Toyota Tacoma 2002-06

Oil Pump

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Inspection



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the oil pump from the engine and disassemble it.
  4.  
  5. Coat the relief valve with engine oil and check that it falls smoothly into the valve hole by its own weight.
  6.  
  7. If it doesn-t, replace the relief valve. If necessary, replace the oil pump assembly.

    Click image to see an enlarged view

    Fig. Relief valve inspection

  8.  
  9. Place the drive and driven rotors into the oil pump body.
  10.  
  11. Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
  12.  
  13. Standard tip clearance is 0.060 to 0.160 mm (0.0024 to 0.0063 in.).
  14.  
  15. If the tip clearance is greater than maximum, replace the rotors as a set.

    Click image to see an enlarged view

    Fig. Measuring rotor tip clearance

  16.  
  17. Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.
  18.  
  19. Standard side clearance is 0.030 to 0.090 mm (0.0012 to 0.0035 in.).
  20.  
  21. If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.

    Click image to see an enlarged view

    Fig. Measuring side clearance

  22.  
  23. Using a feeler gauge, measure the clearance between the driven rotor and body.
  24.  
  25. Standard body clearance is 0.250 to 0.325 mm (0.0098 to 0.0128 in.).
  26.  
  27. If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.

    Click image to see an enlarged view

    Fig. Measuring body clearance

  28.  

Removal & Installation



1gr-FE Engine
2WD
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  6.  
  7. Drain the engine coolant. Drain the engine oil.
  8.  
  9. Remove the engine from the vehicle and position it in a suitable holding fixture.
  10.  
  11. Remove the oil level gauge guide. Remove the water inlet. Remove the belt tensioner.
  12.  
  13. Remove the idler pulley number two subassembly. Remove the idler pulley number one sub assembly. Remove the crankshaft pulley.
  14.  
  15. Remove the lower oil pan. Remove the strainer and pickup tube. Remove the upper oil pan.
  16.  
  17. Remove the ignition coil assembly. Remove the cylinder head cover. Remove the camshaft timing oil control valve assembly.
  18.  
  19. Remove the VVT sensor. Remove the oil filter bracket subassembly.
  20.  
  21. Remove the timing chain case cover retaining bolts. Remove the cover from the engine. Remove the O-ring from the left cylinder head.
    NOTE
    Carefully remove the cover by prying between the cover and the cylinder head or block with a suitable tool. Be sure to cover the tip of the suitable tool prior to usage. Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover.


    NOTE
    The oil pump gears are located inside the timing case cover.



    Click image to see an enlarged view

    Fig. Timing chain case cover removal points-4.0L engine

  22.  
  23. Remove the three bolts and remove the oil pipe. Remove the two O-rings. Remove the seven oil pump cover bolts. Remove the gears from the timing chain case cover. Remove the oil pump relief valve.
  24.  

To install:

  1. Coat the oil pump relief valve with clean engine oil. Install the plug, using a new gasket and tighten to 36 ft. lbs.
  2.  
  3. Coat the oil pump gears with clean engine oil. Position the gears in the timing chain case cover with the identification marks facing oil pump cover side. Install the cover. Alternately tighten the bolts to 80 inch lbs. Install the oil pipe, tighten the bolts to 80 inch lbs.
  4.  
  5. Install a new front case oil seal. Install a new O-ring onto the left cylinder head.
  6.  
  7. Apply continuous beads (0.12-0.16 inch in diameter) of seal packing, part number 08826-00080 or equivalent to the four locations shown in the illustration.

    Click image to see an enlarged view

    Fig. Timing chain case cover seal packing locating points-4.0L engine



    Click image to see an enlarged view

    Fig. Timing chain case cover sealant application-4.0L engine

  8.  
  9. Apply continuous beads (0.12-0.16 inch in diameter) of seal packing, part number 08826-00080 or equivalent to all parts except the water pump part: for the water pump part use, part number 08826-00080 or equivalent, to the timing chain cover. Do not apply seal packing to portion -A- in the illustration.
    NOTE
    Remove any oil from the contact surfaces. Install the timing chain case cover within three minutes and tighten the bolts within fifteen minutes of applying the seal packing.

