INSTALL OIL PUMP RELIEF VALVE
Coat the relief valve with engine oil.
Insert the relief valve and spring into the timing chain cover hole.
Install a new gasket to the plug.
Using a 27 mm socket wrench, install the plug.
INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
Place the timing chain cover on wooden blocks.
Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
Note
Keep the lip free from foreign matter.
Do not tap the oil seal at an angle.
INSTALL WATER PUMP ASSEMBLY
Install a new gasket and the water pump with the 8 bolts.
INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
Using a 10 mm socket hexagon wrench, install the timing chain cover plug.
| *1 | Water Pump O-ring |
| *2 | Water Pump Upper O-ring |
| *3 | Oil Pump O-ring |
Install 3 new O-rings to the timing chain cover sub-assembly as shown in the illustration.
| *a | Drive Rotor Spline |
| *b | Crankshaft Timing Gear |
Align the drive rotor spline of the oil pump and crankshaft timing gear as shown in the illustration.
Apply seal packing to the timing chain cover sub-assembly in a continuous line as shown in the following illustration.
| *1 | Cylinder Head Sub-Assembly | *2 | Cylinder Block Sub-assembly |
| *a | 2.0 mm (0.0787 in.) | *b | 2.5 mm (0.0984 in.) |
| *c | 5.0 mm (0.197 in.) | *d | 6.0 mm (0.236 in.) |
| *e | 7.0 mm (0.276 in.) | *f | 8.0 mm (0.315 in.) or more |
| *g | 20 mm (0.787 in.) | *h | 54 mm (2.13 in.) |
| *i | 56.5 mm (2.22 in.) | *j | 58 mm (2.28 in.) |
| *k | 2.5 to 4.0 mm (0.0984 to 0.157 in.) | *l | 5.0 to 6.0 mm (0.197 to 0.236 in.) |
| *m | 9.0 to 13 mm (0.354 to 0.512 in.) | *n | 10 to 14 mm (0.394 to 0.551 in.) |
| *o | 12 to 16 mm (0.472 to 0.630 in.) | *p | Seal Packing |
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Note
When 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 15 minutes after applying seal packing.
Do not add the engine oil for at least 4 hours after the installation.
Do not start the engine for at least 4 hours after the installation.
w/ Air Conditioning:
Install the timing chain or belt cover sub-assembly with the 16 bolts and nut, and tighten the 16 bolts and nut in the sequence shown in the illustration.
| *a | Types of nut and bolt | *b | Tightening Order |
|
Bolt | |
Nut |
| Bolt Length | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
w/o Air Conditioning:
Install the timing chain or belt cover sub-assembly with the 18 bolts and nut, and tighten the 18 bolts and nut in the sequence shown in the illustration.
| *a | Types of nut and bolt | *b | Tightening Order |
|
Bolt | |
Nut |
| Bolt Length | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
w/ Air Conditioning:
Remove the seal packing from the 2 bolt holes for the No. 1 compressor mounting bracket.
Note
Do not use any cleaners to remove the seal packing.
INSTALL OIL PAN SUB-ASSEMBLY
Install the stud bolt.
| *a | 9.0 mm (0.354 in.) |
| *b | 19.0 mm (0.748 in.) |
Using an E6 "torx" socket wrench, install the stud bolts.
Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder block sub-assembly and oil pan sub-assembly.
| *a | 8.0 mm (0.315 in.) |
| *b | 6.5 mm (0.256 in.) |
| *c | Seal Packing |
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.) |
Note
Install the oil pan sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not add the engine oil for at least 4 hours after the installation.
Do not start the engine for at least 4 hours after the installation.
Install a new gasket to the oil strainer sub-assembly.
Install the oil pan sub-assembly with the 16 bolts and 2 nuts, and tighten the 16 bolts and 2 nuts in the sequence shown in the illustration.
| Bolt Length | ||||||
|---|---|---|---|---|---|---|
|
|
Bolt A |
|
Bolt B |
|
Nut |
INSTALL OIL PAN SUB-ASSEMBLY NO.2
Remove any old packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.
| *a | 6.0 mm (0.236 in.) |
| *b | Seal Packing |
Apply seal packing as shown in the illustration.
