Toyota 4Runner 2001-06

Oil Pan

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Removal & Installation



1GR-FE Engine

The 4.0L (1GR-FE) Engine uses a two piece oil pan, consisting of a lower (No. 2) and upper oil pan.

  1. Drain the engine oil.
  2.  
  3. Raise and safely support the front end with suitable jackstands.
  4.  
  5. Remove the under covers.
  6.  
  7. Remove the oil dipstick tube.
  8.  
  9. If equipped with 4WD, disconnect and lower the front axle as far as possible for clearance.
  10.  
  11. Remove the 10 bolts and two nuts from the lower oil pan.
  12.  
  13. The lower oil pan is sealed with a Formed-In-Place Gasket (FIPG) sealer and it may be difficult to break the seal. Toyota recommends their special tool (09032-00100), which is a blade, mounted in a holder that can be tapped with a hammer. The blade is positioned at the seal joint and tapped with a hammer around the oil pan flange, cutting the seal. Cut the sealer to break the lower oil pan loose.
    WARNING
    Use care not to damage the oil pan flange when removing the oil pan.

  14.  
  15. Remove the oil strainer and gasket.
  16.  
  17. Remove the four flywheel housing cover bolts and remove the housing under cover.
  18.  
  19. Remove the upper oil pan mounting bolts and nuts.
  20.  
  21. Using a suitable prybar, pry loose the upper pan at the locations shown and remove the pan.
  22.  
  23. Remove the O-ring from the oil pump body.

    Click image to see an enlarged view

    Fig. Upper oil pan fastener locations-4.0L (1GR-FE) Engine



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    Fig. Upper oil pan prying locations-4.0L (1GR-FE) Engine



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    Fig. Replace the oil pump body O-ring when removing the upper oil pan-4.0L (1GR-FE) Engine

  24.  

To install:

  1. Clean the mating surfaces of the lower and upper pan.
  2.  
  3. Install a new O-ring on the oil pump body.
  4.  
  5. Apply a continuous 3-4mm dia. bead of silicone gasket material to the upper oil pan mating surface. If parts are not assembled within three minutes of applying time, the sealer starts to skin over and cure, the effectiveness of the sealer is lost, and must be removed and reapplied.

    Click image to see an enlarged view

    Fig. Apply a continuous 3-4mm dia. bead of silicone gasket material to the upper oil pan-4.0L engine

  6.  
  7. Install the upper oil pan and tighten the bolts evenly and in several passes, to:

    10mm head: 80 inch lbs. (9 Nm)
     
    12mm head: 14 ft. lbs. (19 Nm)
     

  8.  
  9. The bolts are different lengths. See the illustration for identification.

    A: 25mm
     
    B: 40mm
     
    C: 14mm

    Click image to see an enlarged view

    Fig. Upper oil pan bolt identification-4.0L engine

     

  10.  
  11. Install the four flywheel housing cover bolts and tighten to 27 ft. lbs. (37 Nm).
  12.  
  13. Insert the flywheel housing under cover.
  14.  
  15. Install the oil strainer using a new gasket. Tighten the mounting nuts to 80 inch lbs. (9 Nm).
  16.  
  17. Apply a continuous 3-4mm diameter bead of silicone gasket material to the lower oil pan mating surface. If parts are not assembled within three minutes of applying time, the sealer starts to skin over and cure, the effectiveness of the sealer is lost, and must be removed and reapplied.
  18.  
  19. Install the lower pan and tighten the mounting bolts and nuts to 80 inch lbs. (9 Nm).
  20.  
  21. Reconnect the front axle components if previously disconnected.
  22.  
  23. Install a new O-ring to the oil dipstick tube. Apply a light coat of clean engine oil to the O-ring. Push the dipstick tube into the guide hole of the oil pan. Tighten the mounting bolt to 80 inch lbs. (9 Nm).
  24.  
  25. Reinstall the engine under covers.
  26.  
  27. Fill the engine with oil to the correct level.
  28.  
  29. Start the engine and check for leaks.
  30.  

2RZ-FE & 3RZ-FE Engines
  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the 16 mounting bolts and two nuts to the oil pan.
  10.  
  11. Remove the oil pan from the engine.
  12.  

Be careful not to damage the oil pan flanges of the oil pan and cylinder block.

