CAMSHAFT INSTALLATION


  1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A01DO3CE01
      Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

      Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

    4. Check that there is no clearance between the camshaft timing gear assembly flange and camshaft.

    5. A01DSPH

      Tighten the flange bolt while holding the camshaft.

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

    6. Check the lock of the camshaft timing gear assembly.


      1. Fix the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

    7. A01DU3NE01
      Text in Illustration
      *1 Advance Side Path
      *2 Retard Side Path
      *3 Open
      *4 Close
      A01DPL5 Rubber
      A01DOXP Vinyl Tape

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

      3. A01DMY0E01
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path

        Apply air at approximately 200 kPa (2.0 kgf/cm2, 28 psi) to the 2 open paths.

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. A01DR8PE01
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Hold Pressure
        *4 Decompress

        Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

        Tech Tips

        This operation releases the lock pin at the most retarded position.

      5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path.

        Note

        Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    8. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not use air pressure to perform the smooth operation check.

    9. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear assembly locks at the most retarded position.

    10. A01DT9EE01
      Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt

      Remove the flange bolt and camshaft timing gear assembly.

      Note


      • Do not remove the other 3 bolts.

      • If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

  2. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A01DTWQE01
      Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note

      Be sure not to turn the camshaft timing exhaust gear in the advanced direction.

    4. Check that there is no clearance between the gear flange and camshaft.

    5. A01DPH9

      Tighten the flange bolt while holding the camshaft.

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

    6. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear assembly locks.

    7. A01DTGYE01
      Text in Illustration
      *1 Advance Side Path
      *2 Retard Side Path
      *3 Open
      *4 Close
      A01DPL5 Rubber
      A01DOXP Vinyl Tape

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

      3. A01DQPPE01
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path

        Apply air at approximately 200 kPa (2.0 kgf/cm2, 28 psi) to the 2 open paths (the advance side path and retard side path).

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. A01DNIWE01
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Hold Pressure
        *4 Decompress

        Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

        Tech Tips

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

      5. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path.

        Note

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    8. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    9. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

    10. A01DSKOE01
      Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt

      Remove the flange bolt and camshaft timing exhaust gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

  3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A01DO3CE01
      Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

      Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

    4. Check that there is no clearance between the camshaft timing gear assembly flange and camshaft.

    5. A01DSPH

      Install the flange bolt while holding the camshaft.

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

    6. Check the lock of the camshaft timing gear assembly.


      1. Fix the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A01DTWQE01
      Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note

      Be sure not to turn the camshaft timing exhaust gear in the advanced direction.

    4. Check that there is no clearance between the gear flange and camshaft.

    5. A01DPH9

      Install the flange bolt while holding the camshaft.

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

    6. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear assembly locks.

  5. INSTALL NO. 3 CAMSHAFT


    1. A01DODZE01

      Check that the notch is aligned with the "0" timing mark of the timing chain cover.

    2. A01DN2GE01
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear.

    3. Clean the camshaft housing LH and camshaft journals and apply engine oil to them.

    4. A01DOL4E01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

    5. A01DNJ6E01
      Text in Illustration
      *a Place on camshaft timing gear

      Install the chain to the No. 3 camshaft, and then install the camshaft to the camshaft housing LH.

      Tech Tips


      • Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain.

      • Install the camshaft so that the timing mark is facing upward.

  6. INSTALL NO. 4 CAMSHAFT


    1. Clean the camshaft housing LH and camshaft journals and apply engine oil to them.

    2. A01DMC4E01
      Text in Illustration
      *1 Mark Plate (yellow)
      *2 Timing Mark

      Pass the No. 4 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear.

      Tech Tips

      The mark plate is yellow.

    3. A01DSF3

      While lifting up the No. 4 camshaft, pass the No. 3 chain tensioner assembly through the No. 2 chain and set it in place.

    4. Install the No. 4 camshaft to the camshaft housing LH, and then install the No. 3 chain tensioner assembly with the bolt.

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

  7. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Clean the camshaft bearing caps and apply engine oil to them.

    2. A01DOL4E01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

    3. A01DLZWE01
      Text in Illustration
      *1 Bolt
      *2 Washer
      *a Installation of Bolts and Washers for Temporary Installation of camshaft housing
      *b Part Installation
      A01DQPB Bolt A
      A01DMKT Bolt B

      Check the marks and numbers on the camshaft bearing caps, and then remove the replacement bolts and washers in the order shown in the illustration. Immediately after removing the bolts and washers for temporary installation of the camshaft housing in the location for a bearing cap, install the bearing cap with the bolts in the order shown in the illustration.

