OIL PUMP INSTALLATION


  1. INSTALL SCAVENGING PUMP ASSEMBLY


    1. Temporarily install the scavenging pump assembly and a new gasket with the 6 bolts.

    2. A016144E01

      Using several steps, uniformly install and tighten the 6 bolts in the sequence shown in the illustration.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
  2. INSTALL NO. 3 OIL PIPE


    1. Install a new O-ring to the No. 3 oil pipe.

    2. Connect the No. 3 oil pipe to the scavenging pump assembly and align the bolt holes.

      Note


      • Be careful not to damage the O-ring.

      • Do not rotate the oil pipe when connecting it to the scavenging pump.

    3. A0161C4

      Install the No. 3 oil pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  3. INSTALL NO. 2 OIL PIPE


    1. Install a new O-ring and oil pipe seal to the No. 2 oil pipe.

    2. Connect the No. 2 oil pipe to the scavenging pump assembly and align the bolt holes.

      Note


      • Be careful not to damage the O-ring.

      • Do not rotate the oil pipe when connecting it to the scavenging pump.

    3. A015YVU

      Install the No. 2 oil pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  4. INSTALL NO. 1 OIL PIPE


    1. Install a new O-ring and oil pipe seal to the No. 1 oil pipe.

    2. Connect the No. 1 oil pipe to the scavenging pump assembly and align the bolt holes.

      Note


      • Be careful not to damage the O-ring.

      • Do not rotate the oil pipe when connecting it to the scavenging pump.

    3. A0160ZR

      Install the No. 1 oil pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  5. INSTALL INLET WATER PIPE


    1. A015ZWJ

      Apply soapy water to 2 new O-rings and install them to the inlet water pipe.

    2. Install the inlet water pipe to the heat exchanger assembly.

  6. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove any old packing material remaining on the sealing surfaces before applying seal packing.

    2. Clean and degrease the contact surfaces of the timing chain cover sub-assembly, cylinder head, and cylinder block and confirm that no oil, moisture, or other foreign matter remains on the surfaces.

      A015Z9UE01
    3. A01615S

      Install a new oil pump gasket.

    4. A015ZXR

      Install a new O-ring.

    5. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the illustration.

      A01637WE02
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A0163GDE01
        Apply seal packing as follows
        Area Seal Packing Diameter Application Position from Inside Edge of Cover
        Continuous Line Area 2.5 to 3.5 mm (0.0984 to 0.1378 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 0.5 mm (0.0197 in.)
        Diagonal Line Area 2.5 to 3.5 mm (0.0984 to 0.1378 in.) 5.5 mm (0.217 in.)

      Note


      • If 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 add engine oil for at least 2 hours after installing the timing chain cover sub-assembly.

      • Do not start the engine for at least 2 hours after installing the timing chain cover sub-assembly.

    6. A0161B4

      Align the oil pump drive rotor spline and the crankshaft as shown in the illustration. Install the spline and timing chain cover sub-assembly to the crankshaft.

    7. A015ZAHE02

      Temporarily install the timing chain cover sub-assembly with the 30 bolts and nut.

      Bolt Length
      Item Length Thread Diameter
      Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.165 in.) 8 mm (0.315 in.)
      Bolt C 70 mm (2.756 in.) 8 mm (0.315 in.)
      Bolt D 35 mm (1.378 in.) 10 mm (0.394 in.)
      Bolt E 80 mm (3.150 in.) 10 mm (0.394 in.)
      Bolt F 80 mm (3.150 in.) 10 mm (0.394 in.)
      Bolt G 80 mm (3.150 in.) 8 mm (0.315 in.)

      Note

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

    8. A0161YUE01

      Tighten the 11 bolts in several steps, in the sequence shown in the illustration.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    9. A0162C7E01

      Temporarily install the v-ribbed belt tensioner assembly with the standard bolt and hexagon bolt.

    10. A0160NRE01

      Tighten the 21 bolts and nut in several steps, in the sequence shown in the illustration.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Use a 6 mm socket hexagon wrench to tighten the bolt numbered 22 in the illustration.

    11. A015Z0PE01

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

  7. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (for Bank 1)


    1. A0160O5E01

      Turn the camshaft timing gear assembly intermediate shaft index slot in the counterclockwise direction by hand, to set it to the maximum retard angle position.

      Tech Tips


      • When a camshaft lobe opens a valve, the intermediate shaft becomes difficult to turn.

