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Oil Pump ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
  1. DRAIN ENGINE OIL (See  OIL FILTER SUB-ASSY   ) 
  2. REMOVE FRONT WHEEL RH 
  3. REMOVE FRONT WIPER ARM HEAD CAP 
  4. REMOVE FR WIPER ARM RH (See  REPLACEMENT  ) 
  5. REMOVE FR WIPER ARM LH (See  REPLACEMENT  ) 
  6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See  REPLACEMENT  ) 
  7. REMOVE WIPER LINK ASSY (See  REPLACEMENT  ) 
  8. REMOVE COWL TOP TO COWL BRACE INNER NO. 1 (See  REPLACEMENT  ) 
  9. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (See  REPLACEMENT  ) 
  10. REMOVE FRONT FENDER APRON SEAL RH 
  11. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See  REPLACEMENT  ) 
  12. REMOVE GENERATOR ASSY (See  REPLACEMENT  ) 
  13. REMOVE VANE PUMP V BELT (See  REPLACEMENT  ) 
  14. REMOVE ENGINE MOVING CONTROL ROD (See  TIMING BELT  ) 
  15. REMOVE ENGINE MOUNTING STAY NO. 2 RH (See  TIMING BELT  ) 
  16. REMOVE GENERATOR BRACKET NO. 2 (See  TIMING BELT  ) 
  17. REMOVE CRANKSHAFT PULLEY (See  TIMING BELT  ) 

    SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)

  18. REMOVE TIMING BELT NO. 1 COVER 
  19. REMOVE TIMING BELT NO. 2 COVER (See  TIMING BELT  ) 
  20. REMOVE ENGINE MOUNTING BRACKET RH (See  TIMING BELT  ) 
  21. REMOVE TIMING BELT GUIDE NO. 2 
  22. REMOVE TIMING BELT (See  TIMING BELT  ) 
  23. REMOVE TIMING BELT IDLER SUB-ASSY NO. 2 
  24. REMOVE CAMSHAFT TIMING PULLEY (See  REPLACEMENT  ) 

    SST 09960-10010 (09962-01000, 09963-01000), 09249-63010

  25. REMOVE TIMING BELT NO. 3 COVER (See  REPLACEMENT  ) 
  26. REMOVE TIMING BELT IDLER SUB-ASSY NO. 1 (See  REPLACEMENT  ) 
  27. REMOVE CRANKSHAFT TIMING PULLEY (See  OIL PUMP SEAL  ) 

    SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)

  28. REMOVE EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE) (See  EXHAUST PIPE ASSEMBLY (4WD)  ) 
  29. REMOVE EXHAUST PIPE ASSY FRONT (2WD DRIVE TYPE) (See  EXHAUST PIPE ASSEMBLY (2WD)  ) 
  30. REMOVE EXHAUST PIPE ASSY FRONT (4WD DRIVE TYPE) (See  EXHAUST PIPE ASSEMBLY (4WD)  ) 
  31. REMOVE MANIFOLD CONVERTER INSULATOR NO. 3 (See  REPLACEMENT  ) 
  32. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2 (See  REPLACEMENT  ) 
  33. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO. 2 (See  REPLACEMENT  ) 
  34. REMOVE OIL LEVEL GAGE GUIDE (See  REPLACEMENT  ) 
  35. REMOVE GENERATOR BELT ADJUSTING BAR 
    1. Remove the 2 bolts, the 2 nuts and the adjusting bar.
    Fig 1: Removing 2 Bolts, 2 Nuts And Adjusting Bar
    G02608790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH 
    1. Disconnect the compressor connector.
    2. Remove the 4 bolts, the adjusting bar bracket and the compressor.

    HINT:

    The hoses are off to the side instead of detaching.

    Fig 2: Removing Adjusting Bar Bracket
    G02608791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1 
    1. Remove the 2 bolts and the compressor mounting bracket No. 1.
    Fig 3: Removing Compressor Mounting Bracket No. 1
    G02608792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. SEPARATE ENGINE MOUNTING INSULATOR RR (4WD DRIVE TYPE) 
    1. Remove the 2 nuts and disconnect the engine mounting insulator RR.
    Fig 4: Disconnecting Engine Mounting Insulator RR
    G02608793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. SEPARATE ENGINE MOUNTING INSULATOR FR 
    1. Remove the 4 nuts and separate the engine mounting insulator FR.
    NOTE: Do not remove the engine mounting insulator FR.
  40. REMOVE ENGINE MOUNTING INSULATOR RH 
    1. Remove the bolt and disconnect the power steering return hose cramp from the frame.
      Fig 5: Removing Engine Mounting Insulator FR
      G02608794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts.
    3. Place a wooden block on a jack underneath the engine.
    4. Jack-up the engine and remove the engine mounting insulator RH.
    NOTE: Be careful not to damage the oil pan.
    Fig 6: Removing Engine Mounting Insulator RH
    G02608795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 4 bolts, the nut and the bracket.
    Fig 7: Removing Nut And Bracket
    G02608796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE OIL PAN SUB-ASSY NO. 2 
    1. Remove the 10 bolts and the 2 nuts.
      Fig 8: Removing Oil Pan Bolts
      G02608797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of SST between oil pan No.1 and oil pan No.2, cut off the sealer and remove the oil pan No.2.

