OIL PUMP (w/ DPF) INSTALLATION

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old seal packing (FIPG material).

    2. A01BHUXE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF
      *1 Seal Packing

      Apply seal packing to the timing gear case as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note

      After applying seal packing, install the timing gear case assembly within 3 minutes and tighten the bolts within 15 minutes.

    3. A01BHVHE04
      Text in Illustration
      *1 New Gasket

      Install a new gasket to the groove of the timing gear case.

    4. Install 2 new O-rings.

    5. A01BDDTE01

      Align the "2" marks of the No. 1 balanceshaft driven gear and oil pump drive gear.

    6. Align the mark on the oil pump drive gear with the mark on the timing gear case.

    7. A01BBZS

      w/ DPF:

      Install the timing gear case with the union bolt and 8 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for union bolt
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      Text in Illustration
      A01BAZL Bolt A
      A01BE9I Bolt B
      A01BG19 Union bolt
    8. A01BBNC

      w/o DPF:

      Install the timing gear case with the union bolt and 8 bolts.

      Torque:
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for union bolt
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      Text in Illustration
      A01BAZL Bolt
      A01BE9I Union bolt
    9. A01BFZ0E01

      Remove the screw plug and gasket.

    10. Pour approximately 50 cc (3.05 cu. in.) of engine oil into the oil pump.

    11. Install a new gasket and the screw plug.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  2. INSTALL INJECTION GEAR


    1. Install a new O-ring and the fuel supply pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Temporarily install the injection gear with the nut.

      Tech Tips

      Make sure that the key slot of the injection gear fits over the key (protrusion) of the supply pump.

    3. A01BF3PE01

      Align the "3" marks of the No. 2 balanceshaft driven gear and injection gear.

    4. A01BCCDE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the injection gear.

    5. A01BHW8E01

      Temporarily install the injection gear set nut.

    6. Using SST, tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  3. INSTALL CRANKSHAFT TIMING GEAR


    1. A01BCWFE01

      Position the crankshaft timing gear with the "1" timing marks facing forward.

    2. Align the key groove of the crankshaft timing gear with the set key on the crankshaft.

    3. Using SST and a hammer, tap on the timing gear to install it.

      SST
      09223-00010

  4. INSTALL NO. 1 IDLE GEAR SHAFT


    1. A01BDU4E01
      Text in Illustration
      *1 Engine Oil

      Apply a coat of engine oil to the No. 1 idle gear shaft.

    2. A01BD2SE07
      Text in Illustration
      *1 Oil Hole

      Install the No. 1 gear shaft as shown in the illustration.

  5. INSTALL NO. 1 IDLE GEAR


    1. A01BBEME03
      Text in Illustration
      *1 Cutout Mark

      Mount the No. 1 idle gear in a vise.

      Tech Tips

      Make sure the cutout mark of the idle gear faces down.

      Note

      Be careful not to damage the gear.

    2. A01BAO0E03
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

    3. Install the No. 2 idle sub gear.

    4. Install the wave washer.

      Tech Tips

      Fit the pins on the gears between the spring ends.

    5. Using snap ring pliers, install the shaft snap ring.

    6. A01BDZ3E03
      Text in Illustration
      *1 Service Bolt

      Using SST, align the holes of the No. 1 idle gear and No. 2 idle sub gear by turning the No. 2 idle sub gear clockwise, and install a service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    7. Remove the No. 1 idle gear from the vise and turn it upside down.

    8. A01BFECE03
      Text in Illustration
      *a Upward

      Mount the No. 1 idle gear and No. 2 idle sub gear in a vise.

      Note

      Be careful not to damage the gears.

    9. A01BH1KE02
      Text in Illustration
      *1 Service Bolt

      Remove the service bolt.

    10. A01BB0NE03
      Text in Illustration
      *1 Wave Washer
      *2 No. 1 Idle Sub Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

    11. Install the No. 1 idle sub gear.

    12. Install the wave washer.

      Tech Tips

      Fit the pins on the gears between the spring ends.

