Removal and Installation

OIL PUMP

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE ENGINE ASSEMBLY
(a) Remove the engine.

3. INSTALL ENGINE STAND
4. REMOVE ENGINE WIRE
5. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY
6. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
7. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
8. REMOVE FAN AND GENERATOR V BELT
9. REMOVE NO. 2 ENGINE COVER
10. REMOVE NO. 1 ENGINE COVER
11. REMOVE COOLER COMPRESSOR ASSEMBLY
12. REMOVE ENGINE MOUNTING BRACKET LH
13. REMOVE ENGINE MOUNTING BRACKET RH
14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
15. REMOVE WATER PUMP PULLEY
16. REMOVE INJECTOR DRIVER
17. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
18. REMOVE NO. 2 SURGE TANK STAY
19. DISCONNECT WATER HOSE JOINT
20. REMOVE CRANKSHAFT PULLEY
21. REMOVE WATER INLET
22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
23. REMOVE OIL STRAINER SUB-ASSEMBLY
24. REMOVE OIL PAN SUB-ASSEMBLY
25. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
26. REMOVE NO. 1 FUEL PIPE
27. DISCONNECT NO. 2 FUEL PIPE
28. REMOVE FUEL PUMP ASSEMBLY
29. REMOVE NO. 2 FUEL PIPE
30. REMOVE IGNITION COIL ASSEMBLY
31. REMOVE NO. 1 OIL PIPE
32. REMOVE NO. 2 OIL PIPE
33. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
34. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
35. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove the bolt and wiring harness clamp bracket.

(b) Remove the 25 bolts and 2 nuts shown in the illustration.

(c) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT: Tape the screwdriver tip before use.

(d) Remove the gasket.

INSTALLATION
1. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing: Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent
Standard seal diameter: 5.0 to 5.5 mm (0.197 to 0.217 in.)

NOTICE:
^ Be sure to clean and degrease the contact surfaces, especially indicated by C in the illustration.
^ When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
^ Install the chain cover within 3 minutes.
^ Do not start the engine for at least 2 hours after installing.

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

Seal packing:
For oil related part: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent
For water related part: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent

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 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

Apply seal packing as follows (Part 1):

Apply seal packing as follows (Part 2):

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

(e) Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

Bolt length:

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

(f) Tighten the 3 bolts shown in the illustration.
Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf) for bolt A
21 N*m (214 kgf*cm, 15 ft.*lbf) for bolts except A

(g) Tighten the 3 bolts shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

(h) Tighten the 7 bolts and 2 nuts as shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

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

(i) Fully tighten the 12 bolts as shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

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

(j) Install the wiring harness bracket with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

2. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
4. INSTALL NO. 2 OIL PIPE
5. INSTALL NO. 1 OIL PIPE
6. INSTALL IGNITION COIL ASSEMBLY
7. INSTALL NO. 2 FUEL PIPE
8. INSTALL FUEL PUMP ASSEMBLY
9. CONNECT NO. 2 FUEL PIPE
10. INSTALL NO. 1 FUEL PIPE
11. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
12. INSTALL OIL STRAINER SUB-ASSEMBLY
13. INSTALL OIL PAN SUB-ASSEMBLY
14. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
15. INSTALL WATER INLET
16. INSTALL CRANKSHAFT PULLEY
17. INSTALL WATER HOSE JOINT
18. INSTALL NO. 2 SURGE TANK STAY
19. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
20. INSTALL INJECTOR DRIVER
21. INSTALL WATER PUMP PULLEY
22. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
23. INSTALL ENGINE MOUNTING BRACKET LH
24. INSTALL ENGINE MOUNTING BRACKET RH
25. CONNECT COOLER COMPRESSOR ASSEMBLY
26. INSTALL NO. 1 ENGINE COVER
27. INSTALL NO. 2 ENGINE COVER
28. INSTALL FAN AND GENERATOR V BELT
29. INSTALL ENGINE WIRE
30. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
31. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
32. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY
33. REMOVE ENGINE STAND
34. INSTALL ENGINE ASSEMBLY
(a) Install the engine.

35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
36. PERFORM INITIALIZATION
(a) Perform initialization

NOTICE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.

37. CHARGE REFRIGERANT
38. CHECK FOR FUEL LEAKS
39. CHECK FOR ENGINE COOLANT LEAKS
40. CHECK FOR ENGINE OIL LEAKS
41. CHECK FOR EXHAUST GAS LEAKS
42. CHECK FOR LEAKAGE OF REFRIGERANT
43. ADJUST SHIFT LEVER POSITION
44. CHECK SHIFT LEVER POSITION
45. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
(a) Check and adjust the front wheel alignment.

46. CHECK IGNITION TIMING
47. CHECK IDLE SPEED
48. CHECK CO/HC
49. CHECK ENGINE OIL LEVEL