Oil Dipstick / Pan Installation
Note: The following steps pertain to Tacoma, 4Runner and
Tundra donor vehicles, where the installation of a rear-sump oil pan is
required. If the donor vehicle is a T100, the oil pan may not need replacement.
See our application guide for details. If switching between a 4×2 and 4×4 T100
oil pan, only the pan and oil sump will be changed.
With the engine secured upright in the engine stand, drain
any oil from the engine. Drain any coolant from the block using the block
coolant plug. Remove the oil dipstick and tube from the engine.
Carefully turn the engine upside down in stand.
Remove the 6mm bolts securing the pan to the block.
Carefully break the sealant bead and remove the oil pan from the engine. Be
careful not to score the engine block, rear seal housing, or oil pump housing
surfaces.
Turn the engine upright once again.
Using the provided ¼” X 18 NPT size tap, thread the hole in
the oil pump housing that the original dipstick tube came from. It may be
necessary to first drill this hole, using a 7/16” drill bit. Be sure to thread
the hole from the outside of the engine. CAUTION: Take precautions to keep ALL
metal particles out of engine. If applicable: the oil pan kit may have come
with a small freeze plug. This can be pressed into the original dipstick hole
in the oil pump, as an alternative to the threaded pipe plug. No drilling or
tapping would be necessary with the freeze plug.
Install the provided ¼” pipe plug in the newly tapped hole,
from the outside of the engine. See Picture #1 & 1A
Oil Dipstick Plug Installed
Freeze Plug Installed, Alternative to Threaded Plug
If the auxiliary oil dipstick hole exists for the new
dipstick (see illustration), carefully drive the original plug from the block,
this is done from the under-side of engine using a punch and hammer. This hole
exists on 1999 and earlier 5VZ-FE engine blocks. See Pic #2
Factory Installed Dipstick Hole Plug
If an auxiliary hole does not exist (2000 and later models),
a new hole will have to be drilled in the block to accept the oil dipstick tube
adapter. Turn the engine back over in the stand. A hole that is center and
perpendicular with the face of the existing landing will have to be drilled
(using a U or 3/8” drill bit. We recommend the use of the ORS Dip Stick Drill
Guide, ORS-EC093, to ensure accuracy when drilling this hole.
If using the Dipstick Drill Guide:
Install the guide to the block over the dip stick “landing”.
This is near the bottom of the block, in the center of the driver side.
Use 2 10mm x 20mm bolts on the bottom 2 holes with one
washer between the block and guide.
Install the 10mm x 30mm bolt in the top hole with 7 washers
between the block and guide.
Tighten all hardware. See Pic #3
Dipstick Drill Guide Installed
The exhaust manifold/header may require removal to fit the
drill, a 90 degree drill is recommended.
Insert a U-size (or 3/8” if U not available) drill bit into
the guide tube and drill a hole completely through the engine block. The U size
will help to ensure a tight fit of the new adapter, but 3/8” is close. NOTE:
this hole was not perfectly centered from the factory, nor will our drill guide
perfectly center the hole on this landing. See pictures
Hole Properly Drilled in Block
Drilled Hole will intersect the bottom-inside corner of engine block
Drive the new oil dipstick adapter into the side of the
block, from the outside. The adapter will stop once the machined “step” has
reached the block. See pic #6
Dipstick adapter installed in block
Re-install the LH engine mount and bracket.
Install the O-ring on the new dipstick tube (may be
pre-installed) and insert tube into adapter. Bolt the tube bracket to the
alternator bracket/head, exchanging it for existing bracket.
Make sure all metal particles are out of the crankcase area.
Turn the engine upside down once again. Remove the oil sump assembly.
Cover the engine crankcase components to prevent
contamination while cleaning. Carefully clean the oil pan mounting surface on
the block. Remove the oil sump gasket from the block and carefully clean the
sealing surface. Verify that all studs in the block are still “snug”.
Install the new oil sump gasket and oil sump onto the block.
Re-arrange the fasteners on the 5VZ oil baffle to accommodate the new oil sump
(if necessary). Note: do NOT use the 3VZ baffle that fits between the block and
pan. Tighten the 6mm nuts to 66 lbs-in. Tighten all nuts and bolts on the oil
baffle, and re-check the torque on the 6mm sump nuts. See pic
Oil Pan Sum Installed
Apply a bead of the Toyota FIPG (sealer) to the new oil pan.
Be sure to drive the sealer into the grooves of the oil pan and around the
mounting holes to ensure a good seal.
Install the oil pan on the engine block and torque the
mounting bolts to 52 lbs-in. using a “criss-cross” pattern. Make a second pass
to re-check fastener torque. Install and tighten the provided oil drain plug
and gasket in the oil pan. See pic
Oil Pan Installed (4x4 IFS Pan)
Turn the engine back over in the stand.