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Standard seal diameter |
|---|
| 3.0 to 4.0 mm (0.118 to 0.157 in.) |
Note
Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
Do not add the engine oil for at least 4 hours after the installation.
Do not start the engine for at least 4 hours after the installation.
Install the No. 2 oil pan sub-assembly with the 18 bolts and 2 nuts, and tighten the 18 bolts and 2 nuts in the sequence shown in the illustration.
Install a new gasket and the oil pan drain plug.
INSTALL CRANKSHAFT PULLEY
Align the pulley set key with the key groove of the pulley, and slide it on the pulley.
Using SST, install a new pulley bolt.
Note
Do not reuse the pulley bolt.
INSTALL CRANKSHAFT POSITION SENSOR
Apply engine oil to the O-ring.
Install the crankshaft position sensor with the bolt.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Apply seal packing as shown in the illustration.
Install the 2 gaskets to the head cover.
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Note
Remove any oil from the contact surface.
Install the crankcase within 3 minutes after applying seal packing.
Do not start the engine for at least 4 hours after installing.
Temporarily install the cover with the 19 bolts and 2 nuts.
Fully tighten the bolts (A) shown in the illustration.
Fully tighten the bolts (B) shown in the illustration.
Tech Tips
Make sure the tightening torque of bolts (A).
INSTALL IGNITION COIL ASSEMBLY
Install the ignition coils with the bolts.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Temporarily install the belt tensioner with the 2 bolts.
Tech Tips
Make sure that the belt tensioner is in contact with the engine block.
Check that the bolt holes of the belt tensioner and timing chain cover are aligned.
Install the tensioner by tightening the 2 bolts in the order shown in the illustration.
INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
Install the idler pulley sub-assembly No.1, collar and pulley plate with the bolt.
Note
Check that the pulley plate and collar are assembled properly to the idler pulley No.1.
INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (w/ Air Conditioning)
Note
Install the compressor mounting bracket No. 1 exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.
Temporarily install the compressor mounting bracket No. 1 with the 3 bolts.
Tech Tips
Temporarily install the compressor mounting bracket No. 1 with the 3 bolts so that the bracket can be moved by hand.
Push the compressor mounting bracket No. 1 toward the cylinder block as shown in the illustration and tighten bolt B.
Tech Tips
Make sure there is no clearance between the cylinder block and compressor mounting bracket No. 1 as shown in the illustration.
Uniformly tighten the 4 bolts in the order shown in the illustration.
INSTALL GENERATOR ASSEMBLY
Install the generator assembly with the 3 bolts.
Install the generator wire with the nut to terminal B.
Install the terminal cap.
Connect the generator connector.
INSTALL THERMOSTAT
Install a new gasket to the thermostat.
Install the thermostat with the jiggle valve upward.
Tech Tips
The jiggle valve may be set within 10° of either side of the prescribed position.
INSTALL WATER INLET
Install a new gasket and the water inlet with the bolt and 2 nuts.
INSTALL WATER BY-PASS PIPE NO.1
Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.
INSTALL FAN PULLEY
Install the fan spacer and fan pulley with the 4 nuts.
INSTALL INTAKE MANIFOLD
Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Connect the ventilation hose No.3.
INSTALL INJECTOR ASSEMBLY
Tech Tips
w/ Dual VVT-i:
Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.
Apply a light coat of gasoline or spindle oil to new O-rings, and then install one onto each fuel injector assembly.
Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe sub-assembly and the O-ring of the fuel injector assembly.
Apply a light coat of gasoline or spindle oil to the O-ring again, and then install the fuel injector assembly into the fuel delivery pipe sub-assembly by turning it right and left.
| *A | w/ Dual VVT-i |
| *B | w/o Dual VVT-i |
|
Turn |
|
Push |
Note
Be careful not to twist the O-ring.
