Oil Pump: Installation

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-residue solvent, clean both sealing surfaces.
2. Apply seal packing to the oil pump as shown.

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE: Avoid applying an excessive amount to the surface. Be particularly careful near oil passage.
   Fig 1: Applying Seal Packing To Oil Pump

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Install a nozzle that has been cut to a 2 -- 3 mm (0.08 -- 0.12 in.) opening.
   • Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
   • Immediately remove nozzle from the tube and reinstall cap.
3. Install a new O-ring to 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 2: Installing Oil Pump

   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 and 6 mm hexagon head 

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

   HINT:

   • Use a 6 mm hexagon wrench for the hexagon head bolt.
   • Each bolt length is indicated in Fig 3 .

   Bolt length:

   35 mm (1.38 in.) for A of 12 mm head

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

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

   40 mm (1.57 in.) for D of 14 mm head

   30 mm (1.18 in.) for E of 6 mm hexagon head

   Fig 3: Identifying Oil Pump Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

HINT:

Use bolt 12 mm (0.47 in.) in length.

Fig 4: Locating Oil Strainer Nuts & Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No.1 oil pan, cylinder block, oil pump and rear oil seal retainer.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-residue solvent, clean both sealing surfaces.
2. Apply seal packing to the No.1 oil pan as shown.

   Seal packing: Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to a 2 -- 3 mm (0.08 -- 0.12 in.) opening.
   • Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
   • Immediately remove nozzle from the tube and reinstall cap.
     Fig 5: Applying Seal Packing To No.1 Oil Pan

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the No.1 oil pan with the 19 bolts, stud bolt and 2 nuts.

   HINT:

   Each bolt length is indicated in Fig 6 .

   Bolt length:

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

   25 mm (0.98 in.) for B of 12 mm head

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

   35 mm (1.38 in.) for D of 10 mm head

   Fig 6: Identifying No.1 Oil Pan Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Set the No.1 oil pan as shown.
   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 be stretched.
5. Uniformly tighten the bolts, and nuts in several passes.

   Torque: 

   7.5 N.m (80 kgf.cm, 66 in.lbf) for 10 mm head 

   28 N.m (290 kgf.cm, 21 ft.lbf) for 12 mm head 

Install the baffle plate with the 4 bolts and 2 nuts.

Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

HINT:

Use bolts 12 mm (0.55 in.) in length.

Fig 7: Locating Oil Pan Baffle Plate Nuts & Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No.1 and No.2 oil pans.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-residue solvent, clean both sealing surfaces.
   NOTE: Do not use a solvent which will affect the painted surfaces.
2. Apply seal packing to the No. 2 oil pan as shown.

   Seal packing: Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to a 3 -- 4 mm (0.12 -- 0.16 in.) opening.
     Fig 8: Applying Seal Packing To No. 2 Oil Pan

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
   • Immediately remove nozzle from the tube and reinstall cap.
3. Install the No.2 oil pan with the 20 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

   Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

   HINT:

   Use bolts 14 mm (0.55 in.) in length.

1. Install the a new gasket to the oil filter bracket.
2. Install the oil filter, oil cooler and filter bracket assembly with the 2 bolts and nut.

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

3. Connect the oil pressure switch connector.

1. Install a new O-ring to the dipstick guide.
2. Apply soapy water to the O-ring.
3. Push in the dipstick guide end into the guide hole of the No.1 oil pan.
4. Install the dipstick guide with the bolt.

   Torque: 15 N.m, (155 kgf.cm, 11 ft.lbf) 

   Fig 9: Locating Oil Dipstick Guide Bolt & O-ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the dipstick.