      • The position where the intermediate shaft stops is the maximum retard angle.

    2. A016058

      Install a new O-ring to the timing chain cover.

    3. A0160VO

      Align the joint of the camshaft timing control motor assembly LH and the keyway of the camshaft timing gear assembly, and install the camshaft timing control motor assembly LH with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note


      • Check that [L] is printed on the label of the camshaft timing control motor assembly LH.

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor assembly LH (the surface that contacts the timing chain cover sub-assembly).

      • When installing the camshaft timing control motor assembly LH, do not use excessive force.

      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor assembly LH.

      • Install the camshaft timing control motor assembly LH with the arrow facing upward, as shown in the illustration.

      • Do not drop the camshaft timing control motor assembly LH. If dropped, replace it.

      • Do not disassemble the camshaft timing control motor assembly LH. If disassembled, replace it.

  8. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (for Bank 2)


    1. A0160G4E01

      Turn the camshaft timing gear assembly intermediate shaft index slot in the counterclockwise direction by hand, to set it to the maximum retard angle position.

      Tech Tips


      • When a camshaft lobe opens a valve, the intermediate shaft becomes difficult to turn.

      • The position where the intermediate shaft stops is the maximum retard angle.

    2. A015YZG

      Install a new O-ring to the timing chain cover.

    3. A01637C

      Align the joint of the camshaft timing control motor assembly RH and the keyway of the camshaft timing gear assembly, and install the camshaft timing control motor assembly RH with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note


      • Check that [R] is printed on the label of the camshaft timing control motor assembly RH.

      • Do not allow foreign matter to contact the oil seal face of the camshaft timing control motor assembly RH (the surface that contacts the timing chain cover sub-assembly).

      • When installing the camshaft timing control motor assembly RH, do not use excessive force.

      • Align the timing chain cover sub-assembly knock pin with the camshaft timing control motor pin hole to install the camshaft timing control motor assembly RH.

      • Install the camshaft timing control motor assembly RH with the arrow facing upward, as shown in the illustration.

      • Do not drop the camshaft timing control motor assembly RH. If dropped, replace it.

      • Do not disassemble the camshaft timing control motor assembly RH. If disassembled, replace it.

  9. INSTALL SPARK PLUG TUBE GASKET


    1. A015ZC7E01

      Install the 8 new spark plug tube gaskets to each cylinder head sub-assembly.

      Note


      • Install the gaskets in the correct direction.

      • Push in each gasket until its bottom surface contacts the cylinder head.

  10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 1)


    1. A0161DZ

      Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.

    2. Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.

      Note

      Remove any oil from the contact surface.

    3. A0160RHE01

      Apply seal packing as shown in the illustration.

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

      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.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly LH.

    4. A0163HNE02

      Install the cylinder head cover sub-assembly LH with 3 new seal washers and the 16 bolts.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    5. Install a new fuel pump spacer gasket.

  11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A015Z76

      Install 2 new oil hole gaskets and 2 new O-rings to the camshaft bearing caps.

    2. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

      Note

      Remove any oil from the contact surface.

    3. A0161LGE01

      Apply seal packing as shown in the illustration.

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

      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.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover sub-assembly.

    4. A01604XE02

      Install the cylinder head cover sub-assembly with 3 new seal washers and the 16 bolts.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    5. Install a new fuel pump spacer gasket.

  12. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. A0160DVE01

      Using SST, tap in a new oil seal until its surface is flush with the timing chain case edge.

      SST
      09223-22010
      09506-35010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap on the oil seal at an angle.

      • Do not install the oil seal excessively.

  13. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A0160SO

      Install the crankshaft timing gear key.

  14. INSTALL CRANKSHAFT PULLEY


    1. A016158E01

      Align the pulley set key with the key groove of the pulley, and slide on the pulley.

    2. Using SST, install the pulley bolt.

      SST
      09213-38010
      09330-00021
      Torque:
      330 N*m  { 3365 kgf*cm, 243 ft.*lbf }
  15. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Install 2 new gaskets to the oil filter bracket sub-assembly.