After installing the fuel injector assembly, check that it turns smoothly. If not, reinstall it with a new O-ring.
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
Apply a light coat of gasoline or spindle oil to new O-rings and install them to the injector spacers.
Note
Make sure that the O-rings are installed between the parts correctly.
Install the 4 injector spacers to the cylinder head sub-assembly.
Install 4 new injector vibration insulators to the cylinder head sub-assembly.
Install the 2 No. 1 delivery pipe spacers to the cylinder head sub-assembly.
| *A | w/ Dual VVT-i |
| *B | w/o Dual VVT-i |
Temporarily install the fuel delivery pipe sub-assembly together with the 4 fuel injector assemblies with the 2 bolts.
Note
Do not drop the fuel injector assemblies when installing the fuel delivery pipe sub-assembly.
Make sure that the fuel injector assembly turns smoothly.
Tighten the 2 bolts.
Apply a light coat of gasoline or spindle oil to a new O-ring.
Install the fuel pressure pulsation damper assembly with the 2 bolts.
Connect the 4 fuel injector connectors.
Connect the No. 2 fuel hose to the fuel pressure regulator assembly, and slide the clamp to secure the hose.
Connect the vacuum hose to the fuel pressure regulator assembly.
INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY
Tech Tips
w/ Dual VVT-i:
Perform "Inspection After Repairs" after replacing the throttle body assembly Click here.
| *a | Protrusion |
| *b | Groove |
Install a new gasket onto the intake manifold.
Tech Tips
Align the protrusion of the gasket with the groove of the intake manifold.
Install the throttle body assembly with the 4 bolts.
Connect the No. 2 water by-pass hose to the throttle body assembly, and slide the clamp to secure the hose.
Connect the water by-pass hose to the throttle body assembly, and slide the clamp to secure the hose.
Connect the throttle motor connector.
CONNECT ENGINE WIRE
Connect the +B terminal and connector of the starter.
Install the connectors and nut as shown in the illustration.
Connect the clamps of the engine wire and earth cable.
Connect the connectors of the ECM.
Install the wire harness support of the engine ECM.
INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning)
Temporarily install the bolt A to install the compressor.
Install the compressor completely by tightening the 4 bolts in the order shown in the illustration.
Note
In order to prevent misalignment, which causes belt rattle, tightening of the bolts must be performed in the order shown.
Connect the suction tube clamp with the bolt.
Connect the compressor connector.
INSTALL OIL LEVEL GAGE GUIDE
Install the gauge guide with the bolt.
INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
INSTALL VANE PUMP ASSEMBLY
Install the vane pump with the 2 bolts.
Connect the PS fluid pressure switch connector.
CONNECT FUEL HOSE NO.2
Connect the fuel hose No.2 to the delivery pipe.
CONNECT FUEL HOSE
Connect the No. 1 fuel hose to the fuel pressure pulsation damper assembly Click here.
INSTALL INTAKE AIR CONNECTOR
Temporarily install the intake air connector to the throttle body assembly.
Connect the vacuum hose to the intake air connector.
Connect the No. 2 PCV hose to the cylinder head cover sub-assembly, and slide the clamp to secure the hose.
Install the intake air connector with the 2 bolts.
Tighten the 2 hose clamps.
CONNECT UNION TO CONNECTOR TUBE HOSE
Connect the union to connector tube hose to the intake manifold.
CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
Connect the fuel vapor feed hose to the VSV.
CONNECT RADIATOR HOSE OUTLET
Connect the radiator outlet hose to the clamp.
CONNECT RADIATOR HOSE INLET
Connect the radiator inlet hose to the clamp.
INSTALL FAN AND GENERATOR V BELT
Install the drive belt to the pulleys except the drive belt tensioner pulley.
Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.
Note
The backside of the drive belt should face the tensioner pulley.
Check that the drive belt is properly set to each pulley.
