Installation [08/2015 - ]: Procedure

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INSTALL TIMING CHAIN COVER ASSEMBLY

Install a new gasket to the cylinder head sub-assembly.
Apply a light coat of engine oil to a new No. 2 oil strainer gasket and a new oil pump gasket.
Install the No. 2 oil strainer gasket and oil pump gasket to the stiffening crankcase assembly.

Align the positions of the drive rotor spline and crankshaft timing gear or sprocket as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Crankshaft Timing Gear or Sprocket
*a	Drive Rotor Spline

Apply seal packing to the timing chain cover assembly at the points shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	28 mm (1.10 in.)	*b	25 mm (0.984 in.)
*c	26 mm (1.02 in.)	*d	2.5 mm (0.0984 in.)
*e	3.0 mm (0.118 in.)	*f	7.0 mm (0.276 in.) or more
*g	5.0 mm (0.197 in.)	*h	13 mm (0.512 in.) or more
*i	7.0 mm (0.276 in.)	*j	3.0 mm (0.118 in.) or more
*k	2.5 to 3.5 mm (0.0984 to 0.138 in.)	-	-

Seal packing

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.

Seal Packing Application Specification

Line Type and Area	Seal Packing Diameter	Application Area	Seal Packing Application Length
Line Type and Area	Coating Width	Application Area	Seal Packing Application Length
Dashed Line	3.0 mm (0.118 in.)	2.5 mm (0.0984 in.)	-
Dashed Line	-	2.5 mm (0.0984 in.)	-
A - A	2.5 to 3.5 mm (0.0984 to 0.138in.)	2.5 mm (0.0984 in.)	-
A - A	-	2.5 mm (0.0984 in.)	-
B - B	5.0 mm (0.197 in.)	3.0 mm (0.118 in.)	28 mm (1.10 in.)
B - B	Width 7.0 mm (0.276 in.) or more Thickness 3.0 mm (0.118 in.) or more	3.0 mm (0.118 in.)	28 mm (1.10 in.)
C - C	7.0 mm (0.276 in.)	5.0 mm (0.197 in.)	25 mm (0.984 in.)
C - C	Width 13 mm (0.512 in.) or more Thickness 3.0 mm (0.118 in.) or more	5.0 mm (0.197 in.)	25 mm (0.984 in.)
D - D	2.5 to 3.5 mm (0.0984 to 0.138in.)	-	-
D - D	-	-	-
E - E	5.0 mm (0.197 in.)	-	26 mm (1.02 in.)
E - E	-	-	26 mm (1.02 in.)

NOTE:

Using non-residue solvent, clean and remove any oil from the installation surface.
Install the part within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
Do not add engine oil for at least 2 hours after installation.
Do not start the engine within 2 hours after installation.

Temporarily install the timing chain cover assembly with the 3 nuts and 19 bolts.

Fig 1: Timing Chain Cover Assembly Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Types of nuts and bolts	*b	Tightening Order
	Bolt		Nut

Bolt Length

Item	Length	Thread Diameter
Bolt A	30 mm (1.18 in.)	8 mm (0.315 in.)
Bolt B	35 mm (1.38 in.)	10 mm (0.394 in.)

NOTE:

Do not apply oil to bolts. Clean off if any oil is applied to bolts.
When tightening the 15th bolt shown in the illustration, be careful not to damage the installation surface of the crankshaft position sensor.

Tighten the 19 bolts and 3 nuts in several steps, in the sequence shown in the illustration.
Bolt A, Nut

Torque: 21 N.m (214 kgf/cm, 15 ft.lbf)

Bolt B

Torque: 55 N.m (561 kgf/cm, 41 ft.lbf)

INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
Refer to PROCEDURE - Step 1
INSTALL CRANKSHAFT PULLEY ASSEMBLY
Refer to PROCEDURE - Step 43
INSTALL CRANK POSITION SENSOR
Refer to PROCEDURE - Step 1
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the V-ribbed belt tensioner assembly with the 2 bolts in the order shown in the illustration.
  Torque: 21 N.m (214 kgf/cm, 15 ft.lbf)
  
