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Installation [08/2015 - 08/2018]: Procedure

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  1. INSTALL WATER INLET PIPE 
    1. Apply soapy water to 2 new O-rings and install them to the water inlet pipe.
    2. Install the water inlet pipe to the No. 1 heat exchanger cover.
  2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Apply a light coat of engine oil to a new oil pump gasket.
    2. Install the oil pump gasket to the cylinder block.
    3. Apply a light coat of engine oil to a new O-ring.
    4. Install the O-ring to the oil pan sub-assembly.
    5. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.
      GTY550972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Continuous Line Area *b Dashed Line Area
      *c Diagonal Line Area - -

      Seal packing

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

      1. Apply Seal Packing As Follows
        Area Seal Packing Diameter Application Position from Inside Edge of Cover
        Continuous line area 3.0 to 4.0 mm (0.118 to 0.157 in.) 2.5 mm (0.0984 in.)
        Dashed line area 6.4 mm (0.252 in.) or more, or within OK area shown in illustration 7.0 mm (0.276 in.)
        Diagonal line area 3.0 to 4.0 mm (0.118 to 0.157 in.) 5.5 mm (0.217 in.)
        GTY557448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Seal Packing Thickness
      *b Seal Packing Width
      *c OK Area
      NOTE:
      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after installing.
    6. Align the oil pump drive rotor spline and crankshaft as shown in the illustration. Install the spline and timing chain cover sub-assembly to the crankshaft.
      GTY147828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Temporarily install the timing chain cover with the 28 bolts and nut.
      GTY574115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Bolt

      Item Length Thread Diameter
      Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.17 in.) 8 mm (0.315 in.)
      Bolt C 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt D 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt E 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt F 80 mm (3.15 in.) 10 mm (0.394 in.)
      TEXT IN ILLUSTRATION

      *1 Nut
      NOTE:

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

    8. Tighten the 3 bolts in several steps in the sequence shown in the illustration.
      Fig 1: Timing Chain Cover Tightening Sequence (1 Of 3)
      GTY594673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    9. Temporarily install the fluid coupling bracket with the 4 bolts.
      GTY550117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Bolt

      Item Length Thread Diameter
      Bolt A 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt B 80 mm (3.15 in.) 10 mm (0.394 in.)
    10. Temporarily install the V-ribbed belt tensioner assembly with the standard bolt and 6 mm hexagon wrench bolt.
    11. Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.
      Fig 2: Timing Chain Cover Tightening Sequence (2 Of 3)
      GTY129569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    12. Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.
      Fig 3: Timing Chain Cover Tightening Sequence (3 Of 3)
      GTY542324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

      GTY147829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Install 5 new O-rings to the No. 2 camshaft bearing cap and No. 3 camshaft bearing cap.
    2. Install the gasket to the cylinder head cover sub-assembly LH.
      NOTE:

      Remove any oil from the contact surface.

    3. Apply seal packing as shown in the illustration.
      GTY559114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      TEXT IN ILLUSTRATION

      Seal Packing
      NOTE:
      • Remove any oil from the contact surface.
      • Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    4. Install the cylinder head cover sub-assembly LH washer with a new seal and the 14 bolts.
      GTY592498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A 

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

      except bolt A 

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

      NOTE:

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

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Install 5 new O-rings to the No. 1 camshaft bearing cap and No. 3 camshaft bearing cap.
    2. Install the gasket to the cylinder head cover sub-assembly.
      NOTE:

      Remove any oil from the contact surface.

    3. Apply seal packing as shown in the illustration.
      GTY559113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

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

      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.
    4. Install the cylinder head cover sub-assembly washer with a new seal and the 14 bolts.
      GTY545596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A 

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

      except bolt A 

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

      NOTE:

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

  5. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  6. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Install the crankshaft timing gear key to the crankshaft.
  7. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 3

  8. CONNECT WIRE HARNESS CLAMP BRACKET 
    1. Connect the wire harness clamp bracket to the timing chain cover sub-assembly with the bolt.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  9. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the No. 1 idler pulley sub-assembly with the bolt.

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

  10. INSTALL WATER PUMP PULLEY 

    Refer to PROCEDURE - Step 2

  11. INSTALL WATER INLET HOUSING 

    Refer to PROCEDURE - Step 3

  12. INSTALL AIR PIPE SUB-ASSEMBLY 
    1. Connect the 2 hoses.
    2. Install the air pipe sub-assembly with the bolt.

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

  13. INSTALL NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 12

  14. INSTALL NO. 2 CYLINDER HEAD COVER 

    Refer to PROCEDURE - Step 14

  15. INSTALL FRONT WATER BY-PASS JOINT 
    1. Install 2 new gaskets and the front water by-pass joint with the 4 nuts to the cylinder head.

