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Installation [11/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL NO. 2 CYLINDER HEAD GASKET 
    1. Place a new No. 2 cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
      GTY648610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lot No.
      Front of Engine
      NOTE:
      • Remove any oil from the contact surfaces.
      • Pay attention to the installation direction.
    2. Apply seal packing to the No. 2 cylinder head gasket as shown in the illustration.

      Seal Packing

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

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the No. 2 cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying seal packing.
      GTY632657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Cylinder Head Gasket
      *a 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *d 38.2 mm (1.50 in.)
      *e 110.0 mm (4.33 in.)
      Front of Engine
      Seal Packing
  2. INSTALL CYLINDER HEAD LH 

    Refer to PROCEDURE - Step 3

  3. INSTALL CYLINDER HEAD GASKET 
    1. Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
      GTY677377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lot No.
      Front of Engine
      NOTE:
      • Remove any oil from the contact surfaces.
      • Pay attention to the installation direction.
    2. Apply seal packing to the cylinder head gasket as shown in the illustration.

      Seal Packing

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

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying seal packing.
      GTY672314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Gasket
      *a 5.0 to 7.0 mm (0.197 to 0.276 in.)
      *b 3.0 to 5.0 mm (0.118 to 0.197 in.)
      *c 7.0 to 9.0 mm (0.276 to 0.354 in.)
      *d 38.5 mm (1.52 in.)
      *e 144.0 mm (5.67 in.)
      Front of Engine
      Seal Packing
  4. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  5. INSTALL SENSOR WIRE 

    Refer to PROCEDURE - Step 8

  6. INSTALL VALVE STEM CAP 

    Refer to PROCEDURE - Step 9

  7. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 10

  8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  9. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  10. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  11. INSTALL CAMSHAFT BEARING CAP (for Bank 2) 

    Refer to PROCEDURE - Step 16

  12. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 17

  13. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) 

    Refer to PROCEDURE - Step 18

  14. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 

    See step  8

  15. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 

    See step  9

  16. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 21

  17. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 22

  18. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 23

  19. INSTALL CAMSHAFT 

    Refer to PROCEDURE - Step 26

  20. INSTALL NO. 2 CAMSHAFT 

    Refer to PROCEDURE - Step 27

  21. INSTALL CAMSHAFT BEARING CAP (for Bank 1) 

    Refer to PROCEDURE - Step 28

  22. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 29

  23. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) 

    Refer to PROCEDURE - Step 30

  24. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 

    See step  21

  25. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 

    See step  22

  26. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 33

  27. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 34

  28. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 35

  29. INSTALL NO. 2 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 38

  30. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 39

  31. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 41

  32. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 42

  33. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 43

  34. INSPECT VALVE TIMING 

    Refer to PROCEDURE - Step 44

  35. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  36. INSTALL TIMING CHAIN CASE OIL SEAL 

    See step  1

  37. INSTALL OIL PAN SUB-ASSEMBLY 
    1. Install 2 new oil pan gaskets to the timing chain cover assembly.
    2. Apply seal packing in a continuous line as shown in the illustration.

      Seal Packing

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

      Seal Packing Diameter

      3.0 to 4.0 mm (0.118 to 0.157 in.)

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the oil pan sub-assembly within 3 minutes of applying seal packing.
      • Do not start the engine for at least 2 hours after installation.
      GTY673981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
    3. Install the oil pan sub-assembly with the 16 bolts and 2 nuts in the order shown in the illustration.
      Fig 1: Engine Oil Pan Bolts And Nuts Tightening Sequence
      GTY681938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque *b Bolt and Nut Tightening Order
      Bolt Nut

      Bolt (A) 

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

      Bolt (B), (C), (D) 

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

      Nut 

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

      Bolt Length

      Item Length
      Bolt (A) 16 mm (0.630 in.)
      Bolt (B) 45 mm (1.77 in.)
      Bolt (C) 25 mm (0.984 in.)
      Bolt (D) 70 mm (2.76 in.)
    4. Wipe off any excess seal packing with a clean piece of cloth.
      GTY622288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Wipe off the Seal Packing
  38. INSTALL OIL STRAINER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 53

  39. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 54

  40. INSTALL SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 58

  41. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 59

  42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 60

  43. INSTALL WATER OUTLET 

    Refer to PROCEDURE - Step 61

  44. INSTALL OIL COOLER PIPE 

    Refer to PROCEDURE - Step 63

  45. INSTALL OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  46. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 5

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

    Refer to PROCEDURE - Step 12

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

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 2

  51. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  52. INSTALL WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 74

  53. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 

    Refer to PROCEDURE - Step 75

  54. INSTALL CRANKSHAFT PULLEY 

    See step  2

  55. INSTALL WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 1

  56. INSTALL WATER PUMP PULLEY 

    Refer to PROCEDURE - Step 2

  57. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  58. INSTALL SENSOR WIRE 

    Refer to PROCEDURE - Step 4

  59. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to INSTALLATION [11/2016 - ]

  60. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 2

  61. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 3

  62. INSTALL NO. 2 ENGINE MOUNTING STAY RH 

    Refer to PROCEDURE - Step 9

  63. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  64. INSTALL NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 17

  65. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 15

  66. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 16

  67. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 18

  68. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1

  69. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  70. INSTALL INJECTOR DRIVER 

    Refer to PROCEDURE - Step 1

  71. INSTALL NO. 5 CYLINDER BLOCK INSULATOR 

    Refer to PROCEDURE - Step 25

  72. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET 

    Refer to PROCEDURE - Step 26

  73. INSTALL NO. 4 CYLINDER BLOCK INSULATOR 

    Refer to PROCEDURE - Step 27

  74. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  75. INSTALL V-RIBBED BELT 

    See step  1

  76. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 30

  77. INSTALL RADIATOR PIPE CLAMP 

    Refer to PROCEDURE - Step 31

  78. INSTALL ENGINE HANGERS 

    See step  63

  79. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 

    Refer to INSTALLATION [11/2016 - ] 

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