OIL PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

PROCEDURE


  1. INSTALL TIMING CHAIN CASE ASSEMBLY AND ENGINE WATER PUMP ASSEMBLY


    1. Apply a light coat of engine oil to the 4 new O-rings.

    2. Install the 4 O-rings to the cylinder block sub-assembly and cylinder head sub-assembly.

    3. Clean and degrease the contact surfaces of the timing chain case assembly, cylinder head sub-assembly and cylinder block sub-assembly.

    4. Apply a coating of seal packing to the timing chain case assembly at the points shown in the illustration.

      B00275UC01
      *a 46 mm (1.81 in.) *b 50 mm (1.97 in.)
      *c 2.0 to 3.0 mm (0.0787 to 0.118 in.) *d 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      *e 3.0 to 4.0 mm (0.118 to 0.158 in.) *f 1.5 to 2.5 mm (0.0591 to 0.0984 in.)
      *g 13 to 15 mm (0.512 to 0.591 in.) *h 9.0 to 11 mm (0.354 to 0.433 in.)
      *i 31 to 33 mm (1.22 to 1.30 in.) - -
      Seal packing
      for line area D
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent.
      for line area A-A, B-B, C-C and E
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Seal Packing Application Specification
      Line Type and Area Seal Packing Diameter Application Area Seal Packing Application Length
      Dashed Line 1.5 to 2.5 mm (0.0591 to 0.0984 in.) 2.0 to 3.0 mm (0.0787 to 0.118 in.) -
      A - A 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.0 to 3.0 mm (0.0787 to 0.118 in.) 46 mm (1.81 in.)
      B - B 2.5 to 3.5 mm (0.0984 to 0.138 in.) 2.0 to 3.0 mm (0.0787 to 0.118 in.) 50 mm (1.97 in.)
      D 1.5 to 2.5 mm (0.0591 to 0.0984 in.) 3.0 to 4.0 mm (0.118 to 0.158 in.) -

      Note


      • Using non-residue solvent, clean and remove any oil from the installation surface.

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

      • Do not add engine oil for at least 2 hours after installation.

      • Do not start the engine within 2 hours after installation.

    5. Temporarily install the timing chain case assembly with the 15 bolts.

      B0026QSC01
      *a Type of bolt *b Tightening
      Bolt Length
      Item Length Thread Diameter
      Bolt A 30 mm (1.18 in.) 8.0 mm (0.315 in.)
      Bolt B 45 mm (1.77 in.) 8.0 mm (0.315 in.)
      Bolt C 65 mm (2.56 in.) 8.0 mm (0.315 in.)
      Bolt D 30 mm (1.18 in.) 10 mm (0.394 in.)

    6. Temporarily install a new gasket and the engine water pump assembly with the 8 bolts.

    7. Tighten the 23 bolts in the order shown in the illustration.

      Torque:
      for bolt A, B and C
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for bolt D
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Note

      Check the torque of bolt 1 after tightening bolt 23.

  2. INSTALL INJECTION PUMP INSULATOR

    Click here

  3. INSTALL SUPPLY PUMP ASSEMBLY

    Click here

  4. INSTALL NO. 1 CHAIN TENSIONER SLIPPER

    Click here

  5. TEMPORARILY INSTALL NO. 1 CHAIN VIBRATION DAMPER

    Click here

  6. INSTALL CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR WITH NO. 1 CHAIN SUB-ASSEMBLY

    Click here

  7. TIGHTEN NO. 1 CHAIN VIBRATION DAMPER

    Click here

  8. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  9. INSTALL SUPPLY PUMP SHAFT NUT

    Click here

  10. INSTALL CAMSHAFT TIMING SPROCKET

    Click here

  11. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    Click here

  12. INSTALL NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  13. INSTALL NO. 2 CHAIN TENSIONER SLIPPER

    Click here

  14. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

  15. INSTALL TIMING CHAIN GUIDE

    Click here

  16. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  17. INSTALL OIL PUMP DRIVE GEAR


    1. Install the oil pump drive gear to the crankshaft.

  18. INSTALL TIMING CHAIN COVER PLATE

    Click here

  19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Apply a light coat of engine oil to a new timing chain case gasket.