  10.  
  11. Align the key way of the oil pump drive motor with the rectangular portion of the crankshaft timing gear and slide the timing chain case cover into place. Oil pump drive rotor spline alignment-4.0L engine

    Click image to see an enlarged view

    Fig.



    Click image to see an enlarged view

    Fig. Timing chain case cover bolt location and torque sequence-4.0L engine

  12.  
  13. Install the timing chain case cover bolts. Tighten the bolts and nuts uniformly in several steps to 17 ft. lbs.
    NOTE
    Do not wrap the chain and slipper over the timing chain case cover seal line.

  14.  
  15. Continue the installation in the reverse order of the removal procedure.
  16.  
  17. When installing the cylinder head cover apply a continuous bead (0.08-0.12 inch) of seal packing, part number 08826-00080 or equivalent, to the cylinder head. Install the seal washers onto the bolts. Install the cylinder head cover bolts and nuts. Tighten bolts -A- to 7.4 ft. lbs. Tighten bolts -B- to 80 inch lbs. Tighten nuts to 80 inch lbs.
    NOTE
    Be sure to remove any oil from the contact surfaces of the cylinder head cover and the cylinder head. Install the cover within three minutes after applying the seal packing. Tighten the bolts to specification within fifteen minutes after installing the cover. Do not add engine oil for at least two hours after installing the cover.

  18.  
  19. Be sure to fill the engine with the proper grade and type engine coolant.
  20.  
  21. Be sure to fill the engine with the proper grade and type engine oil.
  22.  
  23. Start the engine and check for leaks, correct as required.
  24.  

4WD
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  6.  
  7. Drain the engine coolant. Drain the engine oil.
  8.  
  9. Remove the power steering gear assembly.
  10.  
  11. If equipped with 4WD, remove the front differential carrier assembly.
  12.  
  13. Remove the V bank cover. Remove the radiator support to frame seal, left side. Remove the fan shroud.
  14.  
  15. Remove the air cleaner assembly. Remove the oil level gauge. Remove the water inlet.
  16.  
  17. Separate the vane pump assembly. Remove the alternator. Remove the air conditioning compressor and position it to the side.
  18.  
  19. Remove the belt tensioner assembly. Remove the idler pulley number two subassembly. Remove the idler pulley number one subassembly. Remove the crankshaft pulley.
  20.  
  21. Remove the lower oil pan. Remove the oil strainer and pickup tube assembly. Remove the upper oil pan.
  22.  
  23. Remove the intake manifold. Remove the cylinder head cover assembly.
  24.  
  25. Remove the camshaft timing oil control valve assembly. Remove the VVT sensor. Remove the oil filter bracket subassembly.
    NOTE
    Carefully remove the cover by prying between the cover and the cylinder head or block with a suitable tool. Be sure to cover the tip of the suitable tool prior to usage. Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover.


    NOTE
    The oil pump gears are located inside the timing case cover.

  26.  
  27. Remove the three bolts and remove the oil pipe. Remove the two O-rings. Remove the seven oil pump cover bolts. Remove the gears from the timing chain case cover. Remove the oil pump relief valve.
  28.  

To install:

  1. Coat the oil pump relief valve with clean engine oil. Install the plug, using a new gasket and tighten to 36 ft. lbs.
  2.  
  3. Coat the oil pump gears with clean engine oil. Position the gears in the timing chain case cover with the identification marks facing oil pump cover side. Install the cover. Alternately tighten the bolts to 80 inch lbs. Install the oil pipe, tighten the bolts to 80 inch lbs.
  4.  
  5. Install a new front case oil seal. Install a new O-ring onto the left cylinder head.
  6.  
  7. Apply continuous beads (0.12-0.16 inch in diameter) of seal packing, part number 08826-00080 or equivalent to the four locations shown in the illustration.
  8.  
  9. Apply continuous beads (0.12-0.16 inch in diameter) of seal packing, part number 08826-00080 or equivalent to all parts except the water pump part: for the water pump part use, part number 08826-00080 or equivalent, to the timing chain cover. Do not apply seal packing to portion -A- in the illustration.
    NOTE
    Remove any oil from the contact surfaces. Install the timing chain case cover within three minutes and tighten the bolts within fifteen minutes of applying the seal packing.