      Torque:
      for bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      for bolt B
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


      • Be sure to follow the numerical order when performing this procedure.

      • Do not drop bolts and washers for temporary installation of the camshaft housing into the cylinder head.

    4. Check the torque of each bolt again.

  8. CONNECT CHAIN SUB-ASSEMBLY (for Bank 2)


    1. A01DPNXE01
      Text in Illustration
      *1 Paint Mark

      Align the paint marks on the camshaft timing gear and No. 1 chain and install the No. 1 chain to the camshaft timing gear.

      Tech Tips

      If the paint marks are not aligned, align them by turning the camshaft slightly.

  9. INSTALL CAMSHAFT


    1. A01DNOOE01

      Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be installed easily.

      Tech Tips

      When turning the crankshaft, engine oil may spray out of the oil holes.

    2. A01DSG1E01
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear.

    3. Clean the camshaft housing RH and camshaft journals and apply engine oil to them.

    4. A01DOL4E01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

    5. A01DU1CE01
      Text in Illustration
      *a Place on camshaft timing gear

      Install the chain to the camshaft, and then install the camshaft to the camshaft housing RH.

      Tech Tips


      • Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain.

      • Install the camshaft so that the timing mark is facing upward.

  10. INSTALL NO. 2 CAMSHAFT


    1. Clean the camshaft housing RH and camshaft journals and apply engine oil to them.

    2. A01DUJYE01
      Text in Illustration
      *1 Mark Plate (yellow)
      *2 Timing Mark

      Pass the No. 2 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear.

      Tech Tips

      The mark plate is yellow.

    3. A01DMN3

      While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain and set it in place.

    4. Install the No. 2 camshaft to the camshaft housing RH, and then install the No. 2 chain tensioner assembly with the bolt.

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

  11. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Clean the camshaft bearing caps and apply engine oil to them.

    2. A01DOL4E01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

    3. A01DSHGE01
      Text in Illustration
      *1 Bolt
      *2 Washer
      *a Installation of Bolts and Washers for Temporary Installation of camshaft housing
      *b Part Installation
      A01DQPB Bolt A
      A01DMKT Bolt B

      Check the marks and numbers on the camshaft bearing caps, and then remove the replacement bolts and washers in the order shown in the illustration. Immediately after removing the bolts and washers for temporary installation of the camshaft housing in the location for a bearing cap, install the bearing cap with the bolts in the order shown in the illustration.

      Torque:
      for bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      for bolt B
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


      • Be sure to follow the numerical order when performing this procedure.

      • Do not drop bolts and washers for temporary installation of the camshaft housing into the cylinder head.

    4. Check the torque of each bolt again.

  12. CONNECT CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A01DTL9E01
      Text in Illustration
      *1 Paint Mark

      Align the paint marks on the camshaft timing gear and No. 1 chain and install the No. 1 chain to the camshaft timing gear.

      Tech Tips

      If the paint marks are not aligned, align them by turning the camshaft slightly.

  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01DRWLE01

      Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark.

    2. Turn the crankshaft slightly to eliminate the slack in the chain.

      Tech Tips

      Make sure there is some slack in the chain around the area where the chain tensioner is installed.

    3. A01DRXIE01
      Text in Illustration
      *1 Stopper Plate
      *a Push

      While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

    4. While turning the stopper plate of the tensioner counterclockwise, insert a pin of φ1.27 mm (0.0500 in.) into the holes in the stopper plate and tensioner to fix the stopper plate in place.

    5. Install the chain tensioner with the 2 bolts.

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

    6. Remove the pin from the No. 1 chain tensioner.

  14. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

    2. Check that each camshaft timing mark is positioned as shown in the illustration.

      A01DLW5E01
      Text in Illustration
      *1 Timing Mark - -
      *a Viewpoint - -

      Tech Tips

      for Intake Camshaft:

      Be sure to check mark A at the point when marks B, C and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      A01DTKVE01

    3. If the valve timing is misaligned, reinstall the timing chain.

    4. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.

  15. INSTALL TIMING CHAIN COVER PLATE


    1. Install a new gasket and the timing chain cover plate with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  16. POUR ENGINE OIL

    A01DUBY

    Tech Tips

    Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.

  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

    2. A01DMZN

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Text in Illustration
      A01DQPB 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.