    2. Install the timing chain case gasket to the timing chain case assembly.

    3. Clean and degrease the contact surfaces of the timing chain cover sub-assembly and timing chain case assembly.

    4. Apply a coating of seal packing to the timing chain cover sub-assembly at the points shown in the illustration.

      B0026R3C01
      *a 2.0 to 3.0 mm (0.0787 to 0.118 in.) *b 2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
      Standard seal packing diameter
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

      Note


      • Using non-residue solvent, clean and remove any oil from the installation surface.

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

      • Do not add engine oil for at least 2 hours after installation.

      • Do not start the engine within 2 hours after installation.

    5. Temporarily install the timing chain cover sub-assembly with the 20 bolts.

      B0027EQC01
      *a Type of bolt *b Tightening
      Bolt Length
      Item Length Thread Diameter
      Bolt A 40 mm (1.57 in.) 8.0 mm (0.315 in.)
      Bolt B 25 mm (0.984 in.) 8.0 mm (0.315 in.)

    6. Tighten the 20 bolts in the order shown in the illustration.

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

      Note

      Check the torque of bolt 1 after tightening bolt 20.

  20. INSTALL FRONT CRANKSHAFT OIL SEAL

    Click here

  21. INSTALL OIL PAN SUB-ASSEMBLY


    1. Clean and degrease the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.

    2. B0025WCC01
      B0024II Seal Packing

      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 diameter
      3.5 to 4.5 mm (0.138 to 0.177 in.)

      Note


      • Remove any oil from the contact surface.

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

      • Do not add engine oil within 2 hours after installation.

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

    3. B002689C02
      B0068HS Bolt
      B006964 Nut

      Install the oil pan sub-assembly to the cylinder block sub-assembly with the 23 bolts and 2 nuts.

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

      Note

      Check the torque of all nuts and bolts labeled A again.

  22. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  23. INSTALL OIL PAN COVER SILENCER


    1. Install the oil pan cover silencer to the oil pan sub-assembly with the 5 bolts.

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

  24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


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

    2. Install a new cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets to the cylinder head cover sub-assembly.

    3. Clean and degrease the contact surfaces of the cylinder head cover sub-assembly and cylinder head sub-assembly.

    4. Apply seal packing as shown in the illustration.

      B0027PYC01
      *1 Timing Chain Cover Sub-assembly *2 Timing Chain Case Assembly
      *3 Cylinder Head Sub-assembly *4 No. 3 Camshaft Bearing Cap
      *a Seal Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.) *b Application Width: 7.0 mm (0.276 in.)
      *c Application Width: 9.0 mm (0.354 in.) *d Application Width: 11.0 mm (0.433 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 6.0 mm (0.118 to 0.236 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not add engine oil for at least 2 hours after installation.

      • Do not start the engine within 2 hours after installation.

    5. B0026S6C01
      B0068HS Bolt
      B006964 Nut
      B0069AV Nozzle Holder Clamp Seat

      Tighten the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and camshaft position sensor in the order shown in the illustration.

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

      Note


      • When reusing the camshaft position sensor, check the O-rings.

      • Make sure that the O-ring is not cracked or jammed when installing it on the cylinder head cover sub-assembly.

      • Replace with a new part if it is dropped or if it receives a strong impact.

      • Check the torque of bolts 1 to 4 again.

  25. INSTALL NOZZLE HOLDER GASKET

    Click here

  26. TEMPORARILY INSTALL INJECTOR ASSEMBLY

    Click here

  27. INSTALL GENERATOR BRACKET SUB-ASSEMBLY

    Click here

  28. INSTALL NO. 1 ENGINE HANGER

    Click here

  29. INSTALL NO. 1 WATER HOSE CLAMP BRACKET (w/ DPF)

    Click here

  30. INSTALL CRANKSHAFT PULLEY

    Click here

  31. INSTALL CRANKSHAFT PULLEY COVER

    Click here

  32. INSTALL VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater)

    Click here

  33. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly to the timing chain cover sub-assembly with 3 bolts.

