Oil Pump: Service and Repair

OIL PUMP

COMPONENTS:

REMOVAL
1. REMOVE COOL AIR INTAKE DUCT SEAL
2. REMOVE ENGINE ROOM SIDE COVER LH
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
6. DISCHARGE FUEL SYSTEM PRESSURE
7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
9. REMOVE FRONT WHEEL
10. REMOVE ENGINE UNDER COVER
11. REMOVE NO. 2 ENGINE UNDER COVER
12. REMOVE ENGINE UNDER COVER REAR LH
13. REMOVE ENGINE UNDER COVER REAR RH
14. DRAIN ENGINE OIL
15. DRAIN ENGINE COOLANT
16. REMOVE FRONT EXHAUST PIPE ASSEMBLY
17. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
18. REMOVE NO. 1 AIR CLEANER INLET
19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
21. DISCONNECT UNION TO CHECK VALVE HOSE
22. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE
23. DISCONNECT INLET RADIATOR HOSE
24. DISCONNECT OUTLET RADIATOR HOSE
25. DISCONNECT RADIATOR RESERVOIR TANK HOSE
26. DISCONNECT INLET HEATER WATER HOSE
27. DISCONNECT OUTLET HEATER WATER HOSE
28. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE
29. REMOVE DISCHARGE HOSE SUB-ASSEMBLY
30. REMOVE ECM COVER
31. DISCONNECT ENGINE WIRE
32. DISCONNECT FUEL MAIN TUBE
33. DISCONNECT NO. 3 FUEL HOSE
34. DISCONNECT FUEL TUBE SUB-ASSEMBLY
35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR
36. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY
37. DISCONNECT HEIGHT CONTROL SENSOR LINK
38. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH
39. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH
40. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH
41. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH
42. DISCONNECT POWER STEERING LINK WIRE HARNESS
43. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
44. REMOVE ENGINE AND TRANSMISSION ASSEMBLY
45. INSTALL ENGINE HANGERS
46. REMOVE STARTER ASSEMBLY
47. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
48. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY
49. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
50. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
51. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY
52. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
53. FIX ENGINE ON ENGINE STAND
54. REMOVE V-RIBBED BELT
55. REMOVE NO. 2 ENGINE COVER
56. REMOVE NO. 1 ENGINE COVER
57. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
58. REMOVE GENERATOR ASSEMBLY
59. REMOVE COOLER COMPRESSOR ASSEMBLY
60. REMOVE ENGINE MOUNTING BRACKET LH
61. REMOVE ENGINE MOUNTING BRACKET RH
62. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
63. REMOVE WATER PUMP PULLEY
64. REMOVE ENGINE WIRE
65. REMOVE INJECTOR DRIVER
66. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
67. REMOVE NO. 2 SURGE TANK STAY
68. DISCONNECT WATER HOSE JOINT
69. REMOVE CRANKSHAFT PULLEY
70. REMOVE WATER INLET
71. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
72. REMOVE OIL PAN SUB-ASSEMBLY
73. REMOVE OIL STRAINER SUB-ASSEMBLY
74. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
75. REMOVE NO. 1 FUEL PIPE
76. DISCONNECT NO. 2 FUEL PIPE
77. REMOVE FUEL PUMP ASSEMBLY
78. REMOVE NO. 2 FUEL PIPE
79. REMOVE IGNITION COIL ASSEMBLY
80. REMOVE NO. 1 OIL PIPE
81. REMOVE NO. 2 OIL PIPE
82. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
83. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
84. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

a. Remove the bolt and wiring harness clamp bracket.

b. Remove the 25 bolts and 2 nuts as 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.

85. REMOVE TIMING CHAIN CASE OIL SEAL
a. Using a screwdriver, pry out the oil seal.

HINT: Tape the screwdriver tip before use.

INSTALLATION

1. INSTALL TIMING CHAIN CASE OIL SEAL
a. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST 09223-22010, 09506-35010

NOTICE:
^ Keep the lip free of foreign matter.
^ Do not tap on the oil seal at an angle.
^ Make sure that the oil seal edge does not stick out of the timing chain case.

2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

a. Apply seal packing in a continuous line to the engine unit as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 5.0 to 5.5 mm (0.197 to 0.217 inch)

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 illustration.
Seal packing: 08826-00080 or equivalent 08826-00100 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:

c. Install a new gasket.

