Oil Pump ASSY: Replacement

1. Remove the bolt holding the guide to the LH cylinder head.
2. Pull out the guide together with the level gage from the oil pan.
3. Remove the O-ring from the guide.

1. Remove the 4 bolts and sensor.
2. Remove the gasket from the sensor.

1. Disconnect the 2 water by-pass hoses from the oil cooler.
2. Disconnect the oil pressure switch connector.
3. Remove the stud bolt, 2 nuts and the filter bracket together oil filter and oil cooler assembly.
4. Remove the gasket from the filter bracket.

1. Disconnect the sensor connector.
2. Remove the bolt and sensor.
   Fig 2: Cutting Through Sealer And Removing Oil Pan

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 13 bolts and 2 nuts.
2. Insert the blade of SST between the oil pan No.1 and oil pan No.2, cut through the sealer and remove the oil pan No.2.

   SST 09032-00100

Remove the 4 bolts, 2 nuts and baffle plate.

Fig 3: Locating Oil Pan Baffle Plate Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 18 bolts and 2 nuts.
   Fig 4: Locating Oil Pan Sub-Assy Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan.

Fig 5: Removing Oil Pan Using Screwdriver

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt, 2 nuts, oil strainer and gasket.
   Fig 6: Removing Bolt Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 8 bolts.

   HINT:

   Use a 6 mm hexagon wrench for the hexagon head bolt.

2. Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block.
3. Remove the O-ring from the cylinder block.
   Fig 7: Removing O-Ring From Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, pry out the seal.

HINT:

Tape the screwdriver tip.

Fig 8: Prying Out Seal Using Screwdriver

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1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
   NOTE: Be careful not to tap the oil seal in at an angle.
2. Apply a small amount of MP grease to the oil seal lip.
   Fig 9: Taping In Oil Seal Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply seal packing to the oil pump as shown in the illustration.

   Seal packing: Part No. 08226-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pump within 3 minutes after applying seal packing.
   • Do not put into engine oil for at least 2 hours after installing.
   Fig 10: Applying Seal Packing To Oil Pump

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply engine oil to the O-ring.
3. Install a new O-ring on the cylinder block.
4. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.
   Fig 11: Install O-Ring On Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the oil pump with the 8 bolts. Uniformly tighten the bolts in several passes.

   Torque: 

   15.5 N.m (160 kgf.cm, 11 ft.lbf) for 12 mm head (A, C), stud bolt (B) and 6 mm hexagon head (E) 

   30.5 N.m (310 kgf.cm, 22 ft.lbf) for 14 mm head (D) 

   HINT:

   • Use a 6 mm hexagon wrench for the hexagon head bolt.
   • Each bolt length is indicated below.

   Bolt length:

   50 mm (1.97 in.) for A of 12 mm head

   106 mm (4.17 in.) for B of 12 mm head

   30 mm (1.18 in.) for C of 12 mm head

   44 mm (1.73 in.) for D of 14 mm head

   28 mm (1.10 in.) for E of 6 mm hexagon head

   NOTE: Do not reuse the stud bolt (B).
   Fig 12: Installing Oil Pump

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL OIL STRAINER SUB-ASSY 
   1. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

      Torque: 7.5 N.m (76 kgf.cm, 66 in. lbf) 

      HINT:

      Use a bolt that is 12 mm (0.47 in.) in length.

      Fig 13: Installing Gasket And Oil Strainer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL OIL PAN SUB-ASSY 
   1. Apply seal packing to the oil pan as shown in the illustration.

      Seal packing: Part No. 08226-00080 or equivalent 

      NOTE:

      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not put into engine oil for at least 2 hours after installing.
      • Remove any oil from the contact surface.
      Fig 14: Identifying Seal Packing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 15: Installing Oil Pump Bolt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Temporarily install the oil pan with the 18 bolts and 2 nuts.

      HINT:

      Each bolt length is indicated in the illustration.

      Bolt length:

      A: 20 mm (0.79 in.) of 10 mm head

      B: 35 mm (1.38 in.) of 10 mm head

      C: 60 mm (2.36 in.) of 12 mm head

      D: 25 mm (0.98 in.) of 12 mm head

   3. Set the No.1 oil pan as shown in the illustration.
      NOTE: Make sure the clearance between the rear ends of the No.1 oil pan and cylinder block is 0.2 mm (0.008 in.) or less. If the clearance is more than 0.2 mm (0.008 in.), the No.1 oil pan will deform when tightening the bolts, stud bolts and nuts.
   4. Uniformly tighten the bolts, stud bolts and nuts in several passes.

      Torque: 

      7.5 N.m (76 kgf.cm, 66 in. lbf) for 10 mm head 

      28 N.m (286 kgf.cm, 21 ft.lbf) for 12 mm head 

8. INSTALL OIL PAN BAFFLE PLATE 
   1. Install the baffle plate with the 4 bolts and 2 nuts

      Torque: 7.5 N.m (76 kgf.cm, 66 in. lbf) 

      Fig 16: Installing Oil Pan Baffle Plate

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSTALL OIL PAN SUB-ASSY NO.2 
   1. Apply seal packing to the oil pan as shown in the illustration.

      Seal packing: Part No. 08226-00080 or equivalent 

      NOTE:

      • Remove any oil from the contact surface.
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not put into engine oil for at least 2 hours after installing.
   2. Install oil pan with the 13 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

      Torque: 7.5 N.m (76 kgf.cm, 66 in. lbf) 

      Fig 17: Installing Oil Pan Sub-Assy No.2

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL ENGINE OIL LEVEL SENSOR 
    1. Install a new gasket to the sensor as shown in the illustration.
    2. Install the sensor with the 4 bolts.

       Torque: 6.9 N.m (70 kgf.cm, 61 in. lbf) 

       HINT:

       Use a bolt that is 16 mm (0.63 in.) in length.

       Fig 18: Identifying Engine Oil Level Sensor

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Install the sensor with the bolt.

       Torque: 6.5 N.m (65 kgf.cm, 58 in. lbf) 

       HINT:

       Use bolt that is 17 mm (0.67 in.) in length.

    2. Connect the sensor connector.
12. INSTALL OIL FILTER BRACKET SUB-ASSY 
    1. Install a new gasket to the filter bracket.
    2. Install the filter bracket, oil filter and oil cooler assembly with the stud bolt and 2 nuts.

       Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    3. Connect the oil pressure switch connector.
    4. Connect the 2 water by-pass hoses to the oil cooler.
13. INSTALL OIL LEVEL GAGE GUIDE 
    1. Install a new O-ring to the gage guide.
    2. Apply soapy water to the O-ring.
    3. Push in the gage guide end into the guide hole of the No. 1 oil pan.
    4. Install the gage guide with the bolt.

       Torque: 15 N.m (153 kgf.cm, 133 in. lbf) 

    5. Install the gage.
       Fig 19: Installing O-Ring To Gage Guide

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. INSTALL CRANKSHAFT TIMING PULLEY (See  OVERHAUL  ) 
15. INSTALL TIMING BELT IDLER SUB-ASSY NO.1 (See  OVERHAUL  ) 
16. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 (See  OVERHAUL  ) 
17. INSTALL TIMING BELT (See  REPLACEMENT  ) 
18. REMOVE ENGINE STAND 
19. ASSEMBLE ENGINE AND TRANSMISSION (See  REPLACEMENT  ) 
20. INSTALL ENGINE AND TRANSMISSION ASSEMBLY TO VEHICLE (See  REPLACEMENT  )