OIL PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note:

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

  • When replacing the fuel supply pump, common rail assembly, 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. A201761C01

      *1

      Front Crankshaft Oil Seal

      *2

      Timing Chain Cover Sub-assembly

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

      09223-50010

      Standard Depth

      0 to 0.6 mm (0 to 0.236 in.)

      Note:

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

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

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

      Note:

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

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

  2. INSTALL STRAIGHT SCREW PLUG

    Tip:

    Perform this procedure only when replacement of the straight screw plug.

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

      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 sub-assembly.

    2. Remove any old seal packing material.

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

      A294969C01

      *a

      15 mm or more

      -

      -

      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 there is oil on the contact surfaces, 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 sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

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

    4. A291678C01

      *a

      Adhesive
      V100136

      Bolt and New Seal Washer

      Apply adhesive to the 3 bolts (B) and bolt (D).

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Temporarily install the timing chain cover sub-assembly 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.)

      Bolt D

      45 mm (1.77 in.)
      Tip:

      Bolt B and C are identical.

    6. Tighten the 12 bolts (B), (C) and (D).

      22.5 N*m

      229 kgf*cm

      17 ft.*lbf

    7. Tighten the bolt (A).

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  4. INSTALL CRANKSHAFT PULLEY

    Click here

  5. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  6. CONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS

    1. A291679C02

      *a

      Protrusion

      Install the crankshaft position sensor wire harness with the bolt and clip.

      8.8 N*m

      90 kgf*cm

      78 in.*lbf

      Note:

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

  7. INSTALL CAMSHAFT POSITION SENSOR

    Click here

  8. INSTALL OIL STRAINER SUB-ASSEMBLY

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

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

    3. A142992C01

      Install the oil strainer sub-assembly with the 3 bolts.

      Bolt A

      42 N*m

      428 kgf*cm

      31 ft.*lbf

      Bolt B

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  9. INSTALL OIL CHECK VALVE SUB-ASSEMBLY

    1. Using a 5 mm hexagon wrench, install the oil check valve sub-assembly with the bolt.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  10. INSTALL OIL FILTER BRACKET

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

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

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  11. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY

    Click here

  12. INSTALL OIL FILTER ELEMENT

    Click here

  13. INSTALL OIL PAN SUB-ASSEMBLY

    1. Remove any old seal packing material.

    2. A291680C01

      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

      Acceptable Seal Packing Application Range

      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 sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

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

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

      10.5 N*m

      107 kgf*cm

      8 ft.*lbf

  14. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. Remove any old seal packing material.

    2. A201847C01

      Apply seal packing to the cylinder head cover sub-assembly 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 sub-assembly.

      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 sub-assembly as shown in the parts of the illustration A and B.

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

      4. Install the cylinder head cover gasket to the groove of the cylinder head cover sub-assembly 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 G and H.

        A294970C02

        *a

        Triangle Tab of Cylinder Head Cover Gasket

        *b

        Protrusion of Cylinder Head Cover

        *c

        Cylinder Head Cover Pin

        *d

        Cutout of Cylinder Head Cover
        A263853C01

        *a

        Correct

        *b

        Incorrect
        V100155

        Rib of Cylinder Head Cover Gasket
        Note:

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

    4. A298826C01
      V100137

      Nut

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Tip:

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

  15. INSTALL NOZZLE HOLDER CLAMP SEAT

    1. A263982

      Install the 4 nozzle holder clamp seats.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  16. INSTALL OIL FILLER CAP SUB-ASSEMBLY

    1. Add new engine oil and install the oil filler cap sub-assembly.

  17. INSTALL VENTILATION HOSE

    1. A263897C03

      *a

      Upper Side

      *b

      Front of Vehicle

      *c

      Paint Mark

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

  18. INSTALL NO. 1 WIRE HARNESS CLAMP BRACKET

    1. Install the No. 1 wiring harness clamp bracket with the bolt.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  19. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A294971C01

      *a

      Correct

      *b

      Incorrect
      V100145

      Paint Mark

      Engage the 8 clamps to install the 2 vacuum transmitting hose assemblies.

      Tip:

      • Make sure that the paint marks of the vacuum transmitting hose assemblies at the location (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 hose assemblies at the location (B) in the illustration are aligned as shown in the illustration. Any of the "Correct" alignments are acceptable for each location.

