Toyota RAV4 2000-05

Oil Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Right-hand engine undercover
     

  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Front exhaust pipe
     
    Rear end stiffener plate
     
    Oil dipstick
     
    17 bolts and 2 nuts from the oil pan
     

  8.  
  9. Insert the blade of the Oil Pan Seal Cutting tool 09032-00100 between the oil pan and the cylinder block; then, cut off the applied sealer and remove the oil pan
    NOTE
    Do not use the tool for the oil pump body side and rear oil seal retainer.

  10.  
  11. Remove the bolts, nuts, oil strainer and gasket.
  12.  
  13. Carefully suspend the engine with a sling device.
  14.  
  15. Remove or disconnect the following:

    Timing belt
     
    No. 2 idler pulley and crankshaft timing pulley
     
    Oil pump-s pulley, using the Variable Pin Wrench Set 09960-10010
     
    Crankshaft Position (CKP) sensor
     
    Oil pump, by discarding the gasket
     

  16.  

To install:

  1. Install or connect the following:
    NOTE
    The long bolts are 35mm and all the others are 25mm.



    Oil pump, using a new gasket. Tighten the 12 bolts to 82 inch lbs. (9 Nm).
     



    CKP sensor
     
    Oil pump pulley. Tighten the nut to 18 ft. lbs. (24 Nm).
     
    Crankshaft timing pulley and No. 2 idler pulley
     
    Timing belt
     

  2.  
  3. Remove the engine sling.
  4.  
  5. Install the oil strainer with a new gasket. Tighten the nuts/bolts to 48 inch lbs. (5 Nm).
  6.  
  7. Remove any old sealant from the oil pan flange and thoroughly clean both sealing surfaces.
  8.  
  9. Apply a 3-5mm bead of sealant to the oil pan flange.
    NOTE
    The pan must be installed within 5 minutes of sealant application or the procedure will have to be repeated.

  10.  
  11. Install or connect the following:

    Oil pan. Tighten the 17 bolts and 2 nuts to 48 inch lbs. (5 Nm).
     
    Dipstick
     
    Rear end stiffener plate. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Front exhaust pipe
     
    Negative battery cable
     
    Hood
     

  12.  
  13. Refill the engine with oil.
    WARNING
    Be sure to prime the oil pump prior to initial engine start-up or engine damage may occur because of low oil pressure.

  14.  
  15. Start the engine and check for leaks.
  16.  
  17. Recheck the engine oil level.
  18.  
  19. Install the right-hand engine undercover.
  20.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Right-hand engine undercover
     

  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Front exhaust pipe
     
    Rear end stiffener plate
     
    Oil dipstick
     
    17 bolts and 2 nuts from the oil pan
     

  8.  
  9. Insert the blade of the Oil Pan Seal Cutting tool 09032-00100 between the oil pan and the cylinder block; then, cut off the applied sealer and remove the oil pan
  10.  


NOTE
Do not use the tool for the oil pump body side and rear oil seal retainer.

  1. Remove the bolts, nuts, oil strainer and gasket.
  2.  
  3. Carefully suspend the engine with a sling device.
  4.  
  5. Remove or disconnect the following:

    Timing belt
     
    No. 2 idler pulley and crankshaft timing pulley
     
    Oil pump-s pulley, using the Variable Pin Wrench Set 09960-10010
     
    Crankshaft Position (CKP) sensor
     
    Oil pump, by discarding the gasket
     

  6.  

To install:

  1. Install or connect the following:

    Oil pump, using a new gasket. Tighten the 12 bolts to 82 inch lbs. (9 Nm).
     

  2.  


NOTE
The long bolts are 35mm and all the others are 25mm.



CKP sensor
 
Oil pump pulley. Tighten the nut to 18 ft. lbs. (24 Nm).
 
Crankshaft timing pulley and No. 2 idler pulley
 
Timing belt
 

  1. Remove the engine sling.
  2.  
  3. Install the oil strainer with a new gasket. Tighten the nuts/bolts to 48 inch lbs. (5 Nm).
  4.  
  5. Remove any old sealant from the oil pan flange and thoroughly clean both sealing surfaces.
  6.  
  7. Apply a 3-5mm bead of sealant to the oil pan flange.
  8.  


