Oil Pan Conversion

3.4L (5VZ-FE) Oil Pan Conversion

Off Road Solutions 3.4L Rear Sump Oil Pan Conversion Instructions

  1. Note: These instructions 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.
  2. Secure the 3.4L engine in an 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.
  3. Carefully turn the engine upside down in stand.
  4. Remove the 6mm bolts securing the pan to the block. Carefully break the sealant bead and remove the oil pan from the engine.
  5. Turn the engine upright once again.
  6. Using the provided ¼” X 18 NPT size tap, thread the hole in the oil pump housing that the original dipstick tube came from. Be sure to thread the hole from the outside of the engine. CAUTION: Be sure to keep ALL metal particles out of engine. Completely cover the internal engine parts before tapping!
  7. Install the provided dipstick hole plug in the newly tapped hole, from the outside of the engine.

    ¼” pipe plug installed

    ¼” pipe plug installed

  8. If the auxiliary oil dipstick hole exists for the new dipstick (see illustration), carefully drive the original plug from the block. This hole exists on 1999 and earlier 5VZ-FE engine blocks.

    Factory installed dipstick plug

    Factory installed dipstick plug

  9. 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. Using a 3/8” or “U” size drill bit, drill a hole that is center and perpendicular with the face of the existing landing. We strongly recommend the use of the ORS Dip Stick Drill Guide, ORS EC093, to ensure accuracy when drilling this hole.
  10. If using the ORS Dipstick Drill Guide:
  11. 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.
  12. Use 2 10mm x 20mm bolts on the bottom 2 holes with one washer between the block and guide.
  13. Install the 10mm x 30mm bolt in the top hole with 7 washers between the block and guide.
  14. Tighten all hardware.

    Dipstick Drill Guide installed

    Dipstick Drill Guide installed

  15. The exhaust manifold/header may require removal to fit the drill, a 90 degree drill is recommended.
  16. 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.

    Hole properly drilled in block

    Hole properly drilled in block

  17. 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.

    Dipstick adapter installed in block

    Dipstick adapter installed in block

  18. Install the O-ring on the new dipstick tube and insert tube into adapter. Bolt the tube bracket to the head, exchanging it for existing bracket.
  19. Make sure all metal particles are out of the crankcase area. Turn the engine upside down once again. Remove the oil sump assembly.
  20. 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”.
  21. Install the new oil sump gasket and oil sump onto the block. Re-arrange the fastening nuts on the oil baffle to accommodate the new oil sump (if necessary). 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.
  22. 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.
  23. Install the oil pan on the engine block and torque the mounting bolts to 52 lbs-in. using a “criss-cross” pattern. Install and tighten the provided oil drain plug and gasket in the oil pan.
  24. Turn the engine back over in the stand.