    2. A0163EH

      Install the oil filter bracket sub-assembly with the 2 bolts and 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A015ZVB

      Install the oil filter bracket stay with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
  16. INSTALL FRONT WATER BY-PASS JOINT


    1. A01633J

      Install the front water by-pass joint and 2 new gaskets with the 4 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
  17. INSTALL NO. 3 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. A0163F5

      Install the No. 3 V-bank cover bracket sub-assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  18. INSTALL NO. 4 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. A01635G

      Install the No. 4 V-bank cover bracket sub-assembly with the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  19. INSTALL IGNITION COIL ASSEMBLY


    1. A0160Z7E01

      Install the 8 ignition coil assemblies with the 8 bolts.

      Note

      Do not damage the ignition coil assemblies when installing them.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    2. Connect the 8 ignition coil connectors.

  20. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A0162JT

      Install the No. 2 water by-pass pipe sub-assembly with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. Connect the 3 water by-pass hoses with the 3 hose clamps.

  21. INSTALL WATER INLET HOUSING


    1. A0162EY

      Install a new gasket to the water pump.

    2. Install the water inlet housing with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
  22. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A0162Y5E03

      Connect the No. 3 water by-pass hose to the water inlet housing.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  23. CONNECT WATER INLET HOSE


    1. A0160CTE02

      Connect the water inlet hose to the water inlet housing.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  24. CONNECT NO. 5 WATER BY-PASS HOSE


    1. A016102E02

      Connect the No. 5 water by-pass hose to the water inlet housing.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  25. CONNECT NO. 2 RADIATOR HOSE


    1. A0161KB

      Connect the No. 2 radiator hose to the water inlet housing.

  26. INSTALL WATER PUMP PULLEY


    1. A0160TUE01

      Temporarily install the pulley with the 4 bolts.

    2. Using a screwdriver or an equivalent, hold the pulley and tighten the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Tape the screwdriver tip before use to avoid damage.

  27. INSTALL OIL PUMP DRIVE SHAFT PULLEY


    1. Temporarily install the oil pump drive shaft pulley with the 4 bolts.

    2. A016325E01

      Using SST, hold the oil pump drive shaft pulley and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )
      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
  28. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A0161UQ

      Install the bolt and idler pulley.

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }
  29. INSTALL GENERATOR ASSEMBLY


    1. A0161MB

      Using an E8 "TORX" socket wrench, set the generator with the 2 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A0163K8

      Install the generator with the 2 bolts and 2 nuts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    3. A0161DX

      Install the wire harness bracket with the nut.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    4. A016244E01

      Connect the harness to the +B terminal with nut A.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    5. Install the oil cooler tube with bolt B.

      Torque:
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }
    6. Connect wire harness clamp C.

    7. Connect generator connector D.

  30. INSTALL COMPRESSOR AND PULLEY


    1. A01624A

      Install the bracket with the bolt.

    2. A015YMA

      Using an E8 "TORX" socket, install the compressor and pulley with the 2 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A0160HCE01

      Install the compressor and pulley with the 2 bolts and 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Tighten the bolts in the order shown in the illustration to install the compressor.

  31. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape attached to the hose.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and pulley.

      Compressor oil
      ND-OIL 8 or equivalent
    3. Install the O-ring onto the discharge hose sub-assembly.

    4. A01624P

      Install the discharge hose sub-assembly onto the compressor and pulley with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
  32. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. Remove the vinyl tape attached to the hose.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and pulley.

      Compressor oil
      ND-OIL 8 or equivalent
    3. Install the O-ring onto the No. 1 cooler refrigerant suction hose.

    4. A015ZMQ

      Install the No. 1 cooler refrigerant suction hose onto the compressor and pulley with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    5. Engage each clamp.

    6. Connect the connector.

  33. INSTALL V-RIBBED BELT


    1. A01609IE02

      Install the V-ribbed belt as shown in the illustration.

    2. Rotate the V-ribbed belt tensioner pulley counterclockwise, and then remove the bar.

      Note

      Check that the drive belt is properly set to each pulley.

    3. A015Z08E03

      Check that the belt is properly positioned on each pulley.

    4. Start the engine and check that the belt turns smoothly and no abnormal noise occurs.

  34. INSTALL FUEL PUMP SPACER


    1. Install the 2 fuel pump spacers.

  35. INSTALL FUEL PUMP ASSEMBLY (for Bank 1)

    Click here

  36. INSTALL FUEL PUMP ASSEMBLY (for Bank 2)

    Click here

  37. CONNECT WIRE HARNESS


    1. A015ZRQ

      Connect the ground wire with the bolt and clamp.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A016393

      Connect the ground cable with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A015ZJD

      Connect the wire to the engine room No. 1 relay block. (for RHD)

    4. Connect the clamp. (for RHD)

    5. A015YZ0

      Connect the wire harness with the nut. (for RHD)

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    6. Install the No. 1 engine room relay block cover. (for RHD)

    7. A0163JO

      Connect the 7 clamps and connect the 5 connectors.