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

  34. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the No. 1 idler pulley sub-assembly to the generator bracket sub-assembly with the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  35. INSTALL THERMOSTAT

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  36. INSTALL WATER INLET

    Click here

  37. INSTALL WATER OUTLET SUB-ASSEMBLY

    Click here

  38. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  39. TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  40. TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

    Click here

  41. INSTALL TURBO OIL OUTLET PIPE

    Click here

  42. TEMPORARILY INSTALL TURBOCHARGER STAY

    Click here

  43. TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

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  44. TIGHTEN TURBOCHARGER STAY

    Click here

  45. INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  46. CONNECT NO. 1 AND NO. 2 TURBO WATER HOSE

    Click here

  47. INSTALL NO. 1 WATER BY-PASS PIPE

    Click here

  48. INSTALL NO. 3 WATER BY-PASS PIPE

    Click here

  49. INSTALL PCV HOSE (except Cold Area Specification Vehicles)

    Click here

  50. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


  51. INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY


  52. INSTALL NO. 1 TURBO INSULATOR


  53. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


  54. INSTALL AIR FUEL RATIO SENSOR (w/ DPF)

    Click here

  55. INSTALL NO. 1 INJECTOR HOLDER (w/ DPF)

    Click here

  56. CONNECT NO. 4 WATER BY-PASS HOSE (w/ DPF)

    Click here

  57. INSTALL NO. 5 WATER BY-PASS HOSE (w/ DPF)

    Click here

  58. INSTALL PCV PIPE (for Cold Area Specification Vehicles)

    Click here

  59. INSTALL IDLER PULLEY ASSEMBLY (w/o Air Conditioning System)

    Click here

  60. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

    Click here

  61. INSTALL HOSE BRACKET

    Click here

  62. TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  63. TIGHTEN INJECTOR ASSEMBLY

    Click here

  64. TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  65. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  66. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  67. INSTALL NO. 1 FUEL PIPE (w/ DPF)

    Click here

  68. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  69. INSTALL INTAKE MANIFOLD

    Click here

  70. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  71. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  72. INSTALL NO. 3 FUEL PIPE (w/ DPF)

    Click here

  73. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  74. INSTALL NO. 1 FUEL HOSE

    Click here

  75. INSTALL NO. 2 FUEL HOSE

    Click here

  76. INSTALL FUEL PUMP MOTOR WIRE

    Click here

  77. INSTALL FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  78. INSTALL MANIFOLD STAY

    Click here

  79. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  80. INSTALL NO. 2 FUEL PIPE

    Click here

  81. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  82. INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  83. INSTALL NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  84. INSTALL VACUUM CONTROL VALVE SET

    Click here

  85. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

    Click here

  86. INSTALL CONNECTING WIRE

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  87. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  88. INSTALL NO. 2 EGR PIPE

    Click here

  89. INSTALL EGR VALVE BRACKET

    Click here

  90. INSTALL DIESEL TURBO PRESSURE SENSOR

    Click here

  91. INSTALL GAS FILTER

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  92. INSTALL ENGINE COVER BRACKET

    Click here

  93. INSTALL PIPE CLAMP (w/ DPF)

    Click here

  94. TEMPORARILY INSTALL NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  95. TEMPORARILY INSTALL NO. 1 VACUUM PIPE (w/ DPF)

    Click here

  96. TIGHTEN NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  97. TIGHTEN NO. 1 VACUUM PIPE (w/ DPF)

    Click here

  98. INSTALL EXHAUST GAS TEMPERATURE SENSOR (w/ DPF)

    Click here

  99. INSTALL DIFFERENTIAL PRESSURE SENSOR (w/ DPF)

    Click here

  100. INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  101. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  102. INSTALL INTERCOOLER AIR TUBE

    Click here

  103. INSTALL ENGINE WIRE

  104. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  105. INSTALL NO. 2 HOSE TO HOSE TUBE

    Click here

  106. INSTALL ENGINE ASSEMBLY

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