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. Fully tighten the 3 bolts as shown in the illustration.
Torque:
43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt A
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolts except A

g. Fully tighten the 3 bolts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

h. Fully tighten the 7 bolts and 2 nuts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

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 Nm (214 kgf-cm, 15 ft. lbs.)

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

j. Install the bolt and wiring harness bracket.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
5. INSTALL NO. 2 OIL PIPE
6. INSTALL NO. 1 OIL PIPE
7. INSTALL IGNITION COIL ASSEMBLY
8. INSTALL NO. 2 FUEL PIPE
9. INSTALL FUEL PUMP ASSEMBLY
10. CONNECT NO. 2 FUEL PIPE
11. INSTALL NO. 1 FUEL PIPE
12. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
13. INSTALL OIL STRAINER SUB-ASSEMBLY
14. INSTALL OIL PAN SUB-ASSEMBLY
15. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
16. INSTALL WATER INLET
17. INSTALL CRANKSHAFT PULLEY
18. INSTALL WATER HOSE JOINT
19. INSTALL NO. 2 SURGE TANK STAY
20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
21. INSTALL INJECTOR DRIVER
22. INSTALL ENGINE WIRE
23. INSTALL WATER PUMP PULLEY
24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
25. INSTALL ENGINE MOUNTING BRACKET LH
26. INSTALL ENGINE MOUNTING BRACKET RH
27. CONNECT COOLER COMPRESSOR ASSEMBLY
28. INSTALL GENERATOR ASSEMBLY
29. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
30. INSTALL NO. 1 ENGINE COVER
31. INSTALL NO. 2 ENGINE COVER
32. INSTALL V-RIBBED BELT
33. INSTALL ENGINE HANGERS
34. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY
35. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
36. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
37. INSTALL STARTER ASSEMBLY
38. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
39. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
40. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY
41. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
42. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
43. CONNECT POWER STEERING LINK WIRE HARNESS
44. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH
45. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH
46. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH
47. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH
48. CONNECT HEIGHT CONTROL SENSOR LINK
49. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY
50. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR
51. CONNECT FUEL TUBE SUB-ASSEMBLY
52. CONNECT NO. 3 FUEL HOSE
53. CONNECT FUEL MAIN TUBE
54. CONNECT ENGINE WIRE
55. INSTALL ECM COVER
56. CONNECT DISCHARGE HOSE SUB-ASSEMBLY
57. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
58. CONNECT INLET HEATER WATER HOSE
59. CONNECT OUTLET HEATER WATER HOSE
60. CONNECT INLET RADIATOR HOSE
61. CONNECT OUTLET RADIATOR HOSE
62. CONNECT RADIATOR RESERVOIR TANK HOSE
63. CONNECT NO. 2 FUEL VAPOR FEED HOSE
64. CONNECT UNION TO CHECK VALVE HOSE
65. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
66. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
67. INSTALL NO. 1 INLET AIR CLEANER
68. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
69. INSTALL FRONT EXHAUST PIPE ASSEMBLY
70. ADD ENGINE OIL
71. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
72. ADD ENGINE COOLANT
73. CHARGE REFRIGERANT
74. CHECK FOR FUEL LEAKS
75. CHECK FOR ENGINE COOLANT LEAKS
76. CHECK FOR ENGINE OIL LEAKS
77. CHECK FOR EXHAUST GAS LEAKS
78. CHECK FOR LEAKAGE OF REFRIGERANT
79. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
80. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
81. ADJUST SHIFT LEVER POSITION
82. CHECK SHIFT LEVER POSITION
83. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
84. CHECK IGNITION TIMING
85. CHECK IDLE SPEED
86. CHECK CO/HC
87. CHECK ENGINE OIL LEVEL
88. INSTALL ENGINE UNDER COVER REAR LH
89. INSTALL ENGINE UNDER COVER REAR RH
90. INSTALL NO. 2 ENGINE UNDER COVER
91. INSTALL ENGINE UNDER COVER
92. INSTALL V-BANK COVER SUB-ASSEMBLY
93. INSTALL ENGINE ROOM SIDE COVER LH
94. INSTALL ENGINE ROOM COVER SIDE RH
95. INSTALL COOL AIR INTAKE DUCT SEAL
96. PERFORM INITIALIZATION

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