    3. Install 3 new gaskets.

    4. Install a new gasket to the cylinder head cover.

    5. Install the seal washers to the bolts.

    6. A01DOZ9E01

      Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A and D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B and C
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Standard Bolt
      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 65 mm (2.56 in.)
      D 60 mm (2.36 in.)
      Text in Illustration
      A01DQPB Bolt A
      A01DMKT Bolt B
      A01DPHJ Bolt C
      A01DPT1 Bolt D

      Note

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

  18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.

    2. A01DUN4

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      2.0 to 3.0 mm (0.0787 to 0.118 in.)
      Text in Illustration
      A01DQPB 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.

    3. Install 3 new gaskets.

    4. Install a new gasket to the cylinder head cover.

    5. Install the seal washers to the bolts.

    6. A01DNJ7E01

      Temporarily install the cylinder head cover with the 12 bolts. Tighten the bolts uniformly in several steps.

      Torque:
      for bolt A and D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B and C
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Standard Bolt
      Item Length
      A 25 mm (0.984 in.)
      B 35 mm (1.38 in.)
      C 70 mm (2.76 in.)
      D 60 mm (2.36 in.)
      Text in Illustration
      A01DQPB Bolt A
      A01DMKT Bolt B
      A01DPHJ Bolt C
      A01DPT1 Bolt D

      Note

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

  19. CONNECT FUEL PIPE SUB-ASSEMBLY


    1. Connect the fuel pipe with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  20. INSTALL REAR CYLINDER HEAD COVER


    1. Temporarily install the cover with the 3 bolts.

    2. A01DU8PE01

      Tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  21. INSTALL NO. 2 OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

      Note

      Do not touch the mesh when installing the oil control valve filter.

    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

    3. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

    4. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

    5. Tighten the oil pipe union (on the head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  22. INSTALL NO. 1 OIL PIPE


    1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

      Note

      Do not touch the mesh when installing the oil control valve filter.

    2. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

    3. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

    4. Tighten the oil pipe union (on the cylinder head side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

    5. Tighten the oil pipe union (on the head cover side).

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  23. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)


    1. A01DM5OE01
      Text in Illustration
      *a Upward
      *b Rearward

      Install the water by-pass pipe with the 3 bolts.

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

    2. Connect the 2 hoses.

      Tech Tips

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

  24. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01DMABE01
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Push the dipstick guide end into the guide hole.

    4. Install the dipstick guide with the bolt.

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

    5. Install the dipstick.

  25. INSTALL GENERATOR ASSEMBLY


    1. Install the generator bracket to the generator with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Install the generator with the 2 bolts.

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

    3. Install the generator bracket with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Connect the wire harness clamp.

    5. Install the wire harness with the 2 bolts.

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

    6. Connect the generator connector to the generator.

    7. Connect the generator wire with the nut.

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

    8. Close the terminal cap.

  26. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  27. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket with the bolt.

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

    2. Attach the clamp.

  28. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. for Integrated Type:

      Install the No. 2 idler pulley with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

    2. for Separate Type:

      Install the No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  29. CONNECT VANE PUMP ASSEMBLY


    1. Connect the vane pump with the 2 bolts.

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

    2. Attach the 2 wire harness clamps.

    3. Connect the 2 connectors.

  30. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 6 ignition coils with the 6 bolts.

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

    2. Connect the 6 ignition coil connectors.

  31. INSTALL NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. Install the No. 2 emission control valve set with the 3 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A01DSXDE01
      Text in Illustration
      *1 Paint Mark
      *2 Rib
      *a Upper
      *b LH Side

      Align the paint mark with the projection and connect the No. 1 air hose.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the No. 2 emission control valve set connector.

  32. INSTALL EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. Install the emission control valve set with the 3 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A01DRLUE01
      Text in Illustration
      *1 Rib
      *2 Paint mark
      *a RH Side
      *b Upper

      Align the paint mark with the projection and connect the No. 1 air hose.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the emission control valve set connector.

  33. INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)


    1. A01DS0TE01
      Text in Illustration
      *1 New Gasket
      *2 No. 2 Air Tube

      Install 2 new gaskets to the No. 2 air tube.

    2. Install the No. 2 air tube with the 2 bolts and 2 nuts.

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

  34. INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. A01DQXXE01
      Text in Illustration
      *1 New Gasket
      *2 Air Tube

      Install 2 new gaskets to the air tube.

    2. Install the air tube with the 2 bolts and 2 nuts.

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

  35. INSTALL INTAKE AIR SURGE TANK


    1. Install a new gasket to the intake air surge tank.

    2. A01DQ0IE01
      Text in Illustration
      *1 Nut

      Install the intake air surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    3. Install the No. 1 surge tank stay with the 2 bolts.

