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Oil Pump Assembly: Replacement

  1. Remove front wheel RH.
  2. Remove front fender apron seal RH.
  3. Remove engine under cover No. 1.
  4. Drain engine oil.
    1. Install a new gasket after draining engine oil.

      Torque  : 45 N.m (459 kgf.cm, 33 ft.lbf)

  5. Remove front suspension upper brace center (w/front suspension brace upper center).
  6. Remove V belt No. 1 (A/C compressor to crankshaft pulley).

    See SPECIFICATIONS & DRIVE BELT ROUTING .

  7. Remove vane pump V belt.

    See SPECIFICATIONS & DRIVE BELT ROUTING .

  8. Remove engine moving control rod.

    See ENGINE .

  9. Remove engine mounting stay No. 2 RH.

    See ENGINE .

  10. Remove generator bracket No. 2.
  11. Remove crankshaft pulley.

    See REMOVAL (ES 300) .

    SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030)

  12. Remove timing belt No. 1 cover.
  13. Remove timing belt No. 2 cover.

    See REMOVAL (ES 300) .

  14. Remove transverse engine mounting bracket.
  15. Remove timing belt guide No. 2.
  16. Remove timing belt.

    See REMOVAL (ES 300) .

  17. Remove exhaust pipe No. 1 support bracket.

    See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .

  18. Remove exhaust pipe assembly front.
  19. Remove exhaust pipe support bracket No. 1.
  20. Separate compressor and magnetic clutch.
    1. Remove the 2 bolts, nut and drive belt adjusting bar bracket.
      Fig 1: Locating Bolts, Nut & Drive Belt For Removal
      G01213430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts, the generator bracket adjusting bar with wire harness clamp bracket.
      Fig 2: Locating Nuts For Removal
      G01213431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the compressor, magnetic clutch connector and the wire harness clamp.
    4. Remove the 3 bolts, the compressor and magnetic clutch.
    NOTE: Hang up the hoses instead of detaching.
    Fig 3: Locating Compressor & Magnetic Clutch Bolts
    G01213432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. Remove timing belt idler sub-assembly No. 2.

    See WATER PUMP ASSEMBLY .

  22. Remove camshaft timing pulley.

    See CAMSHAFT .

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

  23. Remove timing belt idler sub-assembly No. 1
    1. Using a 10 mm socket hexagon wrench, remove the timing belt idler sub-assembly No. 1 and the plate washer.
  24. Remove crankshaft timing pulley.

    See OIL PUMP .

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

  25. Remove timing belt No. 3 cover.
  26. Remove compressor mounting bracket No. 1.
    1. Remove the 2 bolts and compressor mounting bracket No. 1.
    Fig 4: Removing Compressor Mounting Bracket No. 1
    G01213433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. Remove oil level gauge guide.
    1. Remove the bolt and oil level gauge guide.
  28. Separate engine mounting insulator assembly front.
    1. Remove the 3 nuts and a bolt, and separate the engine mounting insulator front.
    Fig 5: Separating Engine Mounting Insulator
    G01213434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. Remove transverse engine mounting insulator.
    1. Remove the bolt and disconnect the power steering return hose clamp from the frame.
    2. Remove the 4 nuts.
    3. Place a wooden block between the jack and engine, and set the jack, then remove the engine mounting insulator.
    4. Handle a jack up to remove the engine mounting insulator RH.
    NOTE: Be careful not to damage the contact surfaces of the oil pan.
    Fig 6: Removing Transverse Engine Mounting Insulator
    G01213435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. Remove transverse engine mounting bracket.
    1. Remove the 4 bolts, nut and bracket.
    Fig 7: Removing Transverse Engine Mounting Bracket
    G01213436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. Remove oil pan sub-assembly No. 2
    1. Remove the 10 bolts and 2 nuts.
      Fig 8: Removing Oil Pan Sub-Assembly No. 2
      G01213437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the oil pan sub-assembly No. 2.

      SST 09032-0010

    NOTE: Be careful not to damage the oil pan No. 2 flange.
    Fig 9: Displaying SST Removal Use
    G01213438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. Remove oil strainer sub-assembly.
    1. Remove the bolt, 2 nuts and oil strainer sub-assembly.
  33. Remove oil pan sub-assembly.
    1. Remove the 17 bolts and 2 nuts.
      Fig 10: Removing Oil Pan Sub-Assembly
      G01213439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan.
    NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
    Fig 11: Prying Portions Between Cylinder Block & Oil Pan
    G01213440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. Remove Crank Position (CKP) sensor.
    1. Disconnect the CKP sensor connector.
    2. Remove the bolt and CKP sensor.
  35. Remove oil pump assembly.
    1. Remove the 9 bolts, O-ring and oil pump.
    Fig 12: Removing Oil Pump
    G01213441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. Install oil pump assembly.
    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 in at an angle.
    2. Apply a small amount of MP grease to the oil seal lip.
      NOTE: Keep the lip off foreign materials.
    3. Apply engine oil to the O-ring.
      Fig 13: Installing Oil Pump
      G01213442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new O-ring on the cylinder block.
      Fig 14: Installing O-Ring To Cylinder Block
      G01213443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply seal packing to the oil pump assembly, as shown in Fig 15.

      Seal Packing  : Part No. 08226-00080 or equivalent.

      Fig 15: Applying Seal Packing To Oil Pump
      G01213444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the oil pump assembly within 3 minutes after applying seal packing.
      • Do not put oil into engine within 2 hours after installing.
    6. 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.
    7. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes.