    8. Install the 2 ground wires with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. A01608K

      Connect the 3 clamps and 8 connectors.

    10. A016370

      Connect the 5 connectors and grommet to the engine room ECU box.

    11. A015ZEV

      Engage the claw and connect the No. 4 connector holder to the engine room ECU box.

    12. A01628L

      Connect the 3 connectors and connector clamp.

  38. INSTALL ENGINE ROOM ECU COVER


    1. A01627R

      Install the engine room ECU cover with 3 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
  39. INSTALL WIRE HARNESS CLAMP BRACKET (for LHD)


    1. A0162F8

      Install the wire harness clamp bracket with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. Install the wire harness clamp to the clamp bracket.

    3. A016319

      Install the No. 7 engine room relay block with the 2 bolts and nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
  40. INSTALL WIRE HARNESS CLAMP BRACKET (for RHD)


    1. A015Z8NE01

      Install the wire harness clamp bracket with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. Install the wire harness clamp to the clamp bracket.

    3. A0162TN

      Install the No. 7 engine room relay block with the 2 bolts and nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
  41. INSTALL BATTERY TRAY (for LHD)


    1. A0163HY

      Install the battery tray with the 3 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
  42. INSTALL BATTERY TRAY (for RHD)


    1. A015ZVG

      Install the battery tray with the 3 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
  43. INSTALL POWER STEERING ECU ASSEMBLY


    1. A016155

      Install the power steering ECU assembly to the battery tray with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    2. Connect the connectors (A), (B) and (C) to the power steering ECU assembly.

      A0160LZE01
    3. Securely lock the connectors (A) and (B).

  44. INSTALL NO. 1 BATTERY TRAY SUPPORT

  45. INSTALL BATTERY (for LHD)


    1. Install the battery.

    2. Install the battery insulator.

    3. Install the battery clamp with a nut.

      Torque:
      2.9 N*m  { 30 kgf*cm, 26 in.*lbf }
    4. Connect the cable to the positive (+) battery terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    5. A0162W7

      Connect the 2 clamps.

  46. INSTALL BATTERY (for RHD)


    1. Install the battery.

    2. Install the battery insulator.

    3. Install the battery clamp with a nut.

      Torque:
      2.9 N*m  { 30 kgf*cm, 26 in.*lbf }
    4. Connect the cable to the positive (+) battery terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    5. A0163BE

      Connect the 2 clamps.

  47. INSTALL RADIATOR ASSEMBLY

    Click here

  48. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A015ZYF

      Install the air cleaner case sub-assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. Connect the vacuum switching valve connector and clamp.

    3. A0163D8

      Connect the vacuum hose and 2 clamps.

  49. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A015YT4

      Install the air cleaner cap sub-assembly with air cleaner hose and lock the 2 clamps.

      Tech Tips

      Tightening torque for the hose clamp located between the air cleaner cap sub-assembly and air cleaner hose assembly is as follows.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A015ZWF

      Connect the air cleaner hose to the throttle body with the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. A015YRW

      Connect the 2 ventilation hoses with the 2 hose clamps.

    4. A01622I

      Connect the mass air flow meter connector and wire harness clamp.

  50. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  51. ADD ENGINE OIL


    1. Add fresh oil.

      Standard Oil Grade
      Oil Grade Oil Viscosity (SAE)

      • API grade SL "Energy-Conserving", SM "Energy-Conserving", SN "Resource-Conserving" or ILSAC multigrade engine oil


      • 5W-30

      • 10W-30

      API grade SL, SM or SN multigrade engine oil
      • 15W-40

      • 20W-50

      Standard Capacity
      Item Specified Condition
      Drain and refill with oil filter change 9.3 liters (9.8 US qts, 8.2 Imp. qts)
      Drain and refill without oil filter change 8.2 liters (8.7 US qts, 7.2 Imp. qts)
      Dry fill 10.5 liters (11.1 US qts, 9.2 Imp. qts)
    2. Install the oil filler cap.

