OIL PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A004PX8E02
      Text in Illustration
      *1 Oil Seal
      *2 Timing Chain Cover

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

      SST
      09223-50010
      Standard depth
      0 to 0.6 mm (0 to 0.236 in.)

      Note


      • Keep the lip of the oil seal free from foreign matter.

      • Do not tap in the oil seal at an angle.

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

      Note


      • Do not allow foreign matter to contact the lip of the oil seal.

      • Do not allow MP grease to contact the dust seal.

  2. INSTALL STRAIGHT SCREW PLUG

    Tech Tips

    It is not necessary to replace the straight screw plug if there is no damage to the straight screw plug and no sign of oil leaks.


    1. Using a 10 mm socket hexagon wrench, install a new gasket and the straight screw plug.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  3. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Install a new gasket and O-ring to the timing chain cover.

    2. Remove any old seal packing material.

    3. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

      A004SDKE02
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Apply Seal Packing as Follows
      Area Seal Packing Diameter (Round) Seal Packing Dimension (Flat) Seal Packing Application Length
      A - A 2.0 to 4.0 mm (0.0787 to 0.157 in.) - -
      B - B 8.0 to 10 mm (0.315 to 0.394 in.) - 30 mm (1.18 in.)
      C - C - 13 mm (0.512 in.) or more wide and 6.0 mm (0.236 in.) or more thick 15 mm (0.591 in.)

      Note


      • Be sure to clean and degrease the contact surfaces, especially the 4 areas indicated by the arrows in the illustration.

      • When the contact surfaces are wet, wipe them off with an oil-free cloth before applying seal packing.

      • When applying seal packing to area C - C, apply it in the direction of the white arrows in the illustration.

      • Install the timing chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

    4. A004OMZE02
      Text in Illustration
      *1 Adhesive
      A004NAK Bolt and New Seal Washer

      Apply adhesive to the 4 bolts labeled B.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Temporarily install the timing chain cover and a new seal washer with the 13 bolts.

      Bolt Length
      Item Specified Condition
      Bolt A 60 mm (2.36 in.)
      Bolt B 30 mm (1.18 in.)
      Bolt C 30 mm (1.18 in.)

      Tech Tips

      Bolt B and C are identical.

    6. Tighten the 12 bolts labeled B and C.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

    7. Tighten the bolt labeled A.

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

  4. INSTALL CRANKSHAFT PULLEY

    Click here

  5. INSTALL WATER PUMP ASSEMBLY

    Click here

  6. CONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A004N5BE01
      Text in Illustration
      *1 Protrusion

      Install the sensor wire harness with the bolt and clip.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

      Note

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

  7. INSTALL CAMSHAFT POSITION SENSOR


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

      Note

      Make sure that the O-ring is not cracked or jammed when installing the sensor.

    2. Install the sensor with the bolt.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  8. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new O-ring to the oil strainer.

    2. Apply a light coat of engine oil to the O-ring.

    3. Install the oil strainer with the 3 bolts.

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

  9. INSTALL OIL FILTER BRACKET


    1. Install a new gasket to the oil filter bracket.

    2. Install the oil filter bracket with the 4 bolts.

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

  10. INSTALL OIL FILTER ELEMENT

    Click here

  11. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing material.

    2. A004PN1E02
      Text in Illustration
      *a 4.0 to 7.0 mm

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Dimension
      Area Seal Packing Diameter Seal Packing Application Length
      A - A 4.0 to 7.0 mm (0.157 to 0.276 in.) 12 mm (0.472 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

    3. Install the oil pan with the 18 bolts and 2 nuts.

      Torque:
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

  12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old seal packing material.

    2. A004OQ8E02
      *1 8.0 mm
      *2 10 mm
      *3 6.0 mm

      Apply seal packing to the cylinder head as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Dimension
      Area Seal Packing Diameter Seal Packing Application Length
      A 6.0 mm (0.236 in.) 8.0 mm (0.315 in.)
      B 6.0 mm (0.236 in.) 10 mm (0.394 in.)

