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OIL PUMP INSTALLATION

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CAUTION / NOTICE / HINT

Note:

  • When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.

  • w/DPF

    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines (Click here).

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PROCEDURE


  1. Click here

    INSTALL OIL PUMP ASSEMBLY


    1. Install the oil pump with the 4 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  2. Click here

    INSTALL REAR CRANKSHAFT OIL SEAL

    Click here

  3. Click here

    INSTALL REAR ENGINE OIL SEAL RETAINER

    B001ZMHE01
    Table 1.
    *1 Cylinder Block:
    *2 Rear Engine Oil Seal Retainer:
    Note:

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


    1. B001VTIE05
      Table 2.
      *1 Seal Diameter: 3.0 to 5.0 mm
      *2 2.5 mm (0.0984 in.)
      *3 2.0 mm (0.0787 in.)

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

      Seal diameter
      3.0 to 5.0 mm (0.118 to 0.197 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Note:

      • Remove any oil from the contact surface.

      • Install the rear engine oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    2. Apply engine oil to the oil seal lip.

    3. Make sure that the lip of the oil seal is properly installed.

    4. B001ZBBE02

      Install and uniformly tighten the 10 bolts in the order shown in the illustration.

      10 N*m 102 kgf*cm 7 ft.*lbf
      Note:

      • When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.

      • When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.

  4. Click here

    INSTALL OIL REGULATOR ASSEMBLY


    1. Install the oil regulator with the 4 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  5. Click here

    INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

    Note:

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


    1. Install the cylinder block oil hole gasket.

    2. Apply a light coat of engine oil to 3 new O-rings and set the 3 O-rings to the oil regulator and scavenging pump.

    3. B001W41E03
      Table 3.
      *1 8.5 mm (0.335 in.)
      *2 Seal Diameter: 3.5 to 4.0 mm

      Apply seal packing to the No. 1 oil pan as shown in the illustration.

      Standard seal diameter
      3.5 to 4.0 mm (0.134 to 0.157 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Note:

      • For the 3 bolt holes labeled with arrows, apply the seal packing on the outer edges. For the other bolt holes, apply the seal packing on the inner edges.

      • Make sure to apply a continuous bead of seal packing as shown in the illustration. If the bead breaks, overlap 3 mm (0.118 in.) of seal packing and continue the bead.

      • Remove any oil and old seal packing from the contact surface.

      • Install the No. 1 oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing.

    4. B001XGFE02
      Table 4.
      *1 Nut
      *2 Oil Reflector Plate

      Install the No. 1 oil pan and oil reflector plate with the 20 bolts and 2 nuts.

      25 N*m 250 kgf*cm 18 ft.*lbf
      Table 5. Bolt Length
      Item Quantity Length
      Bolt A 7 70 mm (2.76 in.)
      Bolt B 8 20 mm (0.787 in.)
      Bolt C 5 30 mm (1.18 in.)
  6. Click here

    INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to a new O-ring, and install it to the oil strainer.

    2. Install the oil strainer with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  7. Click here

    INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Note:

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


    1. B002020E03
      Table 6.
      *1 9.0 mm (0.354 in.)
      *2 Seal Diameter: 5 to 6 mm

      Apply seal packing to the No. 2 oil pan as shown in the illustration.

      Standard seal diameter
      5.0 to 6.0 mm (0.197 to 0.236 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Note:

      • For the bolt and pin holes, make sure to apply seal packing to the inner sides.

      • Make sure to apply a continuous bead of seal packing as shown in the illustration. If the bead breaks, overlap 3.0 mm (0.118 in.) of seal packing and continue the bead.

      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing.

    2. Install the No. 2 oil pan with the 10 bolts and 2 nuts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  8. Click here

    INSTALL ENGINE OIL LEVEL SENSOR


    1. Install a new gasket and the sensor with the 4 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  9. Click here

    INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. B001WGUE02
      Table 7.
      *1 New O-Ring

      Apply a light coat of engine oil to 2 new O-rings, and set them to the oil filter bracket.

    2. Install the oil filter bracket with the 3 bolts and 2 nuts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    3. Connect the 2 wire harness clamps.

  10. Click here

    INSTALL OIL FILTER ELEMENT

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  11. Click here

    INSTALL TIMING GEAR COVER SPACER (w/ Intercooler)


    1. Install the timing gear cover spacer with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
  12. Click here

    INSTALL CRANKSHAFT PULLEY

    Click here

  13. Click here

    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. B001YH8E02

      Install the V-ribbed belt tensioner with the 5 bolts.

      for bolt A and C
      43 N*m 438 kgf*cm 32 ft.*lbf
      for bolt B
      21 N*m 214 kgf*cm 15 ft.*lbf
      Table 8. Bolt Length
      Item Quantity Length
      Bolt A 1 116 mm (4.57 in.)
      Bolt B 2 40 mm (1.58 in.)
      Bolt C 2 95 mm (3.74 in.)

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

      43 N*m 438 kgf*cm 32 ft.*lbf

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

      10 N*m 102 kgf*cm 7 ft.*lbf
  14. Click here

    CONNECT NO. 2 OIL COOLER HOSE


    1. Align the white paint marks on the oil cooler hose and oil filter bracket and connect the hose.

      Note:

      Make sure to maintain a space between the oil cooler hose and crankshaft pulley and the oil cooler hose and V-ribbed belt idler pulley.

  15. Click here

    CONNECT NO. 1 OIL COOLER HOSE


    1. Face the pink paint mark on the oil cooler hose toward the front side of the engine and connect the hose to the oil filter bracket.

      Note:

      Make sure to maintain a space between the oil cooler hose and crankshaft pulley.

  16. Click here

    INSTALL STIFFENER INSULATOR RH (w/ Intercooler)


    1. Install the stiffener insulator RH with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  17. Click here

    INSTALL NO. 2 INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. Install a new gasket and connect the No. 2 inlet turbo oil pipe with the union bolt.

      29 N*m 296 kgf*cm 21 ft.*lbf
  18. Click here

    CONNECT NO. 2 OUTLET TURBO OIL HOSE

  19. Click here

    INSTALL NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring, and install it to the No. 1 engine oil level dipstick guide.

    2. Install the No. 1 engine oil level dipstick guide with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  20. Click here

    CONNECT NO. 1 OUTLET TURBO OIL HOSE

  21. Click here

    INSTALL GENERATOR ASSEMBLY


    1. B001Y5ME02

      Temporarily install the generator with the 3 bolts and 2 nuts.

    2. Uniformly tighten the 3 bolts and 2 nuts in the order shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf

    3. Connect the generator cable and install the nut and bolt.

      for bolt
      13 N*m 133 kgf*cm 10 ft.*lbf
      for nut (130A Type and 150A Type:)
      9.8 N*m 100 kgf*cm 87 in.*lbf
      for nut (180A Type:)
      12 N*m 122 kgf*cm 9 ft.*lbf
  22. Click here

    INSTALL NO. 1 INTAKE AIR CONNECTOR PIPE

    Click here

  23. Click here

    INSTALL ENGINE ASSEMBLY


    1. Install the engine assembly to the vehicle (Click here).

  24. Click here

    CONNECT TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).


    1. Connect the cables to negative (-) main battery and sub-battery terminals.