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Oil Pump ASSY: Replacement

  1. REMOVE ENGINE W/ TRANSMISSION ASSEMBLY (See  REPLACEMENT  ) 
  2. REMOVE TIMING BELT (See  TIMING BELT  ) 
  3. REMOVE CRANKSHAFT TIMING PULLEY (See  OVERHAUL  ) 
  4. REMOVE OIL DIPSTICK AND GUIDE 
  5. REMOVE ENGINE OIL LEVEL SENSOR 
  6. REMOVE OIL FILTER SUB-ASSY 
  7. REMOVE OIL FILTER BRACKET SUB-ASSY 
    1. Disconnect the oil pressure switch connector.
    2. Remove the stud bolt, 2 nuts, oil filter bracket and gasket.
  8. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Disconnect the sensor connector.
    2. Remove the bolt and sensor.
  9. REMOVE OIL PAN SUB-ASSY NO. 2 
    1. Remove the 12 bolts and 2 nuts.
    2. Insert the blade of SST between the No. 1 and No. 2 oil pans, cut through the sealer and remove the No. 2 oil pan.

      SST 09032-00100

      NOTE: Be careful not to damage the contact surface of the oil pans.
      Fig 1: Removing Oil Pan Sub-Assy No. 2
      G02958940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE OIL PAN BAFFLE PLATE 
    1. Remove the 3 bolts, 2 nuts and baffle plate.
      Fig 2: Removing Oil Pan Baffle Plate
      G02958941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE OIL PAN SUB-ASSY 
    1. Remove the 17 bolts, 2 nuts and oil pan.
      Fig 3: Removing Oil Pan Nuts & Bolts
      G02958942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the oil pan by prying the areas between the cylinder block and oil pan.
      NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
      Fig 4: Removing Oil Pan By Prying Areas Between Cylinder Block & Oil Pan Using Screwdriver
      G02958943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE OIL STRAINER SUB-ASSY 
    1. Remove the bolt, 2 nuts, oil strainer and gasket.
  13. REMOVE OIL PUMP ASSY 
    1. Remove the stud bolt and 7 bolts.

      HINT:

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

      Fig 5: Removing Oil Pump Bolts
      G02958944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the oil pump by prying the areas between the oil pump and cylinder block.
      Fig 6: Removing Oil Pump By Prying Areas Between Oil Pump & Cylinder Block Using Screwdriver
      G02958945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the cylinder block.
  14. REMOVE OIL PUMP SEAL 
    1. Using a screwdriver, pry out the seal.

      HINT:

      Tape the screwdriver tip before use.

      NOTE: To protect the oil pump body while prying out the seal, place a wooden block between the screwdriver and oil pump body.
      Fig 7: Prying Out Oil Pump Seal
      G02958946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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 09316-60011 (09316-00011)

      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 8: Installing Oil Pump Seal
      G02958947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL OIL PUMP ASSY 
    1. Apply seal packing to the oil pump as shown in Fig 9.
      • Seal packing: Part No. 08826-00080 or equivalent 
      • Seal width: 2 to 3 mm (0.08 to 0.12 in) 
      NOTE:
      • Wipe off any oil from the contact surface.
      • Install the oil pump within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil for at least 2 hours after installing.
        Fig 9: Applying Seal Packing To Oil Pump
        G02958948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply engine oil to a new O-ring.
    3. Install the O-ring to the cylinder block.
      Fig 10: Installing O-Ring To Cylinder Block
      G02958949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Attach the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump onto the crankshaft.
    5. Install the oil pump with a new stud bolt and the 7 bolts. Uniformly tighten the bolts in several passes.

      Torque: 

      • 15.5 N.m (153 kgf.cm, 11 ft.lbf) for bolt A, B, C and E 
      • 30.5 N.m (311 kgf.cm, 22 ft.lbf) for bolt D 

      HINT:

      • Use a 6 mm hexagon wrench for the hexagon head bolt.
      • Each bolt length is as shown in BOLT LENGTH SPECIFICATION TABLE .