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

    4. Attach the wire harness clamp.

    5. Install the No. 2 surge tank stay with the 2 bolts.

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

    6. Install the throttle body bracket with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    7. A01DNIQE01
      Text in Illustration
      *a Front
      *b Matchmark
      *c Top

      Connect the No. 1 ventilation hose.

    8. Connect the No. 1 vacuum switching valve connector.

    9. Connect the No.1 fuel feed hose.

      Tech Tips

      Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

    10. A01DTUJE01
      Text in Illustration
      *a Front
      *b Matchmark
      *c RH

      Connect the throttle body connector.

    11. Connect the No. 4 water by-pass hose.

    12. Connect the No. 5 water by-pass hose.

      Tech Tips

      Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

    13. Connect the 2 heater hose clamps.

  36. INSTALL AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)


    1. A01DS57E01
      Text in Illustration
      *1 Rib
      *2 Paint Mark
      *a RH Side
      *b Upper

      for Bank 1 Side:

      Align the paint mark with the projection and connect the air tube assembly to the emission control valve set.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    2. A01DS7EE01
      Text in Illustration
      *1 Paint Mark
      *2 Rib
      *a Upper
      *b LH Side

      for Bank 2 Side:

      Align the paint mark with the projection and connect the air tube assembly to the No. 2 emission control valve set.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Install the 3 bolts.

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

  37. INSTALL FAN SHROUD


    1. Install the fan pulley to the water pump.

    2. Place the shroud together with the coupling fan between the radiator and engine.

      Note

      Be careful not to damage the radiator core.

    3. A01DMZAE01
      Text in Illustration
      *1 Paint Mark

      Align the paint marks on the heads of the water pump stud bolts with the paint marks of the same color on the outer edge of the fluid coupling flange and install the fluid coupling to the water pump.

    4. Temporarily install the fluid coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand.

    5. A01DQ2X

      Attach the claws of the shroud to the radiator as shown in the illustration.

    6. Install the shroud with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    7. Install the fan and generator V-belt Click here.

    8. Tighten the 4 nuts of the fluid coupling fan.

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

  38. CONNECT OIL COOLER TUBE (w/ Air Cooled Transmission Oil Cooler)


    1. A01DUNE

      Connect the oil cooler tube with the 2 bolts, and attach the claw to close the flexible hose clamp.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  39. CONNECT OIL COOLER TUBE (w/ Warmer)


    1. A01DN6Y

      Connect the oil cooler tube with the 2 bolts, and attach the claw to close the flexible hose clamp.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  40. INSTALL RADIATOR RESERVOIR


    1. Install the radiator reservoir with the 3 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Connect the reservoir hose to upper side of the radiator tank upper.

  41. INSTALL NO. 2 RADIATOR HOSE


    1. A01DMV1E01
      Text in Illustration
      *1 Paint Mark
      *2 Protrusion
      *a Upper

      Connect the No. 2 radiator hose so that its paint mark aligns with the radiator protrusion as shown in the illustration.

      Tech Tips


      • Make sure the paint mark of the No. 1 air injection system hose is facing upward.

      • Make sure the direction of the hose clamp is as shown in the illustration.

    2. A01DSA8E01
      Text in Illustration
      *1 Paint Mark
      *2 Protrusion
      *a Front
      *b Upper

      Connect the No. 2 radiator hose so that its paint mark aligns with the water inlet housing protrusion as shown in the illustration.

      Tech Tips


      • Make sure the paint mark of the No. 1 air injection system hose is facing upward.

      • Make sure the direction of the hose clamp is as shown in the illustration.

  42. INSTALL NO. 1 RADIATOR HOSE


    1. A01DP53E01
      Text in Illustration
      *1 Paint Mark
      *2 Protrusion
      *a Front
      *b Upper

      Connect the No. 1 radiator hose to the water inlet housing shown in the illustration labeled A.

      Tech Tips


      • Make sure the paint mark of the No. 1 radiator hose is facing upward.

      • Make sure the direction of the hose clamp is as shown in the illustration.

    2. Connect the No. 1 radiator hose so that its paint mark aligns with the radiator protrusion as shown in the illustration labeled B.

      Tech Tips


      • Make sure the paint mark of the No. 1 radiator hose is facing upward.

      • Make sure the direction of the hose clamp is as shown in the illustration.

  43. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Attach the wire harness clamp.

    3. Install the air cleaner filter element.

  44. INSTALL AIR CLEANER CAP AND HOSE


    1. A01DTUYE01
      Text in Illustration
      *a Top
      *b Front
      *c RH
      *d Align cutout portion of hose with protrusion of throttle
      *e Paint Mark

      Install the air cleaner cap and hose.