  10.  
  11. Align the key way of the oil pump drive motor with the rectangular portion of the crankshaft timing gear and slide the timing chain case cover into place.
  12.  
  13. Install the timing chain case cover bolts. Tighten the bolts and nuts uniformly in several steps to 17 ft. lbs.
    NOTE
    Do not wrap the chain and slipper over the timing chain case cover seal line.

  14.  
  15. Continue the installation in the reverse order of the removal procedure.
  16.  
  17. When installing the cylinder head cover apply a continuous bead (0.08-0.12 inch) of seal packing, part number 08826-00080 or equivalent, to the cylinder head. Install the seal washers onto the bolts. Install the cylinder head cover bolts and nuts. Tighten bolts -A- to 7.4 ft. lbs. Tighten bolts -B- to 80 inch lbs. Tighten nuts to 80 inch lbs.
    NOTE
    Be sure to remove any oil from the contact surfaces of the cylinder head cover and the cylinder head. Install the cover within three minutes after applying the seal packing. Tighten the bolts to specification within fifteen minutes after installing the cover. Do not add engine oil for at least two hours after installing the cover.

  18.  
  19. Be sure to fill the engine with the proper grade and type engine coolant.
  20.  
  21. Be sure to fill the engine with the proper grade and type engine oil.
  22.  
  23. Start the engine and check for leaks, correct as required.
  24.  

2RZ-FE Engine

NOTE
The oil pump assembly is mounted in the timing chain cover. To properly service the oil pump, the timing chain cover should be removed from the cylinder block.

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

    Engine undercover
     
    Front differential and halfshaft assembly, if equipped with 4WD
     
    Upper radiator hose from the radiator
     
    Oil dipstick guide, by removing the bolt
     
    Power steering drive belt, by loosening the lockbolt and adjusting bolt, if equipped with power steering
     
    No. 2 fan shroud, by removing the 2 clips
     
    No. 1 fan shroud, by removing the 4 bolts
     
    Drive belt, if equipped with air conditioning
     
    Alternator drive belt, fan (with fan clutch), water pump pulley and the fan shroud
     
    Cylinder head
     
    Air conditioning compressor and bracket, if equipped with air conditioning
     
    Alternator, adjusting bar and bracket
     
    Crankshaft Position (CKP) sensor, by removing the 2 bolts
     
    Stiffener plates by removing the 8 bolts, if equipped with 2WD
     
    Flywheel housing undercover and dust seal
     
    Oil pan.
     
    Oil strainer and gasket
     
    Crankshaft pulley
     
    Timing chain cover
     
    Oil pump from the front cover, by removing the 9 screws
     
    Oil pump cover, drive rotor, driven rotor and O-ring
     

  8.  
  9. Remove the relief valve, as follows:
    1. Using snapring pliers, remove the snapring for the relief valve.
    2.  
    3. Remove the retainer, spring(s) and relief valve from the front cover.
    4.  

  10.  

To install:

  1. Install the relief valve, as follows:
    1. Install the relief valve, spring(s) and retainer to the valve cover.
    2.  
    3. Using snapring pliers, install the snapring to hold the relief valve.
    4.  

  2.  
  3. Install the drive and driven rotors as follows:
    1. Place the drive and driven rotors into the pump body.
    2.  
    3. Place a new O-ring to the pump body.
    4.  
    5. Install the pump cover with the 9 screws.
    6.  

  4.  
  5. Install the remaining components in the reverse order of removal.
  6.  
  7. Fill the cooling system and fill the engine with oil.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check for leaks.
  12.  
  13. Adjust ignition timing. Road test the vehicle for proper operation.
  14.  
  15. Recheck all fluid levels.
  16.  

