CAMSHAFT INSTALLATION


  1. INSTALL CAMSHAFT


    1. Apply engine oil to the camshaft journals and bearings.

    2. A01CJ0HE07
      Text in Illustration
      *1 Alignment Mark

      Match the alignment marks of the camshaft timing gear and oil pump gear, and install the camshaft.

    3. Install the camshaft with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  2. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL


    1. Apply MP grease to the timing chain or belt cover oil seal lip.

    2. A01CGY6E01

      Using SST and a hammer, tap in a new timing chain or belt cover oil seal to the timing gear case so that the timing chain or belt cover oil seal is flush with the timing gear case edge.

      SST
      09223-78010

      Note


      • Be careful not to tap the timing chain or belt cover oil seal at an angle.

      • Keep the gap between the timing gear case edge and the timing chain or belt cover oil seal free of foreign matter.

  3. INSTALL TIMING GEAR CASE


    1. Remove any seal packing material from the contact surfaces.

    2. A01CH97E02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.5 mm (0.984 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the timing gear case within 3 minutes of applying the seal packing.

      • Do not expose the seal packing to engine oil for at least 2 hours after installation.

    3. Install the timing gear case with the 15 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  4. INSTALL OIL SEPARATOR ASSEMBLY


    1. Install 3 new O-rings.

    2. Install the oil separator assembly with the 5 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  5. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01CGWXE01
      Text in Illustration
      *1 Timing Gear Case
      *2 Front End Plate
      *3 Gasket
      *4 Cylinder Block
      *5 Cutter
      *a Cut

      Using a cutter, cut the gasket so that it is flush with the lower surface of the cylinder block.

    2. Remove seal packing material from the contact surfaces.

    3. A01CJB3E02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.5 mm (0.138 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the oil pan sub-assembly within 3 minutes of applying the seal packing.

      • Do not expose the seal packing to engine oil for at least 2 hours after installation.

    4. Install the oil pan sub-assembly with the 26 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  6. INSTALL FLYWHEEL HOUSING STAY LH


    1. Install the flywheel housing stay LH with the 4 bolts.

      Torque:
      for M14 bolt
      132 N*m  { 1349 kgf*cm, 97 ft.*lbf }
      for M12 bolt
      97 N*m  { 989 kgf*cm, 72 ft.*lbf }

  7. INSTALL FLYWHEEL HOUSING STAY RH


    1. Install the flywheel housing stay RH with the 4 bolts.

      Torque:
      for M14 bolt
      132 N*m  { 1349 kgf*cm, 97 ft.*lbf }
      for M12 bolt
      97 N*m  { 989 kgf*cm, 72 ft.*lbf }

  8. INSTALL CRANKSHAFT PULLEY


    1. Install the crankshaft pulley and spacer to the crankshaft.

      Tech Tips

      Align the crankshaft pulley set key with the key groove of the crankshaft pulley.

    2. Apply a light coat of engine oil to the threads of the nut.

    3. Step 1:


      1. Using a 46 mm socket wrench, tighten the nut.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

        Tech Tips

        Insert a screwdriver through the inspection hole of the flywheel housing into the ring gear of the flywheel sub-assembly to prevent the ring gear from turning together with the crankshaft.

    4. Step 2:


      1. A01CHGIE01
        Text in Illustration
        *1 Paint Mark
        A01CHW8 RH

        Mark the RH of each crankshaft pulley bolt head with paint.

      2. Further tighten the bolts 90° as shown in the illustration.

      3. Check that each paint mark is now at a 90° angle to the RH.

  9. INSTALL CRANKSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

      Note

      When reusing the crankshaft position sensor, inspect the O-ring.

    2. Install the crankshaft position sensor with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Make sure that the O-ring is not cracked and does not come out of position during installation.

    3. Connect the crankshaft position sensor connector.

  10. INSTALL CAMSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

      Note

      When reusing the camshaft position sensor, inspect the O-ring.

    2. Install the camshaft position sensor with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Make sure that the O-ring is not cracked and does not come out of position during installation.

    3. Connect the camshaft position sensor connector.

  11. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 3 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  12. INSTALL IDLE PULLEY BRACKET


    1. Install the idle pulley bracket with the 3 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  13. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. Connect the cooler compressor assembly with the 4 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    2. Connect the connector.

    3. Connect the cooler pipe with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  14. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. A01CH6IE05
      Text in Illustration
      *1 Seal Packing

      Apply a continuous bead of seal packing (diameter 2.2 to 2.7 mm (0.0866 to 0.106 in.)) as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Seal diameter
      2.2 to 2.7 mm (0.0866 to 0.106 in.)

      Note


      • Remove any oil from the contact surfaces.

      • Install the engine water pump assembly within 3 minutes of applying the seal packing.

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

    2. Install the engine water pump assembly with the 8 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  15. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  16. INSTALL SUPPLY PUMP ASSEMBLY

    Click here

  17. INSTALL CYLINDER HEAD GASKET

    Click here

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  19. ADD ENGINE OIL


    1. Add new engine oil.

      Standard Oil Grade
      Oil Grade Oil Viscosity (SAE)

      API (CJ-4)

      JASO (DH-2)

      ACEA (E-6, E-9)

      - 5W-30

      - 10W-30

      - 15W-40
      Standard Capacity
      Item Specified Condition
      Drain and refill without oil filter change 5.2 liters (5.5 US qts, 4.6 Imp. qts)
      Drain and refill with oil filter change 6.5 liters (6.9 US qts, 5.7 Imp. qts)
      Dry fill 8.7 liters (9.2 US qts, 7.7 Imp. qts)

    2. Install the oil filler cap.

  20. ADD ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly, radiator drain cock plug or engine drain plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Do not substitute plain water for engine coolant.


