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Engine Oil Pump Assembly: Replacement

  1. Remove Rear Floor Board No. 2 
  2. Remove Deck Floor Box Rear 
  3. Remove Rear Floor Board No. 3 
  4. Disconnect Battery Negative Terminal 
  5. Remove Radiator Support Opening Cover. See  Figure . 
  6. Remove Front Wheel RH 
  7. Remove Engine Under Cover LH. See  Figure . 
  8. Remove Engine Under Cover RH. See  Figure . 
  9. Drain Engine Coolant 
  10. Drain Engine Oil 
  11. Remove Windshield Wiper Link Assembly. See  Figure . 
  12. Remove Cowl Top Panel Sub-Assembly Outer Front. See  Figure . 
  13. Remove Air Cleaner Assembly 
    1. Loosen the clamp, then disconnect the air cleaner inlet No. 1 from the air cleaner case.
      Fig 1: Disconnect The Air Cleaner Inlet No. 1 From The Air Cleaner Case
      G02617085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the intake air flow meter connector, then remove the wire harness clamp.
    3. Loosen the clamp, then remove the 2 bolts and air cleaner assembly.
      Fig 2: Removing 2 Bolts And Air Cleaner Assembly
      G02617086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. Remove Air Cleaner Inlet No. 2 
    1. Remove the clip and air cleaner inlet No. 2.
      Fig 3: Remove The Clip And Air Cleaner Inlet No. 2
      G02617087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Suspend Brake Master Cylinder Reservoir Sub-Assembly 
    1. Disconnect the connector.
    2. Remove the 2 bolts.
    3. Separate the claw fitting, then suspend the brake master cylinder reservoir with rope.
    NOTE: Be careful of the angle of the brake master cylinder reservoir when suspending to prevent air from coming into the hose.
    Fig 4: Separate The Claw Fitting, Then Suspend The Brake Master Cylinder Reservoir.
    G02617088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Remove Reservoir Bracket 
    1. Disconnect the hose from the brake master cylinder reservoir bracket.
    2. Remove the 3 bolts and wire harness clamp, then remove the brake master cylinder reservoir bracket.
      Fig 5: Remove The Brake Master Cylinder Reservoir Bracket
      G02617089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Remove Windshield Washer Jar 
    1. Loosen the bolt which holds the head lamp RH.
    2. Disconnect the connector and remove the wire harness clamp.
    3. Remove the bolt and bracket.
      Fig 6: Remove Windshield Washer Jar Assembly
      G02617090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut.
    5. Slightly lift the head lamp RH and separate the claw fitting, then remove the washer jar assembly.
    6. Disconnect the hose from the washer jar assembly.
      Fig 7: Separate The Claw Fitting, Then Remove The Washer Jar Assembly
      G02617091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. Remove Cylinder Head Cover Sub-Assembly 
    1. Disconnect the fuel injector connector and ignition coil connector. See Figure
    2. Remove the 3 bolts and wire harness clamp, then disconnect the wire harness.
      Fig 8: Remove The 3 Bolts And Wire Harness Clamp
      G02617092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the brake master cylinder reservoir cover.
      Fig 9: Remove The Brake Master Cylinder Reservoir Cover
      G02617093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the ventilation hose and ventilation hose No. 2.
      Fig 10: Disconnect The 2 Ventilation Hoses
      G02617094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and ignition coil.
      Fig 11: Remove The Bolts And Ignition Coils
      G02617095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 9 bolts and 2 nuts, then remove the cylinder head cover.
      Fig 12: Remove The 9 Bolts And 2 Nuts, Then Remove The Cylinder Head Cover
      G02617096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. Remove Vacuum Switching Valve Assembly No. 2 
    1. Disconnect the connector and hose.
    2. Remove the bolt and vacuum switching valve assembly.
      Fig 13: Remove The Bolt And Vacuum Switching Valve Assembly
      G02617097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. Remove Fan And Generator V Belt 
  21. Remove Water Pump Assembly. See  Figure . 

    SST 09960-10010 (09962-01000, 09963-00600)

  22. Remove Crankshaft Damper Sub-Assembly 
    1. Using SST, hold the crankshaft damper and loosen the crankshaft bolt.

      SST 09213-58013 (91111-50845), 09330-00021

      NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.
      Fig 14: Using SST, Hold The Crankshaft Damper And Loosen The Crankshaft Bolt
      G02617098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the crankshaft bolt until the 2 to 3 threads of the bolt is tightened to the crankshaft.
    3. Using SST, remove the crankshaft damper.

      SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

    4. Remove the crankshaft bolt.
      Fig 15: Using SST, Remove The Crankshaft Damper
      G02617099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. Remove Engine Mounting Insulator Sub-Assembly RH 
    1. Put a wooden block on a jack underneath the oil pan to support the oil pan.
      Fig 16: Put A Wooden Block On A Jack Underneath The Oil Pan To Support The Oil Pan
      G02617100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and 4 nuts, then remove the engine mounting insulator RH.
      Fig 17: Remove The 3 Bolts And 4 Nuts, Then Remove The Engine Mounting Insulator
      G02617101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. Remove Engine Mounting Spacer 
    1. Remove the 2 bolts and engine mounting spacer.
      Fig 18: Remove The 2 Bolts And Engine Mounting Spacer
      G02617102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. Remove Transverse Engine Mounting Bracket 
    1. Remove the 4 bolts and engine mounting bracket.
      Fig 19: Remove The 4 Bolts And Engine Mounting Bracket
      G02617103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. Remove Camshaft Timing Oil Control Valve Assembly 
    1. Disconnect the connector.
    2. Remove the bolt and camshaft timing oil control valve assembly.
      Fig 20: Remove The Bolt And Camshaft Timing Oil Control Valve Assembly
      G02617104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. Remove Crank Position Sensor. See  Figure . 
  28. Remove Oil Pump Assembly 
    1. Remove the 15 bolts and nut.
      Fig 21: Remove The 15 Bolts And Nut
      G02617105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a Torx socket wrench E8, remove the stud bolt.
      Fig 22: Using A Torx Socket Wrench E8, Remove The Stud Bolt
      G02617106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver with its tip wrapped in tape, remove the oil pump assembly by prying out between the cylinder head and cylinder block.
      NOTE: Be careful not to damage the contact surfaces of the oil pump assembly, cylinder head and cylinder block.
      Fig 23: Remove The Oil Pump Assembly By Prying Out Between The Cylinder Head And Cylinder Block
      G02617107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 O-rings.
      Fig 24: Remove The 2 O-Rings
      G02617108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. Remove Oil Pump Seal 
    1. Using a screwdriver with its tip wrapped in tape, remove the oil seal.
      Fig 25: Remove Oil Pump Seal
      G02617109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. Install Oil Pump Seal 
    1. Using SST, uniformly tap in a new oil seal until its surface is flush with the oil pump edge.

      SST 09950-60010 (09951-00250, 09951-00380, 09952-06010), 09950-70010 (09951-07100)

      HINT:

      Be careful not to tap the oil seal at an angle.

    2. Apply a light coat of multipurpose grease No. 2 to the lip of the new oil seal.
      NOTE: Keep the lip free of foreign objects.
      Fig 26: Install Oil Pump Seal
      G02617110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. Install Oil Pump Assembly 
    1. Install 2 new O-rings to the 2 locations as shown in the illustration.
    2. Apply seal packing to the engine body and oil pump as shown in the illustration below.

      Seal packing: 

      Water pump part part No. 08826-00100 or equivalent 

      Other part part No. 08826-00080 or equivalent 

      NOTE:
      • Remove pump any oil from the contact surface.
      • Install the oil pump within 3 minutes, and tighten the bolts within 15 minutes after applying seal packing.
      • Do not expose the seal packing to engine oil within 2 hours of installation.
      Fig 27: Install 2 New O-Rings To The 2 Locations
      G02617111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 28: Apply Seal Packing To The Engine Body And Oil Pump
      G02617112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the drive rotor spline of the oil pump with the rectangular portion of the crankshaft, then slide the oil pump assembly into place.
      Fig 29: Align The Drive Rotor Spline Of The Oil Pump With The Rectangular Portion Of The Crankshaft
      G02617113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a Torx socket wrench E8, install the stud bolt.

      Torque: 10 N.m (102 kgf.cm, 7.4 ft.lbf) 

      Fig 30: Using A Torx Socket Wrench E8, Install The Stud Bolt
      G02617114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the oil pump assembly with the 15 bolts and nut as illustrated.

      Torque: 

      32 N.m (326 kgf.cm, 24 ft.lbf) for bolt A 

      11 N.m (112 kgf.cm, 8.1 ft.lbf) for bolt B 

      11 N.m (112 kgf.cm, 8.1 ft.lbf) for bolt C 

      24 N.m (245 kgf.cm, 18 ft.lbf) for nut D 

      24 N.m (245 kgf.cm, 18 ft.lbf) for bolt E 

      NOTE:
      • Be careful that the chain does not contact the seal packing when installing the oil pump assembly.
      • Install the engine mounting bracket RH and water pump assembly within 15 minutes after installing the oil pump assembly.
      Fig 31: Install The Oil Pump Assembly With The 15 Bolts And Nut
      G02617115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. Install Crank Position Sensor. See  Figure . 
  33. Install Camshaft Timing Oil Control Valve Assembly 
    1. Apply a light coat of engine oil to the O-ring.
    2. Install the camshaft timing oil control valve assembly with the bolt.

      Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

  34. Install Transverse Engine Engine Mounting Bracket 

    Torque: 55 N.m (561 kgf.cm, 41 ft.lbf) 

  35. Install Engine Mounting Spacer 

    Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

  36. Install Engine Mounting Insulator Sub-Assy RH 
    1. Install the engine mounting insulator RH with the 3 bolts and 4 nuts.

      Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

      Fig 32: Install The Engine Mounting Insulator With The 3 Bolts And 4 Nuts
      G02617116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. Install Crankshaft Damper Sub-Assembly 
    1. Align the hole of the crankshaft damper with the straight pin, then install the crankshaft damper.
    2. Using SST, hold the crankshaft damper and tighten the crankshaft bolt.

      SST 09213-58013 (91111-50845), 09330-00021

      Torque: 128 N.m (1305 kgf.cm, 95 ft.lbf) 

      NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.
      Fig 33: Using SST, Hold The Crankshaft Damper And Tighten The Crankshaft Bolt
      G02617117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. Install Water Pump Assembly. See  REPLACEMENT 

    SST 09960-10010 (09962-01000, 09963-00600)

  39. Install Fan And Generator V Belt. See  REPLACEMENT  . 
  40. Inspect Drive Belt Deflection And Tension. See  SERVICE DATA  . 
  41. Install Vacuum Switching Valve Assembly No. 2 
  42. Install Cylinder Head Cover Sub-Assembly 
    1. Apply seal packing to the 2 locations as shown in the illustration, then install the cylinder head cover.

      Seal packing: Part No. 08826-00080 or equivalent 

      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover within 3 minutes after applying seal packing.
      • Do not start the engine within 2 hours of installing.
      Fig 34: Apply Seal Packing To The 2 Locations
      G02617118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cylinder head cover with the 9 bolts and 2 nuts.
      3. Fig 35: Install The Cylinder Head Cover With The 9 Bolts And 2 Nuts
      G02617119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using several steps, tighten the bolts and nuts with the specified torque in the sequence shown in the illustration.

      Torque: 10 N.m (102 kgf.cm, 74 ft.lbf) 

    4. Install the ignition coil with the bolt.

      Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

    5. Install the brake master cylinder reservoir cover to the cylinder head cover.
    6. Install the wire harness and brake master cylinder reservoir cover with the 3 bolts.

      Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 

    7. Connect the fuel injector connector and ignition coil connector.
  43. Install Windshield Washer Jar Assembly 

    Torque: 

    4.9 N.m (50 kgf.cm, 43 in.lbf) for bolt A 

    14 N.m (143 kgf.cm, 10 ft.lbf) for bolt B 

    5.5 N.m (56 kgf.cm, 49 in.lbf) for nut 

    Fig 36: Install Windshield Washer Jar Assembly
    G02617120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. Install Reservoir Bracket 

    Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) 

  45. Install Brake Master Cylinder Reservoir Sub-Assembly 

    Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) 

  46. Install Air Cleaner Inlet No. 2 
  47. Install Air Cleaner Assembly 

    Torque: 

    7.0 N.m (71 kgf.cm, 62 in.lbf) for Bolt 

    3.0 N.m (31 kgf.cm, 27 in.lbf) for Clamp 

  48. Install Cowl Top Panel Sub-Assembly Outer Front. See  Figure . 
  49. Install Windshield Wiper Link Assembly. See  Figure . 
  50. Add Engine Oil. 
  51. Connect Battery Negative Terminal 

    Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 

  52. Install Rear Floor Board No. 3 
  53. Install Deck Floor Box Rear 
  54. Install Rear Floor Board No .2 
  55. Add Engine Coolant. See  REPLACEMENT  . 
  56. Check For Engine Coolant Leaks 
  57. Inspect Engine Oil Leaks 
  58. Install Radiator Support Opening Cover 
  59. Install Engine Under Cover RH 
  60. Install Engine Under Cover LH 
  61. Install Front Wheel RH 

    Torque: 103 N.m (1050 kgf.cm, 76 ft.lbf) 

  62. Power Window Control System Initialize. See  INITIALIZATION  . 
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