To install:

  1. Before installing the oil pans, thoroughly clean the contact surfaces.
  2.  
  3. Apply sealant 08826-00080 or equivalent Formed In-Place Gasket (FIPG) sealer to the oil pan. Parts should be assembled within five minutes of application. Otherwise the sealer starts to skin over, looses its effectiveness and must be removed and reapplied.
  4.  
  5. Install the oil pan and mounting bolts. Tighten the bolts and nuts to 9 ft. lbs. (13 Nm).
  6.  
  7. Install the engine undercover. Lower the vehicle.
  8.  
  9. Fill the engine with oil. Connect the negative battery cable, start the engine and check for leaks.
  10.  

2UZ-FE Engine

Like some of the other Toyota truck engines, the 4.7L (2UZ-FE) Engine uses a two-piece oil pan, separated by a baffle plate. Toyota calls the upper part of the oil pan the No. 1 oil pan, while the lower section is called the No. 2 oil pan. Please note that the oil pump is not inside the oil pan. The oil pump body bolts to the front of the engine, driven off the front of the crankshaft. For oil pump removal and installation, please see -Oil Pump,- -Removal and Installation- in this section.

Oil pan removal and installation is a major job since Toyota recommends that the engine be removed from the vehicle for oil pump and oil pan service. Toyota specifies that when the oil pump is services, the oil pan and strainer should be removed and cleaned. Oil pan installation takes some care since the pan must be positioned very precisely. This is best done with the engine out of the vehicle and mounted on an appropriate engine stand. Use care and keep all parts as clean as possible.

The following procedure is based on Toyota-s oil pump and oil pan service procedures that include removing the engine from the vehicle.

  1. Remove the engine from the vehicle.
  2.  
  3. Mount the engine to a suitable engine stand.
  4.  
  5. Remove the oil dipstick.
  6.  
  7. Remove the lower half of the oil pan (Toyota calls it the No. 2 oil pan). There should be 24 bolts and two nuts. The lower oil pan is sealed with a Formed-In-Place Gasket (FIPG) sealer and it may be difficult to break the seal. Toyota recommends their special tool, which is a blade, mounted in a holder that can be tapped with a hammer. The blade is positioned at the seal joint and tapped with a hammer around the oil pan flange, cutting the seal. Use care not to damage the oil pan sealing flanges, especially if using substitute tools.

    Click image to see an enlarged view

    Fig. Numerous engine components must be removed to service this two-piece oil pan-4.7L (2UZ-FE) Engine



    Click image to see an enlarged view

    Fig. Apply Formed In-Place Gasket (FIPG) sealer in places indicated-4.7L (2UZ-FE) Engine

  8.  
  9. Between the lower oil pan and the upper oil pan (Toyota calls it the No. 1 oil pan), there is a baffle plate. Remove the two bolts and two nuts and separate the baffle plate from the upper oil pan.
    NOTE
    The upper oil pan uses four different length bolts. Take care to correctly identify each bolt, its length and location. It is good practice to punch holes in a piece of corrugated cardboard to closely resemble the bolt pattern of the upper oil pan. Insert the bolts in the cardboard in their corresponding locations as they are removed.

  10.  
  11. Remove the 18 bolts and two nuts from the upper pan. There are several points around the pan and engine block where it is approved to pry the upper pan from the block. Use care not to damage the sealing surface of the engine block or the upper oil pan.
  12.  

To install:

  1. Clean all parts well. If necessary, remove the two bolts and two nuts and remove the oil strainer and gasket. Clean the strainer well. Install the strainer with a new gasket and torque the fasteners to 66 inch lbs. (7.5 Nm).
  2.  
  3. Make sure all old FIPG sealer is removed. The pan sealing flanges and the engine block sealing surfaces must be clean of all oil and grease or the new FIPG sealer will not work. Apply a 1 / 8 inch (3mm) bead of FIPG sealer to the upper oil pan flange. If pan is not installed within three minutes of applying time, the sealer starts to skin over and cure, the effectiveness of the sealer is lost, and must be removed and reapplied. Install the bolts just a few turns, making sure all bolt holes line up. Make sure the clearance between the rear ends of the upper oil pan and the engine block is 0.008 inch (0.2mm) or less. If the clearance is more than this, the upper oil pan will be stretched. Uniformly torque the bolts and nuts in several passes as follows:
    1. Tighten all bolts with a 10mm head to 66 inch lbs. (7.5 Nm).
    2.  
    3. Tighten all bolts with a 12mm head to 21 ft. lbs. (28 Nm).

      Click image to see an enlarged view

      Fig. Upper oil pan bolt identification-4.7L (2UZ-FE) Engine

    4.  