      1. Install the air cleaner cap and hose with the bolt and fasten the 4 hook clamps.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      2. Tighten the clamp.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      3. Attach the 4 clamps and connect the ventilation hose, vacuum hose and mass air flow meter connector.

        Tech Tips

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

  45. INSTALL BATTERY TRAY

  46. INSTALL BATTERY

  47. INSTALL BATTERY HOLD DOWN CLAMP


    1. Install the battery hold down clamp with the 2 nuts.

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

  48. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  50. ADD ENGINE COOLANT


    1. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. Tighten the radiator drain cock plug by hand.

    3. Add engine coolant.

      Standard Capacity
      Item Specified Condition
      for Automatic Transmission w/o Warmer w/o Rear Heater 10.5 liters (11.1 US qts, 9.2 Imp. qts)
      w/ Rear Heater 12.3 liters (13.0 US qts, 10.8 Imp. qts)
      w/ Warmer w/o Rear Heater 11.0 liters (11.6 US qts, 9.7 Imp. qts)
      w/ Rear Heater 12.8 liters (13.5 US qts, 11.3 Imp. qts)
      for Manual Transmission w/o Rear Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Rear Heater 12.5 liters (13.2 US qts, 11.0 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

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

      • Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

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

    5. Install the reservoir cap.

    6. Install the radiator cap.*1

    7. Start the engine and stop it immediately.*2

    8. Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

    9. Repeat steps *1, *2 and *3 until the coolant level does not decrease.

      Tech Tips

      Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

    10. Install the radiator cap.*4

    11. Set the air conditioning as follows.*5

      Item Condition
      Fan speed Any setting except off
      Temperature Toward WARM
      Air conditioning switch Off

    12. Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

      CAUTION:


      • Wear protective gloves. Hot areas on the parts may injure your hands.

      • Be careful of the fan.

      • Be careful as the engine, radiator and radiator hoses are hot and can cause burns.

      Note


      • Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

      • Do not start the engine when there is no coolant in the radiator reservoir.

      • Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may burn out or overheat.

      Tech Tips


      • Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.

      • The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.

    13. Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

      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.

    14. If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

    15. If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.

      If the coolant level is below the F line, repeat steps *4 through *8.

      If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

  51. ADD ENGINE OIL


    1. Add fresh oil.

      Standard Engine Oil
      Oil Grade Oil Viscosity (SAE)
      API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil

      0W-20

      5W-20

      5W-30

      10W-30
      API grade SL, SM or SN multigrade engine oil

      15W-40

      20W-50
      Standard Oil Capacity (w/o Oil Cooler)
      Item Specified Condition
      Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 Imp. qts)
      Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 Imp. qts)
      Dry fill 6.9 liters (7.3 US qts, 6.1 Imp. qts)
      Standard Oil Capacity (w/ Oil Cooler)
      Item Specified Condition
      Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 Imp. qts)
      Drain and refill with oil filter change 6.2 liters (6.6 US qts, 5.5 Imp. qts)
      Dry fill 7.1 liters (7.5 US qts, 6.2 Imp. qts)

  52. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm2, 18 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

  53. INSPECT FOR ENGINE OIL LEAK


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

  54. INSTALL V-BANK COVER


    1. A01DQA1E01
      Text in Illustration
      *1 Pin
      *2 Hook

      Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

  55. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 13 clips.

  56. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A01DQWQ

      Hook the engine under cover to the vehicle body as shown in the illustration.

    2. Install the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  57. INSTALL FRONT BUMPER COVER LOWER


    1. Install the front bumper cover lower with the 5 bolts and clip.

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

  58. INSPECT IGNITION TIMING

    Note


    • Turn all electrical systems off.


    • Perform the inspection when the cooling fan motor is turned off.


    1. Warm up the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / IGN Advance.

      3. Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

      4. Check that the ignition timing advances immediately when the engine speed is increased.

    3. A01DR2AE05

      When not using the intelligent tester:


      1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

        SST
        09843-18040
        Text in Illustration
        *a Front view of DLC3

        Note

        Be sure not to improperly connect the terminals. This may damage the engine.

      2. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.

        Note


        • Use a timing light that detects primary signals.


        • After the inspection, be sure to wrap the wire harness with tape.

      3. A01DQOIE01

        Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

      4. Remove SST from the DLC3.

      5. Inspect the ignition timing during idling.

        Standard ignition timing
        7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

      6. Disconnect the timing light from the engine.