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

    2. Connect the No. 2 water by-pass hose to the front water by-pass joint, and slide the clamp to secure the hose.
  16. CONNECT NO. 10 WATER BY-PASS HOSE 
    1. Connect the No. 10 water by-pass hose to the front water by-pass joint, and slide the clamp to secure the hose.
      GTY607584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 9 Water By-pass Hose
      *2 No. 10 Water By-pass Hose
      *a Paint Mark (Orange)
      *b Paint Mark (Yellow)
  17. CONNECT NO. 9 WATER BY-PASS HOSE 
    1. Connect the No. 9 water by-pass hose to the front water by-pass joint, and slide the clamp to secure the hose.
  18. INSTALL NO. 1 WATER BY-PASS PIPE 
    1. Install the No. 1 water by-pass pipe with the 2 bolts.

      Torque: 18 N.m (184 kgf/cm, 13 ft.lbf) 

  19. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Connect the No. 2 water by-pass hose and No. 3 water by-pass hose to the water by-pass pipe sub-assembly, and slide the 2 clamps to secure the hoses.
    2. Install the water by-pass pipe sub-assembly with the 2 bolts.

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

  20. INSTALL AIR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  21. INSTALL NO. 1 WATER BY-PASS HOSE 
    1. Connect the No. 1 water by-pass hose to the water inlet housing and front water by-pass joint, and slide the 2 clamps to secure the hoses.
  22. INSTALL GENERATOR ASSEMBLY 

    (Refer to INSTALLATION [08/2015 - 08/2018] )

  23. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 7

  24. INSTALL ENGINE OIL COOLER 

    (Refer to INSTALLATION [08/2015 - 08/2018] ).

  25. INSTALL OIL FILTER BRACKET 

    See step  4

  26. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY 

    See step  1

  27. INSTALL OIL FILTER ELEMENT 

    (Refer to REPLACEMENT [08/2015 - 08/2018] )

  28. INSTALL NO. 2 FUEL TUBE SUB-ASSEMBLY 
    1. Connect the No. 2 fuel tube sub-assembly with the 2 bolts.

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

  29. INSTALL COOLER COMPRESSOR ASSEMBLY 
    1. Install the cooler compressor assembly with the 2 stud bolts.
      Fig 4: Cooler Compressor Assembly Tightening Sequence
      GTY603584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the 2 bolts and 2 nuts.

      Tighten the bolts and nuts in the order shown in the illustration to install the cooler compressor assembly.

      Torque: 25 N.m (250 kgf/cm, 18 ft.lbf) 

  30. CONNECT NO. 2 AIR INJECTION SYSTEM HOSE 

    Refer to PROCEDURE - Step 5

  31. CONNECT NO. 3 AIR INJECTION SYSTEM HOSE 

    Refer to PROCEDURE - Step 6

  32. INSTALL INTAKE MANIFOLD 

    (Refer to INSTALLATION [08/2015 - 08/2018] )

  33. INSTALL NO. 2 ENGINE WIRE 
  34. INSTALL ENGINE WIRE 
  35. CONNECT OUTLET HEATER WATER HOSE C 
    1. Connect the outlet heater water hose C to the No. 1 water by-pass pipe, and slide the clamp to secure the hose.
      GTY543961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a RR
      *b LH
      *c 45°

      HINT: 

      Install the outlet heater water hose C so that the direction of the hose clamp is as indicated in the illustration.

  36. CONNECT INLET HEATER WATER HOSE C 
    1. Connect the inlet heater water hose C to the water by-pass pipe sub-assembly, and slide the clamp to secure the hose.
      GTY581195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a RR
      *b LH
      *c 45°

      HINT: 

      Install the inlet heater water hose C so that the direction of the hose clamp is as indicated in the illustration.

  37. INSTALL AIR CLEANER HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 13

  38. INSTALL AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 14

  39. INSTALL RADIATOR ASSEMBLY 

    (Refer to INSTALLATION [08/2015 - 08/2018] ).

  40. ADD ENGINE OIL 

    See step  9

  41. INSPECT FOR OIL LEAK 

    See step  10

  42. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 2

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