CAMSHAFT OIL CONTROL VALVE INSTALLATION


  1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01CFM8E05

      Apply a light coat of engine oil to 4 new O-rings and install them to the 4 camshaft timing oil control valve assemblies.

    2. A01CCE3E01

      Install the 4 oil control valves with the 4 bolts.

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

      Note

      Make sure that each O-ring is not cracked or does not jump out of position during installation.

    3. Connect the 4 oil control valve connectors.

    4. A01CFTD

      Connect the wire harness clamp.

  2. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    NOTICE
    DO NOT apply oil to the bolts listed below:
    Tightening Part
    Surge Tank and Intake Manifold
    No. 1 Surge Tank Stay and Surge Tank
    Throttle Body Bracket and Surge Tank

    1. Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.

    2. A01CFH3

      Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
    3. A01CG8R

      Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01CFDY

      Connect the connector to the intake air control valve assembly.

    5. A01CD28

      Connect the 2 water by-pass hoses to the throttle body assembly.

    6. A01CBUZ

      Connect the fuel vapor feed hose to the intake air surge tank assembly.

    7. A01CEHY

      Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.

    8. A01CF6M

      Connect the ventilation hose.

    9. Connect the union to connector tube hose.

  3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A01CB66

      Install the air cleaner cap sub-assembly to the air cleaner case with the 2 clamps.

    2. A01CAN5

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

    3. Connect the ventilation hose.

    4. A01CBVZE01

      Connect the purge line hose.

    5. Connect the 2 wire harness clamps and mass air flow meter connector.

  4. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug (for Bank 1).

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

    3. Tighten the cylinder block drain cock plug (for Bank 2, w/ Cylinder Block Drain Cock Plug).

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

    4. Loosen the air drain cock plug.

    5. Add engine coolant.

      Standard Capacity
      10.6 liters (11.2 US qts, 9.3 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 is a combination of low phosphates and organic acids).

      • Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

        If the engine coolant level is low, add engine coolant.

    6. Add engine coolant to the radiator reserve tank until engine coolant overflows from the air drain cock plug hole. Then tighten the air drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    7. A01CGIAE02
      Text in Illustration
      *a B Line

      Continue adding engine coolant until it reaches the B line. (*1)

    8. Install the reserve tank cap. (*2)

    9. Run the engine at about 2000 rpm to warm it up until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes. (*3)

      CAUTION:


      • Wear protective gloves.

      • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

      • Keep your hands away from the fan and No. 2 fan.

      Note


      • If the radiator reserve tank runs out of engine coolant just after the engine is started, stop the engine immediately, wait until the engine coolant has cooled down, and then add engine coolant.

      • Make sure that the radiator reserve tank still has some engine coolant in it.

      • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

      • If there is not enough engine coolant, the engine may overheat or be seriously damaged.

    10. Stop the engine and wait until the engine coolant cools down. (*4)

    11. A01CFOIE05
      Text in Illustration
      *a Full Line
      *b Low Line

      Check that the engine coolant level is between the full line and low line. (*5)

      Tech Tips


      • If the engine coolant level is below the low line, remove the reserve tank cap and repeat steps from (*1) to (*5).

      • If the engine coolant level is above the full line, drain engine coolant so that the engine coolant level is between the full line and low line.

  5. INSPECT FOR ENGINE COOLANT LEAK


    1. Remove the radiator reservoir cap.

      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.

    2. A01CB9EE01

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

    3. Warm up the engine.

    4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks.

      If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

    5. Reinstall the radiator reservoir cap.

  6. INSPECT FOR OIL LEAK


    1. Start the engine, and check that there are no oil leaks.

  7. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01CCP4

      Fit the 3 retainers and install the V-bank cover sub-assembly.

  8. INSTALL RADIATOR COVER SUB-ASSY (for ALPHARD)


    1. Install the radiator cover sub-assembly with the 4 clips.

  9. INSTALL RADIATOR COVER SUB-ASSEMBLY (for VELLFIRE)


    1. Install the radiator cover sub-assembly with the 4 clips.

  10. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY


    1. A01CCFB

      Install the outer cowl top panel with the 8 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Connect the 2 clamps to the outer cowl top panel.

    3. Remove the protective tape.

  11. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01CBAK

      Install the brake master cylinder reservoir with bracket to the outer cowl top panel with the 2 nuts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  12. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. Install the windshield wiper motor and link assembly Click here.

  13. INSTALL NO. 1 ENGINE UNDER COVER