      SST 09032-00100

    NOTE:
    • Be careful not to damage the contact surface of oil pan No. 1 where oil pan No. 2 is mounting.
    • Do not damage flange portion of oil pan No. 2 when removing.
    Fig 9: Inserting Blade Of SST Between Oil Pan No. 1 And Oil Pan No. 2
    G02608798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE OIL STRAINER SUB-ASSY 
    1. Remove the bolt, the 2 nuts, the oil strainer and the gasket.
  44. REMOVE OIL PAN SUB-ASSY 
    1. Remove the 2 bolts and the flywheel housing under cover.
      Fig 10: Removing Flywheel Housing Under Cover
      G02608799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen and remove the 17 bolts and the 2 nuts uniformly.
      Fig 11: Removing 17 Bolts And 2 Nuts
      G02608800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.
    NOTE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.
    Fig 12: Removing Oil Pan
    G02608801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Disconnect the crankshaft position sensor connector.
    2. Remove the bolt and the crankshaft position sensor.
  46. REMOVE OIL PUMP ASSY 
    1. Remove the 9 bolts.
    2. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.
    3. Remove the O-ring.
    Fig 13: Removing Oil Pump Bolts
    G02608802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL OIL PUMP SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.

      SST 09223-00010

      NOTE:
      • Be careful not to tap the oil seal at an angle.
      • Keep the lip free of foreign objects.
    2. Apply MP grease to the oil seal lip.
  48. INSTALL OIL PUMP ASSY 
    1. Remove any old seal packing material from the contact surface.
      Fig 14: Installing Oil Pump Seal
      G02608803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.
      Fig 15: Identifying Oil Pump Seal
      G02608804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown.

      Seal packing: Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from contact surface.
      • Apply seal packing to the inner side of the bolt holes.
      • Install the oil pump within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
      Fig 16: Applying Continuous Bead Of Seal Packing
      G02608805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.
      Fig 17: Aligning Key Of Oil Pump Drive Gear With Keyway
      G02608806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.

      Torque: 

      Bolt A 8.0 N.m (82 kgf.cm, 71 in.lbf) 

      Bolt B 20 N.m (199 kgf.cm, 14 ft.lbf) 

      Bolt C 43 N.m (439 kgf.cm, 32 ft.lbf) 

    Fig 18: Installing Oil Pump With 9 Bolts
    G02608807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL CRANKSHAFT POSITION SENSOR 

    Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) 

  50. INSTALL OIL PAN SUB-ASSY 
    1. Remove any old seal packing from the contact surface.
    2. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown. See Fig 19.

      Seal packing: Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Apply seal packing to the outer side of the bolt holes in the region "X".
      • Apply seal packing to the inner side of the bolt holes in the region "Y".
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
    3. Install the oil pan No.1 with the 17 bolts and the 2 nuts. Tighten the bolts uniformly in several steps.

      Torque: 

      10 mm head 8.0 N.m (82 kgf.cm, 71 in.lbf) 

      12 mm head 20 N.m (199 kgf.cm, 14 ft.lbf) 

      14 mm head 37 N.m (379 kgf.cm, 27 ft.lbf) 

    4. Install the flywheel housing under cover with the 2 bolts.

      Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 

    Fig 19: Applying Continuous Bead Of Seal Packing (1 Of 2)
    G02608808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL OIL STRAINER SUB-ASSY 
    1. Install a new gasket and the oil strainer with the bolt and the 2 nuts.

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

  52. INSTALL OIL PAN SUB-ASSY NO. 2 
    1. Remove any old seal packing from the contact surface.
    2. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown.

      Seal packing: Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Apply seal packing to the inner side of the bolt holes.
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil within 2 hours after installing.
      Fig 20: Applying Continuous Bead Of Seal Packing
      G02608809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil pan No. 2 with the 10 bolts and the 2 nuts.

