Oil Pump: Service and Repair

OIL PUMP

COMPONENTS:

REMOVAL
1. REMOVE COOL AIR INTAKE DUCT SEAL
2. REMOVE ENGINE ROOM SIDE COVER LH
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
6. DISCHARGE FUEL SYSTEM PRESSURE
7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
9. REMOVE FRONT WHEEL
10. REMOVE ENGINE UNDER COVER
11. REMOVE NO. 2 ENGINE UNDER COVER (for 2WD)
12. REMOVE ENGINE UNDER COVER REAR LH (for 2WD)
13. REMOVE ENGINE UNDER COVER REAR RH (for 2WD)
14. DRAIN ENGINE OIL
15. DRAIN ENGINE COOLANT
16. DRAIN DIFFERENTIAL OIL (for 4WD)
17. REMOVE FRONT EXHAUST PIPE ASSEMBLY
18. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
19. REMOVE NO. 1 INLET AIR CLEANER
20. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
22. DISCONNECT UNION TO CHECK VALVE HOSE
23. DISCONNECT NO.2 FUEL VAPOR FEED HOSE
24. DISCONNECT INLET RADIATOR HOSE
25. DISCONNECT OUTLET RADIATOR HOSE
26. DISCONNECT RADIATOR RESERVOIR TANK HOSE
27. DISCONNECT INLET HEATER WATER HOSE
28. DISCONNECT OUTLET HEATER WATER HOSE
29. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE
30. REMOVE DISCHARGE HOSE SUB-ASSEMBLY
31. REMOVE ECM COVER
32. DISCONNECT ENGINE WIRE
33. DISCONNECT FUEL MAIN TUBE
34. DISCONNECT NO. 3 FUEL HOSE
35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD)
36. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD)
37. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD)
38. SEPARATE FRONT SPEED SENSOR LH (for 4WD)
39. SEPARATE FRONT SPEED SENSOR RH (for 4WD)
40. REMOVE FRONT AXLE HUB LH NUT (for 4WD)
41. REMOVE FRONT AXLE HUB RH NUT (for 4WD)
42. REMOVE TIE ROD ASSEMBLY LH (for 4WD)
43. REMOVE TIE ROD ASSEMBLY RH (for 4WD)
44. DISCONNECT HEIGHT CONTROL SENSOR LINK (for 2WD)
45. DISCONNECT HEIGHT CONTROL SENSOR LINK (for 4WD)
46. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)
47. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)
48. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)
49. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)
50. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD)
51. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD)
52. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD)
53. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD)
54. REMOVE FRONT AXLE ASSEMBLY LH (for 4WD)
55. REMOVE FRONT AXLE ASSEMBLY RH (for 4WD)
56. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSEMBLY (for Automatic Transmission)
57. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 2WD)
58. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 4WD)
59. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)
60. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD)
61. REMOVE ENGINE AND TRANSMISSION ASSEMBLY (for 2WD)
62. REMOVE ENGINE AND TRANSMISSION ASSEMBLY (for 4WD)
63. INSTALL ENGINE HANGERS
64. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
65. REMOVE STARTER ASSEMBLY
66. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)
67. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
68. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 2WD)
69. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 4WD)
70. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
71. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
72. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)
73. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
74. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
75. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY (for Automatic Transmission)
76. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD)
77. REMOVE FRONT FRAME ASSEMBLY (for 4WD)
78. FIX ENGINE ON ENGINE STAND
79. REMOVE V-RIBBED BELT
80. REMOVE NO. 2 ENGINE COVER
81. REMOVE NO. 1 ENGINE COVER
82. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
83. REMOVE GENERATOR ASSEMBLY
84. REMOVE COOLER COMPRESSOR ASSEMBLY (for 2WD)
85. REMOVE OIL FILTER BRACKET (for 4WD)
86. REMOVE COOLER COMPRESSOR ASSEMBLY (for 4WD)
87. REMOVE ENGINE MOUNTING BRACKET LH
88. REMOVE ENGINE MOUNTING BRACKET RH
89. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
90. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)
91. REMOVE WATER PUMP PULLEY
92. REMOVE ENGINE WIRE
93. REMOVE INJECTOR DRIVER
94. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
95. REMOVE NO. 2 SURGE TANK STAY
96. REMOVE WATER HOSE JOINT
97. REMOVE CRANKSHAFT PULLEY
98. REMOVE WATER INLET
99. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
100. REMOVE OIL STRAINER SUB-ASSEMBLY (for 4WD)
101. REMOVE OIL PAN SUB-ASSEMBLY
102. REMOVE OIL STRAINER SUB-ASSEMBLY
103. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
104. REMOVE NO. 1 FUEL PIPE
105. DISCONNECT NO. 2 FUEL PIPE
106. REMOVE FUEL PUMP ASSEMBLY
107. REMOVE NO. 2 FUEL PIPE
108. REMOVE IGNITION COIL ASSEMBLY
109. REMOVE NO. 1 OIL PIPE
110. REMOVE NO. 2 OIL PIPE
111. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
112. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
113. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

