Oil Pump Installation

Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

SST

09223-22010
09506-35010

NOTICE:

1. Keep the lip free from foreign matter.
   
2. Do not tap on the oil seal at an angle.
   
3. Make sure that the oil seal edge does not protrude from the timing chain case.
   

Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.

NOTICE:

Be sure to clean and degrease the contact surfaces, especially the surfaces indicated in the illustration.

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

Install the oil pump gasket.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

Text in Illustration

*1	Seal Diameter
	Seal Packing

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

Seal packing:

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

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

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.
   

Application Specification:

Area	Seal Packing Diameter	Application Position from Inside Seal Line
Continuous Line Area	4.5 mm (0.177 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Short Dashed Line Area	3.5 mm (0.138 in.) or more	2.0 to 3.0 mm (0.0787 to 0.118 in.)
Dashed Line Area	3.5 mm (0.138 in.) or more	3.0 to 4.0 mm (0.118 to 0.158 in.)
Diagonal Line Area	6.0 mm (0.236 in.) or more	5.0 mm (0.197 in.)

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

Install the timing chain cover with the 26 bolts, labeled A, B, C and D, and the 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Standard Bolt:

Item	Length
Bolt A	25 mm (0.984 in.)
Bolt B	55 mm (2.17 in.)
Bolt C	35 mm (1.38 in.)
Bolt D	65 mm (2.56 in.)

NOTICE:

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

Tighten the bolts in area 1.

Torque:

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

HINT:

Tighten the bolts from bottom to top as shown in the illustration.

Tighten the bolts in area 2.

Torque:

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

Tighten the bolts in area 3.

Torque:

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

HINT:

Tighten the bolts and nuts from top to bottom as shown in the illustration.

Tighten the bolts in area 4.

Torque:

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

HINT:

Tighten the bolts from bottom to top as shown in the illustration.

NOTICE:

1. Do not start the engine for at least 2 hours after installation.
   
2. Wipe off any seal packing that seeped out around the surfaces of the oil pan and head cover and make sure that there is no seal packing seeping out around the edges.
   

Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

Install a new 3 O-rings to the timing chain cover.

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

Seal packing:

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

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan within 3 minutes after applying seal packing.
   

Install the oil pan with the 17 bolts (A, B, C, D and E) and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

for bolt A, B, C and E, and nut:

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

for bolt D:

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

Standard Bolt:

Item	Length
Bolt A	60 mm (2.36 in.)
Bolt B	45 mm (1.77 in.)
Bolt C	25 mm (0.984 in.)
Bolt D	16 mm (0.630 in.)
Bolt E	70 mm (2.76 in.)

NOTICE:

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

Install a new gasket to the oil strainer.

HINT:

Align the protrusion of the gasket with the groove of the oil strainer.

Install the oil strainer with the 2 nuts.

Torque:

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

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

Seal packing:

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

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the No. 2 oil pan within 3 minutes after applying seal packing.
   

Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

Torque:

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

Text in Illustration

	Bolt
	Nut

NOTICE:

1. Tighten the nuts first. After tightening the bolts, check that the nuts and bolts are tightened to the specified torque.
   
2. Do not start the engine for at least 2 hours after the installation.
   

Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

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 3 new gaskets.

Install a new gasket to the cylinder head cover.

Install the seal washers to the bolts.

Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

Torque:

for bolt A and D:

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

for bolt B and C:

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

Standard Bolt:

Item	Length
A	25 mm (0.984 in.)
B	35 mm (1.38 in.)
C	65 mm (2.56 in.)
D	60 mm (2.36 in.)

Text in Illustration

	Bolt A
	Bolt B
	Bolt C
	Bolt D

NOTICE:

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

Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

2.0 to 3.0 mm (0.0787 to 0.118 in.)

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 3 new gaskets.

Install a new gasket to the cylinder head cover.

Install the seal washers to the bolts.

Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

Torque:

for bolt A and D:

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

for bolt B and C:

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

Standard Bolt:

Item	Length
A	25 mm (0.984 in.)
B	35 mm (1.38 in.)
C	70 mm (2.76 in.)
D	60 mm (2.36 in.)

Text in Illustration

	Bolt A
	Bolt B
	Bolt C
	Bolt D

NOTICE:

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

Connect the fuel pipe with the 2 bolts.

Torque:

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

Temporarily install the cover with the 3 bolts.

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

Torque:

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

Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

NOTICE:

Do not touch the mesh when installing the oil control valve filter.

Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

Tighten the oil pipe union (on the cylinder head side).

Torque:

65 N*m{663 kgf*cm, 48 ft.*lbf}

NOTICE:

If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

Tighten the oil pipe union (on the head cover side).

Torque:

65 N*m{663 kgf*cm, 48 ft.*lbf}

Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

NOTICE:

Do not touch the mesh when installing the oil control valve filter.

Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

Tighten the oil pipe union (on the cylinder head side).

Torque:

65 N*m{663 kgf*cm, 48 ft.*lbf}

NOTICE:

If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

Tighten the oil pipe union (on the head cover side).

Torque:

65 N*m{663 kgf*cm, 48 ft.*lbf}

Using SST, install the crankshaft pulley with the pulley set bolt.

SST

09213-54015(91651-60855)
09330-00021

Torque:

260 N*m{2651 kgf*cm, 192 ft.*lbf}

Install the oil filter bracket and a new gasket with the 2 nuts and bolt.

Torque:

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

Temporarily install the V-ribbed belt tensioner with the 5 bolts.

Standard Bolt:

Item	Length
A	70 mm (2.76 in.)
B	33 mm (1.30 in.)

Text in Illustration

	Bolt A
	Bolt B

Tighten bolts 1 and 2 in numerical order.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Tighten the other bolts.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

for Separate Type:
Install the 2 idler pulley cover plates, 2 No. 2 idler pulleys and 2 No. 2 idler pulley cover plates with the 2 bolts.

Torque:

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

for Integrated Type:
Install the 2 No. 2 idler pulleys with the 2 bolts.

Torque:

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

Install the No. 1 idler pulley with the bolt.

Torque:

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

HINT:

"DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.

Install the 3 water by-pass hoses.

Apply soapy water to a new O-ring and install the O-ring to the water outlet pipe.

Install a new O-ring to the water outlet pipe.

Install a new gasket to the water pump.

Install the water inlet with the 5 bolts.

Torque:

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

Connect the 3 water by-pass hoses.

Install the water by-pass pipe with the 3 bolts.

Torque:

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

Connect the 2 hoses.

HINT:

The direction of the hose clamp is indicated in the illustration.

Install a new O-ring to the dipstick guide.

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

Push the dipstick guide end into the guide hole.

Install the dipstick guide with the bolt.

Torque:

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

Install the dipstick.

Install the 6 ignition coils with the 6 bolts.

Torque:

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

Connect the 6 ignition coil connectors.

Install the No. 2 emission control valve set with the 3 nuts.

Torque:

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

Install the emission control valve set with the 3 nuts.

Torque:

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

Install the engine assembly (LandCruiser RM000002B5J026X.html).