  Fig 2: V-Ribbed Belt Tensioner Assembly Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley sub-assembly to the timing chain cover assembly with the bolt.
  Torque: 43 N.m (438 kgf/cm, 32 ft.lbf)
INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY
Refer to PROCEDURE - Step 1
INSTALL AIR CLEANER BRACKET
1. Install the air cleaner bracket to the timing chain cover assembly with the bolt.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the oil level dipstick guide.
3. Install the oil level dipstick guide to the timing chain cover assembly with the bolt.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY
1. Install the oil level dipstick sub-assembly.
INSTALL WATER OUTLET SUB-ASSEMBLY
1. Install a new O-ring to the timing chain cover assembly.
2. Install the water outlet sub-assembly to the timing chain cover assembly with the 2 bolts and nut.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)

INSTALL NO. 6 WATER BY-PASS HOSE

Connect the No. 6 water by-pass hose with the 2 clips as shown in the illustration.

*a	Upper Side
*b	Front Side
*c	LH Side
*d	45°
*e	Paint Mark

HINT:

Install the clips so that they are positioned as shown in the illustration.

INSTALL CAMSHAFT BEARING CAP OIL HOLE GASKET
Refer to PROCEDURE - Step 19
INSTALL CYLINDER HEAD COVER GASKET
Refer to PROCEDURE - Step 20
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Refer to PROCEDURE - Step 21
CONNECT NO. 3 VENTILATION HOSE
Refer to PROCEDURE - Step 22
INSTALL NO. 1 TURBO WATER PIPE
Refer to PROCEDURE - Step 23

CONNECT ENGINE WIRE

for Engine Upper Side:
1. Connect the engine wire to the cylinder head cover sub-assembly with the bolt.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
2. Attach the clamp and connect the No. 3 ventilation hose to the engine wire.
3. Connect the connector to the air fuel ratio sensor.
4. Connect the 2 connectors to the 2 camshaft position sensors.
for Engine Front Side:
1. Connect the engine wire to the timing chain cover assembly with the bolt and 3 nuts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
2. Attach the clamp and connect the 5 connectors.
for Engine LH Side:
1. Attach the clamp and connect the connector.
2. Connect the connector and engine wire with the 2 bolts.
  Torque: 21 N.m (214 kgf/cm, 15 ft.lbf)
Attach the claw to connect the connector holder to the engine room ECU box.
Attach the wire harness clamp and connect the engine wire with the nut.
Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)

Connect the connector to the ECM and lock with the lever.

NOTE:

When connecting a connector, make sure that dirt, water and other foreign matter is not stuck between the connector and ECM.
Make sure that the lever is securely lowered.

Connect the 4 connectors.

INSTALL ENGINE ROOM ECU COVER
Refer to PROCEDURE - Step 37 [08/2015 - 10/2016] , or refer to PROCEDURE - Step 37 [10/2016 - 09/2020] , or refer to PROCEDURE - Step 37 [09/2020 - ]
CONNECT SUCTION HOSE
1. Remove the vinyl tape from the suction hose.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose.
  Compressor Oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring to the suction hose.
  NOTE:
  Keep the O-ring and O-ring fitting surface free of foreign matter.
4. Connect the suction hose to the suction pipe sub-assembly with the nut.
  Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf)
INSTALL IGNITION COIL ASSEMBLY
Refer to PROCEDURE - Step 2
CONNECT NO. 4 VENTILATION HOSE
See step 2
INSTALL COOLER COMPRESSOR ASSEMBLY
Refer to INSTALLATION [08/2015 - 10/2017] , or refer to INSTALLATION [10/2017 - 09/2020] , or refer to INSTALLATION [09/2020 - 11/2021] , or refer to INSTALLATION [11/2021 - 09/2022] , or refer to INSTALLATION [09/2022 - ]
INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)
Refer to INSTALLATION [08/2015 - ]
INSTALL RADIATOR ASSEMBLY
Refer to INSTALLATION [08/2015 - ]