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

  53. INSTALL ENGINE MOUNTING BRACKET RH 

    Torque: 

    Bolt A 54 N.m (551 kgf.cm, 40 ft.lbf) 

    Nut B 54 N.m (551 kgf.cm, 40 ft.lbf) 

    Bolt C 44 N.m (449 kgf.cm, 32 ft.lbf) 

    Fig 21: Installing Engine Mounting Bracket RH
    G02608810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL ENGINE MOUNTING INSULATOR RH 

    Torque: 

    Nut A 95 N.m (969 kgf.cm, 70 ft.lbf) 

    Nut B 87 N.m (887 kgf.cm, 64 ft.lbf) 

    Fig 22: Installing Engine Mounting Insulator RH
    G02608811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL ENGINE MOUNTING INSULATOR FR 

    Torque: 

    Nut A 87 N.m (887 kgf.cm, 64 ft.lbf) 

    Nut B 52 N.m (530 kgf.cm, 38 ft.lbf) 

    Fig 23: Installing Engine Mounting Insulator FR
    G02608812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL ENGINE MOUNTING INSULATOR RR (4WD DRIVE TYPE) 

    Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

    Fig 24: Installing Engine Mounting Insulator RR
    G02608813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1 

    Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

  58. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 
    1. Install the compressor and the adjusting bar bracket with the 4 bolts.

      Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

    Fig 25: Installing Compressor And Adjusting Bar Bracket
    G02608814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL GENERATOR BELT ADJUSTING BAR 
    1. Install the adjusting bar with the 2 bolts and the 2 nuts.

      Torque: 

      Nut A 43 N.m (438 kgf.cm, 32 ft.lbf) 

      Bolt B 18 N.m (184 kgf.cm, 13 ft.lbf) 

      Bolt C 8.4 N.m (85 kgf.cm, 74 in.lbf) 

    Fig 26: Installing Adjusting Bar
    G02608815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL OIL LEVEL GAGE GUIDE (See  REPLACEMENT  ) 
  61. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO. 2 (See  REPLACEMENT  ) 
  62. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2 (See  REPLACEMENT  ) 
  63. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3 (See  REPLACEMENT  ) 
  64. INSTALL EXHAUST PIPE ASSY FRONT (2WD DRIVE TYPE) (See  EXHAUST PIPE ASSEMBLY (2WD)  ) 
  65. INSTALL EXHAUST PIPE ASSY FRONT (4WD DRIVE TYPE) (See  EXHAUST PIPE ASSEMBLY (4WD)  ) 
  66. INSTALL EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE) (See  EXHAUST PIPE ASSEMBLY (4WD)  ) 
  67. INSTALL CRANKSHAFT TIMING PULLEY (See  OIL PUMP SEAL  ) 
  68. INSTALL TIMING BELT IDLER SUB-ASSY NO. 1 (See  REPLACEMENT  ) 
  69. INSTALL TIMING BELT NO. 3 COVER (See  REPLACEMENT  ) 
  70. INSTALL CAMSHAFT TIMING PULLEY (See  REPLACEMENT  ) 

    SST 09960-10010 (09962-01000, 09963-01000), 09249-63010

  71. INSTALL TIMING BELT IDLER SUB-ASSY NO. 2 (See  REPLACEMENT  ) 
  72. INSPECT TIMING BELT (See  TIMING BELT  ) 
  73. INSTALL TIMING BELT (See  TIMING BELT  ) 

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

  74. INSTALL CHAIN TENSIONER ASSY NO. 1 (See  TIMING BELT  ) 
  75. INSTALL TIMING BELT GUIDE NO. 2 (See  TIMING BELT  ) 
  76. INSTALL ENGINE MOUNTING BRACKET RH (See  TIMING BELT  ) 
  77. INSTALL TIMING BELT NO. 2 COVER (See  TIMING BELT  ) 
  78. INSTALL TIMING BELT NO. 1 COVER (See  TIMING BELT  ) 
  79. INSTALL CRANKSHAFT PULLEY (See  TIMING BELT  ) 

    SST 09213-54015 (91651-60855), 09330-00021

  80. INSTALL GENERATOR BRACKET NO. 2 (See  TIMING BELT  ) 
  81. INSTALL ENGINE MOUNTING STAY NO. 2 RH (See  TIMING BELT  ) 
  82. INSTALL ENGINE MOVING CONTROL ROD (See  TIMING BELT  ) 
  83. INSTALL VANE PUMP V BELT (See  REPLACEMENT  ) 
  84. INSTALL GENERATOR ASSY (See  REPLACEMENT  ) 
  85. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See  REPLACEMENT  ) 
  86. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE) (See  INSPECTION  ) 
  87. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT (See  REPLACEMENT  ) 
  88. INSTALL COWL TOP TO COWL BRACE INNER NO. 1 (See  REPLACEMENT  ) 
  89. INSTALL WIPER LINK ASSY (See  REPLACEMENT  ) 
  90. INSTALL FR WIPER ARM LH (See  REPLACEMENT  ) 
  91. INSTALL FR WIPER ARM RH (See  REPLACEMENT  ) 
  92. INSTALL FRONT WHEEL RH (See  REPLACEMENT  ) 
  93. ADD ENGINE OIL (See  OIL FILTER SUB-ASSY  ) 
  94. CHECK FOR ENGINE OIL LEAKS 
  95. CHECK FOR EXHAUST GAS LEAKS 
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