Up to 08/2009

2GR-FXE LUBRICATION: OIL PUMP: INSTALLATION

1. INSTALL TIMING CHAIN COVER OIL SEAL

(a) Using SST, tap in a new oil seal until its surface is flush with the timing chain case edge.

SST : 09223-22010

SST : 09506-35010

NOTICE:
* Keep the lip free from foreign matter.
* Do not tap on the oil seal at an angle.
* Make sure that the oil seal edge does not stick out of the timing chain case.
HINT
Tap in the oil seal so that it is positioned within 1.0 mm from the edge of the timing chain case.

(b) Apply a light coat of MP grease to the timing chain cover oil seal lip.

2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove any old packing material remaining on the sealing surfaces before applying seal packing.

(b) Clean and degrease the contact surfaces of the timing chain cover, cylinder head and cylinder block, and confirm that no oil, moisture or other foreign matter remains on the surfaces.

(d) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing:

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

Seal diameter:

3.0 mm (0.118 in.)

NOTICE:
* When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
* Do not add engine oil for at least 2 hours after installing the chain cover.
* Do not start the engine for at least 2 hours after installing the chain cover.
(e) Apply seal packing in a line to the timing chain cover 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:
* If the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
* Do not add the engine oil for at least 2 hours after installing.
* Do not start the engine for at least 2 hours after installing.

Seal Packing Application Chart

(f) Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the chain cover to the crankshaft.

Text in Illustration

(g) Temporarily tighten the timing chain cover with the 23 bolts and 2 nuts.

Bolt Length

NOTICE:
Make sure that there is no oil on the bolt and nut threads.

(h) Fully tighten the 2 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(i) Fully tighten the 2 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(j) Fully tighten the 7 bolts and 2 nuts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

HINT
First tighten the upper bolts and nuts followed by the lower bolts and nuts as shown in the illustration.

(k) Fully tighten the 12 bolts.

Bolt A - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

Except bolt A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

HINT
Tighten the bolts in the order of lower to upper as shown in the illustration.

3. INSTALL OIL PAN SUB-ASSEMBLY Reassembly

4. INSTALL OIL STRAINER SUB-ASSEMBLY Reassembly

5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Reassembly

6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Reassembly

7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Reassembly

8. INSTALL WATER INLET HOUSING Reassembly

9. INSTALL OIL COOLER PIPE (w/ Oil Cooler)

(a) Install a new gasket to the oil pan sub-assembly.

(b) Install the oil cooler pipe with the bolt and 2 nuts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

10. INSTALL CRANKSHAFT PULLEY Installation

11. INSTALL NO. 1 OIL PIPE Reassembly

12. INSTALL OIL PIPE Reassembly

13. INSTALL ENGINE HANGERS Installation

14. REMOVE ENGINE STAND Installation

15. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

HINT
Installation