    3. Install a new cylinder head cover gasket to the cylinder head cover.


      1. Install the cylinder head cover gasket so that the triangle tabs of the cylinder head cover gasket are aligned with the protrusions of the cylinder head cover as shown in the parts of the illustration labeled A and B.

      2. Install the cylinder head cover gasket to the groove of the cylinder head cover moving from C and D in the direction of the black arrows shown in the illustration.

      3. Install the cylinder head cover gasket to the groove of the cylinder head cover moving from C and D towards E as shown by the white arrows in the illustration.

      4. Install the cylinder head gasket to the groove of the cylinder head cover moving from D towards F as shown by the striped arrow in the illustration.

      5. Install the cylinder head cover gasket to the cylinder head cover pins and cutouts as shown in the parts of the illustration labeled G and H.

        A004T5BE02
        Text in Illustration
        *1 Triangle Tab of Cylinder Head Cover Gasket *2 Protrusion of Cylinder Head Cover
        *3 Cylinder Head Cover Pin *4 Cutout of Cylinder Head Cover

        Note

        Make sure that the rib of the cylinder head cover gasket is securely inserted into the groove of the cylinder head cover.

        A004U8AE01
    4. A004U9WE02
      Text in Illustration
      *a CORRECT
      *b INCORRECT
      A004PF6 Rib of Cylinder Head Cover Gasket

      Install the cylinder head cover with the 14 bolts and nut, and tighten the bolts and nut in the order shown in the illustration.

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

      Tech Tips

      Partially tighten the bolt indicated by the number 6 in the illustration until the cylinder head cover contacts the cylinder head, and then tighten the bolts and nut in the order shown in the illustration.

  13. INSTALL NOZZLE HOLDER CLAMP SEAT


    1. A004PYZ

      Install the 4 nozzle holder clamp seats.

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

  14. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  15. INSTALL VENTILATION HOSE

    Tech Tips

    The direction of the hose clamp is indicated in the illustration.

    A004RZUE01
    Text in Illustration
    *1 Paint Mark
    *a Upper Side
    *b Front Side of Vehicle

  16. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A004PR7E02
      Text in Illustration
      *a CORRECT
      *b INCORRECT
      A004MWX Paint Mark

      Attach the 10 clamps to install the 2 vacuum transmitting hoses.

      Tech Tips


      • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled A in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

      • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled B in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

  17. INSTALL VACUUM REGULATING VALVE ASSEMBLY

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  18. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  19. INSTALL INJECTOR ASSEMBLY

    Click here

  20. INSTALL NO. 1 NOZZLE LEAKAGE PIPE

    Click here

  21. INSTALL NO. 2 NOZZLE LEAKAGE PIPE


    1. Temporarily install the No. 2 nozzle leakage pipe and a new gasket with the check valve and bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the bolt.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

  22. INSTALL NO. 3 FUEL HOSE

  23. INSTALL FUEL TUBE SUB-ASSEMBLY

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  24. INSTALL FUEL HOSE PROTECTOR

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  25. INSTALL WATER INLET HOUSING


    1. Install a new gasket and the inlet housing with the 3 nuts.

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

  26. INSTALL NO. 4 WATER BY-PASS HOSE

  27. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install a new O-ring to the No. 2 water by-pass pipe.

    2. Install the No. 2 water by-pass pipe with the 2 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  28. INSTALL NO. 1 OIL COOLER BRACKET


    1. A004S1SE02

      Apply engine oil to the 2 new O-rings labeled B in the illustration.

      Note

      Do not apply engine oil to the new O-ring labeled A in the illustration.

    2. Install 3 new O-rings to the oil cooler bracket.

    3. Install the No. 1 oil cooler bracket with the 6 bolts and nut.

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

  29. INSTALL NO. 1 TURBO OIL PIPE


    1. A004SPEE02
      Text in Illustration
      *1 Gasket

      Install the No. 1 turbo oil pipe and 2 new gaskets with the 2 union bolts.