    1. Add engine coolant.

      Standard capacity
      14.2 liters (15.0 US qts, 12.5 Imp. qts)

      Tech Tips

      TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

    2. Check the coolant level inside the radiator by squeezing the inlet radiator hose and outlet radiator hose several times by hand. If the coolant level goes down, add coolant.

    3. Install the radiator cap sub-assembly.

    4. Slowly pour coolant into the radiator reservoir until it reaches the F line.

    5. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens.

        While the thermostat is open, circulate the coolant for several minutes.

      2. Maintain the engine speed at a speed between 2500 and 3000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        Note


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. Stop the engine and wait until the coolant cools down to ambient temperature.

    7. Remove the radiator cap sub-assembly and check the coolant level.

      If the coolant level has dropped, add coolant.

    8. Check the coolant level inside the radiator reservoir assembly again.

      If the coolant level is below the F line, add coolant to F line.

  21. ADD POWER STEERING FLUID

  22. BLEED AIR FROM FUEL SYSTEM


    1. A01CHFE

      Loosen the bleeder plug.

      Text in Illustration
      A01CHW8 Bleeder Plug

      Note

      Make sure that the drain plug and bleeder plug of the filter on the fuel tank side are closed.

    2. A01CHX4

      Bleed air using the priming pump on the fuel tank side.

      Note


      • Place a container, etc. underneath the fuel filter to prevent fuel from spraying.

      • The hand pump must be pushed with a full stroke during pumping.

      • The maximum hand pump pumping speed is 2 strokes per second.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.

    3. Tighten the bleeder plug.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

    4. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

        Tech Tips

        If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    5. Turn the ignition switch off.

    6. Connect the intelligent tester to the DLC3.

    7. Turn the ignition switch to ON and turn the intelligent tester on.

    8. Clear the DTCs Click here.

    9. Start the engine.*1

    10. A01CJCTE05
      Text in Illustration
      *a

      Reference

      (Active Test operation)

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    11. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

      A01CHBIE15
      Text in Illustration
      *a Active Test operation *b Time
      *c ON *d OFF
      *e 1st time *f 2nd time
      *g 5th time *h 10 seconds
      *i 3 minutes or more - -

    12. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

    13. Enter the following menus: Powertrain / Engine and ECT / DTC.

    14. Read Current DTCs.


      1. If no DTCs are output, air bleeding is completed.

      2. If DTCs are output, perform the following procedure.

    15. Clear the DTCs Click here.

    16. Repeat steps *1 to *3.

    17. Enter the following menus: Powertrain / Engine and ECT / DTC.

    18. Read Current DTCs.

      OK
      No DTCs are output

  23. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  24. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before each inspection, turn the A/C switch off.


    1. Fill the radiator with coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 20 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator assembly and engine water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  25. BLEED AIR FROM POWER STEERING SYSTEM


    1. Check the fluid level Click here.

    2. Jack up the front of the vehicle and support it with stands.

    3. Turn the steering wheel.


      1. With the engine stopped, turn the steering wheel slowly from lock to lock several times.

    4. Lower the vehicle.

    5. Start the engine.


      1. Run the engine at idle for a few minutes.

    6. Turn the steering wheel.


      1. With the engine idling, turn the steering wheel left or right to the full lock position and keep it in that position for 2 to 3 seconds, then turn the steering wheel to the opposite full lock position and keep it there for 2 to 3 seconds (*1).

      2. Repeat this procedure (*1) several times.

    7. Stop the engine.

    8. A01CGMDE01

      Check for foaming or emulsification.

      Tech Tips

      If the system has to be bled twice because of forming or emulsification, be sure to check for fluid leaks in the system.

    9. Check the fluid level Click here.

  26. INSPECT POWER STEERING FLUID LEVEL


    1. Keep the vehicle level.

    2. A01CIZFE03

      With the engine stopped, check the fluid level in the fluid reservoir.

      If necessary, add fluid.

      Fluid
      ATF DEXRON II or III, or equivalent.

      Tech Tips

      If the fluid is hot, check that the fluid level is within the HOT range on the fluid reservoir. If the fluid is cold, check that the fluid level is within the COLD range.

    3. Start the engine and run it at idle.

    4. Turn the steering wheel from lock to lock several times to raise fluid temperature.

      Fluid temperature
      50 to 60°C (122 to 140°F)
    5. A01CGMDE01

      Check for foaming or emulsification.

      If foaming or emulsification is identified, bleed the power steering system Click here.

    6. A01CJDRE01

      With the engine idling, measure the fluid level in the fluid reservoir.

    7. Stop the engine.

    8. Wait a few minutes and remeasure the fluid level in the fluid reservoir.

      Maximum fluid level rise
      6 mm (0.24 in.)

      If any problem is found, bleed the power steering system Click here.

    9. Check the fluid level.

  27. INSPECT FOR EXHAUST GAS LEAK


    1. If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  28. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

        Note

        Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

      2. Connect the intelligent tester to the DLC3.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurizes common rail interior and checks for fuel leaks Stop or Start

        • The fuel pressure inside the common rail is increased to a specified value and the engine speed is increased to 2000 rpm when Start is selected

        • The above conditions are preserved while the control parameter of the test is Start

    2. Check for leaks from the fuel system while performing the Active Test (with a fuel pressure applied).