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Installation [11/2017 - ]: Procedure

  1. INSTALL TIMING CHAIN COVER ASSEMBLY 
    NOTE:
    • Tighten the bolts within 10 minutes of applying seal packing.
    • Do not add engine oil for at least 2 hours after installation.
    • Do not start the engine for at least 2 hours after installation.
    1. Clean the contact surfaces of the engine assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
      GTY824531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Assembly Side *b Timing Chain Cover Assembly Side
      Clean - -
      NOTE:

      Be sure to clean the contact surfaces, especially the surfaces shown in the illustration.

    2. Apply a light coat of engine oil to a new oil pump gasket.
    3. Install the oil pump gasket.
    4. Apply seal packing in a continuous line to the engine unit as shown in the illustration.
      GTY837751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Diameter
      Seal Packing

      Seal Packing

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

      Seal Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      NOTE:

      Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

    5. Apply seal packing to the timing chain cover assembly as shown in the illustration.
      GTY824262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Dashed Line Area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)      		 *b Continuous Line Area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *c Alternate Long and Short Dashed Line Area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)      		 *d Dashed Line Area
      (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)
      *e 9.0 mm (0.354 in.) *f 3.0 mm (0.118 in.)
      *g 6.0 mm (0.236 in.) or more - -

      Seal Packing

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

      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      NOTE:
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • Install the timing chain cover assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      Application Specification

      Area Seal Packing Diameter Application Position from Inside Seal Line
      Dashed Line Area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)      		 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Continuous Line Area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)      		 6.0 mm (0.236 in.) or more 1.0 to 2.0 mm (0.0394 to 0.0787 in.)
      Alternate Long and Short Dashed Line Area
      (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)      		 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.157 in.)
      Dashed Line Area
      (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)      		 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.0787 to 0.118 in.)
    6. Align the drive rotor spline and the crankshaft as shown in the illustration. Install the timing chain cover assembly.
      GTY821570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft
      *a Drive Rotor Spline
      *b 15°
    7. w/ Stud Bolt:
      1. Install the 26 bolts and 2 nuts in the order shown in the illustration.
        Fig 1: Timing Chain Cover Assembly (W/ Stud Bolt) Bolts And Nuts Tightening Sequence
        GTY948660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Torque *b Bolt and Nut Tightening Order
        *c Nut - -

        Bolt Length

        Item Length
        (A) 28 mm (1.10 in.)
        (B) 55 mm (2.17 in.)
        (C) 60 mm (2.36 in.)
        (D) 40 mm (1.57 in.)
        NOTE:

        Make sure that there is no oil on the threads of the bolts.

        Torque

        Bolt (A), (B) 

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

        Bolt (C), (D) 

        43 N.m (438 kgf/cm, 32 ft.lbf)

        Nut 

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

        NOTE:
        • Tighten the bolts and nuts within 10 minutes of applying seal packing.
        • Do not add engine oil for at least 2 hours after installation.
        • Do not start the engine for at least 2 hours after installation.
    8. w/o Stud Bolt:
      1. Install the 28 bolts in the order shown in the illustration.
        Fig 2: Timing Chain Cover Assembly (W/o Stud Bolt) Bolts And Nuts Tightening Sequence
        GTY946705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Torque *b Bolt Tightening Order

        Bolt Length

        Item Length
        (A) 45 mm (1.77 in.)
        (B) 28 mm (1.10 in.)
        (C) 55 mm (2.17 in.)
        (D) 60 mm (2.36 in.)
        (E) 40 mm (1.57 in.)
        NOTE:

        Make sure that there is no oil on the threads of the bolts.

        Torque

        Bolt (A), (B), (C) 

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

        Bolt (D), (E) 

        43 N.m (438 kgf/cm, 32 ft.lbf)

        NOTE:
        • Tighten the bolts within 10 minutes of applying seal packing.
        • Do not add engine oil for at least 2 hours after installation.
        • Do not start the engine for at least 2 hours after installation.
  2. INSTALL TIMING CHAIN CASE OIL SEAL 
    1. Using SST and a hammer, tap in a new timing chain case oil seal until its surface is flush with the timing chain cover assembly edge.
      GTY790630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-22010 
      • SST: 09506-35010 

      Oil Seal Protrusion Height

      0 to 1.0 mm (0 to 0.0394 in.)

      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap on the oil seal at an angle.
      • Make sure that the oil seal edge does not protrude from the timing chain cover assembly.
  3. INSTALL TIMING CHAIN COVER PLATE 

    Refer to PROCEDURE - Step 30

  4. INSTALL OIL STRAINER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 52

  5. INSTALL OIL PAN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 53

  6. INSTALL OIL LEVEL SENSOR BRACKET 

    See step  1

  7. INSTALL ENGINE OIL LEVEL SENSOR 

    See step  2

  8. INSTALL OIL PIPE WITH STRAINER SUB-ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 56

  9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 57

  10. INSTALL SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 59

  11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 60

  12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 61

  13. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  14. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Install the No. 1 engine cover to the cylinder head cover sub-assembly with the 2 clips.
  15. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 3

  16. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY 
    1. for 2WD:

      Install the oil filter bracket sub-assembly and a new gasket with the 2 nuts and 2 bolts.

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

    2. for AWD:
      1. Install the oil filter bracket sub-assembly and a new gasket with the 2 nuts and bolt.

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

      2. Install the No. 1 oil filter bracket to the cooler compressor with magnet clutch assembly and oil filter bracket sub-assembly with the nut and bolt.

        Torque: 25 N.m (255 kgf/cm, 18 ft.lbf) 

  17. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the timing chain cover assembly with the nut.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    2. Install the wire harness clamp bracket to the timing chain cover assembly with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    3. Install the wire harness clamp bracket to the cylinder head cover sub-assembly LH with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    4. for 2WD:
      1. Install the wire harness clamp bracket to the oil filter bracket sub-assembly with the bolt.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  18. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 1

  19. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 2

  20. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 3

  21. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 4

  22. INSTALL WATER OUTLET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 69

  23. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  24. INSTALL NO. 2 WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 23

  25. INSTALL NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 24

  26. INSTALL NO. 2 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 25

  27. INSTALL NO. 6 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 26

  28. INSTALL WATER PUMP PULLEY 

    Refer to PROCEDURE - Step 3

  29. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 29

  30. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 28

  31. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to INSTALLATION [11/2017 - ]

  32. INSTALL ENGINE WIRE 

    Refer to PROCEDURE - Step 27

  33. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 

    Refer to INSTALLATION [11/2017 - ]

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