OIL PUMP (w/o 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.


  1. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Install 2 new O-rings.

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

    3. A01BHQME03

      Install the driven rotor to the timing gear case with the mark facing the cylinder block side.

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

    5. A01BCJ1E04

      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 packing diameter
      4.0 mm (0.16 in.)

      Note

      Install the timing gear case within 3 minutes and tighten the bolts within 15 minutes of applying FIPG.

    6. A01BDDTE01

      Align the "2" marks of the No. 1 balanceshaft driven gear with the one on the oil pump drive gear.

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

    8. A01BEE2E01

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

      Torque:
      for union bolt (A)
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    9. Remove the screw plug and gasket.

    10. A01BEYZ

      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:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  2. INSTALL CRANKSHAFT TIMING GEAR


    1. A01BCKNE02

      Position the crankshaft timing gear with timing mark "1" facing outward.

    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

  3. 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

      Fit the key (protrusion) of the fuel supply pump into the key slot of the injection gear.

    3. A01BF3PE01

      Align the "3" marks of the No. 2 balanceshaft driven gear with the one on the injection gear.

    4. A01BCCDE01

      Install a new O-ring to the injection gear.

    5. Install the injection gear set nut.

    6. A01BHQFE01

      Using SST, tighten the nut.

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

  4. INSTALL NO. 1 IDLE GEAR SHAFT


    1. A01BDU4E02

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

    2. A01BD2SE01

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

  5. INSTALL NO. 1 IDLE GEAR


    1. A01BFG9E02

      Align the "5" timing marks of the No. 1 idle gear and crankshaft timing gear.

    2. Using SST, turn the injection gear and align the "4" timing marks of the No. 1 idle gear and injection gear, and then mesh the gears.

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

  6. INSTALL IDLE GEAR THRUST PLATE


    1. A01BHFOE02

      Position the thrust plate with the protrusion facing forward.

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

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

    3. Remove the service bolt.

  7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Align the key groove of the sensor plate with the set key.

    2. Install the sensor plate with the cupped side facing outward.

  8. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. A01BI0TE01

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

      SST
      09649-17010
      09950-70010   ( 09951-07100 )
      Oil seal protrusion from the flat-end surface
      0 to 0.5 mm (0 to 0.020 in.)

    2. Apply MP grease to the oil seal lip.

      Note

      Keep the lip clean. Prevent dirt and dust from adhering to the oil seal lip.

  9. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL


    1. A01BEW9E01

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

      SST
      09608-32010
      09950-70010   ( 09951-07100 )
      Oil seal protrusion from the flat-end surface
      0 to 0.5 mm (0 to 0.020 in.)

    2. Apply MP grease to the oil seal lip.

      Note

      Keep the lip clean. Prevent dirt and dust from adhering to the oil seal lip.

  10. INSTALL TIMING GEAR COVER


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

    2. A01BA9ZE04

      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 packing diameter
      4.0 mm (0.16 in.)

      Note

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

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

    4. Install the timing gear case with the 14 bolts and 2 nuts.

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

  11. 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 }

  12. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old packing (FIPG material).

    2. A01BFHEE01

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

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

      Note

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

    3. A01BAZAE01

      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 packing diameter
      4.0 mm (0.16 in.)

      Note

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

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

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

  13. INSTALL ENGINE OIL LEVEL SENSOR


    1. Install a new gasket to the engine oil level sensor.

    2. Install the engine oil level sensor with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    3. Connect the engine oil level sensor connector.

  14. INSTALL CRANKSHAFT PULLEY


    1. Align the pulley set key with the key groove of the pulley and install the pulley.

    2. A01BHJJE01

      Using SST, install the pulley bolt.

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

  15. 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 }

  16. 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 }

  17. 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 }

  18. INSTALL INJECTOR ASSEMBLY

    Click here

  19. INSTALL FUEL SUPPLY PUMP ASSEMBLY

    Click here

  20. INSTALL COMMON RAIL ASSEMBLY

    Click here

  21. INSTALL EGR COOLER ASSEMBLY

    Click here

  22. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  23. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install a new gasket and the diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the 2 diesel throttle body connectors.

    3. w/o DPF:


      1. Install the wire harness clamp with the bolt.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      2. Connect the diesel turbo pressure sensor connector and vacuum switching valve connector.

  24. 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.

  25. INSTALL CRANKSHAFT POSITION SENSOR

    A01BAAT

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

    2. A01BFNV

      Install the crankshaft 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 crankshaft position sensor.

    3. Connect the 3 wire harness clamps.

    4. A01BB55

      Connect the crankshaft position sensor to the No. 1 vacuum pipe.

    5. Connect the crankshaft position sensor connector.

  26. INSTALL TIMING BELT

    Click here

  27. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump.

    2. Install the vacuum pump with the 2 nuts.

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

  28. INSTALL TIMING GEAR COVER INSULATOR


    1. Install the timing gear cover insulator with the bolt.

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

  29. 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.

  30. REMOVE ENGINE STAND

  31. INSTALL ENGINE ASSEMBLY

    Click here