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

      Note

      Make sure the gasket of union bolt A contacts the No. 1 turbo oil pipe as shown in the illustration when tightening the union bolt.

  30. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Install a new O-ring to the No. 3 water by-pass pipe.

    2. Install the No. 3 water by-pass pipe with the 2 bolts.

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

  31. INSTALL NO. 8 WATER BY-PASS HOSE

  32. INSTALL NO. 6 WATER BY-PASS HOSE

  33. INSTALL OIL COOLER ASSEMBLY

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  34. INSTALL WATER BY-PASS HOSE

    Click here

  35. INSTALL NO. 1 CYLINDER BLOCK INSULATOR


    1. A004SA1

      Install the No. 1 cylinder block insulator to the cylinder block.

      Note

      Be sure to install the oil cooler before installing the No. 1 cylinder block insulator.

  36. INSTALL INTAKE MANIFOLD

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  37. INSTALL NO. 2 INTAKE MANIFOLD

    Click here

  38. INSTALL ENGINE COVER BRACKET

    Click here

  39. INSTALL GAS FILTER BRACKET

    Click here

  40. INSTALL NO. 1 GAS FILTER

    Click here

  41. INSTALL DIESEL TURBO PRESSURE SENSOR


    1. A004RTFE03
      Text in Illustration
      *1 Protrusion

      Install the sensor with the bolt.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

      Note

      Make sure the protrusion of the gas filter bracket is inserted into the hole of the sensor.

    2. Connect the vacuum hose.

  42. INSTALL INTAKE MANIFOLD INSULATOR

    Click here

  43. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  44. INSTALL NO. 4 FUEL HOSE

  45. INSTALL INJECTION PIPE SUB-ASSEMBLY

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  46. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  47. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Install the engine oil level dipstick guide with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    3. Install the engine oil level dipstick.

  48. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  49. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

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  50. INSTALL EGR VALVE BRACKET


    1. Install the 2 EGR valve brackets with the 3 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 in.*lbf }

  51. CONNECT NO. 8 WATER BY-PASS HOSE

  52. INSTALL NO. 7 WATER BY-PASS HOSE

  53. INSTALL DIESEL THROTTLE BODY ASSEMBLY


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

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    2. Connect the No. 6 and No. 7 water by-pass hoses.

  54. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner with the 3 bolts.

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

      Note

      As the heads of the bolts are not as thick as those of typical bolts, be careful not to damage them during installation.

  55. INSTALL ENGINE MOUNTING BRACKET


    1. Temporarily install the engine mounting bracket with the 2 bolts labeled A.

    2. A004SGBE02

      Temporarily install the 2 bolts and 2 nuts labeled B in the illustration.

    3. Tighten the 2 bolts labeled A in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    4. Tighten the 2 bolts and 2 nuts labeled B in the illustration.

      Torque:
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

  56. INSTALL NO. 4 WATER BY-PASS PIPE


    1. Install a new O-ring to the No. 4 water by-pass pipe.

    2. Install the No. 4 water by-pass pipe with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  57. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A004O6QE01
      Text in Illustration
      *1 No. 2 Idler Pulley Cover Plate
      *2 No. 2 Idler Pulley

      Install the No. 2 idler pulley and No. 2 idler pulley cover plate with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note

      Make sure the No. 2 idler pulley cover plate is facing the direction shown in the illustration.

  58. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the No. 1 idler pulley with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  59. INSTALL IDLER PULLEY COVER PLATE


    1. Install the idler pulley cover plate to the No. 1 idler pulley.

  60. INSTALL VACUUM PUMP ASSEMBLY


    1. Apply a light coat of engine oil to 2 new O-rings.

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

    3. Install the vacuum pump with 3 new bolts.

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

    4. Connect the vacuum hose.

  61. INSTALL GENERATOR ASSEMBLY

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  62. CONNECT ENGINE WIRE


    1. Connect the connectors and attach the clamps, and then connect the engine wire to the engine with the bracket bolts.

  63. INSTALL ENGINE ASSEMBLY

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