sub-assembly securely.

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

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.
   

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the coolant starts to flow inside the hose.

2. Maintain the engine speed at 2500 to 3000 rpm.
   

3. Press the No. 2 radiator hose and No. 3 radiator hose 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.
      

Stop the engine and wait until the coolant cools down.

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

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

Warm up and stop the engine, and then wait for 5 minutes.

Check that the engine oil level is between the low level and full level marks on the engine oil level dipstick.
If low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not fill with engine oil above the full level mark.

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

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.