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Installation [08/2015 - ]: Procedure

  1. INSTALL FRONT CRANKSHAFT OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
      GTY700896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-22010 
      • SST: 09506-35010 
      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 case.
  2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head and cylinder block.
      GTY229083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A Cylinder head and cylinder block side *B Timing chain cover sub-assembly side
      *a Clean and degrease - -
      NOTE:

      Be sure to clean and degrease the contact surfaces, especially the surfaces indicated 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 as shown in the illustration.
      GTY169490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      TEXT IN ILLUSTRATION

      *1 Seal Diameter
      Seal Packing
    5. Apply seal packing to the timing chain cover in a continuous line as shown in the following illustration.

      Seal packing

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

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

      GTY696433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Be sure to apply seal packing *b Dashed line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent)
      *c Continuous line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) *d Alternate long and short dashed line area (Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent)
      *e Diagonal line area (Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent) *f 3.0 to 4.0 mm
      *g 2.0 to 3.0 mm - -
      NOTE:
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • Install the chain cover 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
      Continuous Line Area 4.5 mm (0.177 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Alternate Long and Short Dashed Line Area 3.5 mm (0.138 in.) or more 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Dashed Line Area 3.5 mm (0.138 in.) or more 3.0 to 4.0 mm (0.118 to 0.158 in.)
      Diagonal Line Area 6.0 mm (0.236 in.) or more 5.0 mm (0.197 in.)
    6. Align the oil pump drive rotor spline and crankshaft as shown in the illustration. Install the drive rotor and chain cover to the crankshaft.
      GTY706842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Drive Rotor Spline
      *2 Crankshaft
    7. Install the timing chain cover sub-assembly with the 26 bolts, labeled A, B, C and D, and the 2 nuts. Tighten the bolts and nuts uniformly in several steps.

      Standard Bolt

      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 55 mm (2.17 in.)
      Bolt C 35 mm (1.38 in.)
      Bolt D 65 mm (2.56 in.)
      Fig 1: Timing Chain Cover Sub-Assembly Bolt Tightening Sequence
      GTY706358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut - -
      *a Area 1 *b Area 2
      *c Area 3 *d Area 4
      NOTE:

      Make sure that there is no oil on the bolt threads.

    8. Tighten the bolts in area 1.

      Torque: 47 N.m (479 kgf/cm, 35 ft.lbf) 

      HINT: 

      Tighten the bolts from bottom to top as shown in the illustration.

    9. Tighten the bolts in area 2.

      Torque: 23 N.m (235 kgf/cm, 17 ft.lbf) 

    10. Tighten the bolts in area 3.

      Bolt 

      Torque: 23 N.m (235 kgf/cm, 17 ft.lbf) 

      Nut 

      Torque: 22 N.m (224 kgf/cm, 16 ft.lbf) 

      HINT: 

      Tighten the bolts and nuts from top to bottom as shown in the illustration.

    11. Tighten the bolts in area 4.

      Torque: 23 N.m (235 kgf/cm, 17 ft.lbf) 

      HINT: 

      Tighten the bolts from bottom to top as shown in the illustration.

      NOTE:
      • Do not start the engine for at least 2 hours after installation.
      • Wipe off any seal packing that seeped out around the surfaces of the oil pan and head cover and make sure that there is no seal packing seeping out around the edges.
  3. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan sub-assembly.
    2. Install a new 3 O-rings to the timing chain cover.
    3. Apply seal packing in a continuous line as shown in the illustration.
      GTY216287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Install the oil pan sub-assembly within 3 minutes after applying seal packing.
    4. Install the oil pan sub-assembly with the 17 bolts (A, B, C, D and E) and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
      GTY731168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A, B, C and E, and nut 

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

      for bolt D 

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

      Standard Bolt

      Item Length
      Bolt A 60 mm (2.36 in.)
      Bolt B 45 mm (1.77 in.)
      Bolt C 25 mm (0.984 in.)
      Bolt D 16 mm (0.630 in.)
      Bolt E 70 mm (2.76 in.)
      TEXT IN ILLUSTRATION

      *1 Nut
      NOTE:

      Do not start the engine for at least 2 hours after installing.

  4. INSTALL OIL STRAINER SUB-ASSEMBLY 
    1. Install a new gasket and the oil strainer sub-assembly with the 2 nuts.

      Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf) 

  5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Apply seal packing in a continuous line as shown in the illustration.
      GTY217704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.
    2. Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
      Fig 2: Identifying Oil Pan, Bolts & Nuts
      GTY178084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      TEXT IN ILLUSTRATION

      Bolt
      Nut
      NOTE:
      • Tighten the nuts first. After tightening the bolts, check that the nuts and bolts are tightened to the specified torque.
      • Do not start the engine for at least 2 hours after the installation.
  6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover sub-assembly and cylinder head cover.
    2. Apply seal packing as shown in the illustration.
      GTY722662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      TEXT IN ILLUSTRATION

      Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    3. Install 3 new gaskets.
    4. Install a new gasket to the cylinder head cover.
    5. Install the seal washers to the bolts.
    6. Temporarily install the cylinder head cover sub-assembly with the 12 bolts. Tighten the bolts uniformly in several steps.
      Fig 3: Cylinder Head Cover Sub-Assembly Bolts Tightening Sequence
      GTY727040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A and D 

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

      for bolt B and C 

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

      Standard Bolt

      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 65 mm (2.56 in.)
      D 60 mm (2.36 in.)
      TEXT IN ILLUSTRATION

      Bolt A
      Bolt B
      Bolt C
      Bolt D
      NOTE:

      Do not start the engine for at least 2 hours after installation.