a. Remove the bolt and wiring harness clamp bracket.

b. Remove the 25 bolts and 2 nuts as shown in the illustration.

c. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT: Tape the screwdriver tip before use.

d. Remove the gasket.

114. REMOVE TIMING CHAIN CASE OIL SEAL
a. Using a screwdriver, pry out the oil seal.

HINT: Tape the screwdriver tip before use.

INSTALLATION

1. INSTALL TIMING CHAIN CASE OIL SEAL
a. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST 09223-22010, 09506-35010

NOTICE:
^ Keep the lip free of foreign matter.
^ Do not tap on the oil seal at an angle.
^ Make sure that the oil seal edge does not stick out of the timing chain case.

2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

a. Apply seal packing in a continuous line to the engine unit as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Seal diameter: 5.0 to 5.5 mm (0.197 to 0.217 inch)

NOTICE:
^ Be sure to clean and degrease the contact surfaces, especially the surfaces indicated by C in the illustration.
^ When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
^ Install the chain cover within 3 minutes.
^ Do not start the engine for at least 2 hours after installing.

b. Apply seal packing in a continuous line to the timing chain cover as shown in the illustration.
Seal packing: 08826-00080 or equivalent 08826-00100, THREE BOND 1282B or equivalent

NOTICE:
^ When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
^ Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

Apply seal packing as follows

c. Install a new gasket.

d. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

e. Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

Bolt Length:

NOTICE: Make sure that there is no oil on the bolt threads.

f. Fully tighten the 3 bolts as shown in the illustration.
Torque:
43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt A
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolts except A

g. Fully tighten the 3 bolts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

h. Fully tighten the 7 bolts and 2 nuts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

HINT: Tighten the bolts and nuts in the order of upper to lower as shown in the illustration.

i. Fully tighten the 12 bolts as shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

HINT: Tighten the bolts in the order of lower to upper as shown in the illustration.

