Oil Pump Installation

Apply soapy water to 2 new O-rings and install them to the water inlet pipe.

Install the water inlet pipe to the No. 1 heat exchanger cover.

Apply a light coat of engine oil to a new gasket.

Install the gasket to the cylinder block.

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

Install the O-ring to the oil pan.

Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Seal packing:

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

1. Application Specification:

   Area	Seal Packing Diameter	Application Position from Inside Edge of Cover
   Continuous line area	3.0 to 4.0 mm (0.118 to 0.157 in.)	2.5 mm (0.0984 in.)
   Dashed line area	6.4 mm (0.252 in.) or more, or within OK area shown in illustration	7.0 mm (0.276 in.)
   Diagonal line area	3.0 to 4.0 mm (0.118 to 0.157 in.)	5.5 mm (0.217 in.)

Text in Illustration

*1	Seal Packing Thickness mm (in.)
*2	Seal Packing Width mm (in.)
*3	Thickness
*4	Width
	OK Area

NOTICE:

1. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   
2. Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   

Align the oil pump drive rotor spline and crankshaft as shown in the illustration and install the chain cover.

Temporarily install the 26 bolts and nut.

Standard Bolt:

Item	Length	Thread Diameter
Bolt A	25 mm (0.984 in.)	8 mm (0.315 in.)
Bolt B	55 mm (2.17 in.)	8 mm (0.315 in.)
Bolt C	70 mm (2.76 in.)	8 mm (0.315 in.)
Bolt D	35 mm (1.38 in.)	10 mm (0.394 in.)
Bolt E	55 mm (2.17 in.)	10 mm (0.394 in.)
Bolt F	80 mm (3.15 in.)	10 mm (0.394 in.)

NOTICE:

Make sure that there is no oil on the bolt threads.

Tighten the 3 bolts in several steps in the sequence shown in the illustration.

Torque:

47 N*m{479 kgf*cm, 35 ft.*lbf}

Temporarily install the fan bracket with the 5 bolts.

Standard Bolt:

Item	Length	Thread Diameter
Bolt A	70 mm (2.76 in.)	8 mm (0.315 in.)
Bolt B	80 mm (3.15 in.)	10 mm (0.394 in.)

Text in Illustration

	Bolt A
	Bolt B

Temporarily install the belt tensioner with the bolt and 6 mm hexagon bolt.

Text in Illustration

	Bolt
	6 mm Hexagon Bolt

Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.

Torque:

47 N*m{479 kgf*cm, 35 ft.*lbf}

Tighten the 22 bolts and nut labeled 12 to 34 in several steps in the sequence shown in the illustration.

Torque:

23 N*m{235 kgf*cm, 17 ft.*lbf}

NOTICE:

1. Do not start the engine for at least 2 hours after the installation.
   


2. After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.
   

Text in Illustration

Labeled A

Check the torque of each bolt and nut again.

Apply MP grease to the lip of a new front crankshaft oil seal.

NOTICE:

1. Do not allow foreign matter to contact the lip of the oil seal.
   
2. Do not allow MP grease to contact the dust seal.
   

Using SST and a hammer, tap in the front crankshaft oil seal to a depth between 0 and 1.0 mm (0 to 0.0394 in.) from the timing chain cover edge.

SST

09223-22010
09506-35010

NOTICE:

1. Keep the lip free from foreign matter.
   
2. Do not tap the front crankshaft oil seal at an angle.
   

Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).

Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

NOTICE:

Remove any oil from the contact surface.

Apply seal packing as shown in the illustration.

Seal packing:

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

Text in Illustration

Seal Packing

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   

Install a new seal washer to the bolt.

Temporarily install the cylinder head cover sub-assembly LH with the 14 bolts. Tighten the bolts uniformly in several steps.

Torque:

for bolt A:

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

for bolt B:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Standard Bolt:

Item	Length	Thread Diameter
Bolt A	70 mm (2.76 in.)	8 mm (0.315 in.)
Bolt B	25 mm (0.984 in.)	6 mm (0.236 in.)

Text in Illustration

	Bolt A
	Bolt B

NOTICE:

Do not start the engine for at least 2 hours after the installation.

Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).

Install a new cylinder head cover gasket RH to the cylinder head cover sub-assembly RH.

NOTICE:

Remove any oil from the contact surface.

Apply seal packing as shown in the illustration.

Seal packing:

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

Text in Illustration

Seal Packing

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   

Install a new seal washer to the bolt.

Temporarily install the cylinder head cover sub-assembly RH with the 14 bolts. Tighten the bolts uniformly in several steps.