2TR-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine and position it in a suitable holding fixture.
  6.  
  7. Remove the air intake connector. Remove the alternator.
  8.  
  9. Remove the belt tensioner assembly. Remove the idler pulley subassembly. Remove the air conditioning idler pulley assembly and bracket.
  10.  
  11. Remove the crankshaft position sensor. Remove the camshaft position sensor.
  12.  
  13. Remove the intake manifold. Remove the cylinder head cover.
  14.  
  15. Remove the crankshaft pulley. Remove the oil level gauge subassembly.
  16.  
  17. Remove the lower oil pan. Remove the oil strainer assembly. Remove the upper oil pan.
  18.  
  19. Remove the two nuts and separate the water bypass pipe number one.
  20.  
  21. Remove the nineteen bolts and two nuts retaining the timing chain case cover to its mounting. Remove the timing chain case cover from the engine.
    NOTE
    Carefully remove the cover by prying between the cover and the cylinder head or block with a suitable tool. Be sure to cover the tip of the suitable tool prior to usage. Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover.


    NOTE
    The oil pump gears are located inside the timing case cover.



    Click image to see an enlarged view

    Fig. Timing chain cover removal points-2.7L (2TR-FE) engine

  22.  
  23. Remove and discard the O-rings. Remove the head straight screw plug. Remove the water inlet. Remove the thermostat. Remove the oil seal.
  24.  
  25. Remove the oil pump relief valve. Remove the seven oil pump cover bolts. Remove the gears from the timing chain case cover.
  26.  

To install:

  1. Coat the oil pump gears with clean engine oil. Position the gears in the timing chain case cover with the identification marks facing outward. Check that the rotors revolve smoothly. Install the cover. Alternately tighten the bolts to 80 inch lbs.

    Click image to see an enlarged view

    Fig. Oil pump gear alignment marks-2.7L (2TR-FE) engine

  2.  
  3. Coat the oil pump relief valve with clean engine oil. Install the plug, using a new gasket and tighten to 36 ft. lbs.
  4.  
  5. Install a new front case oil seal. Install the thermostat. Install the water inlet.
  6.  
  7. Apply adhesive, part number 08833-00070 or equivalent to the head straight screw plug. Install the plug and tighten to 12 ft. lbs. Install four new O-rings onto the timing chain case cover.
  8.  
  9. Apply continuous beads of seal packing, part number 08826-00080 or equivalent as shown in the illustration.
    NOTE
    Remove any oil from the contact surfaces. Install the timing chain case cover within three minutes and tighten the bolts within fifteen minutes of applying the seal packing. Do not start the engine for at least four hours after installation of the cover.



    Click image to see an enlarged view

    Fig. Timing chain case cover sealant application-2.7L (2TR-FE) engine

  10.  
  11. Align the oil pump drive rotor spline and the crankshaft, as indicated in the illustration. Install the spline and timing chain case cover onto the crankshaft.

    Click image to see an enlarged view

    Fig. Oil pump drive rotor spline alignment-2.7L (2TR-FE) engine

  12.  
  13. Loosely install the timing chain case cover retaining bolts and nuts.
    NOTE
    If the vehicle is equipped with air conditioning install the bolts that hold the idle pulley bracket in place when installing the idle pulley, as they are for this purpose.

  14.  
  15. Fully tighten the bolts and nuts, except bolts -A- in the following order: Area 1, Area 3 and then Area 2 to 15 ft. lbs.
  16.  
  17. Fully tighten the bolts -A- in the following order: Area 2 and then Area 3 to 34 ft. lbs.
  18.  
  19. Fully tighten the bolts -E- in Area 4 to 15 ft. lbs.

    Click image to see an enlarged view

    Fig. Timing chain case cover bolt location and torque sequence-2.7L (2TR-FE) engine

  20.  
  21. Continue the installation in the reverse order of the removal procedure.
  22.  
  23. When installing the cylinder head cover, apply seal packing, part number 08826-00080 or equivalent, to the cylinder head. Provisionally install the cylinder head cover bolts and nuts. Tighten bolts -A- to 80 inch lbs. Tighten bolts -B- to 80 inch lbs. Retighten bolts -A- to 80 inch lbs.
    NOTE
    Be sure to remove any oil from the contact surfaces of the cylinder head cover and the cylinder head. Install the cover within three minutes after applying the seal packing. Do not add engine oil for at least two hours after installing the cover.

