Installation [10/2015 - ]: Procedure

1. Install a new gasket to the cylinder head sub-assembly.
2. Apply a light coat of engine oil to a new No. 2 oil strainer gasket and a new oil pump gasket.
3. Install the No. 2 oil strainer gasket and oil pump gasket to the stiffening crankcase assembly.
4. Align the positions of the drive rotor spline and crankshaft timing sprocket as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Crankshaft Timing Sprocket
   *a	Drive Rotor Spline

5. 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	2.5 to 3.0 mm (0.0984 to 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

   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
   	Coating Width
   Dashed Line	3.0 mm (0.118 in.)	2.5 mm (0.0984 in.)	-
   	-
   A - A	2.5 to 3.5 mm (0.0984 to 0.138 in.)	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.)
   	Width 7.0 mm (0.276 in.) or more Thickness 3.0 mm (0.118 in.)
   C - C	7.0 mm (0.276 in.)	5.0 mm (0.197 in.)	25 mm (0.984 in.)
   	Width 13 mm (0.512 in.) or more Thickness 3.0 mm (0.118 in.) or more
   D - D	2.5 to 3.0 mm (0.0984 to 0.118 in.)	-	-
   	-
   E - E	5.0 mm (0.197 in.)	-	26 mm (1.02 in.)
   	-

   NOTE:

   • Clean the surfaces with non-residue solvent before applying seal packing.
   • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
   • Do not add oil for at least 2 hours after installation.
   • Do not start the engine for at least 2 hours after installation.
6. Temporarily install the timing chain cover assembly with the 3 nuts and 19 bolts.
   Fig 1: Timing Chain Cover Assembly Nuts And Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque	*b	Tightening Order
   	Bolt		Nut

   Bolt Length

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

   NOTE:

   • Do not apply oil to the bolts. If oil is applied to the bolts, clean it off.
   • When tightening the 15th bolt shown in the illustration, be careful not to damage the installation surface of the crankshaft position sensor.
7. Tighten the 19 bolts and 3 nuts in several steps, in the order 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) 

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 49

Refer to PROCEDURE - Step 18

Refer to PROCEDURE - Step 19

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 42

Refer to PROCEDURE - Step 16

Refer to PROCEDURE - Step 32

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *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.

Refer to PROCEDURE - Step 47

Refer to PROCEDURE - Step 48

Refer to PROCEDURE - Step 26

Refer to PROCEDURE - Step 21

1. 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. Engage the clamp and connect the No. 3 ventilation hose to the engine wire.
   3. Connect the air fuel ratio sensor connector.
2. 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. Engage the clamp and connect the 5 connectors.
3. for Engine LH Side:
   1. Engage the clamp and connect the connector.
   2. Connect the connector with the 2 bolts.

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

4. Engage the claw to connect the connector holder to the engine room ECU box.
5. Connect the engine wire with the nut.

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

6. Push down the lock lever to connect the ECM connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.
7. Connect the 4 connectors.

Refer to PROCEDURE - Step 4

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.
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) 

Refer to PROCEDURE - Step 2

See step  2

Refer to INSTALLATION [10/2015 - ]

Refer to INSTALLATION [10/2015 - 11/2017] , or refer to INSTALLATION [11/2017 - 09/2020] , or refer to INSTALLATION [09/2020 - ]

Refer to INSTALLATION [10/2015 - 11/2017] , or refer to INSTALLATION [11/2017 - ]