Torque:

for bolt A:

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

for bolt B:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Standard Bolt:

Item	Length	Thread Diameter
Bolt A	70 mm (2.76 in.)	8 mm (0.315 in.)
Bolt B	25 mm (0.984 in.)	6 mm (0.236 in.)

Text in Illustration

	Bolt A
	Bolt B

NOTICE:

Do not start the engine for at least 2 hours after the installation.

for Bank 2:

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

   Torque:

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

2. Connect the 4 ignition coil connectors.
   

3. Attach the 3 clamps and connect the engine wire.
   

4. Connect the water by-pass pipe with the 2 bolts.
   

   Torque:

   18 N*m{184 kgf*cm, 13 ft.*lbf}

for Bank 1:

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

   Torque:

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

2. Connect the 4 ignition coil connectors.
   

3. Attach the 4 clamps and connect the engine wire.
   

Align the key groove of the pulley with the pulley set key, and slide on the pulley to install it.

Using SST, install the pulley set bolt.

SST

09213-70011
09330-00021

Torque:

300 N*m{3059 kgf*cm, 221 ft.*lbf}

Text in Illustration

*a	Hold
	Turn

Install the No. 1 idler pulley with the bolt.

Torque:

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

Temporarily install the water pump pulley with the 4 bolts.

Using SST, hold the water pump pulley and tighten the 4 bolts.

SST

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

Torque:

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

Install 2 new gaskets and the water by-pass joint with the 4 nuts.

Torque:

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

Install a new gasket to the engine water pump.

Install the water inlet housing with the 3 bolts.

Torque:

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

Install the water by-pass pipe sub-assembly with the 2 bolts.

Torque:

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

Connect the No. 2 water by-pass hose from the front water by-pass joint.

Connect the 4 hoses.

Install the water by-pass pipe with the 2 bolts.

Torque:

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

Connect the No. 1 water by-pass pipe with the 2 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Connect the heater water hose.

Install a new gasket to the No. 3 air tube.

Install the No. 3 air tube with the 2 stud bolts, 2 nuts and bolt.

Torque:

for bolt and nut:

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

for stud bolt:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

NOTICE:

Make sure the claws of the gasket are not caught between the No. 3 air tube and exhaust manifold.

Install a new gasket to the No. 4 air tube.

Install the No. 4 air tube with the 2 stud bolts, 2 nuts and bolt.

Torque:

for bolt and nut:

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

for stud bolt:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

NOTICE:

Make sure the claws of the gasket are not caught between the No. 4 air tube and exhaust manifold.

Install the wire harness clamp bracket with the bolt.

Torque:

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

Install the fuel hose (Click here).

Install the fuel pipe clamp.

Connect the 2 clamps.

Install the fuel tube (Click here).

Install the 2 bolts.

Torque:

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

Install the No. 3 engine cover.

Text in Illustration

Engine Front

HINT:

Position the No. 3 engine cover so that the arrow mark faces the front of the engine and install it.

Install the No. 4 engine cover.

Text in Illustration

Engine Front

HINT:

Position the No. 4 engine cover so that the arrow mark faces the front of the engine and install it.

Install the stud bolt.

Torque:

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

Install the generator with the 3 bolts and nut.

Torque:

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

Connect the harness bracket to the generator with the bolt.

Torque:

31 N*m{316 kgf*cm, 23 ft.*lbf}

Connect the generator wire with the nut.

Torque:

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

Close the terminal cap.

Connect the generator connector.

Connect the oil cooler tube with the 2 bolts.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Connect the vane pump to the timing chain cover with the 2 bolts.

Torque:

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

Apply engine oil to a new O-ring, and then install the O-ring to the engine oil level dipstick guide.

Install the engine oil level dipstick guide with the bolt.

Torque:

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

Attach the engine wire clamp.

Install the engine oil level dipstick.

Apply a light coat of engine oil to 2 new O-rings.

Install the 2 O-rings to the timing chain cover.

Install the oil filter bracket with the 2 nuts and 2 bolts.

Torque:

35 N*m{357 kgf*cm, 26 ft.*lbf}

Connect the ground wire to the cylinder block.

Install the oil cooler bracket with the 2 nuts.

Torque:

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

Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:

Do not apply adhesive to the oil inlet port of the oil pressure sender gauge.

Install the oil pressure sender gauge.

Torque:

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

NOTICE:

Do not start the engine within 1 hour after installation.

Connect the oil pressure sender gauge connector.

Clean the inside of the oil filter cap, threads and O-ring groove.

Apply a light coat of engine oil to a new O-ring for the cap, and then install the O-ring to the groove of the oil filter cap.

NOTICE:

1. Be sure to install the O-ring in the proper location, otherwise oil may leak.
   
2. Do not twist the O-ring.
   

Set a new oil filter element to the oil filter cap.