  24.  
  25. Be sure to fill the engine with the proper grade and type engine coolant.
  26.  
  27. Be sure to fill the engine with the proper grade and type engine oil.
  28.  
  29. Start the engine and check for leaks, correct as required.
  30.  

3RZ-FE Engine

NOTE
The oil pump assembly is mounted in the timing chain cover. To properly service the oil pump, the timing chain cover should be removed from the cylinder block.

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

    Engine undercover
     
    Front differential and halfshaft assembly, if equipped with 4WD
     
    2 bolts and the air pipe, for California vehicles with 3RZ-FE engine
     
    Upper radiator hose from the radiator
     
    Oil dipstick guide
     
    Power steering drive belt, by loosening the lockbolt and adjusting bolt, if equipped with power steering
     
    No. 2 fan shroud by removing the 2 clips
     
    No. 1 fan shroud by removing the 4 bolts
     
    Drive belt, by loosening the idler pulley nut and adjusting bolt, if equipped with air conditioning
     
    Alternator drive belt, fan (with fan clutch), water pump pulley and the fan shroud
     
    Cylinder head
     
    Air conditioning compressor and bracket with the lines attached, if equipped with air conditioning
     
    Alternator, adjusting bar and bracket
     
    Crankshaft Position (CKP) sensor by removing the 2 bolts
     
    Stiffener plates by removing the 8 bolts, if equipped with 2WD
     
    Flywheel housing undercover and dust seal
     
    Oil pan
     
    Oil strainer and gasket
     
    Crankshaft pulley
     
    Timing chain cover
     
    Oil pump from the front cover by removing the 9 screws
     
    Oil pump cover, drive rotor, driven rotor and O-ring
     

  8.  
  9. Remove the relief valve, as follows:
    1. Using snapring pliers, remove the snapring for the relief valve.
    2.  
    3. Remove the retainer, spring(s) and relief valve from the front cover.
    4.  

  10.  

To install:

  1. Install the relief valve, as follows:
    1. Install the relief valve, spring(s) and retainer to the valve cover.
    2.  
    3. Using snapring pliers, install the snapring to hold the relief valve.
    4.  

  2.  
  3. Install the drive and driven rotors, as follows:
    1. Place the drive and driven rotors into the pump body.
    2.  
    3. Place a new O-ring to the pump body.
    4.  
    5. Install the pump cover with the 9 screws.
    6.  

  4.  
  5. Install the remaining components in the reverse order of removal.
  6.  
  7. Fill the cooling system and fill the engine with oil.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check for leaks.
  12.  
  13. Adjust ignition timing. Road test the vehicle for proper operation.
  14.  
  15. Recheck all fluid levels.
  16.  

5VZ-FE Engine


Click image to see an enlarged view

Fig. Oil pump bolt identification-3.4L engine

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

    Negative battery cable
     
    Engine undercover
     
    Crankshaft timing pulley
     
    Front differential, if equipped with 4WD
     

  4.  
  5. Drain the engine oil from the engine.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Be careful not to damage the baffle plate flange.



    Timing belt and crankshaft gear
     
    Oil cooler tube and clamp, if equipped with automatic transmission
     
    Stiffener plate
     
    Flywheel housing undercover and dust cover
     
    Rear end cover and dust cover
     
    Starter wire clamp
     
    Crankshaft Position (CKP) sensor
     
    Oil pan
     



    Oil strainer
     
    Oil baffle plate
     
    Oil pump body by removing the 8 bolts.
     
    O-ring from the cylinder block
     

  8.  

To install:

  1. Install or connect the following:

    Apply Seal Packing PN 08826-00080 to the oil pump
     
    New O-ring into the groove of the cylinder block
     
    Oil pump to the crankshaft with the spline teeth of the drive rotor engaged with the large teeth of the crankshaft. Tighten the oil pump bolts -A- 15 ft. lbs. (20 Nm) and bolts -B- 31 ft. lbs. (42 Nm)
     
    CKP
     
    Oil pan baffle plate
     
    Oil strainer with a new gasket. Tighten the bolts to 13 ft. lbs. (18 Nm).
     
    Remaining components
     
    Negative battery cable
     

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

 
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