  52. ADD ENGINE COOLANT

    Note

    Before adding coolant, turn the A/C switch OFF.

    Total capacity
    11.9 liters (12.6 US qts, 10.5 Imp. qts)

    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. Add TOYOTA Super Long Life Coolant (SLLC) into the radiator reservoir.

      Capacity
      Approximately 5.0 liters (5.3 US qts, 4.4 Imp. qts)

      Tech Tips


      • LEXUS 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 consists of a combination of low phosphates and organic acids).

      • Contact any authorized LEXUS dealer or repairer or another duly qualified and equipped professional for further details.

      • Thermostat opening timing can be confirmed by squeezing the inlet radiator hose and sensing vibrations when the coolant starts to flow inside the hose.

    4. A015YN3

      Further add coolant into the reservoir until it reaches the FULL line.

    5. Squeeze the No. 1 and No. 2 radiator hoses several times, and then check the coolant level.

      If the coolant level is low, add coolant.

    6. A0161WSE01

      Using a 6 mm socket hexagon wrench, install the vent plug.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }
    7. Bleed air from the cooling system.

      Note

      Before starting the engine, turn the A/C switch off.


      1. While idling the engine for approximately 10 minutes, make sure that the coolant remains at the FULL line by adding coolant as necessary.

      2. A0160C3E01

        After idling the engine for 10 minutes, add coolant to the level shown in the illustration.

        Capacity
        Approximately 2.5 to 3.5 liters (2.6 to 3.7 US qts, 2.2 to 3.1 Imp.qts)
      3. Close the radiator reservoir cap, and run the engine at 1500 to 2000 rpm for 5 minutes.

        Tech Tips

        Thermostat opening timing can be confirmed by squeezing the No. 1 radiator hose and sensing vibrations when the SLLC starts to flow inside the hose.

        CAUTION:

        When squeezing the radiator hose:


        • Wear protective gloves.

        • Be careful as the radiator hose is hot.

        • Keep your hands away from the radiator fan.

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

      CAUTION:

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

    9. A015YN3

      Check the coolant level.

      If the coolant level is below the FULL line, add coolant until it reaches the FULL line.

  53. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  54. CHARGE REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard
      400 to 500g (14.10 to 17.63 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )
      A015ZSYE02

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.


      • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  55. INSPECT FOR OIL LEAK

  56. INSPECT FOR COOLANT LEAK

    Note

    Before performing each inspection, turn the A/C switch OFF.

    CAUTION:

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


    1. A016221

      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 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.

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

  57. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the engine switch on (IG).

        Note

        Do not start the engine.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.

      5. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing in the fuel tank can be heard. If no sounds can be heard, check the instrument panel junction block, fuel pump, ECM and wiring connectors.

    2. Inspect for fuel leaks.


      1. Check that there are no fuel leaks from the fuel system after performing any maintenance. If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the engine switch off.

    4. Disconnect the intelligent tester from the DLC3.

  58. INSTALL NO. 2 ENGINE UNDER COVER

  59. INSTALL ENGINE UNDER COVER

  60. INSTALL NO. 1 AIR CLEANER INLET


    1. A01612G

      Install the No. 1 air cleaner inlet with the bolt and clip.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
  61. INSTALL ENGINE ROOM SIDE COVER RH (for LHD)


    1. A0161AL

      Install the engine room side cover RH with the 3 clips.

  62. INSTALL ENGINE ROOM SIDE COVER RH (for RHD)


    1. A015YK3

      Install the engine room side cover RH with the 4 clips.

  63. INSTALL ENGINE ROOM SIDE COVER LH (for LHD)


    1. A016120

      Install the engine room side cover LH with the 5 clips.

  64. INSTALL ENGINE ROOM SIDE COVER LH (for RHD)


    1. A015Z63

      Install the engine room side cover LH with the 4 clips.

  65. INSTALL COOL AIR INTAKE DUCT SEAL


    1. A015ZFO

      Install the cool air intake duct seal with the 9 clips.

  66. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A0160IP

      Engage the 4 clips to install the V-bank cover sub-assembly.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.

  67. ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)

    A01601XE04
    Text in Illustration
    *1 Approx. 10 m
    *2 Approx. 14 m

    CAUTION:

    Exposure to radio frequency emissions is hazardous to your health. It is hazardous to your health to be within 20 cm (7.87 in.) of the device's radio frequency aperture.