      Torque  :

      1. 10 mm Head  : 8 N.m (82 kgf.cm, 71 in.lbf)
      2. 12 mm Head  : 20 N.m (199 kgf.cm, 14 ft.lbf)
      3. 14 mm Head  : 43 N.m (439 kgf.cm, 32 ft.lbf)

      Fig 16: Displaying Oil Pump Installation
      G01213445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. Install CKP sensor

    Torque  : 8 N.m (82 kgf.cm, 71 in.lbf)

  38. Install oil pan sub-assembly.
    1. Apply seal packing to the oil pan as shown in Fig 17.

      Seal packing  : Part No. 08226-00080 or equivalent

      Fig 17: Applying Seal Packing To Oil Pan Sub-Assembly
      G01213446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surface.
      • Apply seal packing to the outer side of the bolt hole in the region "X".
      • Apply seal packing to the inner side of the bolt hole in the region "Y".
      • Install the oil pan within 3 minutes after applying seal packing.
      • Do not put oil into engine within 2 hours after installing.
    2. Install the oil pan with the 17 bolts and 2 nuts.

      Torque  :

      1. 10 mm head 8 N.m (82 kgf.cm, 71 in.lbf)
      2. 12 mm head 20 N.m (199 kgf.cm, 14 ft.lbf)

  39. Install oil strainer sub-assembly.
    1. Install a new gasket and the oil strainer with the bolt and 2 nuts.

      Torque  : 8 N.m (82 kgf.cm, 71 in.lbf)

  40. Install oil pan sub-assembly No. 2
    1. Apply seal packing to the oil pan as shown in the illustration.

      Seal packing  : Part No. 08226-00080 or equivalent.

      NOTE: Apply seal packing to the inner side of the bolt hole.
    2. Install oil pan No. 2.

      Torque  : 8 N.m (82 kgf.cm, 71 in.lbf)

    NOTE:
    • Remove any oil from the contact surface.
    • Do not put into engine oil within 2 hours after installing.
    Fig 18: Installing Oil Pan Sub-Assembly No. 2
    G01213447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. Install transverse engine mounting bracket

    Torque  :

    1. Bolt A: 54 N.m (550 kgf.cm, 40 ft.lbf)
    2. Nut B: 54 N.m (550 kgf.cm, 40 ft.lbf)
    3. Bolt C: 43 N.m (439 kgf.cm, 32 ft.lbf)

    Fig 19: Installing Transverse Engine Mounting Bracket
    G01213448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. Install transverse engine mounting insulator.

    Torque  :

    1. Nut A: 95 N.m (969 kgf.cm, 70 ft.lbf)
    2. Nut B: 87 N.m (887 kgf.cm, 64 ft.lbf)

    Fig 20: Installing Transverse Engine Mounting Insulator
    G01213449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. Install engine mounting insulator assembly front.

    Torque  :

    1. Bolt A: 87 N.m (887 kgf.cm, 64 ft.lbf)
    2. Nut B: 52 N.m (531 kgf.cm, 38 ft.lbf)

    Fig 21: Installing Engine Mounting Insulator Assembly Front
    G01213450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. Install oil level gauge guide.
    1. Install a new O-ring, bolt and oil level gauge guide.

      Torque  : 8 N.m (82 kgf.cm, 71 in.lbf)

  45. Install compressor mounting bracket No. 1.

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

  46. Install timing belt No. 3 cover.

    See CAMSHAFT .

  47. Install timing belt idler sub-assembly No. 1.
    1. Using a 10 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt.

      Torque  : 34 N.m (347 kgf.cm, 25 ft.lbf)

  48. Install timing belt idler sub-assembly No. 2

    See WATER PUMP .

  49. Install camshaft timing pulley.

    See CAMSHAFT .

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

  50. Install compressor and magnetic clutch.

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

  51. Install exhaust pipe support bracket No. 1.

    See ENGINE .

  52. Install exhaust pipe assembly front.

    See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .

  53. Install exhaust pipe No. 1 support bracket.

    See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .

  54. Inspect timing belt.

    See INSTALLATION (ES 300) .

  55. Install timing belt.

    See TIMING BELT .

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

  56. Install chain tensioner assembly No. 1.

    See INSTALLATION (ES 300) .

  57. Install timing belt guide No. 2.
  58. Install transverse engine mounting bracket.
  59. Install timing belt No. 2 cover.

    See INSTALLATION (ES 300) .

  60. Install timing belt No. 1 cover.

    See INSTALLATION (ES 300) .

  61. Install crankshaft pulley.

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

  62. Install generator bracket No. 2.

    Torque  : 28 N.m (286 kgf.cm, 21 in.lbf)

  63. Install engine mounting stay No. 2 RH.

    See ENGINE .

  64. Install engine moving control rod.

    See ENGINE .

  65. Install vane pump V belt.

    See SPECIFICATIONS & DRIVE BELT ROUTING .

  66. Install V belt No. 1 (cooler compressor to crankshaft pulley).

    See SPECIFICATIONS & DRIVE BELT ROUTING .

  67. Inspect drive belt deflection and tension (reference). See ENGINE .
  68. Install front suspension upper brace center (w/front suspension brace upper center).

    Torque  : 80 N.m (816 kgf.cm, 59 ft.lbf)

  69. Add engine oil.
  70. Inspect oil leak.
  71. Install front wheel RH.

    Torque  : 103 N.m (1051 kgf.cm, 76 ft.lbf)

  72. Check exhaust gas leak.
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