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Installation [08/2015 - ]: Procedure

  1. INSTALL WATER INLET PIPE 
    1. Apply soapy water to 2 new O-rings and install them to the inlet pipe.
      GTY571509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the inlet pipe to the No. 1 heat exchanger cover.
  2. INSTALL TIMING CHAIN COVER SUBASSEMBLY 
    1. Apply a light coat of engine oil to a new oil pump gasket.
      GTY571506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil pump gasket.
    3. Apply a light coat of engine oil to a new O-ring.
      GTY268743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the O-ring.
    5. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.
      GTY539146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.)
        TEXT IN ILLUSTRATION

        *a 27.5 mm (1.08 in.) *b 32.5 mm (1.28 in.)
        *c 35.0 mm (1.38 in.) *d 34.5 mm (1.36 in.)
        *e 16.0 mm (0.630 in.) *f 18.0 mm (0.709 in.)
        g 7.0 mm (0.275 in.) *h Continuous Line Area
        i Dashed Line Area *j Diagonal Line Area
        GTY557449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Seal Packing Thickness mm (in.)
        *b Seal Packing Width mm (in.)
        *c OK Area
      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.
      • 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 chain cover to the crankshaft.
      GTY147828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Temporarily install the timing chain cover with the 28 bolts and nut.
      GTY548119Courtesy 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: Fluid Coupling Bracket Bolts Tightening Sequence
      GTY594672Courtesy 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.
      GTY550118Courtesy 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 belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.
      GTY255060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.
      Fig 2: V-Ribbed Belt Tensioner Assembly Tightening Sequence (1 Of 2)
      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: V-Ribbed Belt Tensioner Assembly Tightening Sequence (2 Of 2)
      GTY542325Courtesy 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 SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 42 [08/2015 - 08/2016] Refer to PROCEDURE - Step 42 [08/2016 - ]

  4. INSTALL CYLINDER HEAD COVER SUBASSEMBLY LH 
    1. Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).
      GTY571580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the gasket to the cylinder head cover.
      NOTE:

      Remove any oil from the contact surface.

    3. Apply seal packing as shown in the illustration.
      GTY545714Courtesy 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 within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after the installation.
    4. Install the cylinder head cover and the seal washer with the 14 bolts in the order shown in the illustration.
      Fig 4: Cylinder Head Cover Bolts Tightening Sequence
      GTY592497Courtesy 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) 

  5. INSTALL CYLINDER HEAD COVER SUBASSEMBLY RH 
    1. Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).
      GTY604869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the gasket to the cylinder head cover.
      NOTE:

      Remove any oil from the contact surface.

    3. Apply seal packing as shown in the illustration.
      GTY545709Courtesy 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 within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
      • Do not start the engine for at least 2 hours after the installation.
    4. Install the cylinder head cover and the seal washer with the 14 bolts in the order shown in the illustration.
      Fig 5: Cylinder Head Cover Bolts Tightening Sequence
      GTY545598Courtesy 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) 

    5. Install the noise filter to the cylinder head cover with the bolt.
      GTY480043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

  6. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the 8 ignition coils with the 8 bolts.

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

  7. INSTALL CRANKSHAFT TIMING GEAR KEY 
    1. Install the crankshaft timing gear key to the crankshaft.
      GTY587387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT WIRE HARNESS CLAMP BRACKET 
    1. Connect the bracket to the timing chain cover with the bolt.
      GTY610828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  9. INSTALL CRANKSHAFT PULLEY 
    1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
    2. Using SST, install the pulley set bolt.
      GTY579211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-70011 
      • SST: 09330-00021 

      Torque: 300 N*m (3059 kgf*cm, 221 ft.*lbf) 

      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
  10. INSTALL NO. 1 IDLER PULLEY SUBASSEMBLY 
    1. Install the idler pulley with the bolt.
      GTY571521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  11. INSTALL WATER PUMP PULLEY 
    1. Temporarily install the pulley with the 4 bolts.
    2. Using SST, hold the pulley and tighten the 4 bolts.
      GTY611438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09960-10010 
        1. 09962-01000
        2. 09963-01000

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

  12. INSTALL WATER INLET HOUSING 
    1. Install a new gasket to the timing chain cover.
      GTY606956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Gasket
    2. Install the water inlet with the 3 bolts.
      GTY610973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  13. INSTALL AIR TUBE SUBASSEMBLY 
    1. Connect the 2 hoses.
      GTY571520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the air tube with the bolt.