    13. Using snap ring pliers, install the snap ring.

    14. A01BH12E03
      Text in Illustration
      *1 Service Bolt
      *a Upward

      Using SST, align the holes of the No. 1 idler gear and No. 1 idle sub gear by turning the No. 1 idle sub gear clockwise, and install a service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )
    15. A01BC82E04
      Text in Illustration
      *a Turn

      Align the "5" timing marks of the idle gear and crankshaft timing gear.

    16. Using SST, turn the injection gear and align the "4" timing marks of the idle gear and injection gear, and then mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    17. A01BFRNE02
      Text in Illustration
      *1 Service Bolt

      Position the thrust plate with the protrusion facing forward.

    18. Align the bolt holes and install the thrust plate with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    19. Remove the service bolt.

  6. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Align the key groove of the No. 1 crankshaft position sensor plate with the set key.

    2. Install the No. 1 crankshaft position sensor plate with the cupped side facing outward.

      Tech Tips

      When replacing the No. 1 crankshaft position sensor plate, perform "Crank Time Compensation Reset" (w/DPF: Click here, w/o DPF: Click here.

  7. INSTALL TIMING GEAR COVER OIL SEAL

    Tech Tips

    There are 2 methods to remove the oil seal.


    1. If the timing gear cover is removed from the cylinder block:


      1. A01BHO4E01

        Using a screwdriver and hammer, tap out the oil seal.

      2. A01BBF6E01

        Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

        SST
        09214-76011

      3. Apply MP grease to the lip of the oil seal.

    2. If the timing gear cover is installed to the cylinder block:


      1. A01BFW6E01

        Using SST, remove the oil seal.

        SST
        09308-10010
        09950-40011   ( 09957-04010 )
        09950-60010   ( 09951-00350 )
      2. A01BAUPE01

        Apply MP grease to the lip of a new oil seal.

      3. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing gear cover edge.

        SST
        09214-76011

  8. INSTALL TIMING GEAR CASE OIL SEAL

    Tech Tips

    There are 2 methods to remove the oil seal.


    1. If the timing gear cover is removed from the cylinder block:


      1. A01BD07E01

        Using a screwdriver and hammer, tap out the oil seal.

      2. A01BDYNE02

        Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

        SST
        09223-15020
        09502-12010
        09950-70010   ( 09951-07100 )

      3. Apply MP grease to the lip of the oil seal.

    2. If the timing gear cover is installed to the cylinder block:


      1. A01BATGE02

        Using a knife, cut through the lip of the oil seal.

      2. Using a screwdriver, pry out the oil seal.

        Note

        Be careful not to damage the crankshaft.

      3. A01BGMXE01

        Apply MP grease to the lip of the oil seal.

      4. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

        SST
        09223-15020
        09502-12010
        09950-70010   ( 09951-07100 )

  9. INSTALL TIMING GEAR COVER


    1. Remove any old seal packing (FIPG material).

    2. A01BFDUE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF
      *1 Seal Packing

      Apply seal packing to the timing gear cover as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note

      Install the timing gear cover within 3 minutes and tighten bolts within 15 minutes of applying seal packing.

    3. A01BCW4

      w/ DPF:

      Install 3 new O-rings to the timing gear case.

    4. A01BHC0E02
      Text in Illustration
      *1 New O-Ring

      w/o DPF:

      Install a new O-ring to the timing gear case.

    5. Install the timing gear cover with the 14 bolts and 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  10. INSTALL OIL STRAINER SUB-ASSEMBLY


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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  11. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing (FIPG material).

    2. A01BHNVE05

      Apply seal packing to the oil pan as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4.0 mm (0.16 in.)

      Note

      Install the oil pan within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

    3. A01BFHEE03

      w/o DPF:

      Apply seal packing to the cylinder block stiffening plate as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4.0 mm (0.16 in.)

      Note

      Install the cylinder block stiffening plate within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

    4. w/ DPF:

      Install the oil pan with the 22 bolts and 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    5. w/o DPF:

      Install the cylinder block stiffening plate and oil pan with the 22 bolts and 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  12. INSTALL CRANKSHAFT PULLEY


    1. Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place to install it.

    2. A01BHJJE01

      Using SST, install the pulley bolt.