j. Install the bolt and wiring harness bracket.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
5. INSTALL NO. 2 OIL PIPE
6. INSTALL NO. 1 OIL PIPE
7. INSTALL IGNITION COIL ASSEMBLY
8. INSTALL NO. 2 FUEL PIPE
9. INSTALL FUEL PUMP ASSEMBLY
10. CONNECT NO. 2 FUEL PIPE
11. INSTALL NO. 1 FUEL PIPE
12. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
13. INSTALL OIL STRAINER SUB-ASSEMBLY
14. INSTALL OIL PAN SUB-ASSEMBLY
15. INSTALL OIL WITH STRAINER PIPE SUB-ASSEMBLY (for 4WD)
16. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
17. INSTALL CRANKSHAFT PULLEY
18. INSTALL WATER INLET
19. INSTALL WATER HOSE JOINT
20. INSTALL NO. 2 SURGE TANK STAY
21. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
22. INSTALL INJECTOR DRIVER
23. INSTALL ENGINE WIRE
24. INSTALL WATER PUMP PULLEY
25. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)
26. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
27. INSTALL ENGINE MOUNTING BRACKET LH
28. INSTALL ENGINE MOUNTING BRACKET RH
29. CONNECT COOLER COMPRESSOR ASSEMBLY (for 2WD)
30. TEMPORARILY TIGHTEN COOLER COMPRESSOR ASSEMBLY (for 4WD)
31. INSTALL OIL FILTER BRACKET (for 4WD)
32. INSTALL COOLER COMPRESSOR ASSEMBLY (for 4WD)
33. INSTALL GENERATOR ASSEMBLY
34. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
35. INSTALL NO. 1 ENGINE COVER
36. INSTALL NO. 2 ENGINE COVER
37. INSTALL V-RIBBED BELT
38. INSTALL ENGINE HANGERS
39. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
40. INSTALL DRIVE PLATE AND RING GEAR SUB ASSEMBLY (for Automatic Transmission)
41. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD)
42. INSTALL FRONT FRAME ASSEMBLY (for 4WD)
43. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
44. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)
45. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)
46. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
47. INSTALL STARTER ASSEMBLY
48. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
49. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
50. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 2WD)
51. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 4WD)
52. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
53. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 2WD)
54. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 4WD)
55. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)
56. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD)
57. CONNECT POWER STEERING LINK WIRE HARNESS (for 2WD)
58. CONNECT POWER STEERING LINK WIRE HARNESS (for 4WD)
59. INSTALL FRONT AXLE ASSEMBLY LH (for 4WD)
60. INSTALL FRONT AXLE ASSEMBLY RH (for 4WD)
61. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD)
62. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD)
63. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD)
64. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD)
65. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)
66. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)
67. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)
68. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)
69. CONNECT HEIGHT CONTROL SENSOR LINK (for 2WD)
70. CONNECT HEIGHT CONTROL SENSOR LINK (for 4WD)
71. INSTALL TIE ROD ASSEMBLY LH (for 4WD)
72. INSTALL TIE ROD ASSEMBLY LH (for 4WD)
73. INSTALL FRONT AXLE HUB LH NUT (for 4WD)
74. INSTALL FRONT AXLE HUB RH NUT (for 4WD)
75. INSTALL FRONT SPEED SENSOR LH (for 4WD)
76. INSTALL FRONT SPEED SENSOR RH (for 4WD)
77. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD)
78. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD)
79. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD)
80. CONNECT NO. 3 FUEL HOSE
81. CONNECT FUEL MAIN TUBE
82. CONNECT ENGINE WIRE
83. INSTALL ECM COVER
84. CONNECT DISCHARGE HOSE SUB-ASSEMBLY
85. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
86. CONNECT INLET HEATER WATER HOSE
87. CONNECT OUTLET HEATER WATER HOSE
88. CONNECT INLET RADIATOR HOSE
89. CONNECT OUTLET RADIATOR HOSE
90. CONNECT RADIATOR RESERVOIR TANK HOSE
91. CONNECT NO. 2 FUEL VAPOR FEED HOSE
92. CONNECT UNION TO CHECK VALVE HOSE
93. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
94. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
95. INSTALL NO. 1 AIR CLEANER INLET
96. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
97. INSTALL FRONT EXHAUST PIPE ASSEMBLY
98. ADD FRONT DIFFERENTIAL OIL (for 4WD)
99. ADD ENGINE OIL (for 2WD)
100. ADD ENGINE OIL (for 4WD)
101. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
102. ADD ENGINE COOLANT
103. CHARGE REFRIGERANT
104. CHECK FOR FUEL LEAKS
105. CHECK FOR ENGINE COOLANT LEAKS
106. CHECK FOR ENGINE OIL LEAKS
107. CHECK FOR EXHAUST GAS LEAKS
108. CHECK FOR LEAKAGE OF REFRIGERANT
109. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
110. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
111. ADJUST SHIFT LEVER POSITION
112. CHECK SHIFT LEVER POSITION
113. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
114. CHECK IGNITION TIMING
115. CHECK ENGINE IDLE SPEED
116. CHECK CO/HC
117. CHECK ENGINE OIL LEVEL
118. CHECK FRONT DIFFERENTIAL OIL LEVEL (for 4WD)
119. INSTALL ENGINE UNDER COVER REAR LH (for 2WD)
120. INSTALL ENGINE UNDER COVER REAR RH (for 2WD)
121. INSTALL NO. 2 ENGINE UNDER COVER (for 2WD)
122. INSTALL ENGINE UNDER COVER
123. INSTALL V-BANK COVER SUB-ASSEMBLY
124. INSTALL ENGINE ROOM SIDE COVER LH
125. INSTALL ENGINE ROOM COVER SIDE RH
126. INSTALL COOL AIR INTAKE DUCT SEAL
127. PERFORM INITIALIZATION

NOTICE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.