        Bolt length:

        Fig 11: Installing Oil Pump Stud Bolt & Bolts
        G02958950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        BOLT LENGTH SPECIFICATION TABLE

        Bolt Bolt Head Size Length
        A 12 mm 50 mm (1.97 in.)
        B 12 mm stud bolt 106 mm (4.17 in.)
        C 12 mm 30 mm (1.18 in.)
        D 14 mm 44 mm (1.73 in.)
        E 6 mm hexagon bolt 28 mm (1.10 in.)
        NOTE: Do not reuse the stud bolt B.
  17. INSTALL OIL STRAINER SUB-ASSY 
    1. Install a new gasket and the oil strainer with the bolt and 2 nuts.

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

  18. INSTALL OIL PAN SUB-ASSY 
    1. Apply the seal packing as shown in Fig 12.
      • Seal packing: Part No. 08826-00080 or equivalent 
      • Seal width: 2 to 3 mm (0.08 to 0.12 in) 
      NOTE:
      • Wipe off any oil from the contact surface.
      • Install the oil pump within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil for at least 2 hours after installing.
        Fig 12: Applying Seal Packing
        G02958951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the oil pan with the 17 bolts, stud bolt and 2 nuts.

      HINT:

      Each bolt length is as shown in BOLT LENGTH SPECIFICATION TABLE .

      Bolt length:

      BOLT LENGTH SPECIFICATION TABLE

      Bolt Bolt Head Size Length
      A 10 mm 35 mm (1.35 in.)
      B 12 mm 56 mm (2.20 in.)
    3. Set the oil pan as shown in Fig 13.
      NOTE: Make sure the clearance between the rear end of the 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 oil pan will deform when tightening the bolts and nuts.
    4. Uniformly tighten the bolts and nuts in several passes.

      Torque: 

      • 7.5 N.m (76 kgf.cm, 66 in.lbf) for bolt A and nut 
      • 28 N.m (286 kgf.cm, 21 ft.lbf) for bolt B 
      Fig 13: Installing Oil Pan
      G02958952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL OIL PAN BAFFLE PLATE 
    1. Install the baffle plate with the 3 bolts and 2 nuts.

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

      HINT:

      Each bolt length is as shown in OIL PAN BAFFLE PLATE .

      Bolt length:

      OIL PAN BAFFLE PLATE

      A 12 mm (0.47 in.)
      B 80 mm (3.15 in.)
      Fig 14: Installing Oil Pan Baffle Plate
      G02958953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL OIL PAN SUB-ASSY NO. 2 
    1. Apply seal packing as shown in Fig 15.
      • Seal packing: Part No. 08826-00080 or equivalent 
      • Seal width: 3 to 4 mm (0.12 to 0.16 in) 
      NOTE:
      • Wipe off any oil from the contact surface.
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not expose the seal to engine oil for at least 2 hours after installing.
    2. Install the oil pan with the 12 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

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

      HINT:

      The bolt length is 14 mm (0.55 in.)

      Fig 15: Installing Oil Pan Sub-Assy No. 2
      G02958954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL ENGINE OIL LEVEL SENSOR 
    1. Install a new gasket to the sensor as shown in Fig 16.
    2. Install the oil level sensor with the 4 bolts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

      HINT:

      The bolt length is 16 mm (0.63 in.).

    Fig 16: Installing Engine Oil Level Sensor
    G02958955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Install the sensor with the bolt.

      Torque: 6.5 N.m (66 kgf.cm, 58 in.lbf) 

  23. INSTALL OIL FILTER BRACKET SUB-ASSY 
    1. Install a new O-ring and the oil filter bracket with the stud bolt and 2 nuts.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

    2. Connect the oil pressure switch connector.
  24. INSTALL OIL FILTER SUB-ASSY 
  25. INSTALL OIL DIPSTICK AND GUIDE 
    1. Install a new O-ring to the oil dipstick guide.
    2. Install the guide with the bolt.

      Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

    3. Install the oil dipstick.
      Fig 17: Installing Oil Dipstick & Guide
      G02958956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL CRANKSHAFT TIMING PULLEY (See  OVERHAUL  ) 
  27. INSTALL TIMING BELT (See  TIMING BELT  ) 
  28. INSTALL ENGINE W/ TRANSMISSION ASSEMBLY (See  REPLACEMENT  ) 
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