  20. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  21. INSTALL INJECTOR ASSEMBLY

    Click hereClick here

  22. INSTALL NO. 1 NOZZLE LEAKAGE PIPE

    Click hereClick here

  23. 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.

      31.5 N*m

      321 kgf*cm

      23 ft.*lbf

    3. Tighten the bolt.

      31.5 N*m

      321 kgf*cm

      23 ft.*lbf

  24. INSTALL NO. 3 FUEL HOSE

    Click here

  25. INSTALL FUEL TUBE SUB-ASSEMBLY

    Click here

  26. INSTALL FUEL HOSE PROTECTOR

    Click here

  27. INSTALL WATER INLET HOUSING

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

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  28. INSTALL NO. 4 WATER BY-PASS HOSE

    1. Install the No. 4 water by-pass hose

  29. 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.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

  30. INSTALL NO. 1 OIL COOLER BRACKET

    1. A298827N01

      Apply engine oil to the 2 new gaskets (B) in the illustration.

      Note:

      Do not apply engine oil to the new gasket (A) in the illustration.

    2. Install 3 new gaskets to the No. 1 oil cooler bracket.

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  31. INSTALL NO. 1 TURBO OIL PIPE

    1. A294395C01

      *1

      Gasket

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

      35 N*m

      357 kgf*cm

      26 ft.*lbf

      Note:

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

  32. 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.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  33. INSTALL NO. 8 WATER BY-PASS HOSE

    1. Install the No. 8 water by-pass hose to the outlet water pipe with the clamp.

  34. INSTALL NO. 6 WATER BY-PASS HOSE

    1. Install the No. 6 water by-pass hose to the outlet water pipe with the clamp.

  35. INSTALL OIL COOLER ASSEMBLY

    Click here

  36. INSTALL WATER BY-PASS HOSE

    Click here

  37. INSTALL NO. 1 CYLINDER BLOCK INSULATOR

    1. A201839

      Install the No. 1 cylinder block insulator to the cylinder block sub-assembly.

      Note:

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

  38. INSTALL INTAKE MANIFOLD

    Click here

  39. INSTALL NO. 2 INTAKE MANIFOLD

    Click here

  40. INSTALL ENGINE COVER BRACKET

    Click here

  41. INSTALL GAS FILTER BRACKET

    Click here

  42. INSTALL NO. 1 GAS FILTER

    Click here

  43. INSTALL DIESEL TURBO PRESSURE SENSOR

    1. A197552C03

      *a

      Protrusion

      Install the turbo pressure sensor with the bolt.

      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.

  44. INSTALL INTAKE MANIFOLD INSULATOR

    Click here

  45. INSTALL COMMON RAIL ASSEMBLY

    1. Install the common rail assembly with the 2 bolts.

      20.5 N*m

      209 kgf*cm

      15 ft.*lbf

  46. INSTALL NO. 4 FUEL HOSE

    1. Install the No. 4 fuel hose, slide the 2 clips to secure it.

  47. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Click hereClick here

  48. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  49. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  50. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  51. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  52. INSTALL EGR VALVE BRACKET

    Click here

  53. CONNECT NO. 8 WATER BY-PASS HOSE

    Click here

  54. INSTALL NO. 7 WATER BY-PASS HOSE

    Click here

  55. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  56. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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

      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.

  57. INSTALL ENGINE MOUNTING BRACKET

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

    2. A294397N01

      Temporarily install the 2 bolts and 2 nuts (B) in the illustration.

    3. Tighten the 2 bolts (A) in the illustration.

      28 N*m

      286 kgf*cm

      21 ft.*lbf

    4. Tighten the 2 bolts and 2 nuts (B) in the illustration.

      80 N*m

      816 kgf*cm

      59 ft.*lbf

  58. 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.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

  59. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

    1. A201747C02

      *1

      No. 2 Idler Pulley Cover Plate

      *2

      No. 2 Idler Pulley Sub-Assembly

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

      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.

  60. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

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

      40 N*m

      408 kgf*cm

      30 ft.*lbf

  61. INSTALL IDLER PULLEY COVER PLATE

    1. Install the idler pulley cover plate to the No. 1 idler pulley sub-assembly.

  62. 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 assembly.

    3. Install the vacuum pump assembly with 3 new bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    4. Connect the vacuum hose, and slide the clip to secure it.

  63. INSTALL GENERATOR ASSEMBLY

    Click here

  64. REMOVE ENGINE TO ENGINE STAND

    Click here