  7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover sub-assembly and cylinder head cover.
    2. Apply seal packing as shown in the illustration.
      GTY722664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      Standard seal diameter

      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      TEXT IN ILLUSTRATION

      Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    3. Install 3 new gaskets.
    4. Install a new gasket to the cylinder head cover.
    5. Install the seal washers to the bolts.
    6. Temporarily install the cylinder head cover sub-assembly with the 12 bolts. Tighten the bolts uniformly in several steps.
      Fig 4: Cylinder Head Cover Sub-Assembly Bolts Tightening Sequence
      GTY712824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A and D 

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

      for bolt B and C 

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

      Standard Bolt

      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 70 mm (2.76 in.)
      D 60 mm (2.36 in.)
      TEXT IN ILLUSTRATION

      Bolt A
      Bolt B
      Bolt C
      Bolt D
      NOTE:

      Do not start the engine for at least 2 hours after installation.

  8. CONNECT FUEL PIPE SUB-ASSEMBLY 
    1. Connect the fuel pipe sub-assembly with the 2 bolts.

      Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf) 

  9. INSTALL REAR CYLINDER HEAD COVER 

    Refer to PROCEDURE - Step 5

  10. INSTALL NO. 2 OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
      NOTE:

      Do not touch the mesh when installing the oil control valve filter.

    2. Install a new gasket and temporarily install the No. 2 oil pipe (on the cylinder head side) with the oil check valve bolt.
    3. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the No. 2 oil pipe (on the head cover side).
    4. Tighten the oil pipe union (on the cylinder head side).

      Torque: 65 N.m (663 kgf/cm, 48 ft.lbf) 

      NOTE:

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

    5. Tighten the oil pipe union (on the head cover side).

      Torque: 65 N.m (663 kgf/cm, 48 ft.lbf) 

  11. INSTALL NO. 1 OIL PIPE 
    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
      NOTE:

      Do not touch the mesh when installing the oil control valve filter.

    2. Install a new gasket and temporarily install the No. 1 oil pipe (on the cylinder head side) with the oil check valve bolt.
    3. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the No. 1 oil pipe (on the head cover side).
    4. Tighten the oil pipe union (on the cylinder head side).

      Torque: 65 N.m (663 kgf/cm, 48 ft.lbf) 

      NOTE:

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

    5. Tighten the oil pipe union (on the head cover side).

      Torque: 65 N.m (663 kgf/cm, 48 ft.lbf) 

  12. INSTALL CRANKSHAFT PULLEY 
    1. Using SST, install the crankshaft pulley with the pulley set bolt.
      GTY737200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-54015 
        1. 91651-60855
      • SST: 09330-00021 

      Torque: 260 N.m (2651 kgf/cm, 192 ft.lbf) 

  13. INSTALL OIL FILTER BRACKET 
    1. Install the oil filter bracket and a new gasket with the 2 nuts and bolt.

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

  14. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.
      GTY728495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Bolt

      Item Length
      A 70 mm (2.76 in.)
      B 33 mm (1.30 in.)
      TEXT IN ILLUSTRATION

      Bolt A
      Bolt B
    2. Tighten bolts 1 and 2 in numerical order.

      Torque: 36 N.m (367 kgf/cm, 27 ft.lbf) 

    3. Tighten the other bolts.

      Torque: 36 N.m (367 kgf/cm, 27 ft.lbf) 

  15. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  16. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the No. 1 idler pulley sub-assembly with the bolt.
      GTY731920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 54 N.m (551 kgf/cm, 40 ft.lbf) 

      HINT: 

      "DOUBLE" is marked on the No. 1 idler pulley sub-assembly to distinguish it from the No. 2 idler pulley sub-assembly.

  17. INSTALL WATER INLET HOUSING 
    1. Install the 3 water by-pass hoses.
    2. Apply soapy water to a new O-ring and install the O-ring to the water outlet pipe.
    3. Install a new O-ring to the water outlet pipe.
    4. Install a new gasket to the water pump assembly.
    5. Install the water inlet housing with the 5 bolts.

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

    6. Connect the 3 water by-pass hoses.
  18. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Install the water by-pass pipe sub-assembly with the 3 bolts.
      GTY723503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the 2 hoses.
      TEXT IN ILLUSTRATION

      *a Upward
      *b Rearward

      HINT: 

      The direction of the hose clamp is indicated in the illustration.

  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new O-ring to the engine oil level dipstick guide.
      GTY725664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Apply a light coat of engine oil to the O-ring.
    3. Push the engine oil level dipstick guide end into the guide hole.
    4. Install the engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.
  20. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 13

  21. INSTALL NO. 2 EMISSION CONTROL VALVE SET 

    Refer to PROCEDURE - Step 14

  22. INSTALL NO. 1 EMISSION CONTROL VALVE SET 

    Refer to PROCEDURE - Step 15

  23. INSTALL ENGINE ASSEMBLY 

    (Refer to INSTALLATION [08/2015 - ] )

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