  4.  
  5. Install the oil pan baffle plate and tighten the nuts and bolts to 66 inch lbs. (7.5 Nm).
  6.  
  7. Install the lower oil pan. It should be clean of any old sealer and any oil or grease. Apply a 1 / 8 inch (3mm) bead of FIPG sealer to the lower oil pan flange and install the oil pan to the upper oil pan without hesitation, before the sealer starts to cure. Install the bolts just a few turns, making sure all bolt holes line up. When satisfied with the lower oil pans position, uniformly tighten the nuts and bolts, in several passes, ending with a torque of 66 inch lbs. (7.5 Nm).
  8.  
  9. Install the engine into the vehicle using the procedures found in this section.
  10.  

5VZ-FE Engine


Click image to see an enlarged view

Fig. Oil pan and related parts-3.4L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Engine undercover
     
    Front differential, if equipped with 4WD
     
    Oil pan, separate it from the engine using SST 09032-00100 and a brass bar
     

  8.  

To install:

  1. Apply seal packing to the oil pan.
  2.  
  3. Install the oil pan to the cylinder block. Tighten the nuts and bolts to 108 inch lbs. (13 Nm)
  4.  


WARNING
If parts are not assembled within 5 minutes of applying time, the effectiveness of the seal packing is lost and must be removed and reapplied.

  1. Install or connect the following:

    Front differential, if removed
     
    Engine undercover
     
    Negative battery cable
     

  2.  
  3. Fill with engine oil.
  4.  
  5. Start the engine and check for leaks.
  6.  



Click image to see an enlarged view

Fig. Removing the oil pan bolts



Click image to see an enlarged view

Fig. A special tool is available to cut through the Formed In-Place Gasket (FIPG) sealant used on the oil pan



Click image to see an enlarged view

Fig. Carefully lower the oil pan



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Fig. View of the oil pan and mounting bolt hole locations



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Fig. Oil pan baffle plate



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Fig. Exploded view of the oil pan and related components on the 3.4L (5VZ-FE) Engine



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Fig. Make sure to clean all old gasket material from the oil pan



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Fig. Toyota-s factory Formed In-Place Gasket (FIPG) sealer



Click image to see an enlarged view

Fig. Formed In-Place Gasket (FIPG) sealer applied to the oil pan

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the crankshaft timing pulley. For additional information, refer to the following topic: -Crankshaft Damper, Removal & Installation-.
  8.  
  9. If equipped with 4WD, remove the front differential.
  10.  
  11. If equipped with A/T, remove the oil cooler tube and clamp.
  12.  
  13. Remove the stiffener plate.
  14.  
  15. Unbolt the flywheel housing dust cover.
  16.  
  17. Disconnect the starter wire clamp.
  18.  
  19. Remove the crankshaft position sensor.
  20.  
  21. Unbolt and lower the oil pan.
  22.  
  23. Using SST 09032-00100 or equivalent and a brass bar, separate the oil pan from the cylinder block.
    WARNING
    Use care not to damage the oil pan flange when removing the oil pan.

  24.  

To install:

  1. Use a razor blade or equivalent to scrape the cylinder block and oil pan mating surfaces of any old sealing material. All traces of the old gasket and sealer must be removed.
  2.  
  3. Clean the pan thoroughly, using solvent if necessary. If the pan has a magnet in it, examine it closely. Excess metal is a sign of engine wear. A few slivers are normal. Use good judgment in relating the amount of debris to the amount of time the pan has been in place.
  4.  
  5. Install the crankshaft position sensor.
  6.  
  7. Apply Formed In-Place Gasket (FIPG) sealer to the oil pan and install the pan to the cylinder block. Tighten the nuts and bolts to 66 inch lbs. (8 Nm). If parts are not assembled within five minutes of applying time, the sealer starts to skin over and cure, the effectiveness of the sealer is lost, and must be removed and reapplied.
  8.  
  9. Attach the flywheel housing under and cover dust.
  10.  
  11. Install the stiffener plate.
  12.  
  13. Connect the starter wire clamp.
  14.  
  15. If equipped with A/T, install the oil cooler tube and clamp.
  16.  
  17. Reinstall the crankshaft timing pulley.
  18.  
  19. On the 4WD, install the front differential.
  20.  
  21. Install the engine undercover.
  22.  
  23. Lower the vehicle.
  24.  
  25. Fill with engine oil.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and check for leaks.
  30.  

 
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