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Installation [02/2017 - ]: Procedure

  1. INSTALL OIL PUMP ASSEMBLY 
    1. Install the oil pump assembly to the stiffening crankcase assembly with the 3 bolts.

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

  2. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove any remaining seal packing and be careful not to drop any oil on the contact surfaces of the cylinder block sub-assembly and No. 2 oil pan sub-assembly.
    2. Apply seal packing in a continuous line as shown in the illustration.
      GTY761441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing Black
      *b 6.0 mm (0.236 in.)
      *c 3.0 to 4.5 mm (0.118 to 0.177 in.)

      Application Specification

      Area Seal Packing Diameter Distance from Center of Bolt Hole to Center of Seal Packing
      (A) - (A) 3.0 to 4.5 mm (0.118 to 0.177 in.) 6.0 mm (0.236 in.)
      (B) - (B) -

      Seal Packing

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

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
      • Do not add engine oil for at least 2 hours after installing the No. 2 oil pan sub-assembly.
    3. Install the No. 2 oil pan sub-assembly with the 10 bolts and 2 nuts.

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

  3. INSTALL NO. 2 CHAIN SUB-ASSEMBLY 
    1. Temporarily install the crankshaft pulley bolt.
    2. Set the crankshaft timing gear key as shown in the illustration.
      GTY429634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the oil pump drive shaft so that the cutout faces upward.
    4. Remove the crankshaft pulley bolt.
    5. Align the yellow mark plates with the timing mark of the oil pump drive gear and oil pump drive shaft gear as shown in the illustration.
      GTY495281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pump Drive Gear
      *2 Oil Pump Drive Shaft Gear
      *a Yellow Mark Plate
      *b Timing Mark
      Engine Front
    6. With the No. 2 chain sub-assembly around the oil pump drive gear and oil pump drive shaft gear, install the oil pump drive gear to the crankshaft and temporarily install the oil pump drive shaft gear to the oil pump drive shaft.
    7. Temporarily install the oil pump drive shaft gear nut.
    8. Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

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

    9. Temporarily install the crankshaft pulley with the crankshaft pulley bolt.
      GTY772296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using SST, hold the crankshaft pulley. Then tighten the oil pump drive shaft gear nut.
      • SST: 09213-5401509330-00021 

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

      HINT: 

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

    11. Remove SST, the crankshaft pulley bolt and crankshaft pulley.
  4. INSTALL CRANKSHAFT TIMING SPROCKET 
    1. Install the crankshaft timing sprocket as shown in the illustration.
      GTY447302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Engine Front
  5. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 24 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 24 [10/2017 - ]

  6. SET NO. 1 CYLINDER TO TDC / COMPRESSION 

    Refer to PROCEDURE - Step 25 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 25 [10/2017 - ]

  7. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 26 [10/2017 - ]

  8. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 27 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 27 [10/2017 - ]

  9. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION 

    Refer to PROCEDURE - Step 28 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 28 [10/2017 - ]

  10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Install a new gasket to the timing chain cover sub-assembly.
      NOTE:

      Remove any oil from the contact surface.

    2. Install the engine water pump assembly to the timing chain cover sub-assembly with the 3 bolts.

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

    3. Remove any remaining seal packing material.
    4. Clean the contact surfaces of the timing chain cover sub-assembly, camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.
      GTY757880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Side *b Timing Chain Cover Sub-assembly Side
      Clean and degrease - -
    5. Install 2 new O-rings to the cylinder head sub-assembly.
    6. Install a new O-ring to the cylinder block sub-assembly.
    7. Apply seal packing to the engine unit as shown in the illustration.
      GTY756475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal Packing

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

      Standard Seal Diameter

      5.0 mm (0.197 in.)

      NOTE:

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

    8. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.
      GTY751839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2.5 mm (0.10 in.) *b 2.5 to 3.5 mm (0.10 to 0.14 in.)
      *c 5.0 mm (0.20 in.) *d 4.5 to 5.5 mm (0.18 to 0.22 in.)
      *e 7.5 mm (0.30 in.) *f 7.0 to 8.0 mm (0.28 to 0.31 in.)

      Seal Packing

      Item Seal Packing
      Dashed line Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Continuous line
      Alternate long and short dashed line Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Application Specification

      Area Seal Packing Diameter Distance from Edge of Cover to: Seal Packing Application Length Distance from Top of Cover to Top of Seal Packing
      Dashed line 2.5 to 3.5 mm (0.0984 to 0.138 in.) Center of seal packing
      2.5 mm (0.0984 in.)      		 - -
      Continuous line 4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.) - - -
      Alternate long and short dashed line 4.0 mm (0.157 in.) Center of seal packing
      3.0 mm (0.118 in.)      		 - -
      (A) - (A) 2.5 to 3.5 mm (0.0984 to 0.138 in.) Center of seal packing
      2.5 mm (0.0984 in.)      		 - -
      (B) - (B) 4.5 to 5.5 mm (0.177 to 0.217 in.) Opposite edge of seal packing
      5.0 mm (0.197 in.)      		 - -
      (C) - (C) 7.0 to 8.0 mm (0.276 to 0.315 in.) Opposite edge of seal packing
      7.5 mm (0.295 in.)      		 - -
      (F) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 15.8 mm (0.622 in.) 50.1 mm (1.97 in.)
      (G) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 10.3 mm (0.406 in.) 155.1 mm (6.11 in.)
      (H) 7.0 to 8.0 mm (0.276 to 0.315 in.) - 19.5 mm (0.768 in.) 165.4 mm (6.51 in.)
      (I) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (15.7 in.)
      (J) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 18.6 mm (0.732 in.) 51.4 mm (2.02 in.)
      (K) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 25.3 mm (0.996 in.) 133.9 mm (5.27 in.)
      (L) 7.0 to 8.0 mm (0.276 to 0.315 in.) - 25.8 mm (1.02 in.) 159.2 mm (6.27 in.)
      (M) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 5.0 mm (0.197 in.) 185.0 mm (7.28 in.)
      (N) 4.5 to 5.5 mm (0.177 to 0.217 in.) - 14.6 mm (0.575 in.) 397.8 mm (15.7 in.)
      (O) 4.0 mm (0.157 in.) Center of seal packing
      3.0 mm (0.118 in.)      		 - -
      NOTE:

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

    9. Clean the bolts and their installation holes.
    10. Apply adhesive to 5 and a half threads or more of the end of the bolt (C).
      GTY423433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    11. Temporarily install the timing chain cover sub-assembly with the 19 bolts and a new seal washer.

      Bolt Length

      Item Length Thread Diameter
      Bolt (A), (C) 35 mm (1.38 in.) 8 mm (0.315 in.)
      Bolt (B) 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt (D) 40 mm (1.57 in.) 6 mm (0.236 in.)
      NOTE:

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

      GTY691002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer
    12. Temporarily install the engine mounting bracket RH with the 3 bolts.

      Bolt Length

      Length Thread Diameter
      80 mm (3.15 in.) 10 mm (0.394 in.)
      NOTE:

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

    13. Install 2 new O-rings to the timing chain cover sub-assembly.
    14. Temporarily install the oil filter bracket with the 4 bolts.

      Bolt Length

      Length Thread Diameter
      35 mm (1.38 in.) 8 mm (0.315 in.)
      NOTE:

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

    15. Fully tighten the 26 bolts in the order shown in the illustration.
      Fig 1: Timing Chain Cover Sub-Assembly Tightening Sequence
      GTY491413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque *b Bolt Tightening Order

      Bolt (A), (C) 

      Torque: 25.5 N*m (260 kgf*cm, 19 ft.*lbf) 

      Bolt (B), (E) 

      Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf) 

      Bolt (D) 

      Torque: 10 N*m (102 kgf*cm, 7 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.
  11. INSTALL TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 1

  12. INSTALL CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 2

  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 34 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 34 [10/2017 - ]

  14. INSTALL CYLINDER HEAD COVER GASKET 

    Refer to PROCEDURE - Step 39 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 39 [10/2017 - ]

  15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 40 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 40 [10/2017 - ]

  16. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  17. INSTALL NO. 1 VACUUM PUMP BRACKET 

    Refer to PROCEDURE - Step 4

  18. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  19. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 2 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 2 [12/2021 - ]

  20. INSTALL THERMOSTAT 

    Refer to PROCEDURE - Step 1

  21. INSTALL WATER INLET 

    Refer to PROCEDURE - Step 2

  22. INSTALL WATER INLET HOSE 

    Refer to PROCEDURE - Step 8

  23. INSTALL WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 11

  24. CONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 9

  25. INSTALL VENTILATION HOSE 

    Refer to PROCEDURE - Step 10

  26. INSTALL EXHAUST MANIFOLD 

    Refer to PROCEDURE - Step 2 [02/2017 - 12/2017] , or refer to PROCEDURE - Step 2 [12/2017 - ]

  27. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 3 [02/2017 - 12/2017] , or refer to PROCEDURE - Step 3 [12/2017 - ]

  28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 19

  29. INSTALL FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 1 [10/2017 - 08/2020] , or refer to PROCEDURE - Step 1 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 1 [12/2021 - ]

  30. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 2 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 2 [10/2017 - 08/2020] , or refer to PROCEDURE - Step 2 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 2 [12/2021 - ]

  31. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 3 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 3 [10/2017 - 08/2020] , or refer to PROCEDURE - Step 3 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 3 [12/2021 - ]

  32. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 4 [10/2017 - 08/2020] , or refer to PROCEDURE - Step 4 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 4 [12/2021 - ]

  33. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 7 [10/2017 - 08/2020] , or refer to PROCEDURE - Step 7 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 7 [12/2021 - ]

  34. INSTALL WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 8 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 8 [10/2017 - 08/2020] , or refer to PROCEDURE - Step 8 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 8 [12/2021 - ]

  35. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 3

  36. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 4

  37. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 4 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 4 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 4 [12/2021 - ]

  38. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 1 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 1 [12/2021 - ]

  39. INSTALL THROTTLE BODY ASSEMBLY 

    Refer to PROCEDURE - Step 2 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 2 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 2 [12/2021 - ]

  40. INSTALL ENGINE HANGER 

    Refer to PROCEDURE - Step 42 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 42 [10/2017 - 08/2020] , or refer to PROCEDURE - Step 42 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 42 [12/2021 - ]

  41. REMOVE ENGINE FROM ENGINE STAND 

    Refer to PROCEDURE - Step 2 [02/2017 - 10/2017] , or refer to PROCEDURE - Step 2 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 2 [12/2021 - ]

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