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

  14. INSTALL NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 9

  15. INSTALL NO. 2 ENGINE COVER 

    Refer to PROCEDURE - Step 11

  16. INSTALL FRONT WATER BY-PASS JOINT 
    1. Install 2 new gaskets and the water by-pass joint with the 4 nuts.
      GTY611163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the No. 2 water by-pass hose to the water by-pass joint.
  17. INSTALL WATER BY-PASS PIPE SUBASSEMBLY 
    1. Connect the 2 hoses.
      GTY611258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water by-pass pipe with the 2 bolts.

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

    3. Connect the air tube with the bolt.
      GTY610956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  18. INSTALL NO. 1 WATER BY-PASS HOSE 
    1. Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.
      GTY610852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  20. CONNECT OIL COOLER TUBE 

    Refer to PROCEDURE - Step 7

  21. CONNECT VANE PUMP ASSEMBLY 

    HINT: 

    Before performing the following procedures, move the spacer until the vane pump can be installed.

    GTY605724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *1 Spacer
    1. Connect the vane pump to the timing chain cover with the 2 bolts.
      GTY610877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  22. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 9

  23. INSTALL OIL FILTER BRACKET (w/o Oil Cooler) 
    1. Apply a light coat of engine oil to 2 new O-rings.
    2. Install the 2 O-rings to the timing chain cover.
      GTY604897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil filter bracket with the 2 bolts and 2 nuts.
      GTY593366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

  24. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) 

    See step  3

  25. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) 

    See step  4

  26. INSTALL NO. 2 WATER BY-PASS PIPE SUBASSEMBLY (w/ Oil Cooler) 
    1. Connect the 4 hoses.
      GTY545961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the water by-pass pipe with the 3 bolts.

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

  27. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY 

    See step  1

  28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 22

  29. INSTALL OIL FILTER ELEMENT 

    See step  5

  30. CONNECT NO. 2 FUEL TUBE SUBASSEMBLY 
    1. Connect the fuel tube with the 2 bolts.
      GTY570555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      TEXT IN ILLUSTRATION

      *a LH Side
      *b RH Side
  31. CONNECT COOLER COMPRESSOR ASSEMBLY 
    1. Install the cooler compressor with the stud bolt.
      Fig 6: Cooler Compressor Tightening Sequence
      GTY148638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the 3 bolts and nut.

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

      NOTE:

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

  32. CONNECT NO. 2 WATER BY-PASS PIPE 
    1. Connect the No. 2 water by-pass pipe to the cylinder head cover with the 3 bolts.
      GTY611090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the 3 hoses.
  33. CONNECT AIR PUMP HOSE AND WIRE HARNESS 
    1. Connect the No. 2 air hose and No. 3 air hose.
      GTY586918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 2 Air Hose
      *2 No. 3 Air Hose
    2. Connect the 2 clamps and air pump wire harness.
  34. CONNECT ENGINE WIRE 
    1. Engine Room RH Side:
      GTY611371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the 5 clamps.
      2. Connect the throttle position sensor and throttle control motor connector.
      3. Connect the 2 air pump connectors.
      4. Install the ground wire with the 2 bolts.

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

      5. Connect the noise filter connector.
      6. Connect the 2 VVT sensor connectors.
      7. Connect the injector connector.
      8. Connect the 4 ignition coil connectors.
      9. Connect the 2 camshaft timing oil control valve connectors.
      10. Connect the 2 clamps and power steering oil pressure switch connector.
        GTY611083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engine Room LH Side:
      GTY611528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the cooler compressor connector.
      2. Connect the 3 clamps.
      3. Connect the camshaft position sensor connector.
      4. Connect the 2 camshaft timing oil control valve connectors.
      5. Connect the engine coolant temperature sensor connector.
      6. Connect the 4 clamps.
        GTY584100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. Install the ground wire with the 2 bolts.

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

      8. Connect the noise filter connector.
      9. Connect the 2 VVT sensor connectors.
      10. Connect the 4 ignition coil connectors.
      11. Connect the injector connector.
      12. Connect the wire harness clamp and 4 air injection control driver connectors.
        GTY601310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      13. Connect the 2 connectors and 2 clips to the engine room junction block.
        GTY555511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      14. Install the engine room relay block cover.
  35. ADD ENGINE OIL 

    See step  6

  36. INSTALL AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 36

  37. INSTALL RADIATOR ASSEMBLY 

    (Refer to INSTALLATION [08/2015 - ] )

  38. INSPECT ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 2

  39. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY 

    (Refer to INSTALLATION [08/2015 - ] )

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