    Note


    • This device complies with FCC radio frequency emission regulations.

    • Perform measurements on a level surface.

    • Make sure that no large pieces of metal are within a 10 m (32.81 ft.) x 14 m (45.93 ft.) area in front of the vehicle. If possible, the surrounding area should also be free of large metal objects.


    1. Before adjusting the radar beam axis, prepare the vehicle as follows:


      1. Check the tire pressure and adjust it if necessary.

      2. Remove all excess weight from the vehicle (luggage, heavy objects, etc.).

    2. Check and adjust the vertical direction of the radar sensor.


      1. A0162T8E02
        Text in Illustration
        *1 Level

        Remove dust, oil, and foreign matter from the radar sensor's level rack.

      2. Set a level on the radar sensor's level rack.

      3. A01609WE02
        Text in Illustration
        *1 FR
        *2 RH
        *3 Level
        *4 Air Bubble
        *5 Bolt A

        Check that the air bubble is within the red frame on the level.

        OK
        The air bubble is within the red frame on the level.
        If the bubble is not within the red frame, use a screwdriver to adjust bolt A until the air bubble is within the red frame.

        Tech Tips


        • The adjustable range within the red frame on the level is +/- 0.2°.

        • The target angle is +0.2° (upward angle of 0.2°).

        Adjustment
        Adjustment Direction Adjustment Procedure Adjustment Angle
        Vertical adjustment Upward direction: Turn bolt A to negative (-) side For every 8.4 rotations of adjustment bolt, sensor moves about 1.0°
        Downward direction: Turn bolt A to positive (+) side
    3. A0161P8E04
      Text in Illustration
      *1 Millimeter Wave Radar Sensor

      Adjust the reflector height.


      1. Adjust the reflector so that the center of the SST reflector is the same height as the millimeter wave radar sensor.

        SST
        09870-60000   ( 09870-60010 )
        09870-60040

        Tech Tips

        Prepare a 10 m (32.81 ft.) string, a string with a sharp-pointed weight (plumb bob), and a 5 m (16.41 ft.) tape measure.

    4. A0163FWE02

      Place the reflector.

      Text in Illustration
      *1 Approx. 5 m

      1. Hang the string (with a weight) from the center of the vehicle rear emblem. Mark the vehicle rear center point on the ground. Repeat the same procedure for the front of the vehicle.

      2. A0160ALE01

        Set one end of the 10 m (32.82 ft.) string on the vehicle rear center point. Run the string over the vehicle front center point to a position 5 m (16.41 ft.) beyond the vehicle front center point, as shown in the illustration. Mark the 5 m (16.41 ft.) position.

      3. Using the tape measure, measure 9.9 mm (0.389 in.) to the right of the 5 m (16.41 ft.) position. Place the reflector at that position.

        A015YROE09
        Text in Illustration
        *1 Reflector Placement Point *2 Millimeter Wave Radar Sensor Position
        *3 Approx. 5 m *4 Approx. 9.9 mm

        Note

        Perform the operation as precisely as possible.

    5. Adjust the radar beam axis.


      1. A0163BLE01

        Connect the intelligent tester to the DLC3.

      2. Turn the engine switch on (IG).

      3. Turn the intelligent tester main switch on, and turn the cruise control main switch on.

        Tech Tips

        If an error message is displayed on the screen, initialization of the distance control ECU may not be completed. Initialize the distance control ECU Click here.

        A0160Q9E04
        A015ZXSE11
    6. Check and adjust the horizontal direction of the radar sensor.


      1. Check that the divergence of the radar beam axis is 0° .

        Standard
        0° (Both right and left)
        If the divergence is not as specified, use a screwdriver to adjust bolt B until the divergence of the radar beam axis is 0°.
      2. A0161CPE02
        Text in Illustration
        *1 Bolt B

        Based on the measured divergence of the beam axis, turn and adjust bolt B for horizontal adjustment of the millimeter wave radar sensor using a screwdriver.

        Adjustment
        Adjustment Direction Adjustment Procedure Adjustment Angle
        Horizontal adjustment Right direction: Turn bolt B to positive (+) side. For every 14.3 rotations of adjustment bolt, sensor moves about 1.0°
        Left direction: Turn bolt B to negative (-) side.

        Tech Tips


        • If "LEFT SIDE: 1.0°" is displayed, the divergence is 1.0° to the left . Turn bolt B approximately 3 turns to the negative (-) side.