NOTE
The pan must be installed within 5 minutes of sealant application or the procedure will have to be repeated.

  1. Install or connect the following:

    Oil pan. Tighten the 17 bolts and 2 nuts to 48 inch lbs. (5 Nm).
     
    Dipstick
     
    Rear end stiffener plate. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Front exhaust pipe
     
    Negative battery cable
     
    Hood
     

  2.  
  3. Refill the engine with oil.
  4.  


WARNING
Be sure to prime the oil pump prior to initial engine start-up or engine damage may occur because of low oil pressure.

  1. Start the engine and check for leaks.
  2.  
  3. Recheck the engine oil level.
  4.  
  5. Install the right-hand engine undercover.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Right side engine undercover
     

  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Front exhaust pipe
     
    Rear end stiffener plate
     
    Oil dipstick
     
    17 bolts and 2 nuts from the oil pan
     

  8.  
  9. Insert the blade of the Oil Pan Seal Cutting tool 09032-00100 between the oil pan and the cylinder block; then, cut off the applied sealer and remove the oil pan.
    NOTE
    Do not use the tool for the oil pump body side and rear oil seal retainer.

  10.  
  11. Remove the bolts, nuts, oil strainer and gasket.
  12.  
  13. Carefully suspend the engine with a sling device.
  14.  
  15. Remove or disconnect the following:

    Timing belt
     
    No. 2 idler pulley and crankshaft timing pulley
     
    Oil pump-s pulley, using the Variable Pin Wrench Set 09960-10010
     
    Crankshaft Position (CKP) sensor
     
    Oil pump, by discarding the gasket
     

  16.  

To install:

  1. Install or connect the following:
    NOTE
    The long bolts are 35mm and all the others are 25mm.



    Oil pump, using a new gasket. Tighten the 12 bolts to 82 inch lbs. (9 Nm).
     



    CKP sensor
     
    Oil pump pulley. Tighten the nut to 18 ft. lbs. (24 Nm).
     
    Crankshaft timing pulley and No. 2 idler pulley
     
    Timing belt
     

  2.  
  3. Remove the engine sling.
  4.  
  5. Install the oil strainer with a new gasket. Tighten the nuts/bolts to 48 inch lbs. (5 Nm).
  6.  
  7. Remove any old sealant from the oil pan flange and thoroughly clean both sealing surfaces.
  8.  
  9. Apply a 3-5mm bead of sealant to the oil pan flange.
    NOTE
    The pan must be installed within 5 minutes of sealant application or the procedure will have to be repeated.

  10.  
  11. Install or connect the following:

    Oil pan. Tighten the 17 bolts and 2 nuts to 48 inch lbs. (5 Nm).
     
    Dipstick
     
    Rear end stiffener plate. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Front exhaust pipe
     
    Negative battery cable
     
    Hood
     

  12.  
  13. Refill the engine with oil.
    WARNING
    Be sure to prime the oil pump prior to initial engine start-up or engine damage may occur because of low oil pressure.

  14.  
  15. Start the engine and check for leaks.
  16.  
  17. Recheck the engine oil level.
  18.  
  19. Install the right side engine undercover.
  20.  

2.4L Engine


Click image to see an enlarged view

Fig. Oil pump-2.4L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    Wait at least 90 seconds after disconnecting the negative battery cable before starting any repair work to prevent air bag and seat belt pretensioner activation.

  4.  
  5. Drain the oil.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the ABS actuator.

    Click image to see an enlarged view

    Fig. ABS actuator removal-2.4L engine

  10.  
  11. Remove the right engine mount insulator.
  12.  
  13. Remove the timing chain.
  14.  
  15. Remove the crankshaft sprocket.
  16.  
  17. Remove the oil pump drive chain and sprockets.
  18.  
  19. Remove the 3 bolts and the oil pump.
  20.  
  21. If disassembling, remove the relief valve spring. Remove the pump body cover.
  22.  
  23. Check the clearance between the tip of the drive rotor and the driven rotor. Clearance should be 0.0138 inch max.
  24.  
  25. Place a straight-edge across the rotors and pump body. Check the side clearance. Clearance should be 0.0063 inch max.
  26.  
  27. Check the clearance between the driven rotor and pump body. Clearance should be 0.0128 inch max.
  28.  
  29. Install the cover. Torque to 78 inch lbs. (8.8 Nm).
  30.  
  31. Install the relief valve. Torque to 36 ft. lbs. (49 Nm).
  32.  
  33. Install the strainer assembly. Torque to 78 inch lbs. (8.8 Nm).
  34.  