      SST
      09213-58014
      09330-00021
      Torque:
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }

  13. INSTALL WATER PUMP ASSEMBLY


    1. Install a new gasket and the water pump with the 5 bolts and 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  14. INSTALL NO. 2 TIMING BELT COVER

    A01BD0OE01

    1. Apply seal packing (FIPG) to the areas shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note

      After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.

    2. Clean the bolts and their holes.

    3. Apply adhesive to 2 or 3 threads at the end of 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the No. 2 timing belt cover with the 4 bolts and nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  15. INSTALL CAMSHAFT TIMING PULLEY


    1. A01BG3CE01

      Install the camshaft timing pulley.

    2. Install the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  16. INSTALL INJECTOR ASSEMBLY

    Click here

  17. INSTALL FUEL SUPPLY PUMP ASSEMBLY

    Click here

  18. INSTALL COMMON RAIL ASSEMBLY

    Click here

  19. INSTALL EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY

    Click here

  20. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  21. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  22. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. A01BC2SE02

      Apply a light coat of engine oil to the O-ring of the oil pressure switching valve.

    2. Install the oil pressure switching valve with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Make sure that the O-ring is not cracked or jammed when installing the oil pressure switching valve.

    3. Connect the oil pressure switching valve connector.

  23. INSTALL CAMSHAFT POSITION SENSOR

    A01BE2P

    1. Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

    2. A01BERQ

      Install the camshaft position sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

      Do not crack or jam the O-ring when installing the camshaft position sensor.

    3. Connect the camshaft position sensor connector.

  24. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01BG70

      Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

    2. TYPE A:

      A01BH83E01
      Text in Illustration
      *1 Clamp *2 Protrusion
      *3 Wire Harness Clamp (A) *4 Wire Harness Clamp (B)
      *5 Wire Harness Clamp (C) - -

      1. Install the wire harness clamp (A) to the crankshaft position sensor connector.

      2. Install the crankshaft position sensor with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

        Note

        Make sure that the O-ring is not damaged or does not jump out of position during installation.

      3. Install a new clamp.

        Note


        • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

        • Make sure the crankshaft position sensor wire harness is installed in the position shown in the illustration.

      4. Attach the crankshaft position sensor connector to the No. 1 vacuum transmitting pipe.

      5. Connect the crankshaft position sensor connector.

      6. Attach the 2 wire harness clamps (B, C).

    3. TYPE B:

      A01BCEJE01
      Text in Illustration
      *1 Clamp *2 Protrusion
      *3 Bracket (Clamp) *4 Wire Harness Clamp (A)
      *5 Wire Harness Clamp (B) *6 Wire Harness Clamp (C)

      1. Install the wire harness clamp (A) to the crankshaft position sensor connector.

      2. Install the crankshaft position sensor with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

        Note

        Make sure that the O-ring is not damaged or does not jump out of position during installation.

      3. Install the bracket (clamp) with the bolt.

        Torque:
        13 N*m  { 132 kgf*cm, 9.5 ft.*lbf }

      4. Install a new clamp.

        Note


        • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

        • Make sure the crankshaft position sensor wire harness is installed in the position shown in the illustration.

      5. Attach the crankshaft position sensor connector to the No. 1 vacuum transmitting pipe.

      6. Connect the crankshaft position sensor connector.

      7. Attach the 2 wire harness clamps (B, C).

      8. Attach the 2 wire harness clamps to the bracket (clamp).

  25. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. Using a 10 mm hexagon wrench, install a new washer and the No. 1 timing belt idler with the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  26. INSTALL TIMING BELT

    Click here

  27. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings and the vacuum pump with the 2 nuts.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }

  28. INSTALL VANE PUMP ASSEMBLY


    1. Install a new vane pump O-ring to the vane pump assembly.

    2. A01BEQHE01

      Install the vane pump assembly with the 2 nuts.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Make sure that the vane pump O-ring is not caught between other parts.

  29. REMOVE ENGINE STAND


    1. Remove the engine from the engine stand.

  30. INSTALL ENGINE ASSEMBLY

    Click here