        • If the value does not change to 0°, it is possible that the sensor is aiming at something different. Reconfirm that there are no reflective materials in the surrounding area.

      3. A0160CJE03
        Text in Illustration
        *1 Metal (such as aluminum foil)

        Reset the radar sensor's driving learning values. Prepare a piece of metal that can block radio waves, such as aluminum foil. Cover the radar sensor's right half with the aluminum foil for 10 seconds.

        Note

        Be sure to keep the reflector in place and make sure that there is nothing between the sensor's left half and the reflector.

        Tech Tips

        When the reset is completed, the buzzer sounds for 10 seconds.

      4. Disconnect the intelligent tester from the DLC3.

    7. Recheck and readjust the vertical direction of the radar sensor.


      1. A0162T8E02
        Text in Illustration
        *1 Level

        Set a level on the radar sensor's level rack.

      2. A01609WE02
        Text in Illustration
        *1 FR
        *2 RH
        *3 Level
        *4 Air Bubble
        *5 Bolt A

        Check that the air bubble is within the red frame on the level.

        OK
        The air bubble is within the red frame on the level.
        If the bubble is not within the red frame, use a screwdriver to adjust bolt A until the air bubble is within the red frame.

        Tech Tips


        • The adjustable range within the red frame on the level is +/- 0.2°.

        • The target angle is +0.2° (upward angle of 0.2°).

        Adjustment
        Adjustment Direction Adjustment Procedure Adjustment Angle
        Vertical adjustment Upward direction: Turn bolt A to negative (-) side For every 8.4 rotations of adjustment bolt, sensor moves about 1.0°
        Downward direction: Turn bolt A to positive (+) side
  68. VEHICLE PREPARATION FOR FOG LIGHT AIMING


    1. Prepare the vehicle:


      • Ensure that that there is no damage or deformation to the body around the fog lights.

      • Fill the fuel tank.

      • Make sure that the oil is filled to the specified level.

      • Make sure that the engine coolant is filled to the specified level.

      • Inflate the tires to the appropriate pressure.

      • Unload the trunk and vehicle, ensuring that the spare tire, tools, and jack are in their original positions.

      • Sit a person of average weight (75 kg, 165 lb) in the driver's seat.

      • Vehicles with height adjustable suspension should set the vehicle height to the lowest setting prior to adjusting the fog light aim.

  69. PREPARATION FOR FOG LIGHT AIMING


    1. A015Z1ZE03

      Prepare the vehicle:


      • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot.

      • Place the vehicle at a 90° angle to the wall.

      • Create a 25 m (82 ft.) distance between the vehicle (fog light bulb center) and the wall.

      • Make sure that the vehicle is on a level surface.

      • Position the front wheels straight ahead.

      • Bounce the vehicle up and down several times to settle the suspension.

        Note

        A distance of 25 m (82 ft.) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

    2. Prepare a piece of thick white paper (approximately 2 m (6.6 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen.

    3. Draw a vertical line down the center of the screen (V line).

    4. Set the screen as shown in the illustration.

      A016286E02

      Tech Tips


      • Stand the screen perpendicular to the ground.

      • Align the V line on the screen with the center of the vehicle.

    5. A0161URE15

      Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration.

      Tech Tips

      Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark.


      1. H Line (Fog light height):

        Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the fog lights.

      2. V LH Line, V RH Line (Center mark positions of left-hand (LH) and right-hand (RH) fog lights):

        Draw two vertical lines so that they intersect the H line at each center mark aligned with the center of the fog light bulbs.

  70. INSPECT FOG LIGHT AIMING


    1. Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting the fog light aiming inspection.

      Note

      Do not keep the fog light covered for more than 3 minutes. The fog light lens is made of synthetic resin, which may melt or be damaged due to excessive heat.

    2. Start the engine.

    3. Turn on the fog light and check if the cutoff line falls within the specified area in the following illustration.

      A0161Q2E13
  71. ADJUST FOG LIGHT ASSEMBLY


    1. A015YO4E01

      Adjust the aim vertically:

      Adjust the aim of each fog light to the specified range by turning each aiming screw with a screwdriver.

      Note

      The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it so that the final turn of the screw is in the clockwise direction.

      Tech Tips

      If it is not possible to correctly adjust the fog light aim, check bulb, fog light unit, and fog light unit reflector installation.