To install:

  1. Install the pump with a new gasket. Torque to 14 ft. lbs. (19 Nm).

    Click image to see an enlarged view

    Fig. The crankshaft key should be at the 9:00 o-clock position and the cutout on the oil pump shaft should be at the 12:00 o-clock position-2001-2005 2.4L engine



    Click image to see an enlarged view

    Fig. The sprocket timing marks should align with the colored chain links-2.4L engine



    Click image to see an enlarged view

    Fig. Tension spring positioning-2.4L engine

  2.  
  3. Install the drive chain and sprockets. The crankshaft key should be at the 9:00 o-clock position and the cutout on the oil pump shaft should be at the 12:00 o-clock position. The sprocket timing marks should align with the colored chain links. Torque the sprocket nut to 22 ft. lbs. (29 Nm).
  4.  
  5. Install the tensioner. Torque to 9 ft. lbs. (12 Nm).
  6.  
  7. Install the oil pan.
  8.  
  9. The remainder of installation is the reverse of removal. Torque the exhaust pipe-to-manifold nuts to 32 ft. lbs. (43 Nm); the pipe-to-pipe nuts to 36 ft. lbs. (49 Nm).
  10.  

Inspection
  1. Remove the relief valve spring.
  2.  
  3. Remove the pump body cover.
  4.  
  5. Check the clearance between the tip of the drive rotor and the driven rotor. Clearance should be 0.0138 inch max.
  6.  
  7. Place a straight-edge across the rotors and pump body. Check the side clearance. Clearance should be 0.0063 inch max.
  8.  
  9. Check the clearance between the driven rotor and pump body. Clearance should be 0.0128 inch max.
  10.  

Installation
  1. Install the pump with a new gasket. Torque to 14 ft. lbs. (19 Nm).
  2.  
  3. Install the drive chain and sprockets. The crankshaft key should be at the 9:00 o-clock position and the cutout on the oil pump shaft should be at the 12:00 o-clock position. The sprocket timing marks should align with the colored chain links. Torque the sprocket nut to 22 ft. lbs. (29 Nm).
  4.  
  5. Install the tensioner. Torque to 9 ft. lbs. (12 Nm).
  6.  
  7. Install the oil pan.
  8.  
  9. The remainder of installation is the reverse of removal. Torque the exhaust pipe-to-manifold nuts to 32 ft. lbs. (43 Nm); the pip-to-pipe nuts to 36 ft. lbs. (49 Nm).
  10.  


    Click image to see an enlarged view

    Fig. The crankshaft key should be at the 9:00 o-clock position and the cutout on the oil pump shaft should be at the 12:00 o-clock position-2.4L engine



    Click image to see an enlarged view

    Fig. The sprocket timing marks should align with the colored chain links-2.4L engine



    Click image to see an enlarged view

    Fig. Tension spring positioning-2.4L engine


Reassembly
  1. Install the cover. Torque to 78 inch lbs. (8.8 Nm).
  2.  
  3. Install the relief valve. Torque to 36 ft. lbs. (49 Nm).
  4.  
  5. Install the strainer assembly. Torque to 78 inch lbs. (8.8 Nm).
  6.  

Removal


Click image to see an enlarged view

Fig. Oil pump-2.4L engine

  1. Drain the oil.
  2.  
  3. Remove the oil pan.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the ABS actuator.
  8.  
  9. Remove the right engine mount insulator.
  10.  
  11. Remove the timing chain.
  12.  
  13. Remove the crankshaft sprocket.
  14.  
  15. Remove the oil pump drive chain and sprockets.
  16.  
  17. Remove the 3 bolts and the oil pump.
  18.  


    Click image to see an enlarged view

    Fig. ABS actuator removal


 
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