After a new belt has been installed, check that the tensioner indicator mark is within range A shown in the illustration.
INSTALL CAMSHAFT POSITION SENSOR
Apply engine oil to the O-ring.
Install the camshaft position sensor with the bolt.
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
Install the engine service hole sub cover with the 5 bolts.
INSTALL FRONT DOOR SCUFF PLATE RH
INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)
Perform the same procedure as above on the opposite side. Click here
INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)
Perform the same procedure as above on the opposite side. Click here
CONNECT BATTERY NEGATIVE TERMINAL
ADD ENGINE OIL
ADD ENGINE COOLANT
Tighten the radiator drain cock plug by hand.
Tighten the cylinder block water drain cock plug.
Fill the radiator reservoir assembly with engine coolant to the top of the inlet.
| Standard Capacity | ||||||
|---|---|---|---|---|---|---|
|
Note
Never use water as a substitute 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 is a combination of low phosphates and organic acids).
Remove the 2-way that is located near the throttle body assembly.
When air is bled and the engine coolant drains out, install the 2-way.
Add coolant through the radiator reservoir assembly filler opening until the coolant reaches the B line and install the radiator reservoir cap sub-assembly. [*1]
Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. [*2]
CAUTION:
Wear protective gloves.
Be careful as the radiator hoses are hot.
Keep your hands away from the radiator fans.
Note
Immediately after starting the engine, if the radiator reservoir assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.
Do not start the engine when there is no engine coolant in the radiator reservoir assembly.
Make sure that the needle does not show an abnormally high temperature.
If there is not enough engine coolant, the engine may overheat.
Tech Tips
Press the No. 2 and No. 3 radiator hoses several times by hand, and then check the level of the engine coolant.
The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
Stop the engine, and wait until the engine coolant cools down to ambient temperature. [*3]
Check the engine coolant level in the radiator reservoir assembly. [*4]
Tech Tips
If the engine coolant level is below the LOW line, repeat step *1 through *4.
If the engine coolant level is above the FULL line, drain engine coolant until the engine coolant level is between the FULL and LOW lines.
CHECK FOR FUEL LEAKS
CHECK FOR ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS
INSTALL ENGINE UNDER COVER NO.2 (w/ Engine Under Cover No.2)
Install the engine under cover No.2 together with the engine side under cover LH and engine side under cover RH (for Wide Body).
INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)
INSPECT CHECK IDLE SPEED AND IGNITION TIMING
Warm up and stop the engine.
Note
A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
When using the intelligent tester:
Connect the intelligent tester to the DLC3.
Start the engine and idle it.
Turn the intelligent tester main switch on.
Enter the following items:
Powertrain / Engine and ECT / Data list / IGN Advance
| Ignition timing |
|---|
| 5 to 15° BTDC at idle |
Tech Tips
Refer to the intelligent tester operator's manual for further detail.
When not using the intelligent tester:
Connect the tester probe of a timing light to the wire of the ignition coil connector for the No.4 cylinder.
Note
Use a timing light that detects the first signal.
After checking, be sure to wrap the wire harness with tape.
Turn the ignition switch to the ON position.
Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
Note
Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
When checking the ignition timing, the transmission should be in the neutral.
Tech Tips
After connecting terminals (TC and CG), engine rpm changes to approximately 1,000 to 1,500 rpm for 5 seconds, then returns to idle speed. This is because the ECM checks that the ISC (idle speed control system) operates properly.
Perform the inspection of the ignition timing after engine rpm is returned to idle speed.
Inspect the ignition timing
| Ignition timing |
|---|
| 3 to 7° BTDC at idle |
Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.
Inspect the ignition timing
| Ignition timing |
|---|
| 5 to 15° BTDC at idle |
Check that the ignition timing advances immediately when the engine speed is increased.
Turn the ignition switch off.
Remove the timing light.
CHECK FUNCTION OF THROTTLE BODY
INSPECT ABS SENSOR SIGNAL
PERFORM INITIALIZATION