Remove any dirt or foreign matter from the installation surface of the engine.

Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

NOTICE:

1. Do not remove the oil filter bracket clip.
   
2. Do not pinch the O-ring for the cap.
   

Using SST, tighten the oil filter cap.

SST

09228-06501

Torque:

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

NOTICE:

1. When tightening the oil filter cap, do not remove the oil filter bracket clip.
   
2. After tightening the oil filter cap, make sure that there is no gap and that the O-ring is not protruding.
   

Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

NOTICE:

Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

Install the oil filter drain plug.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

NOTICE:

Be careful that the O-ring does not get caught between any surrounding parts.

Connect the clamp and engine wire with the bolt.

Torque:

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

for Engine Room RH Side:

1. Connect the 6 clamps.
   

2. Connect the noise filter connector.
   

3. Connect the injector connector.
   

4. Connect the 2 VVT sensor connectors.
   

5. Connect the 4 ignition coil connectors.
   

6. Connect the 2 camshaft timing oil control valve connectors.
   

for Engine Room LH Side:

1. Install the ground wire with the bolt.
   

   Torque:

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

2. Connect the 8 clamps.
   

3. Connect the noise filter connector.
   

4. Connect the engine coolant temperature sensor connector.
   

5. Connect the camshaft position sensor connector.
   

6. Connect the 2 VVT sensor connectors.
   

7. Connect the 4 ignition coil connectors.
   

8. Connect the 2 camshaft timing oil control valve connectors.
   

9. Connect the injector connector.
   

Install the air tube with the 2 bolts.

Torque:

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

Connect the No. 3 air injection system hose.

Attach the wire harness clamp.

Install the cooler compressor with the stud bolt.

Torque:

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

Install the 3 bolts and nut.

Torque:

25 N*m{250 kgf*cm, 18 ft.*lbf}

NOTICE:

Tighten the bolts and nut in the order shown in the illustration to install the cooler compressor.

Install the air cleaner and hose with the 3 bolts, and then tighten the hose clamp.

Torque:

for bolt:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

for hose clamp:

2.5 N*m{25 kgf*cm, 22 in.*lbf}

Attach the clamp and connect the mass air flow meter connector.

Connect the No. 2 PCV hose and No. 1 air hose.

Install the front fender apron trim packing A with the 3 clips.

Add fresh oil and install the oil filler cap.

Standard Oil Grade:

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

Standard Oil Capacity:

Item	Specified Condition
Drain and refill without oil filter change	7.1 liters (7.5 US qts, 6.2 Imp. qts)
Drain and refill with oil filter change	7.5 liters (7.9 US qts, 6.6 Imp. qts)
Dry fill	9.3 liters (9.8 US qts, 8.2 Imp. qts)

Add engine coolant.

Standard Capacity (w/o ATF Warmer):

Item	Specified Condition
w/ Rear Heater	16.5 liters (17.4 US qts, 14.5 Imp. qts)
w/o Rear Heater	13.8 liters (14.6 US qts, 12.1 Imp. qts)

Standard Capacity (w/ ATF Warmer):

Item	Specified Condition
w/ Rear Heater	17.0 liters (18.0 US qts, 15.0 Imp. qts)
w/o Rear Heater	14.2 liters (15.0 US qts, 12.5 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

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. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.
   

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

Install the reservoir cap.

Install the radiator cap.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

HINT:

Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap.*4

Set the air conditioning as follows.*5

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

CAUTION:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful of the fan.
   
3. Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
   

NOTICE:

1. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.
   
2. Do not start the engine when there is no coolant in the radiator reservoir.
   
3. Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
   
4. If there is not enough coolant, the engine may burn out or overheat.
   

HINT:

1. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.
   
2. The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.
   

Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

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.

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.
If the coolant level is below the F line, repeat steps *4 through *8.
If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

Warm up the engine. Then stop the engine and wait for 5 minutes.

Check that the engine oil level is between the dipstick low level mark and full level mark.

NOTICE:

Do not fill engine oil above the full level mark.

HINT:

A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.

1. When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.
   
2. If low quality oil or oil of an inappropriate viscosity is used.
   
3. When driving at high engine speed or with a heavy load, (when towing, or), when driving while accelerating or decelerating frequently.
   
4. When leaving the idling for a long time, or when driving frequently through heavy traffic.
   

When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.

Start the engine. Make sure that there are no oil leaks from the area that was worked on.

Remove the radiator cap.

Check for excessive deposits of rust or scales around the radiator reservoir cap and radiator reservoir filler hole. Also, the engine coolant should be free of oil.
If excessively dirty, replace the engine coolant.

Install the radiator cap.

Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.