Removal and Replacement
OIL PUMPCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
REMOVAL
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE ENGINE UNDER COVER RH
4. DRAIN ENGINE OIL
(a) Install a new gasket after draining engine oil.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
5. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
6. REMOVE V BELT NO.1
7. REMOVE VANE PUMP V BELT
8. REMOVE ENGINE MOVING CONTROL ROD
9. REMOVE ENGINE MOUNTING STAY NO.2 RH
10. REMOVE GENERATOR BRACKET NO.2
11. REMOVE CRANKSHAFT PULLEY
12. REMOVE TIMING BELT NO.1 COVER
13. REMOVE TIMING BELT NO.2 COVER
14. REMOVE ENGINE MOUNTING BRACKET RH
15. REMOVE TIMING BELT GUIDE NO.2
16. REMOVE TIMING BELT
17. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
18. REMOVE FRONT EXHAUST PIPE ASSEMBLY
19. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1
20. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
(a) Remove the 2 bolts, nut and drive belt adjusting bar bracket.
(b) Remove the 2 nuts and generator bracket adjusting bar with the wire harness clamp bracket.
(c) Disconnect the compressor, magnetic clutch connector and wire harness clamp.
(d) Remove the 3 bolts, compressor and magnetic clutch.
HINT: Hang up the hoses instead of detaching.
21. REMOVE NO.2 TIMING BELT IDLER SUB-ASSEMBLY
22. REMOVE CAMSHAFT TIMING PULLEY
23. REMOVE NO.1 TIMING BELT IDLER SUB-ASSEMBLY
(a) Using a 10 mm socket hexagon wrench, remove the timing belt idler and plate washer.
24. REMOVE CRANKSHAFT TIMING PULLEY
25. REMOVE TIMING BELT NO.3 COVER
26. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
(a) Remove the 2 bolts and mounting bracket.
27. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt and gage guide.
28. SEPARATE ENGINE MOUNTING INSULATOR
(a) Remove the 3 nuts and bolt. Then separate the engine mounting insulator.
NOTICE: Do not remove the engine mounting insulator.
29. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the bolt and disconnect the power steering return hose clamp from the frame.
(b) Remove the 4 nuts.
(c) Prepare a jack. Place a wooden block on the jack and set the jack under the engine. Remove the engine mounting insulator.
(d) Raise the jack and lift up the engine. Then remove the engine mounting insulator RH.
NOTICE: Be careful not to damage the contact surfaces of the oil pan.
30. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 4 bolts, nut and bracket.
31. REMOVE NO.2 OIL PAN SUB-ASSEMBLY
(a) Remove the 10 bolts, 2 nuts and oil pan.
(b) Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, cut through the sealer and remove oil pan No. 2.
SST 09032-00100
NOTICE:
^ Do not damage the contact surface of oil pan No. 1 and oil pan No. 2.
^ Do not damage the flange portion of oil pan No. 2 during removal.
32. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the bolt, 2 nuts, oil strainer and gasket.
33. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 2 bolts and flywheel housing under cover.
(b) Uniformly loosen the 17 bolts and 2 nuts. Remove the bolts and nuts.
(c) Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan shown in the illustration.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
34. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
35. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 9 bolts.
(b) Using a screwdriver, remove the oil pump by prying between the oil pump and main bearing cap.
(c) Remove the O-ring.
INSTALLATION
1. INSTALL OIL PUMP ASSEMBLY
(a) Using SST and a hammer, install a new oil seal. Tap the surface of the SST with the hammer until the oil seal's surface is flush with oil pump body edge.
SST 09223-00010
NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the gap between the oil pump body edge and oil seal free from contamination.
(b) Apply a small amount of MP grease to the oil seal lip.
(c) Remove any old seal packing material from the contact surface.
(d) Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.
(e) Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
^ Remove any oil from contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing the oil pump.
(f) Align the key of the oil pump drive gear with the key way located on the crankshaft, and slide the oil pump into place.
(g) Install the oil pump by tightening the 9 bolts uniformly.
Torque:
Bolt A 8.0 Nm (82 kgf-cm, 71 inch lbs.)
Bolt B 20 Nm (203 kgf-cm, 15 ft. lbs.)
Bolt C 43 Nm (439 kgf-cm, 32 ft. lbs.)
2. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
3. INSTALL OIL PAN SUB-ASSEMBLY
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the outer side of the bolt holes in the region "X".
^ Apply seal packing to the inner side of the bolt holes in the region "Y".
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing the oil pan.
(c) Install the oil pan No. 1 by tightening the oil pan's 17 bolts and 2 nuts uniformly.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (204 kgf-cm, 15 ft. lbs.)
14 mm head 37 Nm (379 kgf-cm, 27 ft. lbs.)
(d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
4. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
5. INSTALL NO.2 OIL PAN SUB-ASSEMBLY
(a) Remove any old seal packing from the contact surface.
(b) Apply a continuous bead of seal packing (diameter: 4 to 5 mm (0.16 to 0.20 inch)) as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing the oil pan.
(c) Install the oil pan with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
6. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH.
Torque:
Bolt A 54 Nm (550 kgf-cm, 40 ft. lbs.)
Nut B 54 Nm (550 kgf-cm, 40 ft. lbs.)
Bolt C 43 Nm (439 kgf-cm, 32 ft. lbs.)
7. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH.
Torque:
Nut A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Nut B 87 Nm (887 kgf-cm, 64 ft. lbs.)
8. INSTALL ENGINE MOUNTING INSULATOR
(a) Install the engine mounting insulator.
Torque:
Bolt A 87 Nm (887 kgf-cm, 64 ft. lbs.)
Nut B 52 Nm (531 kgf-cm, 38 ft. lbs.)
9. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O-ring to the gage guide.
(b) Install the gage guide with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
10. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
11. INSTALL TIMING BELT NO.3 COVER
12. INSTALL NO.1 TIMING BELT IDLER SUB-ASSEMBLY
(a) Using a 10 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
13. INSTALL NO.2 TIMING BELT IDLER SUB-ASSEMBLY
14. INSTALL CAMSHAFT TIMING PULLEY
15. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
16. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
17. INSTALL FRONT EXHAUST PIPE ASSEMBLY
18. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
19. INSPECT TIMING BELT
20. INSTALL TIMING BELT
21. INSTALL TIMING BELT TENSIONER ASSEMBLY
22. INSTALL TIMING BELT GUIDE NO.2
23. INSTALL ENGINE MOUNTING BRACKET RH
24. INSTALL TIMING BELT NO.2 COVER
25. INSTALL TIMING BELT NO.1 COVER
26. INSTALL CRANKSHAFT PULLEY
27. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft.lbs.)
28. INSTALL ENGINE MOUNTING STAY NO.2 RH
29. INSTALL ENGINE MOVING CONTROL ROD
30. INSTALL VANE PUMP V BELT
31. INSTALL V BELT NO.1
32. INSPECT DRIVE BELT TENSION
33. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
34. ADD ENGINE OIL
35. CHECK FOR ENGINE OIL LEAKS
36. INSTALL FRONT WHEEL RH
37. CHECK FOR EXHAUST GAS LEAKS